model eewa-109 advanced wheel aligner owner’s...

Model EEWA-109Advanced Wheel Aligner

Owner’s Manual

Form # 5438

"FOR REFERENCE ONLY"For Current Information see www.equiserv.com/techsupport

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Model EEWA-109Advanced Wheel AlignerOwner’s Manual

Print History

First Edition Form #5438 August 1999

Copyright Statement

This manual and the materials contained within are the propertyof Sun, a division of Snap-on Incorporated. The manual, or anysection, page, drawing, or screen capture, may not be repro-duced by any means without the written consent of Sun.

File Information: eng_nt @ c:pubs\aligners\eewa109.p65 wdc 8/99

Snap-on Diagnostics420 Barclay Blvd.Lincolnshire, IL 60069(800) 225-5786


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Advanced PC Aligner Owner's Manual

SAFETY INFORMATION

For your safety, read this manual thoroughlybefore operating the Sun Advanced Aligner

The Sun Advanced Aligner is intended for use by properly trained, skilled automotivetechincians. The safety messages presented in this section and throughout themanual are reminders to the operator to exercise extreme care when performing wheelalignments with this product.

There are many variations in procedures, techniques, tools, and parts for servicingvehicles, as well as the skill of the individual doing the work. Because of the vastnumber of vehcile applications and potential uses of the product, the manufacturercannot possibly anticipate or provide advice or safety messages to cover everysituation. It is the automtoive technician's responsibility to be knowledgeable of thevehicle to be aligned. It is essential to use proper service methods and perform wheelalignments in an appropriate and acceptable manner that does not endanger yoursafety, the safety of others in the work area or the equipment or vehicle being serviced.

It is assumed that, prior to using the Sun Advanced Aligner, the operator has a thoroughunderstanding of the vehicle systems being serviced. In addition, it is assumed he hasa thorough knowledge of the operation and safety features of the alignment rack orlift, and has the proper hand and power tools necessary to perform wheel alignments.

Before using the Sun Advanced Aligner, always refer to and follow the safety messagesand service procedures provided by the manufacturers of the equipment being usedor the vehicle being serviced.

IMPORTANT !! SAVE THESE INSTRUCTION -- DO NOT DISCARD !!



SAFETY INSTRUCTIONS

IMPORTANT!! SAVE THESE INSTRUCTIONS

Risk of electrical shock.••••• Do not operate equipment with a damaged power cord or if the equip-

ment has been dropped or damaged, until it has been examined by aqualified service person.

••••• If an extension cord is necessary, a cord with a current rating equal toor greater than that of the equipment should be used. Cords rated forless current than the equipment can overheat.

••••• Unplug equipment from electrical outlet when not in use. Never usethe cord to pull the plug from the outlet. Grasp plug and pull to dis-connect.

••••• Do not expose the equipment to rain. Do not use on wet surfaces.••••• Plug unit into correct power supply.••••• Do not remove or bypass grounding pin.Contact with high voltages can cause death or serious injury.

Risk of electrical shock. High voltages are present within the console unit.••••• There are no user serviceable items within the console other than the

keyboard and printer.••••• Service on the unit must be performed by qualified personnel.••••• Do not open any part of the console other than noted areas.••••• Turn power switch off and unplug the unit before servicing.Contact with high voltages can cause death or serious injury.

Risk of eye injury. Debris, dirt, and fluids may drop from vehicles.••••• Knock off any loose debris. Clean surfaces as needed to avoid any

materials from falling.••••• Wear approved safety glasses when servicing.Debris, dirt, and fluids can cause serious eye injury.

Risk of crushing. Vehicles may roll off alignment lift if not secured.••••• Leave automatic transmission in park or manual transmission in gear

unless equipment operation steps require vehicle in neutral.••••• Apply parking brake unless equipment operation steps require wheel

movement.••••• Use wheel chocks whenever vehicle is positioned on the lift.••••• Follow rack or lift manufacturer’s safety recommendations when lift-

ing a vehicle.Vehicles rolling off lifts can cause death or serious injury.



Risk of entanglement or crushing. There are moving parts on vehicle lifts dur-ing operation.••••• Keep all persons clear of lifts.••••• Read lift manufacturer’s operation instructions carefully.••••• Follow lift manufacturer’s safety recommendations.Contact with moving parts could cause injury.

Risk of pinching or crushing body parts when jacking vehicles.••••• Keep hands and other body parts away from jacking surfaces.••••• Do not use unapproved adapters (i.e. wooden blocks) when jacking a

vehicle.••••• Do not bypass any jack manufacturer’s safety features.••••• Read jack manufacturer’s operation instructions carefully.••••• Follow jack manufacturer’s safety recommendations.Improperly used or maintained jacks can cause injury.

Risk of burns.••••• Do not touch hot exhaust systems, manifolds, engines, radiators, etc.••••• Wear gloves whenever performing a service near hot components.Hot components can cause burns.

Risk of injury. Tools may break or slip if improperly used or maintained.••••• Use the correct tool for the task.••••• Frequently inspect, clean, and lubricate (if recommended) all tools.••••• Follow recommended procedures when performing vehicle services.Tools that break or slip can cause injury.


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Section 1. Getting Started and Windows

Introduction ................................................. 17Getting Started ............................................ 18

Assembly and Setup .................................. 18Aligner Location ......................................... 18Power ON ................................................... 18

Aligner Components .................................... 19Console ....................................................... 19Measuring Heads ....................................... 20Wheel Clamps ............................................ 21Remote Display Unit .................................. 22Pointing Devices ........................................ 22

Mouse ..................................................... 22Track Ball ................................................ 22GlidePoint ............................................... 22Light Pen ................................................ 22

Sun Home Menu ........................................... 23Aligner ......................................................... 24Service Information .................................... 25

Using Microsoft Windows ........................... 26Program Manager ...................................... 26Windows Operations .................................. 27

Specific Program Groups ........................... 28Main ............................................................ 28

File Manager .......................................... 28Control Panel .......................................... 28Desktop................................................... 29Mouse ..................................................... 29Print Manager ......................................... 29

Accessories ................................................ 30Write ....................................................... 30Paintbrush .............................................. 30

Start Up ...................................................... 31Games ........................................................ 31Windows Help............................................. 31

Windows Maintenance ................................ 32Repair Disk ................................................. 32Hard Disk Management ............................. 32

Scan Disk ............................................... 32Defragmentation ..................................... 32Backup .................................................... 33

Getting Additional Help .............................. 33

Table of Contents

Section 2. Setup Guide

Navigation .................................................... 39Setup Notes................................................... 39Setup Menu ................................................... 40

Customizing the Sun Aligner ..................... 41Rack / Floor ................................................ 41System Setup ............................................. 41Heads ......................................................... 42Keyboard .................................................... 42Turntables................................................... 42Paper Type ................................................. 43Printer Selection ......................................... 43

Personalize Menu ......................................... 44Alignment Order ......................................... 44Skip Allowed ............................................... 45

Skip Runout ............................................ 45Skip Customer Info ................................ 45Skip Inspections ..................................... 45Skip Specifications ................................. 45Skip Caster ............................................. 45

Displays ...................................................... 46Cross Value ............................................ 46Colors ..................................................... 46Dealer ..................................................... 46Volume .................................................... 47Brightness ............................................... 47

Alignment Features .................................... 47Shim Manufacturer Selection ................ 47Diagnostics ............................................. 48Setback/Vehicle Dimensions ................. 48Calibration Check ................................... 48

Alignment Styles ........................................ 49Caster/Camber @ 0 Toe ........................ 49Thrust Line Only ..................................... 49All Readings Position ............................. 50

Language ....................................................... 51Language Selection ................................... 51Spec Database ........................................... 51

Units of Measure .......................................... 52Toe Units .................................................... 52Angle Units ................................................. 53Linear Units ................................................ 53Resolution Selection .................................. 53

Date/Clock Menu .......................................... 54Set Clock .................................................... 54Time and Date Format ............................... 55



Table of ContentsSection 3. Operation Instructions

Introduction .................................................. 61Steps to a 4 Wheel Alignment .................... 63Attach Wheel Clamps .................................. 64Performing a Wheel Alignment .................. 65

Main Menu -- Align Vehicle ........................ 65Clear Aligner Menu .................................... 65Alignment Menu ......................................... 65Customer Menu .......................................... 66Customer Data ........................................... 66Vehicle Manufacturers ............................... 67Vehicle Year and Model ............................. 67Custom Specifications ............................... 67Vehicle Specifications ................................ 68

Illustrate Adjustment .............................. 68Edit .......................................................... 68

Inspection Menu ......................................... 69Pre-Alignment Inspection ...................... 69Tire Inspection ........................................ 69Brake Inspection .................................... 70Under Car Inspection ............................. 70Under Hood Inspection .......................... 70Courtesy Inspection ............................... 71

Runout Compensation ............................... 72Measuring Caster ....................................... 74

Automatic or Manual .............................. 74Advanced Diagnostics ............................... 76

Bent Parts ............................................... 76Rear Readings ........................................... 77

Cross Value / Total Toe ......................... 77Soft-Keys ................................................ 77Zoom ....................................................... 78

Front Readings ........................................... 79Soft-Keys ................................................ 79Front Angle Adjustments ....................... 79Adjustment Illustrations ......................... 80Animated Graphics................................. 80Zoom ....................................................... 80

All Readings ............................................... 81Problem Icons ............................................ 81

Measuring Other Angles ............................. 82Caster / SAI Menu ...................................... 82Measuring SAI & Included Angle ............... 83Steering Angles Menu ................................ 84

Toe Out on Turns ................................... 84Maximum Turns...................................... 85Toe Curve Change ................................. 854 Wheel Steering .................................... 85

Setback / Vehicle Dimensions ................... 86Adjustment Assistant .................................. 87

A-Arm Adjust .............................................. 87Adjust Caster / Camber Menu ................... 88

Live Caster and Camber ........................ 88Elevated Camber ................................... 88

Total Toe (Drag Link) ................................. 89Shim Adjustment ........................................ 89Shim Information ........................................ 90EZ Shim ...................................................... 90Cradle Adjust .............................................. 91EZ Toe ........................................................ 92

Driver Complaints Menu ............................. 93Advanced Diagnostics ............................... 93Pull .............................................................. 93Unlevel Steering ......................................... 94Vibration Diagnostics ................................. 94Treadwear .................................................. 95

Printer Menu ................................................. 95Glossary of Alignment Terms .................... 96

Section 4. Customer Database

Customer Info ............................................... 103Customer Database ..................................... 103Customer Files Menu................................... 104

View Records ............................................. 104Select Disk Drive ........................................ 105Backup Database ....................................... 105Restore Database ...................................... 105

Using Database During Alignments .......... 106New Record ................................................ 106Finding a Record ........................................ 106Specification History .................................. 107Inspection History ...................................... 107All Readings History................................... 107

Saving Complete Alignments ..................... 108Store Name.................................................... 108

Section 5. Maintenance and Service

Maintaining the Aligner ............................... 113Customer Calibration .................................. 114

Camber, SAI, Cross Toe............................ 115Track Toe Calibration ................................ 116Calibration Factors ..................................... 118Calibration History ...................................... 119

Check Sensors ............................................. 119All Sensor Data .......................................... 120Raw Data Display ....................................... 120

Aligner Diagnostic Menu............................. 120Preventative Maintenance Menu ................ 121

Weekly Maintenance .................................. 121Maintenance History .................................. 121Maintenance Day ....................................... 121

User Serviceable Parts ................................ 122Troubleshooting Problems ......................... 123


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Advanced Wheel Aligner

Getting Started andWindows Navigation


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Advanced PC Aligner Owner's ManualGetting Started & Windows

Section 1 Contents -- Getting Started & Windows

Introduction ................................................................................................................... 17Getting Started ............................................................................................................. 18

Assembly and Setup ................................................................................................ 18Aligner Location ....................................................................................................... 18Power ON ................................................................................................................. 18

Aligner Components .................................................................................................... 19Console .................................................................................................................... 19Measuring Heads ..................................................................................................... 20Wheel Clamps .......................................................................................................... 21Remote Display Unit ................................................................................................ 22Pointing Devices ...................................................................................................... 22

Mouse................................................................................................................. 22Track Ball ........................................................................................................... 22GlidePoint .......................................................................................................... 22Light Pen ............................................................................................................ 22

Sun Home Menu ........................................................................................................... 23Aligner ...................................................................................................................... 24Service Information .................................................................................................. 25

Using Microsoft Windows ........................................................................................... 26Program Manager .................................................................................................... 26Windows Operations ................................................................................................ 27

Specific Program Groups ............................................................................................ 28Main .......................................................................................................................... 28

File Manager ...................................................................................................... 28Control Panel ..................................................................................................... 28Desktop .............................................................................................................. 29Mouse................................................................................................................. 29Print Manager .................................................................................................... 29

Accessories .............................................................................................................. 30Write ................................................................................................................... 30Paintbrush .......................................................................................................... 30

Start Up .................................................................................................................... 31Games ...................................................................................................................... 31Windows Help .......................................................................................................... 31

Windows Maintenance ................................................................................................. 32Repair Disk ............................................................................................................... 32Hard Disk Management ........................................................................................... 32

Scan Disk ........................................................................................................... 32Defragmentation ................................................................................................ 32Backup ............................................................................................................... 33

Getting Additional Help ............................................................................................ 33


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Introduction

This section is designed as a starting point for owners and operators of the Sun AdvancedAligner. The Sun Aligner software provides a powerful tool for service centers who offerwheel alignment services. The setup, operation, and maintenance of the Sun Aligner iscovered in sections 2 - 5. In addition, the aligner features the Microsoft WindowsTM operat-ing system software. While the basic operation of Windows is covered in this manual, is notintended to be a reference manual for MS Windows. For detailed instructions on thefunctionality of Windows software, utilize the Microsoft Windows for Workgroups User’sGuide included with the Sun Aligner.

The first part of this section describes what is necessary to get started using the SunAligner. The components of the system are described, and navigation through the softwareis shown. It then describes the Home Menu, the launching point into the many alignerfeatures. Finally, some of the WindowsTM features are described to familiarize the operatorwith the possibilities. WindowsTM allows access to the IBM-based PC system in the aligner,opening up to the world of software products currently available for the Windows platform.In the future, more automotive service products will be Windows-based, allowing the SunAligner to be an integral part of the Service Bay of the Future.

Windows and the Sun Aligner require a very specific set of computer hardware compo-nents. All these components are integrated together to optimize the speed and functionalityof the software. Substitution of these items, or the addition of any other computer compo-nents to the aligner, could compromise proper operation and is not recommended. ConsultSun Technical Support prior to performing any changes to the hardware configuration.

Windows is a very powerful operating system that allows full access to the computer system’sfiles. Do not manipulate, change, or copy any files or system configurations unless quali-fied to do so. Again, the aligner may not operate properly if unauthorized changes havebeen made to the software. In case of accidental changes, a Repair Disk is included withthe Sun Aligner that restores the files and configurations to Sun Factory settings. Keep thisvaluable disk in a safe place.

One of the characteristics of MS Windows is its graphical format and the use of icons andbuttons. The most efficient way to use Windows is with a pointing device. The pointingdevice allows an arrow to move about the screen to a desired function icon or button, andthen activate the function by clicking on the icon. Sun offers several different pointingdevices for the Sun Aligner which is described later in this manual. Please note the point-ing device does not function in the Sun Aligner portion of the software.

Thank you for purchasing the Sun Aligner system. We at Sun are confident this state of theart alignment machine will provide many years of profitable service. Should any additionalassistance or information be required, call the following number in the USA:

1- 800- 225-5786(1-800-CALL-SUN)

Microsoft, MS and MS-DOS are registered trademarks, Windows and the Windows logo are trademarks of MicrosoftCorporation. IBM is a registered trademark of IBM Corporation. Sun is a registered trademark of Snap-on Incorpo-rated.



Getting Started

The Sun Aligner offers extraordinary power and ver-satility. With proper setup, operation, and mainte-nance, the system will provide many years of profit-able service. This section of the manual describeshow to begin enjoying the many features and ben-efits of the Aligner. References are made to othersections of the Sun Aligner Owner's Manual andMicrosoft WindowsTM for Workgroups User’s Guide— have them handy when reading this document.

Assembly and Setup

Installation and setup of a new Sun Aligner is besthandled by a qualified Sun Electric Representative.If unsure of who to contact, refer to the back of thismanual.

The aligner must be calibrated to at least one rack,lift, or other surface where wheel alignments are tobe performed.

The Compact Disc that contains the alignment soft-ware should be placed into the CD-ROM drive priorto software loading. Leave the software CompactDisc in the CD-ROM drive unless the on-screen in-structions say otherwise.

Instructions for operational setup of the Sun Alignerprogram are covered in detail in Section 2 of thisOwner's Manual. The setups for the PC Hardware,MS-DOS, and MS Windows are preset at the fac-tory and should not be altered.

Take a few minutes to read the software licensingagreement that comes with Microsoft WindowsTM andto fill out and send in the registration forms. All thesoftware in the Sun Aligner is property of the re-spective companies who developed it. Unauthorizedcopies or distribution of these software products isstrictly prohibited by federal law.

Aligner Location

Each shop is unique. Locate the aligner in a loca-tion in the spot that provides the most conveniencefor the operator. Remember, visual contact with themonitor is necessary during most steps of a wheelalignment. Most shops position the aligner in frontof the alignment lift, offset to either the left or rightsides.

Power ON

The power switch for the Sun Aligner is located onthe rear of the unit (see Figure 3 on Page 19). Thisswitch turns on all of the aligner's components.Make sure the monitor's power switch and thecomputer's power switch (in lower cabinet) are leftin the ON position at all times.

When the power switch is turned on, the unit ini-tiates the computer bootup. The monitor flickers asthe video system is loaded. Text should appear onthe screen as bootup begins and counting numbersare shown as the memory of the unit is checkedand verified (this count should be about 8000 KB,the equivalent of 8 MB of memory). Many additionallines of computer configuration will appear on screenand scroll up as the computer completes the sys-tem boot sequence. The next screen display will bethe Microsoft WindowsTM for Workgroups Version3.11 graphical logo, indicating the loading of the Win-dows operating system software. Next the screenwill display the Sun Aligner Home Menu screen (Fig-ure 1), indicating the Aligner is ready for operation.This boot sequence should take about one minute.If any problems are encountered during the PowerOn bootup sequence, consult the Maintenance andService section of this Owner's Manual.

Figure 1 - Home Menu Screensee Page 23 for details



Aligner Components

Console

The console houses many of the aligner compo-nents including the power supplies, the computersystem, the head interface components, and pro-vides places for the display monitor, keyboard, andprinter. The measuring heads are hung on the sidebrackets when not in use.

The upper shelf of the console provides a location forthe display monitor and keyboard. The monitor hasits own power switch, which should be left on at alltimes, plus picture controls such as horizontal, ver-tical, and brightness.

The lower part of the console has a printer drawer tokeep the printer away from shop elements. Thedrawer is mounted on a slide mechanism to easeusage and paper replacement. The storage cabinetis the location for the computer system that runs theSun Aligner. The computer has a front mounted on/off switch that should be left in the ON position at alltimes. The computer also contains a CD-ROM drivewhere the operating software is loaded, plus a floppydrive used for backing up customer database infor-mation.

NOTE: Be careful not to damage the computerwhen placing items in the open areas of thestorage cabinet. Do not block the front or rear ofthe computer. Do not clean the lower cabinetwith water to avoid damaging the computer.

The main On/Off switch for the aligner is located onthe rear of the upper console. Next to the switch area series of protective fuses. In the event of a poweroverload, one or more of these fuses may blow,rendering the aligner unusable. Check the fuseswhenever the unit is non-operational. The mainpower cord connects near the switch and fuses.

The head interconnect cables plug into the back ofthe upper console. There are 6 female connectors-- one for each of the 4 heads, one for the optionalremote display unit, and one spare. When thealigner is utilized with a rack wiring kit, all 6 connec-tors are used. The connectors are universal -- itdoes not matter which head is plugged into any of the6 connectors.

On/Off Switch

Head CableConnectors

Head / ClampHanger Bracket

Fuses

Keyboard

Monitor

PrinterDrawer

StorageCabinet

Figure 2 -- Console Front View

Figure 3 -- Console Rear View



Measuring Heads

The operation of the Sun Aligner can be controlled at any of the measuring heads. Study Figure 4 below tobecome familiar with the layout of the head keypads.

Figure 5 below shows some of the components of the Sun Aligner optical measuring heads.

Head Locking Knob

Level Vial

Head Keypad

Cable Receptacle Boom Tube

Cross ToeOptics Module

Track ToeOptics Module

Page Back: Returns to the lastscreen displayed.

Page Forward: Advances to thenext page when there is morethan one page available

Enter: Accepts a selection andadvances program to next step.

No: Rejects an operation

Soft-key toggle: Selects desiredset of soft-keys

Number Keys: Invoke soft-keyfunctions.

Help: On screen assistance forany program function.

Menu: Returns to the MainMenu instantly

Runout: Press this buttonduring wheel runout procedure

Arrow Keys: Move selectionbar and cursor control

Keypad Functions

Figure 4

Figure 5 -- Head Components



Sliding UpperBracket

Tightening Knoband Screw

Wheel Clamps

The wheel clamps allow for placement of the headson a variety of vehicles. Figure 6 identifies the com-ponents of the wheel clamp. See page 3-2 of thismanual for instructions on how to attach the clampto various wheels.

Notice the wheel clamps are adjustable to differentwheel sizes by moving the upper and lower brack-ets. The center slide bracket can be moved to anyposition prior to wheel runout compensation, allow-ing for a clear line of site for the toe measurementsystem.

Remote Display Unit (Optional)

The optional Remote Display unit is handy when ad-justing the vehicle. It is not necessary to be in vi-sual contact with the console monitor, since theRemote Display can show all necessary informa-tion. There are 2 LED windows to show live anglereadings, an LCD display that shows informationabout the current function, and a full operationalkeypad.

Wheel Grabbers

Stub Shaft

Slide Tensioners

Center SlideBracket

AdjustableLower Bracket

Wedge Grips

Extension Rods

Figure 6

Figure 7 -- Remote Display Unit

Right WheelReadings

Left WheelReadings

LCD InformationDisplay

Soft-Keys

OperationalKeypad



Pointing Devices

One of the unique features of the Windows operat-ing system software is the graphical use of iconsand buttons to initiate actions. The best way to navi-gate around the screen to these icons is by using apointing device. There are many different types andbrands of pointing devices for PC’s available today.However, only certain approved devices will oper-ate with the Sun Aligner. Sun Electric offers severaldifferent devices depending on personal preference.Setup of these devices usually occurs at the fac-tory. Installation of these pointing devices in the fieldmay include additional computer hardware and theloading of software and should only be done by aqualified Sun Service Representative. Note thepointing devices function only in Windows applica-tions -- they do not work in the Sun Aligner program.

Microsoft Windows includes an application for con-trolling mouse, track ball and light pen actions.Some Aligners may utilize a light pen whose manu-facturer provides an additional control panel soft-ware program. This will be discussed in the ControlPanel section.

Mouse

The mouse is a pointing device that is moved by thehand with a ball located underneath. The mouse ismoved along a smooth surface which moves the on-screen pointer in Windows. Once the pointer is po-sitioned on the screen at the desired spot, the iconor button is activated by pressing the left hand but-ton on the mouse. Some icons require the left mousebutton be pressed twice in rapid succession (doubleclick). The right hand button provides additional func-tions in some software programs.

Protect the mouse from contamination by liquids.Failure of the on-screen pointer to move or jerky,erratic movements may indicate the mouse is dirty.To clean, remove the roller ball from the undersideof the mouse. Using a cotton swab dipped in rub-bing alcohol, gently clean the surfaces the ball rollsagainst. Replace the ball and test.

Track Ball

The Track Ball is the opposite of a mouse -- thebody of the device remains stationary while the handmoves the ball. When the ball moves, so does theon-screen pointer. Once the pointer is positionedon the screen at the desired spot, the icon or buttonis activated by pressing the left hand button on the

Track Ball. Some icons require the left Track Ballbutton be pressed twice in rapid succession (doubleclick).

To clean, remove the roller ball from the Track Ballbody. Using a cotton swab dipped in rubbing alco-hol, gently clean the surfaces the ball rolls against.Replace the ball and test.

GlidePoint (Track Pad)

The GlidePoint consists of a small, rectangular padthat responds to the movement of a finger on thepad surface. Touching the pad and moving the fin-ger puts the on-screen pointer in motion. Once thepointer is positioned on the screen at the desiredspot, the icon or button is activated by pressing theleft mechanical button on the GlidePoint or by lightlytapping the pad surface. Some icons require the leftbutton be pressed twice, or the pad surface betapped twice, in rapid succession (double click). Theright hand button provides additional functions insome software programs.

The GlidePoint requires no maintenance. Clean thetouch surface with a damp cloth. Also included is asoftware program used to customize and controlGlidePoint operation, accessible from the WindowsProgram Manager. For details of operation and soft-ware settings, see the GlidePoint User’s Guide.

Light Pen (Optional)

The light pen pointer, which looks like an ink penwith a wire leading to the back of the Aligner, is lo-cated next to the keyboard. The pointer on thescreen is activated by removing the light pen fromits holder and pointing it at the screen of the Aligner.When the light pen is positioned close to the screen,the pointer will begin to move. Once the pointer ispositioned on the screen at the desired spot, theicon or button is activated by pressing the light penpoint against the screen. Some icons require thepen be pressed against the screen twice in rapidsuccession (double click). The button located onthe shaft of the light pen is the “right hand button”and provides additional functions in some softwareprograms. For optimum performance of the lightpen, clean the monitor screen regularly with a dampcloth or with a commercial glass cleaner. The tip ofthe pen contains a lens that can be cleaned with acotton swab.

GlidePoint is a registered trademark of Cirque Corporation.



Home Menu

When the system finishes the bootup process, this isthe screen that will come up. From here, all thefunctions included with the Sun Advanced Alignersoftware are accessed. The menu items are selectedusing the pointing device or by using the up/downarrow keys on the keyboard to place a box around theselection, then press the Enter key. The selectionsare:

Alignment Program .... Choosing this selectionlaunches the Sun Wheel Alignment Program. Detailson how to use this program are covered in the SunAdvanced Aligner Series Operation Guide.Vehicle Information System .... All Data, if in-stalled, is accessed here.Service Information .... Displays a rolodex type setof card files that contains information on how to getassistance and information on Sun Electric products.Jump to Windows .... This selection goes to theWindows Program Manager allowing access to allWindows applications and functions.Navigation

AlignmentProgram

ServiceInformation

VehicleInformationSystem

Jump toWindowsProgramMgr

Once the pointing device arrow is over the desiredicon, press the "left button" once. Multiple clicks onthe Alignment Program may cause the unit to attemptto start several sessions at once, usually causing aprogram crash.

Once an alignment session has begun it is possibleto leave the program at any spot and move to otherWindows applications. This is done using the "Alt-Tab" combination on the keyboard. Hold down the Altkey and press the tab button repeatedly to "scroll"through any Windows programs that may be running.Go to Program Manager to start up a program fromthe desktop. You can return to the Alignment Pro-gram at the same point you left by using the Alt-Tabkeys.

Please note that the pointing device does not functionwithin the alignment software.



Sun Aligner Main Menu

When Alignment is selected from the Sun HomeMenu, the system brings up the Sun Aligner program.The initial alignment program load sequence takesapproximately 3 minutes. During the program load-ing, a red bar graph on a "space grid" background isdisplayed showing the progress of the load. Aftercompletion, a logo screen comes up. The logodisplayed depends on the setup for each aligner, withthe default logo being Sun. Pressing any key at thispoint goes to the Main Menu shown above. Instruc-tions for proceeding into the alignment program arecovered in the Sun Advanced Aligner OperationGuide.

IMPORTANT NOTE: The Sun Aligner pro-gram is not a Windows application. It isrunning in a "DOS window". Be careful toopen only one Aligner program. Openingmultiple DOS windows will use up thememory resources of the system and maycause computer lockup, correctable onlyby rebooting the system. Also, the pointingdevices do not function in the Sun Alignerprogram.

Once the Sun Aligner program has begun, it ispossible to temporarily leave the alignment, jump toany function that has been started in Windows, andthen return to the alignment by doing one of thefollowing:

> Pressing and hold the Alt button on the keyboard,then press the Tab key activates a text bar alongthe top the screen. Keep pressing Tab to scrollthrough open windows until the desired item isfound. Let off the Tab key when the desired itemis found.

> Pressing Ctrl-Esc together on the keyboard bringsup a "Task List" box where all open items areshown. Highlight a selection, then double click onit, choose "Switch To", or press Enter on thekeyboard.

When alignments are done for the day, simply turnthe unit's power switch off.



Service Information

When Service Information is selected from the HomeMenu, a rolodex type cardfile system comes up thatcontains information on how to contact Sun. Thisnumber is a resource for technical assistance, ser-vice, product information, and sales. To see theinformation on any of the cards, use the pointingdevice to place the arrow on the name at the top,then select that card.

Additional card can be added to this cardfile -- forexample, the name, address and phone number ofthe local Sun Representative. From the menu bar,choose Card, then Add. Name the card, then typethe information onto the blank card. Be sure to saveany new entries by choosing File, then Save.

Cardfile is an application that comes with MicrosoftWindows. For more information, see the WindowsUser's Guide.

Sun / Snap-on Diagnostics420 Barclay Blvd.Lincolnshire, IL 600691-800-CALL-SUN1-800-225-5786

Jump to Windows Program Manager

When selected from the Sun Home Menu, the Win-dows Program Manager appears, giving full accessto the many Window applications and functions.



Program Manager

Program Manager is the "main menu" or Desktop ofMicrosoft Windows. Its graphical interface includesicons and buttons activated by an on-screen pointerthat is moved to a desired location. ProgramManager's icons fall into two major categories:

> Program Items represent each individual Win-dows application (program). When the pointer isplaced on a Program Item icon using the pointingdevice, and double clicked, the application islaunched (started).

> Program Groups, such as Games, contain atleast one Program Item (usually they containmany items). When a Program Group icon isdouble clicked, it opens up to display all theProgram Items inside. Groups, like all openwindows, can be collapsed to an icon (mini-mized) or expanded to a larger size (maximized)using the up/down arrow buttons in the upperright corner of the window. An example of aminimized Group in the above screen is Net-work. The four rectangular windows in the topportion are Program Groups that have beenopened, displaying their Program Items.

MS Windows is capable of running several applica-tions simultaneously. Once a program has beenstarted, another can begin by returning to ProgramManager and selecting the next application to run.To switch from one running program to another,press and hold the Alt key, then press the Tab key toscroll through each program. Once the desired pro-gram comes up, let off the Alt key to complete theswitch. Another method is to press the Ctrl and Esckeys together. This will bring up a Task List boxwhich displays and allows movement to all openapplications.



Click here to collapse theapplication to an iconTo drag the box or move the

application to another loca-tion, click hold and drag atthe title bar

To resize the applica-tion, move the cursor tothe edge or corner of thebox, press and drag todesired location.

To start or"Launch" an appli-cation, place thecursor over the de-sired icon anddouble click.

Click here toexpand thedisplayed area

Double click to close

The picture above shows many ways to manipulateProgram Groups and Items in WindowsTM. Here aresome other things to know when operating inWindowsTM on the Sun Advanced Aligner:

> If an error occurs, the computer locks up orstops responding, or if all else fails, reboot thecomputer by turning power off, then back on.

> Only start the Sun Aligner program once. Toggleback and forth to Windows using the Alt-Tabkeys.

> If the Sun Aligner program is running, it is notpossible to exit Windows. Just turn the machineoff.

> In order to conserve computer resources, donot start too many unnecessary Windows appli-cations or DOS programs.

> Because of the graphical nature of the desktopand because the user can move icons aroundand alter the makeup at will, no two ProgramManager desktops will appear exactly the same.

> In Program Manager, select "Window", the "Ar-range Icons" to neatly arrange icons on the desk-top.

> Program Groups can be viewed differently byselecting "Window", then "Cascade" or "Tile".

> If the pointing device fails, the keyboard can beused to operate Windows. Pressing and hold-ing the Alt button, then the first letter of the Menu

bar selection opens the drop down menu. Fromthere the up/down arrow keys are used to high-light a selection, then press Enter to enable thefunction. The Tab key is also useful in many"dialog boxes" for highlighting a selection be-fore pressing Enter. All Windows applicationsinclude instructions for utilizing the keyboard intheir user's manuals.

> Additional Windows-based programs can beloaded onto the Sun Aligner, with the limit beingthe memory space available on the hard drive.To see the available memory, go to File Man-ager and click on the folder icon for the "c:\"drive. At the lower left of the screen is shownthe free space and the total drive capacity. Thevalue is shown in megabytes (MB) of memory.

> There are several very important DOS com-mands, such as autoexec.bat and config.sys,and Windows setup files, such as system.ini andwin.ini, that are critical to proper operation ofthe Windows Aligner.Do not tamper with these commands andfiles!

> Do not change Windows Setup items such asdrivers or port settings.

> Sun Electric does not provide telephone or on-site support for Microsoft WindowsTM. See thedocumentation shipped with each Aligner forinformation on Microsoft Customer Support.



Main Program Group

This group contains applications for setting up, con-trolling, and viewing Windows operations. The mostcommonly used applications are File Manager, Con-trol Panel, and Print Manager. Others include:MS-DOS Prompt -- gives access to DOS, the basicPC operating system. DOS is a powerful text-basedcommand language -- do not attempt to work in thissystem unless qualified. Type Exit to return to Win-dows.ClipBook Viewer -- Windows has a "Clipboard"feature allowing text or graphics from applications tobe shared or copied. This program allows viewingclipboard items.Windows Setup -- this program is used to changefundamental Windows parameters. The initial setupitems are done at Sun and should not require chang-ing.

Control Panel

Many of the settings and controls for the look andfeel of Windows are here.

Color -- changes the color scheme of the desktop.Fonts -- used for adding and removing fonts (thestyle of lettering) available to Windows programs.Printers -- for installing and changing printers avail-able for Windows programs. Do not change thesesettings unless changing from the original Sun printer.Date/Time -- used to change these items if incor-rect.

The other items under Control Panel, such as En-hanced and Drivers, are advanced Windows set-tings and are preset at the factory -- do not changethem.

File Manager

This application is a powerful tool for viewing andmanipulating the system files. Directories (sets offiles) can be created or deleted. Files can be moved,copied, deleted, or renamed. Disks can be formattedand copied. Accessible through the Tools menu inFile Manager are Backup, used to save critical filesto external floppy disks (in case of hard drive failure),and Antivirus, used to detect and eliminate computerviruses (programs designed to corrupt and destroydata). See the Windows User's Guide for help usingFile Manager functions.



Print Manager

Print Manager is used to install and configure print-ers for Windows and control the printing of files. Itallows "background" printing, sending files to theprinter while other operations can continue. PrintManager works with the Printers selection in Con-trol Panel, the place where printers are installed,configured, and connected.

Note: If a Sun Aligner comes from the factory withan installed printer, Print Manager will be preset. Donot change these settings. Sun Aligner software isonly compatible with a few printers -- do not changeto a different model without consulting Sun Techni-cal Support. Erratic printing is the likely result ofusing a non-approved unit.

Desktop

Choosing this item allows the setting of a variety ofWindows items including the background pattern, ascreen saver to run when Windows is not beingused, and other desktop (screen setup) settings.Another Control Panel item, Color, sets the colorvariations of the desktop.

Note: The Sun Aligner program has its own screensaver. The WindowsTM screen saver does not workin Aligner.

Mouse

This item controls the basic functions of the mouse ortrack ball pointing devices. Mouse controls includetracking speed (how fast the on-screen pointer moves)and double-click speed (how close together the leftbutton clicks can be). In addition, the left/right buttonscan be swapped for left handed operators.

Light PenIf a Sun Advanced Aligner is equipped with a lightpen, this mouse control screen may also be used tochange pen settings. Some Aligners may utilize alight pen whose manufacturer provides an additionalcontrol panel software program. Look for an icon inProgram Manager or Control Panel.



Accessories Program Group

This group contains many versatile applications thatdemonstrate the power of Windows. Write and Paint-brush will be discussed later. Some of the otheritems are:

Cardfile -- a rolodex type card system for keepingimportant addresses and phone numbers.

Calendar -- an organizer that combines a month-in-a-glance calendar and daily appointmentbook.

Calculator -- an on-screen standard or scientificstyle calculator appears.

Clock -- shows current time and date.Notepad -- a text editor used to write short notes

and create or edit system operation (batch) files.

Paintbrush

Windows Paintbrush is a powerful tool for creatingand manipulating simple or elaborate drawings. Whenthe program starts, a blank drawing area is dis-played with a "Toolbox" along the left side. ThisToolbox contains the tools required to create andedit the drawing -- making boxes, circles, lines orfreehand drawings; filling tools with various coloroptions on the bottom of the screen; various editingtools for clipping items away or erasing; adding textto the drawing. Refer to the MS WindowsTM User'sGuide for more information on how to create draw-ings with Paintbrush.

Windows Write

Write is a basic word-processing application used tocreate and print letters, memos, and other docu-ments. After opening Write the screen is blank andready for typing. Portions of the text in the documentcan be moved, changed, or copied prior to printing.Text can be changed in type style, size, and format.Pictures can be added and resized. Files can besaved for later use or moved to another PC withWindows. Refer to the MS WindowsTM User's Guidefor more information.



Start Up Program Group

Applications contained in this group will automati-cally launch when Windows begins. For the SunAligner, the Home Menu selection must be in theStart Up group in order to bring up the Home Menu.It is not necessary for any other items to be con-tained in this group.

Games Program Group

Windows comes with several computer games. Ifadditional Windows-based games are added theycan be placed in this group.

Windows Help

Microsoft WindowsTM includes an extensive built inuser help system. The Help function is located on themenu bar of most Windows applications. In addition,the F1 function key can be pressed at any time. Thehelp that comes up will be directed where the user islocated at that time. Once inside the Help system,menu bar keys allow navigation to virtually anysubject. When finished with Help, double-click in theupper left corner to close or choose "File", then "Exit"form the menu bar.



Windows Maintenance

Repair Disk

The Repair Disk included with the Sun AdvancedAligner is intended to restore all the DOS and Win-dows commands, settings, and desktop configura-tions to the Sun Factory defaults. This disk should beutilized whenever changes have occurred, eitheruser software induced or due to hardware issues, thatcannot be reset using conventional means. This is avaluable disk -- store it in a safe place.

Please note this Repair Disk will not correct opera-tional problems within the Sun Aligner program. Forassistance in this area, consult the Sun AlignerOperator's Manual.

Using the Repair Disk

1. Turn the Aligner power off.2. Insert the Repair Disk in the floppy drive slot.3. Turn the Aligner power back on.4. Follow any on-screen instruction carefully. Se-

lect the pointing device utilized with the aligner.The Repair Disk will copy files and changeconfigurations.

5. The disk will make needed repairs. After repairsare made, the "A:>" prompt will appear, signalingthe end.

6. Remove the Repair Disk from the floppy drive andturn the aligner power off.

7. After 15 seconds, turn the power back on. Afterthe Aligner is restarted the unit should operateproperly and all DOS and Windows settingsshould be restored to original factory defaults.

8. If the Repair Disk does not correct all functionalissues, contact Sun Technical Support.

Note: After performing this recovery, anyadditional Windows applications, other thanthose supplied by Sun, that have beenadded by the user will continue to reside onthe hard drive. However, the ProgramGroups and Program items, plus the changesthese applications made to the DOS andWindows system files, will be gone. It isrecommended these additional applicationsbe reinstalled using their original programdisks.

Hard Disk Management

Computer hard drives require periodic maintenanceto operate at peak levels. If left unattended for longperiods, the data on the drive will become unorga-nized and spread out. The disk itself may develop badspots. This may cause errors to occur, resulting indata loss. MS-DOS includes tools for maintaining thehard drive that should be run periodically.

Scan Disk

To check the condition and correct hard drive prob-lems, MS-DOS includes a program called "Scandisk".This program cannot be run from Windows. To useScandisk, turn the power off to the Aligner, then turnit back on. When the Sun Home Menu comes up,select "Jump to Windows" to get to Program Man-ager. In Program Manager, choose "File" from themenu bar, then "Exit Windows" from the drop downmenu. After clicking on OK, the display will go to the"C:>" prompt. Then type "cd dos", press Enter, to getto "C:>\DOS>". From this prompt type "scandisk",and Enter. Follow the on-screen instructions to do asurface scan of the hard drive. This may take a fewminutes. When finished, the program will describethe results.

Defragmentation

To organize the data on the hard drive, MS-DOSincludes a program called "Defrag". This programcannot be run from Windows. To use Defrag, exitWindows and get to the "C:\DOS>" prompt as de-scribed under the Scandisk section. From the prompt,type "defrag", then press Enter. Follow the on-screeninstructions for defragmenting the "C" drive.



Backup

Backup is a program that is included with MSWindowsTM for Workgroups 3.11 that allows datafrom the hard drive to be compressed and moved tofloppy disks. This is extremely important for personswho use their Sun Aligner for functions other thanperforming wheel alignments. Any additional soft-ware that has been added to the Windows ProgramManager may have information that would createdifficulties if it were lost. Regular backups to floppiesinsure critical information can be recovered in theevent of a hard drive failure.

Backup is accessed from the File Manager item,which is part of the Main Program group. Follow theon-screen instructions and reference the WindowsUser's Guide for assistance.

Getting Additional Help

Sun is committed to providing the best customersupport in the automotive equipment industry. Onthe back manual is the phone number for Sun Tech-nical Support. These offices are staffed with person-nel ready to provide answers to questions, technicalor otherwise.

Sun will support the software developed by Sun. Forassistance with Microsoft Windows, or any othersoftware added to the Sun Aligner, refer to thedocumentation included with the software producton how to obtain customer support.


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Setup Guide


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Advanced PC Aligner Owner's ManualSetup Guide

Contents -- Setup Guide

Navigation ..................................................................................................................... 39Setup Notes ................................................................................................................... 39Setup Menu ................................................................................................................... 40

Customizing the Sun Aligner ..................................................................................... 41Rack / Floor .............................................................................................................. 41System Setup ........................................................................................................... 41Heads ....................................................................................................................... 42Keyboard .................................................................................................................. 42Turntables ................................................................................................................ 42Paper Type ............................................................................................................... 43Printer Selection ....................................................................................................... 43

Personalize Menu ......................................................................................................... 44Alignment Order ....................................................................................................... 44Skip Allowed ............................................................................................................. 45

Skip Runout ....................................................................................................... 45Skip Customer Info ............................................................................................ 45Skip Inspections ................................................................................................ 45Skip Specifications ............................................................................................ 45Skip Caster ........................................................................................................ 45

Displays .................................................................................................................... 46Cross Value ....................................................................................................... 46Colors ................................................................................................................. 46Dealer ................................................................................................................. 46Volume ............................................................................................................... 47Brightness .......................................................................................................... 47

Alignment Features .................................................................................................. 47Shim Manufacturer Selection ............................................................................ 47Diagnostics ........................................................................................................ 48Setback/Vehicle Dimensions ............................................................................ 48Calibration Check .............................................................................................. 48

Alignment Styles ...................................................................................................... 49Caster/Camber @ 0 Toe ................................................................................... 49Thrust Line Only ................................................................................................ 49All Readings Position ........................................................................................ 50

Language ....................................................................................................................... 51Language Selection ................................................................................................. 51Spec Database ......................................................................................................... 51

Units of Measure .......................................................................................................... 52Toe Units .................................................................................................................. 52Angle Units ............................................................................................................... 53Linear Units .............................................................................................................. 53Resolution Selection ................................................................................................ 53

Date/Clock Menu........................................................................................................... 54Set Clock .................................................................................................................. 54Time and Date Format ............................................................................................. 55


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Navigation

There are several ways to control movement withinthe aligner program. On all Sun Aligner models,the measuring heads are fitted with a keypad thatallows full operation of the unit from any wheel. Theoptional Remote Display Unit has a similar keypad.Study Figure 4 on Page 20 to become familiar withthe functions of each button.

The aligner is equipped with an IBM-style keyboard.All aligner functions can be controlled from the key-board as well. The function keys F1-F12 along thetop row of the keyboard are the equivalent of thehead and Remote Display keypad buttons.

The keyboard also contains a "Print Screen" key.When this key is pressed the currently displayedscreen is captured and printed. The exception tothis is the adjustment animation sequences whichcannot be printed.

The Sun Aligner software is "menu driven" for easeof use. Most of the screens allow choices to bemade about which direction to go to access variousfunctions. Menus with choices will always have aselection "Check Box" on the screen. When thecheck is positioned in a menu item box using theup/down arrow keys, and the Enter button ispressed, that item is activated.

Many areas of the software contain several layersof sub-menus to give the operator maximum controlover the aligner's functions. Upon entering a selec-tion on a menu, there may be additional selectionson the sub-menu, and so on. When moving throughthe network of sub-menus the "Enter" button movesforward and the "Page Back" button moves back-wards one page at a time. The "Menu" button canbe pressed any time to return to the aligner's MainMenu screen shown above.

The Sun Aligner software also utilizes "soft-keys"to streamline the operation and allow movement toadditional functions. The soft-keys are located alongthe bottom of almost every screen in the aligner.Numbered 1 - 4 with dots, they correspond to the 1- 4 dot keys on the remote and head keypad as wellas the F1 - F4 function keys on the optional consolekeyboard. Press the keys on any location and theappropriate soft-key operation will begin.

Setup Notes

> Some setup items require a password for entryand are reserved for Sun service personnel.> Many setup items are done once at the time ofaligner installation and do not need to be changed.Others are software, user-interface related and maybe changed depending on operator preference. Hereis a list of setup items typically found in each cat-egory:

One Time, Upon InstallationHeads, Keyboard, Turntables, PrinterSkip items, Cross values, Colors, LogoDealer phone #, Calibration checkSpecs select method, Printout typeSecurity code word

User Configuration ChangesRack selection,Alignment order, LanguageUnits of Measure, Clock setting, Volume, BrightnessShim man. select, Adv. driver complaint, SetbackCaster/Cam @ 0 toe, Thrust line only, All readingsResolution



Setup

After the unit has successfully powered up it is necessary to give the computer some information about theway alignments will be performed. Configuration of the Sun Aligner takes only a few minutes. Many itemsare setup by the Sun Representative who installs the aligner and will not need to be changed. Other itemsinvolve the flow of the alignment program and the access to certain functions that may need to be changedin the future depending on operator preference and the alignment and diagnostic routines necessary toproperly service vehicles.

All setup items are accessed through Setup Options on the Main Menu. Upon entering Setup Options, therewill be a series of additional menus and sub-menus for the various setup options. Consult the Operationportion of this manual for instructions on how to use the various functions that can be enabled during thealigner setup.

Here is a list of some of the things to tell the SunAligner before beginning to do alignments:-- Type of wheel alignments normally performed.-- The routine the operator is most comfortable with when performing an alignment.-- Which alignment rack or surface is to be utilized-- The units of measurement for toe, caster, camber, and others measurements-- Which software features are a part of the align-ment program sequence-- The Language for the CRT display and theoptional Printer.

To enter the Setup Menu, place the check box nextto Setup on the Main Menu and press the Enterbutton.

Setup Menu choices are:

Select Rack -- which one of 3 calibrated alignmentsurfaces will be utilizedSystem Setup -- setup of hardware items such asheads, keyboard, printer, etc.Personalize -- allows the operator to tailor the pro-gram sequence and options as desiredLanguage -- the software may allow the aligner tooperate in languages other than EnglishUnits -- selection of units which toe, camber, caster,and other angles are displayedDate/Clock -- for resetting the aligner's internalclock

HELP Use the Help function should you require further assistance on Setup procedures.The Sun Aligner has a unique operator help system which is designed to provideinstant access to information relative to the function being used. Use this any timeyou require further assistance by simply pressing the Help key.



Customizing The Sun Aligner

Once the Sun Aligner has powered up and theMain Menu is displayed an alignment can beperformed using the standard default settings.The following pages will assist in the setup andcustomizing of your new Sun Aligner.

1. Rack / FloorThe first item on the Setup Options is used toselect which of three calibrated alignment worksurfaces are to be utilized. In most shops theprimary alignment lift is designated as "Rack A".

Select the rack used to perform most wheel align-ments. Use the up/own arrow keys and pressEnter when the choice is the one with the check boxselected. The rack choice may be changed when-ever using a different surface for performing align-ments. Note: In order to perform accurate align-ments, each lift/rack surface must be properly cali-brated.

2. System SetupThe next item on the Setup Menu is used primarily tosetup various hardware and system options. Placethe check box next to System Setup and pressEnter.

The System Configuration Menu choices are:

Heads -- selection of the various measuring headoptions offered for the Sun Aligner.Keyboard -- which language will the IBM-type key-board be used with.Toe Sensors -- not utilized.Turntables -- the selection for standard mechanicaltypes or special optional electronic models.Printer -- selection for the type of printer used withthe Sun Aligner.



2a. Heads -- choose the measuring head configu-ration for the Sun Aligner model being setup. The SunAdvanced Aligner is equipped with 4 Optical headswith 8 Toe Sensors. The 8 Toe Sensor heads (beamsgoing front/rear, across front, and across rear) offeradditional measurement capabilities and the ability tocheck calibration with every alignment.

When using 4 heads the Sun Aligner can performeither centerline, thrust, or complete 4 wheel align-ments. The 2 head setup can be used to perform fronttotal toe settings, which may be useful on larger trucksor long wheelbas vehicles.

2b. Keyboard -- the Sun Aligner software supportskeyboards designed for a variety of language appli-cations. If such a keyboard is used, this is the placeto go to change the configuration. Select the properkeyboard using the up/down arrow keys to scroll, thenpress Enter once the desired selection is checked.

2c. Turntables -- from the System ConfigurationMenu, place the highlight box over "Turntables" andpress Enter. Most units will operate with standardmechanical-type turntables used on the front of thealignment lift. Sun Electric also offers ElectronicTurntables to automate some measurements. Selec-tions are:

Standard turntables -- mechanical-type utilized onmost alignment lifts and racks (may be Sun Electricor another manufacturer).Electronic turntables -- sophisticated specializedturntables containing electronic components to addadditional capabilities.

Note: Do not select Electronic turntables unless liftis so equipped. Operational problems will be cre-ated if erroneously chosen.



2d. Printer Menu -- the Sun Aligner comesstandard with a dot matrix printer. From the SystemConfiguration Menu choose "Printer". At this point aPrinter Menu screen appears with two setup choices:

Paper type -- select the size of paper to be used inthe printer.Printer selection -- what type of printer drivers areto be used by the program to generate printouts.

2d-i. Paper Type Selection -- the Sun Alignersoftware supports two different paper standards.The 11" size is the standard for the United Statesand North America, while A4 paper is the standard inEurope and many other parts of the world. If incor-rectly set, paper feed length and printout marginswill be affected.

2d-ii. Printer Selection Menu -- the Sun Alignersupports either generic IBM or Epson 9-pin printeremulations plus the Epson 24-pin emulation forhigher resolution printing. Most commercially avail-able dot-matrix printers support one of these printerlanguages. If not, the printer will not function at all orwill print illegible information. Sun always suppliesa compatible printer with the optional printer kits.Select the proper printer based on the unit installedwith the Printer Package.



3. PersonalizeThe Personalize portion of the Setup Options allowsthe operator to tailor the alignment software programbased on personal preferences and the need toinclude specialized procedures.

The Personalize Menu choices are:Alignment order -- alters the order in which certainscreens appear during alignments.Skip allowed -- enables the operator to skip certainitems, or disables the ability to skip these items.Displays -- changes the look of some screens,includes volume and brightness controls.Alignment features -- select certain alignment rou-tines as in the path or on-demand.Alignment styles -- further selection of routines andother special items.Security -- used by Sun to upgrade future softwarereleases, update specifications, and enable certainsoftware options.

3a. Alignment Order -- Use the up/down arrowkeys to select the Alignment function to be changedand press Enter. The instructions at the bottom ofthe Menu say to enter a number (1-6) to designatethe order the items appear during alignments. Usethe arrow keys to scroll the number up or down ortype the desired number on the keyboard. PressEnter when satisfied with the selection. A soft-keyhas been provided to return the Sun Aligner back toits factory default settings. Press soft-key #1 on theremote or on the keyboard to perform this function.After all selections have been made, press Enter.

Note: Some items such as Runout, cannot beremoved from the alignment program. Also, someitems cannot be moved behind others.



3b. Skip Allowed -- this menu allows certainfunctions to be skipped during the alignment pro-gram sequence by pressing the "NO" button on theremote, head keypad, or keyboard. If Skip "NotAllowed" is enabled for any item, the equipmentoperator will not be allowed to bypass that step -- itmust be performed to allow progression of the align-ment program.

Note: Skipping runout, caster sweep, and head level(Surround Sensor models only) is primarily for theconvenience of Sun personnel. Skipping any ofthese items during actual wheel alignments mayresult in incorrect angle measurements and cus-tomer comebacks.

3b-i. Skip Runout -- this is a very important step togenerate accurate alignment readings and shouldnot be skipped for any reason. Recommended se-lection is "Not Allowed".

3b-ii. Skip Customer Info -- if an alignment is notgoing to be printed or stored in the Customer Data-base there is no point entering any information.Recommended selection is "Allowed".

3b-iii. Skip Inspections -- if an alignment is notgoing to be printed or stored in the Customer Data-base there is no point entering any inspection infor-mation. Recommended selection is "Allowed".

3b-iv. Skip Specifications -- if a quick check ofalignment readings is desired, it is best to use theQuick Readings mode, which does not require speci-fication entry. When performing the complete align-ment sequence specification comparison should beused. Recommended selection is "Not Allowed".

3b-v. Skip Caster -- even though many newervehicles do not offer caster adjustment with OEMmethods, it is recommended to measure caster onevery alignment as a diagnostic tool. In some casesit may be acceptable to bypass Caster. Recom-mended selection is "Allowed".



3c. Displays -- Choose Displays from the Custom-ize Interaction Menu. The choices are:

Cross values -- select whether to have Cross val-ues shown on the Front and Rear Readings screensColors -- choices are standard colors onlyLogo -- option which allows the choice of manycustom logos for the Logo screen. This selection ispassword protected -- for Sun Electric personnelonly.Dealer -- the number for the Sun Electric sales orservice representative can be put in for display onthe Logo screenVolume/Brightness -- adjusts aligner sound vol-ume and screen brightness using the soft-keys #2and #3. Test the sound using soft-key #1.

3c-i. Cross Values Selection -- cross values is thedifference between the left and right readings for thecaster and camber angles. These values are usefulfor diagnosing pull conditions, and on some vehiclesa maximum cross value is specified. We highlyrecommend displaying the cross values on screen.

3c-ii. Colors Selection -- the choices for colordisplays are standard colors only.

3c-iii. Dealer -- the Sun Dealer or Sun Servicephone number is entered here. Once entered, thatnumber is displayed on the Logo screen for easyreference.



3c-iv. Volume -- the volume of sounds used duringalignments to signal the operator at various times isadjusted up or down here. Use soft-keys 2 and 3 toadjust.

3c-v. Brightness -- the picture brightness on theCRT is adjustable to accommodate various lightingconditions or operator preferences. Use soft-keys 2and 3 to adjust up or down.

3d. Alignment Features -- from here, additionalsetup items include:

Shim types -- choose the brand of aftermarket rearshim utilized during the rear alignment process onmany front wheel drive cars.Diagnostics -- activates a built-in help system basedon vehicle drivability symptoms.Setback / Dimensions -- choose whether to havethis feature as a step in the alignment process or on-demand when needed.Calibration check -- utilized for setting pass/failcriteria when the 8 sensor system checks calibrationaccuracy on every alignment.

3d-i. Shim Manufacturer Selection -- used toselect a rear wheel alignment shim manufacturer.This enables a special program to determine thecorrect shim to use when aligning the rear wheels onmany front wheel drive vehicles. Any or all of thelisted manufacturers can used.

Note: Choosing more than one shim manufacturerwill slow down the shim calculation time. It is advis-able to select one primary and one secondary shimsupplier.



3d-ii. Diagnostics -- whenplaced in the "Automatic"mode, the Sun Aligner soft-ware examines the caster,camber, SAI, and toe read-ings and specifications duringthe alignment routine and dis-plays an analysis of typicaldriver symptoms or vehicleproblems. This does add addi-tional steps to the alignmentprocess. This same analysiscan be obtained for any ve-

hicle as desired by the operator when the choice of"By request only" is selected. See Page 64 for moredetails.

3d-iii. Setback/Dimensions-- this setup determineswhether the setback and ve-hicle dimension measurementare made automatically by theSun Aligner software as a partof the standard alignment rou-tine. Even if these measure-ments are not setup within thepath they can be selected dur-ing the alignment of any ve-hicle. See Page 86 for detailson how to measure these di-mensions.

3d-iv. Calibration check --the Sun Aligner its with 8 sen-sor toe system has the abilityto perform automatic calibra-tion checks with each align-ment performed and alert theoperator to an out-of -calibra-tion condition. Under the Cali-bration Check Menu is the"Threshold setting" which se-lects the point where a warn-ing message is displayed when

the unit moves out of calibration. The "Forcerecalibration if needed" option requires a passwordto enable.



3e. Alignment Styles -- additional alignmentprogramming setups under the Personalize Menu.Choices are:

Caster/Camber @ 0 toe -- some auto manufactur-ers specify caster and camber be measured witheach wheel straight ahead (zero toe).Thrust line alignment only -- this option allows thealigner operator to only perform 4 wheel or thrust linealignments.Specification selection method -- standard or Eu-ropean specifications.Printout type -- standard or European styles.All readings display position -- changes where inthe program the "All Readings" screen will appear.

3e-i. Caster/Camber @ Zero Toe -- this optionplaces additional steps in the alignment programthat forces caster and camber to be measures oneach side with the wheel pointed straight ahead.This procedure is recommended by several Euro-pean auto manufacturers (i.e. Mercedes Benz) asthe proper method of measuring these angles (seevehicle service manual). The recommended settingfor this option for most vehicles is "Off".

3e-ii. Thrust Line Alignment Only -- this itemgives the operator the ability to dictate which typesof wheel alignment selections are available duringthe alignment program. Selecting "Allow thrust orgeometric alignments" allows the operator to per-form 2 wheel, thrust, or 4 wheel alignments. Select-ing "Allow only thrust alignments" allows only thrustor 4 wheel alignments -- 2 wheel alignments cannotbe done.

The majority of vehicles today require complete 4wheel alignments in order to restore proper handlingand insure long tire life.



3e-iii. Specification SelectionMethod -- this option determinesthe format of the vehicle specifica-tion selection. The standard format,the default, uses the vehicle manu-facturer as a starting point for specselection.

3e-v. All Readings Display Posi-tion -- there are three different align-ment readings screens during thesoftware path -- Front, Rear, and AllReadings (front & rear on the samescreen). This selection allows theoperator to establish when the AllReadings screen will appear, eitherfirst before the front & rear meterscreens or last after the meterscreens.

Note: The recommended position for the AllReadings screen is before the meter screens.This allows the aligner to correctly save theinitial alignment readings for the printout andcustomer database features.



4. LanguageA variety of different languages may be available forthe Sun Aligner. Place the check box next to theselected Language on the SetupOptions Menu and press Enter.

The Language Menu gives the fol-lowing sub-menu selections:

Screen language -- choose the lan-guage all on-screen text will be dis-played.Print language -- choose the lan-guage all for all customer printouts.Spec database -- choose the ve-hicle specification database for thecountry the aligner is used.

4a. Language Selection -- At this time only Englishis supported. Should additional languages becomeavailable, to change the language displayed on thescreen or printout, select the desired item on theLanguage menu. Press the up/down arrow keys untilthe desired language is checked and press Enter. A"scroll bar" on the right side of the screen indicatesadditional choices are available on a second page.Use the arrow keys or "Page Forward" key to moveto page two. All screens will now be in the chosenlanguage. English is the first selection on the listshould it become necessary to change the unit backto the default setting.

4b. Spec Database -- the Sun Aligner CD-ROMsoftware contains wheel alignment specificationsfor the vehicles from many countries and markets.This setup options allows for changing the specdatabase to suit vehicles not con-tained within the standard NorthAmerican database.

Note: Some automotive marketsnot specifically identified on thisscreen have vehicles from a varietyof sources. It may be necessary tochange databases in order to locatespecifications on some vehicles.



5. Units of Measure -- there are many differentunits of measurement for wheel alignment anglesand dimensions depending on local practices, ve-hicle manufacturer requirements, or operator pref-erence. Choose Units of Measure from the SetupMenu to select the units of measure as needed.Once a prescribed unit of measure has been cho-sen, all readings and specifications will be stated inthose units.

Units of Measure Menu -- the choices are:

Toe units -- specify the units in which all toe anglemeasurements will be displayed.Angle units -- specify the units in which all angularmeasurements will be displayed (caster, camber,SAI, included angle, thrust angle, etc.).Linear units -- specify the units in which all linearmeasurements will be displayed (setback, vehicledimensions, etc.)Resolution -- specify what resolution all on-screendigital displays will have

5a. Toe Units Selection -- move the check boxnext to the toe units best suited to the operator'srequirements and press Enter. The choices are, withexamples:

Degrees, Decimal -- 0.5 degreesDegrees and Minutes -- 0' 30"Inch Fractional -- 1/4"Inch Decimal -- 0.25"mm, (14" rim) -- European metric display -- 20 mmmm, (28" tire) -- US metric display -- 20 mmInput tire diameter -- prior to bringing up toe speci-fications during the alignment program, the SunAligner will ask for the actual vehicle tire diameter.The toe specs and readings will then be calculatedbased on that input value.



5b. Angle Units Selection -- move the check boxnext to the angle units best suited to the operator'srequirements and press Enter. Thechoices are, with examples:

Degrees, Decimal -- 0.5 degreesDegrees and Minutes -- 0' 30"Degrees, Fractional -- 1/2 degree

All specifications, on screen read-ings, and printouts will be in thechosen units.

5c. Linear Units -- select the unitsfor any linear-based measurementsduring the alignment program.Choices are English "Inches" or met-ric "MM" millimeters.

5d. Resolution Selection -- usethe Resolution Menu to choose howdigital displays are to be read duringthe alignment program. Choices areNormal ( 0.10 degree or hundredthsof a degree) or High ( 0.01 degree ortenths of a degree) resolution. Re-gardless of choice it won't effect theaccuracy of the Sun Aligner.

The selection will effect the wayAlignment readings are viewed. Ad-justments using a 0.1 degree reso-lution will be easier to obtain thanwhen using the 0.01 degree setting.Aligning the car to within a hundredsof a degree requires a greater de-gree of precision to obtain exactreadings.



6. Date / Clock -- The last item on the Setup Menusets the Date and Clock and the desired format fordisplaying them. The Sun Aligner contains an inter-nal clock, but it may be necessary to reset the clockafter time zone changes or if the computer has beenreset for some reason. From the Setup Menu, placethe highlight bar around the "Date / Clock" item andpress Enter.

Date / Clock Menu -- the choices are:

Set clock -- set the month, day, year, hour, andminute. Adjust the clock using soft-keys #2 [-] toadjust the time backwards and #3 [+] to advance thetime. Use the up/down arrow keys to highlight eachitem.Time format -- choose 24 hour or AM/PMDate format -- choose the desired style for the dateDate order -- choose the order in which the day,month, and year appear when the date is displayed.

6a. Set Clock -- as time changes occur or thesystem loses its date setting, it can be reset here.Use the up/down arrow keys to place a box aroundthe desired change item and use soft-keys 2 and 3to change as needed. Once set, the system retainsthe correct date and time, even when power is turnedoff.



6b. Time Format -- allows the system clock todisplay in the AM/PM format or 24hour military style.

6c. Date Format -- changes the format in which theday, month, and year are displayed.

6c. Date Order -- changes the order in which theday, month, and year are displayed.

This completes the customizing ofthe Sun Aligner. Going through theSetup is an excellent way to see howeasy it is to navigate the software.Everything needed to operate thealigner is either on the menu or afurther explanation can be accessedwith the use of the Help Key. Nowthat the Sun Aligner is setup andready to operate, proceed to theOperation portion of this manual tolearn how to complete a wheel align-ment using the many powerful andeasy to use software features.


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Operation Instructions


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Advanced PC Aligner Owner's ManualOperation Instructions

Contents -- Operation Instructions

Introduction ................................................................................................................... 61Steps to a 4 Wheel Alignment .................................................................................... 63Attach Wheel Clamps................................................................................................... 64

Performing a Wheel Alignment .................................................................................. 65Main Menu -- Align Vehicle ...................................................................................... 65Clear Aligner Menu .................................................................................................. 65Alignment Menu ....................................................................................................... 65Customer Menu ........................................................................................................ 66Customer Data ......................................................................................................... 66Vehicle Manufacturers ............................................................................................. 67Vehicle Year and Model ........................................................................................... 67Custom Specifications ............................................................................................. 67Vehicle Specifications .............................................................................................. 68

Illustrate Adjustment .......................................................................................... 68Edit ..................................................................................................................... 68

Inspection Menu ....................................................................................................... 69Pre-Alignment Inspection .................................................................................. 69Tire Inspection ................................................................................................... 69Brake Inspection ................................................................................................ 70Under Car Inspection ........................................................................................ 70Under Hood Inspection ...................................................................................... 70Courtesy Inspection ........................................................................................... 71

Runout Compensation ............................................................................................. 72Measuring Caster ..................................................................................................... 74

Automatic or Manual ......................................................................................... 74Advanced Diagnostics ............................................................................................. 76

Bent Parts .......................................................................................................... 76Rear Readings ......................................................................................................... 77

Cross Value / Total Toe .................................................................................... 77Soft-Keys ........................................................................................................... 77Zoom .................................................................................................................. 78

Front Readings ......................................................................................................... 79Soft-Keys ........................................................................................................... 79Front Angle Adjustments ................................................................................... 79Adjustment Illustrations ..................................................................................... 80Animated Graphics ............................................................................................ 80Zoom .................................................................................................................. 80

All Readings ............................................................................................................. 81Problem Icons .......................................................................................................... 81

Measuring Other Angles ............................................................................................. 82Caster / SAI Menu .................................................................................................... 82Measuring SAI & Included Angle ............................................................................ 83Steering Angles Menu ............................................................................................. 84

Toe Out on Turns .............................................................................................. 84Maximum Turns ................................................................................................. 85Toe Curve Change ............................................................................................ 854 Wheel Steering ............................................................................................... 85

Setback / Vehicle Dimensions ................................................................................. 86



Adjustment Assistant .................................................................................................. 87A-Arm Adjust ............................................................................................................ 87Adjust Caster / Camber Menu ................................................................................. 88

Live Caster and Camber ................................................................................... 88Elevated Camber ............................................................................................... 88

Total Toe (Drag Link) ............................................................................................... 89Shim Adjustment ...................................................................................................... 89Shim Information ...................................................................................................... 90EZ Shim .................................................................................................................... 90Cradle Adjust ............................................................................................................ 91EZ Toe ...................................................................................................................... 92

Driver Complaints Menu .............................................................................................. 93Advanced Diagnostics ............................................................................................. 93Pull ............................................................................................................................ 93Unlevel Steering ....................................................................................................... 94Vibration Diagnostics ............................................................................................... 94Treadwear ................................................................................................................ 95

Printer Menu .................................................................................................................. 95

Glossary of Alignment Terms..................................................................................... 96



Introduction

The Sun Aligner assists the automotive techni-cian through all aspects of the wheel alignmentfrom gathering of customer information, per-forming vehicle inspections, measuring the im-portant wheel alignment angles, and assistingwith vehicle adjustments if necessary to correctany out of specification conditions.

The Sun Aligner software is "menu driven",meaning that each screen contains severaloptions or selections to choose from. In mostcases the instructions on screen will describewhat actions to take next. Follow these instruc-tions carefully to insure good results.

The following pages outline the steps to per-form a complete wheel alignment. The firstportion details the "programmed steps" to gatherall necessary alignment readings. These stepsare consistent with accepted wheel alignmentpractices in the industry. In some cases thesesteps can be eliminated or skipped in order tospeed up the gathering of alignment readings(see Setup options in section 2).

The second portion describes the many fea-tures designed to assist the technician withdiagnosing and correcting any vehicle align-ment problems. If at any time there is a ques-tion during the alignment process, press theHelp key to access the operator help screens.


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There are many reasons why a wheel alignment maybe performed on a vehicle such as:

Accelerated or uneven tire wearPulls, wandering, or other steering or

handling problemsReplacement of worn suspension or

steering system componentsAfter collision repairs

Routine vehicle maintenance

Regardless of the reasons for alignment, it is impor-tant that the technician perform the steps necessaryto address and correct all problems.

1. Gather information from the vehicle owner --ask about any drivability problems that may besymptoms of misalignment. Inquire if the vehiclehas been in a collision or has had any recent partsreplaced.

2. Perform a test drive to verify owner's complaint-- try to recreate the problem. If unable to duplicate,have the vehicle owner explain further or have him/her drive with you.

3. Inspect the tires for any signs of abnormal wear-- the tires usually reflect any misalignment condi-tions.

4. Perform a thorough inspection of suspensionand steering system components -- many misalign-ment problems are created by worn or damagedcomponents. Replace and defective parts prior toeprforming the alignment. Always check tire pres-sure and ride height. Refer to manufacturer recom-mendations and tolerances when checking suspen-sion and steering systems.

5. Make sure the wheel alignment equipment isaccurate -- periodic maintenance of alignment equip-ment is essential -- regular instrumentation calibra-tion, a level lift surface, free moving turntables andrear slip plates, etc.

6. Place vehicle on the alignment lift -- center thevehicle on the lift and turntables. Place the lift at asolid, level position.

7. Choose the proper alignment type for the vehicle-- the best alignment for the majority of vehicles is a4 wheel alignment.

Steps To Performing A Quality 4 Wheel Alignment

8. Perform runout compensation -- the purpose ofperforming runout is to eliminate any measurementerrors due to the wheel and clamp mounting. Takethe time necessary to perform runout correctly.

9. Measure caster, camber, and toe -- follow theprocedures on the screen carefully. Refer toOperator's Manuals for further instructions.

10. Determine what needs to be done -- study themeasured angles for the front and rear prior toperforming corrections to match misalignment withany symptoms discovered earlier. If necessary, usethe Sun Aligner's advanced functions to diagnosefurther problems (such as SAI / Inculded Angle, Toeout on Turns, Toe Curve Change, etc.). Examine thevehicle and any reference materials to determine theprocedures for angle corrections. Determine whatitems are needed to correct any problems (i.e. after-market kits, special tools, etc.).

11. Make any needed angle corrections -- center thesteering wheel carefully before adjusting toe. If thefront total toe is beyond 1/2o (1/4") in or out, firstadjust the front toe to zero. Then, use this order ofadjustment:

a. Rear camberb. Rear toec. Front casterd. Front cambere. Front toe

Use the many adjustment assistant features builtinto the Sun Aligner to aid with proper angle correc-tion. After performing any caster adjustments,remeasure using the 20o sweep to verify the results.

12. Recenter the steering wheel and readjust fronttoe if needed -- crooked steering wheels are theleading cause of customer dissatisfaction with wheelalignments. This simple step will minimize the num-ber of comebacks.

13. Print the results -- the printout is useful forshowing the customer before and after results. Manyshops keep a printout on file for future reference.

14. Perform a test drive to verify proper alignmentHave all the owner's drivability complaints beensolved? Does the vehicle drive straight? Is the steer-ing wheel straight? If necessary, bring the vehicleback on the alignment lift to correct any issues.



Attach Wheel Clamps/Measuring Heads

Prior to beginning an alignment, attach each wheel clamp/head assembly to a vehicle wheel. The heads withthe extended booms are placed on the front wheel with the booms pointing forward. Note there are severalways the wheel clamps can be attached to accommodate various wheel configurations.

.

Option 1This option is used on many standard stamped steel rims. Use the knifeedge as shown. Apply pressure to secure the clamp from the inside out byturning the lock knob several turns clockwise.

Option 2This option is used on many custom rims with painted or polished surfacesthat need extra care. Set the rubberized surface inside the wheel rim asshown. Apply pressure to secure the clamp from the inside out by turningthe lock knob several turns clockwise.

Option 3This option is used on many standard and custom rims with no inside beadsurface. Use the adapters supplied with the wheel clamp to insert betweenthe wheel tire and the outside edge of the rim. Secure the clamp by turningthe lock knob several turns counter clockwise.

Option 4This option is used on many standard and custom rims as above with lowprofile tires where a thin adapter is required between the wheels tire andrim. Use as option 3.

Option 5This option is used on some standard and custom rims with no opportunityto clamp from the outside in and very narrow edges on the wheel rim. Clampfrom the inside out. Use as option 1.

NOTE: Always secure the wheel clamps using the supplied safetystraps onto each wheel to insure the head does not fall off the vehicle.

An optional Dual Wheel Offset Adapter is available for some pickups, motor homes and larger trucks toaccommodate the difference in track width in the rear due to the dual wheel configuration. To use this adapter,remove the head assembly from the wheel clamp shaft. Place the Offset Adapter on the clamp shaft andtighten the locking knob. Place the head on the adapter shaft, tighten the knob, and mount the clamp usingone of the methods above.



Performing a Wheel Alignment

Step 1. Main Menu -- Align VehiclePerforming a wheel alignment begins at the SunAligner Main Menu screen. Place the highlight boxaround "Align Vehicle" and press Enter.

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TIP: The fastest way to see live readings on avehicle is by pressing soft-key #3, "Readings", onthe Main Menu screen. This will proceed directly torunout compensation and then directly to "All Read-ings" and display camber, toe, and thrust angle.There is no vehicle or customer information when

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Readings is used.

Step 2. Clear Aligner MenuThis menu gives the choice to start a new alignmentor continue with an alignment already in progress. If"Begin new alignment (RESET)” is selected thecomputer memory of the previous alignment is erasedallowing a new customer and vehicle to be setup.

If "Continue current alignment" is selected, all cus-tomer, vehicle, and alignment measurements areretained and the software returns to the alignmentreadings screens.

Step 3. Alignment MenuThis menu is where the type of alignment is selected.The choices are:

Complete 4 wheel (thrust line) -- this type ofalignment measures all angles on all 4 wheels andis preferred for most vehicles.Front only -- uses 4 heads but does not measurerear wheel or thrust angles, creating the possibilityof a crooked steering wheel.Quick readings -- goes to a sub-menu for selectionof front, rear or all readings and eliminates all pre-alignment setup steps.Driver complaints -- a symptom-based trouble-shooting program as an aid to diagnosing drivabilityproblems.



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TIP: Even if the customer is paying for a "FrontWheel Alignment" only, go ahead and measure theangles for all four wheels. It may reveal a problemin the rear that can be pointed out and sold, andprovides the opportunity to get a straight steering

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wheel.

Step 4. Customer MenuThis menu gives the choice of setting up all newinformation for a new customer or utilizing a previ-ously setup customer that is stored in the aligner'sdatabase. To use the customer database software,refer to Section 5 "Customer Database" of thismanual. Also, the option to continue the previousalignment is given here.

Step 5. Customer DataSince the Sun Aligner is equipped with the printerpackage and Customer Database, this screen ap-pears next. It allows entry of all pertinent data aboutthe customer and his vehicle. With the databasesoftware all this information can be saved for laterrecall. For the customer printout, only the fieldshighlighted in red are printed, so it is not necessaryto enter the other information unless the informationis to be saved in the Customer Database. Soft-keys#1 and #3 are used with the database feature, while#2 allows any typed information on-screen to becleared. Once completed with this screen, presssoft-key #4 to continue.

Not Saved:When using a Sun Aligner Customer Database, thismessage appears when a new alignment is selectedand the current work has not been saved. Theselections are to "Save" soft-key #1 or to "Discard"soft-key #2. Saving will secure the information intothe disk database. Pressing discard will erase allprevious alignment information in the system.

Performing a Wheel Alignment ... continued




Step 6. Vehicle ManufacturersThis screen shows the vehicle manufacturers in theSun Aligner specification database. Move the selec-tion bar up, down or sideways with the arrow direc-tion keys to select the manufacturer and press the“Enter” key. The vertical bar on the right indicatesthere are additional choices on a second screen.Use the "Page Down" key on the keyboard or use thedown arrow key on any keypad to scroll past the lastentry on this screen. Selecting soft-key #1 accesses"custom" specifications setup by the technician forvehicles not in the database. Selecting soft-key #2allows access to "floppy stored custom" specs (op-tional). Soft-key #4 continues past this screen with-out any entry.

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TIP: To move to the manufacturer selection quicker,using the press the first letter of the company name.This causes the selection bar to move directly to thefirst name starting with that letter (i.e. press "H" -

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moves to Honda).

Step 7. Vehicle Year and ModelSelect the vehicle year of manufacture using soft-keys #2 and #3 to move up or down to the desiredselection, then press the Enter key. Pressing the Upor Down arrow key on the keyboard also moves theyear choice. Find the model listed on the screen andpress Enter.

Custom Specifications -- alignment specifica-tions that have been added by the operator willreside in a special database. To retrieve thesespecifications go to the Vehicle Manufacturers se-lection screen and press soft-key #1 “Custom”. Anew set of custom specifications can be added to thecustom database from this screen and also by edit-ing standard manufacturers specifications.



Step 9. Vehicle SpecificationsThis screen displays the Year, Manufacturer, andModel of the selected vehicle with Minimum, Pre-ferred and Maximum specifications for the front andrear wheels. Dashes in any position indicate thereare no manufacturer specifications for that wheel orangle. For angles not displayed on this screen, referto the specification book included in the literaturepackage of the Sun Aligner. Soft-key #2 allows thetechnician to view an illustration of the vehicle'salignment angle correction method, while #3 allowsediting of the specifications prior to beginning themeasurements.

Illustrate Adjustment -- illustrations of adjustmentpossibilities can be viewed by pressing soft-key #2.Text describes the adjustment procedures. If morethan one picture is available (separate camber,caster and toe adjustments) the Enter key is used tomove forward through the illustrations. To moveback press the "Page Back" key, and to leave theillustrations at any time use the "NO" key found onany keypad. Once an illustration is displayed, soft-key #2 will bring up a computer animated sequencethat shows movement of the parts and suspension tobetter illustrate the alignment adjustment.

Edit -- it is possible to modify or edit specificationsby pressing the Edit soft-key #3. A selection box willappear on the first specification value. Using theappropriate + or - soft-keys, change the value untilthe desired specification is displayed. Move to anyadditional values to be modified. After editing iscomplete, these specs can be to saved as Customspecifications or utilized for only the current align-ment. The vehicle specifications can be restored tooriginal by pressing the soft-key #1 if they are editedby mistake. The continue soft-key will advance tothe programmed next step.

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TIP: Creating Custom Specifications -- OEM align-ment specifications can change or may not be opti-mal for certain vehicles based on your experience.Creating a custom entry for popular vehicles will

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save time when they come back for alignment.





Step 10. Inspection MenuThe Inspection Menu contains six choices of vehicleinspection lists. These lists allow the alignment tech-nician to perform and print the necessary pre-align-ment checks. Select the appropriate list using thedirectional control keys to move the selection box.Press “Enter” and the list will appear. If none of theinspections are to be performed use soft-key #4continue to advance in the program.

These inspection reports are a valuable tool foralignment specific or non-related reporting of ve-hicle problem areas. These reports can be retainedfor shop files or given to the customer as a servicesales tool to reinforce his comprehension of the workperformed, or the work necessary before an align-ment can be performed. In many cases worn ordamaged components will affect the quality of thewheel alignment.

Pre-alignment Inspection -- as an example, toenter information about the vehicle's suspensionsystem, use the appropriate soft-key to indicatecheck soft-key #1, service soft-key #2 or replacesoft-key #3 for each item on the list. Soft-key #4blank is used to “skip” an item if it doesn’t exist onthe vehicle. The vertical bar on the right indicatesthere are additional items on a second page. Aprintout of the inspection results can be obtained bypressing the “Print” soft-key. Only the inspectionlists selected and completed are included in the finalinspection list printout.

Tire Inspection -- the tire inspection contains aseries of checks for wear or damage. Tire problemsare usually a good indicator of alignment and main-tenance problems. Look for excessive wear or un-usual wear patterns. Complete the list for eachindividual tire then use the appropriate soft-key tomove on to the next tire. Advance the program at anytime using the #4 continue soft-key. Tire pressureand size can be entered for each tire, by the consolekeyboard.




Brake Inspection -- the Brake Inspection listcontains a series of items to check for wear ordamage. Use the appropriate soft-key to indicatecheck, service, or replace for each item on the list.Soft-key #4 is used to “skip” an item if it doesn’t existon the vehicle. The vertical bar on the right indicatesthere are additional items on a second page.

Under Car Inspection -- an under car inspectioncan offer many opportunities for the technician tofurther his services to the customer. Mufflers, cata-lytic convertors, U-joints, and transmission mountsare a few of many items under the vehicle that can beinspected and reported to the customer.

Under Hood Inspection -- an additional area to beconsidered is under the hood. A thorough vehicleinspection is a service to the customer to insurereliable and safe operation while giving the opportu-nity to generate additional revenues to the repairshop.




Courtesy Inspection -- this inspection menu al-lows non-alignment and safety related items to beinspected as a courtesy to the vehicle's owner.Some of the items included are fuses, seat belts,jacks, mirrors, etc.



1

3

Runoutkey

2

Step 11. Runout CompensationCompensating for the amount of runout of vehiclewheel assemblies is an important factor in the align-ment process. If not correctly determined, there willbe errors in the displayed camber and toe angles.Sun utilizes a runout procedure that calculates a trueplane on the wheel assembly by measuring varia-tions in toe and camber planes during a 360 degree

rotation of the wheel.

Attach each wheel clamp/head assembly to a vehiclewheel; the heads with theextended booms are placedon the front wheel with thebooms pointing forward.

Runout Procedure

To wheel perform runout raise the vehicle wheels offthe alignment rack surface using air jacks or othermethod to allow the wheels to rotate freely. Followsteps 1 through 3 carefully.

After the first time the runout button is pressed a lightwill appear on the "Runout" key on the head, indicat-ing the Acraliner is in the runout mode. As the runoutkey is pressed at position 2, the light will blink. Atposition 3 the light will blink and then go off, indicat-ing the runout process is complete for that wheel. Ifthe runout indicator light does not go out after step 3something has gone wrong. Press the runout keyuntil the light goes out, then repeat the complete 1-2-3 runout steps for that wheel.

The computer screen on the will indicate the statusof the wheel runout. Repeat these steps for allwheels.

2. Turn the wheel until the stamped-in number "2"is showing on the wheel-clamp center slide (180deg). Hold the wheel assembly here and pressthe "Runout" key on the head keypad.

1. As indicated on the drawing above , turn thewheel until the stamped-in number "1" is show-ing on the wheel-clamp center slide. Hold thewheel assembly here and press the "Runout"key on the head keypad.

3. Turn the wheel until the stamped-in number "3"is showing on the wheel-clamp center slide (90deg). Hold the wheel assembly here and pressthe "Runout" key on the head keypad.




The Runout Compensation screen shows each wheelof the vehicle. As runout is successfully completedeach wheel to a green color. If a moderate amountof wheel runout is detected, but not enough toinfluence the alignment results, a "Marginal Runout"message will appear and the wheel will turn yellow.It is acceptable to continue at this point. If an highamount runout is detected an "Excessive Runout"message will appear on-screen and the wheel willturn red. This problem must be corrected prior toproceeding. Excessive runout can be caused byincorrect wheel clamp mounting, a bent clamp, abent or loose wheel, or a problem inside the measur-ing head. Once runout is completed on all wheels,lower the vehicle and press "Enter". Soft-key #2provides text and visual instructions for the runoutprocedure.

Here are some important notes regarding runout compensation on the Sun Aligner:

> If two heads has been selected in the aligner Setup only two wheels will be shown.> Runout can be completed or updated at any time and from any screen in the aligner. It is not necessary

to start over if runout needs to be taken again. Any time a wheel is removed from the vehicle, or the clampis removed from the wheel, runout compensation must be repeated on that wheel only.

> The wheel clamp must remain in the straight up position (#3) at the end of the runout procedure. Do notrotate the clamp away from straight up for any reason. Be careful of many rear wheel and 4 wheel driveaxles where turning one raised wheel causes another to move.

> It is not possible to "fake" runout compensation. An "Invalid!" display on the screen means a wheel hasnot been properly compensated.

> Do not skip or shortcut the runout compensation process in any way. It is an important part of obtainingaccurate alignment angles.

After runout compensation is completed the aligner is ready to measure the vehicle's wheel alignment angles,beginning with caster.




The "Loss of Communication" icon will appear on-screen when a head interconnect cable is discon-nected or a head loses communication with the maincomputer. This situation can occur at any timeduring the alignment program and must be correctedprior to proceeding. Runout values are retained andaccurate readings are restored as soon as validcommunications is established.

Step 12. Measure CasterThe caster angle is measured by sweeping througha 20 degree turn of the front wheels. The softwareguides the operator through the steps on-screen.The caster sweep screens show a graphic of thewheels with the direction they should point, an arrowto indicate the turn direction, and a "stop light" thatchanges from green to red, with yellow in the middle,as the turning angle is reached. Always follow thearrow direction and hold the wheel steady until thewheel turns green and the screen advances.

Steer Straight Ahead -- if the front wheels are notfacing straight ahead, the first step of the castersweep directs them properly.

Automatic or Manual Caster Sweep -- the Auto-matic or the Manual caster sweep mode can beselected anytime during the caster swing procedureby pressing the soft-key #1. The mode presentlyselected will be indicated in the top center of thedisplay. The Automatic mode utilizes the opticalsensors to obtain the 10 degree turning angles andautomatically progresses in the program when thisangle is obtained. The Manual mode utilizes theturntable scales to indicate the appropriate 10 de-gree turn and the "Enter" button has to be pressed toprogress in the program.

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TIP: Most vehicles step through the automaticcaster swing mode without a hitch. If a problem isexperienced, try switching to the manual mode -there is no difference in accuracy. Also, even if thealigner toe system is out of service the 100 turn point

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can be obtained from the rack turntables.




Turn 10 Degrees Left -- after starting out with thefront wheels facing straight ahead, the screen willchange to indicate a turn to 10 degrees left. As theturning angle nears 10 degrees the "stop light" willchange from green to yellow. When the wheelsreach exactly 10 degrees the "stop light" indicatorwill change to red and the wheel graphic will changeto green, meaning the measurement has been taken.

Turn 10 Degrees Right -- the screen will change toindicate a turn past straight ahead to 10 degreesright. The "stop light" will behave as above as the 10degree angle is approached. The wheel graphicswill change to green as the measurement is taken.

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TIP: Improving caster measurement accuracy:> Operator variations during sweep -- somecommon things are pulling/pushing the wheel differ-ently and failure to reach the 10 degree mark exactlyand hold steady until the measurement is taken.Some of these variations can be minimized by utiliz-ing a brake pedal depressor during the caster sweepto ensure the wheels do not roll or rock during theturns. In addition, utilizing the steering wheel tomake the turns will take the operators hands andarms away from the measurement process.> Vehicle suspension / steering variations -- if thevehicle has play or looseness in suspension and/orsteering components, this can affect the reactionand tilt of the wheel during turns.> Turntable / Rack condition -- the condition ofthe turntables is critical. They must be free movingand flat with all bearing in place. Also, the vehiclewheels must be positioned in the center of the

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turntables to ensure flatness during the turn.

Steer Straight Ahead -- after the caster angle ismeasured through sweeping the wheels, it is neces-sary to return to a straight ahead position for mea-suring the camber and toe angles. Follow the arrowdirection until the "stop light" indicators and thereverse colors changing of the wheels graphic indi-cates the wheels are pointing straight ahead.




Advanced DiagnosticsAdvanced diagnostics is a troubleshooting tool thattakes the alignment measurements, compares themto manufacturers specification, and describes po-tential vehicle problems. The alignment computersamples all the readings and makes a conclusion ofa potential problem. This diagnostic screen for thefront and rear of the vehicle can be accessed bypressing soft-key #4 "Complaint" on any readingsscreen and the "Advanced diagnostics" from theDriver Complaint Menu. Press Enter to move throughthe diagnostics functions for the front and rear of thevehicle. If desired, Advanced Diagnostics can be-come part of the "alignment path" by using theproper Setup options (see Page 44).

Bent PartsThe suspension angles SAI, Included Angle, andcamber have been used for years to diagnose bentparts. These angles were manually charted on pa-per with the technician making the conclusion basedon his measurements. This technique has beenincorporated into the Sun Aligner to utilize the powerof the computer system. Angles are measured andcompared with vehicle specifications to determine ifa problem exists. An on-screen readout informs thetechnician which components is most likely bent ordamaged. While in the "Advanced diagnostics" sec-tion of the Driver Complaint Menu, keep pressingEnter to view the Bent Parts display for the left andthe right sides.

NOTE: Operator must perform an SAI/caster swingand specifications must be entered before an evalu-ation can be made. If these Advanced Diagnosticsscreens are made part of the alignment path, it isrecommended to configure the "Alignment Order" tomeasure Caster/SAI simultaneously instead of casteronly. See Page 44 for details setup details.




Step 13. Rear ReadingsAfter the caster sweep procedure is completed, theRear Readings screen appears. This screen dis-plays, both in meter and numerical format, the anglemeasurements and information needed to deter-mine if corrections are necessary. The display isdivided into three rows: Camber, Toe and ThrustAngle. The columns represent the left and right sideof the vehicle. The Camber and Toe meters haveminimum, preferred, and maximum specificationsalong the top, a digital readout of live readings, anda color coding to indicate the relationship of livevalues to specification. Gray meters indicate nospecification has been entered for this angle. Redmeters indicate the angle is beyond manufacturer'sspecification. Green meters indicate the live valuesare within the specification.

Cross Value / Total Toe -- the digital readout inbetween the camber meters indicates cross values(side-to-side), the difference between left andright readings. This cross value is importanton many vehicles for proper handling. Thedigital readout between the left and right toemeters indicates the Rear Total Toe (the sumof individual toe).

Soft-keys -- two sets of soft-keys are avail-able on the Rear and Front Readings screens.These keys can be toggled by using the “ ”key.

#1 Measure - menu for measuring additionalangles#2 Illustrate - to assist the technician, anillustration of each angle adjustment is displayed#3 Adjust - accesses menus to assist the techni-cian with angle corrections#4 Zoom - brings a highlighted meter to full screen

Toggle #1 Print - accesses the print and save datamenuToggle #2 Edit - allows editing of specifications,customer information, and inspectionsToggle #3 Setup - allows alteration of any Setupitem during the alignment processToggle #4 Complaint - accesses the Driver Com-plaint menu for additional diagnostic help

Gray MeterNo Specs

Green MeterIn Specs

SpecificationsMin/Pref/Max

Toe Meters

Digital Reading

Thrust Angle

CamberMeters

Soft-Keys

CrossValues

Red MeterOut of Spec




Rear Readings Meter Displays -- the camber, toe,and thrust angle readings are “live” and can bereferenced while making adjustments on the ve-hicle. As the adjustment is made, the meter needlewill move and the digital readout will change. Adjustthe vehicle until the desired readings are obtained.As the readings move from out of specification towithin specification, the meter center color will changefrom red to green. Additional adjustment assistancefor many vehicles is obtained through the AdjustMenu (soft-key #3).

Zoom -- for easier viewing of any individual metermove the white highlight box to the desired meterwith the arrow keys, then press Zoom soft-key #4.The meter will occupy the whole screen. The zoomscreen contains the specifications and shows across value for reference to the other side. Whilezoomed, the arrow keys will navigate the other meterdisplays. Press Unzoom soft-key #4 to return to thecomplete Rear Readings screen.

After viewing the rear readings and, if necessary,making any angle corrections press "Enter" to moveto the Front Readings.

Step 14. Prepare for Front ReadingsBefore front readings are displayed it is necessarythe level the steering wheel and lock it in place usingthe steering wheel holder supplied with the SunAligner. In additional, all measuring heads must beleveled and locked in place. Once these steps arecompleted press Enter to move forward.




Step 15. Front Readings -- the look of the FrontReadings screen is similar to the rear. Measuredcaster is displayed with the top meters. Note thisreading is represented by an icon showing the casterreading to be frozen since caster is not a live read-ing. Camber meters are located in the middle of thescreen and toe meters are at the bottom. Camberand toe are “live” displays which can be referencedwhile making adjustments. The left wheel is repre-sented on the left meter and right wheel on the right.When measurements are within specification thecenter portion of the meter will turn green. If red isdisplayed the readings are outside of specifications.Cross values are displayed between the caster andcamber meters, while total toe is displayed betweenthe individual toe meters.

Soft-keys -- two sets of soft-keys are available onthe Rear and Front Readings screens. These keyscan be toggled by using the “ ” key.

#1 Measure - menu for measuring additionalangles#2 Illustrate - to assist the technician, an illustra-tion of each angle adjustment is displayed#3 Adjust - accesses menus to assist the tech-nician with angle corrections#4 Zoom - brings a highlighted meter to fullscreen

Toggle #1 Print - accesses the print and savedata menuToggle #2 Edit - allows editing of specifications,customer information, and inspectionsToggle #3 Setup - allows alteration of any Setupitem during the alignment processToggle #4 Complaint - accesses the DriverComplaint menu for additional diagnostic help

Front Angle Adjustments -- the Camber and Toeangle values displayed on the meters are live andcan be viewed while making corrections on thevehicle. Caster is a "frozen" value. For assistancewith caster adjustments, along with other functionsthat make camber easier on many vehicles, presssoft-key #3 Adjust. The Adjust Menu is covered indetail on Page 85.

Cross ValueL/R Difference

Red MeterOut of Specs

Caster Meters

Camber Meters

Toe Meters

Soft-keys 1-4

Total ToeGreen MeterIn Specs

SpecificationsMin/Pref/Max




Adjustment Illustrations -- illustrations of angleadjustment possibilities can be viewed by pressingthe soft-key #2 Illustrate. If more than one picture isavailable (separate camber, caster and toe adjust-ments) the “Enter” key can be used to page throughthe illustrations. The "Page Back" key is used tomove backwards. If an illustration for a particularangle does not appear, it is likely the vehicle has noprovision for adjustment. To return to the readingsscreen continue to page back or press the "NO" keyon the head, remote, or keyboard.

The Adjustment Illustrations are a powerful tool toassist the alignment technician. In addition to thepicture, written instructions are provided plus infor-mation on any additional parts, special tools, ormodifications that may be required.

Animated Graphics -- use soft-key #2 Animationto view an animated version of the adjustment pro-cedure. This can be a further aide to understandingwhat needs to done on the vehicle to correct anyalignment angle. Press "Enter" to return to the illus-trations or wait until the animation stops and auto-matically returns you to the illustrations display.

Zoom -- for a zoom image of one meter move thehighlight box to the desired meter with the arrowkeys, then press soft-key #4 Zoom for a close uplook. Press #4 Unzoom to return to the full screendisplay.

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TIP: When adjusting the vehicle, particularly on therear, you can increase the size of the meter to fullscreen for easier viewing by pressing soft-key #4Zoom. Once any meter is zoomed, you can move toother meters using the up/down and left/right arrow

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keys.



Step 16. All ReadingsThis is a summary display that will show both therear and the front readings at the same time. Ifvehicle specifications have been entered the digitaldisplays will be red (out of specification) or green(within specification). In addition, this screen willshow, if measured, Included Angle, SAI, Toe Out onTurns, and Setback. Front and rear camber and toereadings are live from this screens. This display isone of the three "Readings" displays that are avail-able. These three displays will be in a "loop" at theend of the programmed alignment sequence. If the"Front Readings" are displayed the "Rear Readings"and "All Readings" can be displayed by pressing the"Enter" key. Available soft-keys are:

#1 Print -- when selected will display the print/savemenu#4 Vehicle Dimensions -- this is a feature onlyavailable with the 8 toe sensor model.

If measurements or adjustments have to be made,use the "Enter" key to go to either the front or the rearreadings display.

The icon in Figure 9 may appear on any of thereadings screens. This icon indicates the measuringhead is not communicating with the main computer.If this icon appears, check the cable connectionsand refer to the service guide section of this manual.

The icon in Figure 10 indicates a blockage of the toesignal on the optical measuring heads. Check forany item that may be obstructing the line of sightbetween all heads and refer to the service guidesection of this manual.

This completes the Programmed Alignment proce-dure to obtain all basic alignment readings.


Figure 9

Figure 10



Measuring Other Angles

Other Measurements MenuPress soft-key #1 Measure on the front or rearreadings screens for additional angle and diagnosticmeasurements. The choices are Caster / SAI, Steer-ing angles, and Setback / dimensions.

Caster / SAI Menu -- choices are:Caster only -- to repeat the caster sweep to obtaina new caster valueCaster and SAI on turntables -- allows measure-ment of caster and SAI in one sweepSAI only, elevated -- measures SAI with the vehiclewheels elevated

Steering Axis Inclination (SAI) and Included Angle(IA) -- these angles are powerful tools in diagnosingbent or damaged suspension parts. A bent spindle,control arm, strut, frame mounts, or a cradle shiftproblems can be identified. SAI is measured eithervehicle weight loaded on the turntables or with thefront wheels elevated. Included Angle is not actuallyan angle defined on the vehicle -- it is a mathematicalformula. By definition, IA = SAI + CAMBER. Mostlate model vehicles have a specification for IncludedAngle, and a few for SAI. Compare the measuredvalues to spec, but also compare side-to-side (cross)differences.

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TIP: Cross differences for Included Angle should notexceed 1 to 1.5 degrees for most vehicles. If a highcross value is discovered, it may be creating a pullcondition. Generally, the damaged part is on the side

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with the lower IA reading.




Measuring Steering Axis Inclination (SAI) andIncluded Angle -- the measurement method forSAI and Included Angle is similar to the Castermeasurement. The wheels are swung through a 20degree turn and the change in wheel tilt is measured.SAI can be measured either on the turntables or withthe front wheels elevated. For accurate results fol-low the on-screen instructions carefully.

SAI and Included Angle, Elevated

SAI / IA Display -- when SAI / Included Anglemeasurement is completed the results are displayedon the All Readings screen and are available forprintout. These angles are useful for diagnosingbent or damaged parts. The Sun Aligner CD-ROMcontains an Advanced Diagnostics feature that canassist with this diagnosis (see Page 76).

Caster, SAI, Included Angle on Turntables




Steering Angles Menu -- choices are:Toe out on turns -- used for diagnosing damagedsteering componentsMaximum turn angle -- used to measure and adjustmaximum turn on many vehiclesToe curve change -- used for diagnosis of steeringand suspension problems4 Wheel steering -- when a Honda or Mazda with 4wheel steering is selected this option outlines thesteps for proper alignment

Toe Out on Turns (or Turning Radius)Toe out on turns is another diagnostic measurementthat is valuable in troubleshooting a steering andhandling problems.

TOOT or Turning radius, as it is commonly called, isthe difference in the turning angle between theinside and the outside wheel.

TOOT is measured using the turntable scales of thealignment lift. On many vehicle, the manufacturerspecifies the inside wheel to be turned 20 degrees.Other vehicles specify the wheel be turned to adifferent angle, usually "full lock". This is possiblewith the Sun Aligner by selecting "Other turn" on themenu.

Note: the Sun Aligner vehicle database does notcontain specifications for toe out on turns. Refer toan alignment specification book or the vehicle'sshop manual.

The Toe Out On Turns measurement is not auto-matic. Using the turntable scales, identify the inside

wheel turn angle, then read the out-side wheel turn angle and enter theinformation into the computer. Forbest results follow the on-screenscarefully. TOOT results will appearon-screen and are available for print-out.

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TIP: Toe Out on Turns problemsalways indicate a bent or damagedsteering arm, with the problem wheelbeing the one on the outside of the

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turn.




Maximum Turns -- this programallows the measurement of the "fulllock" or maximum turn in each direc-tion. It uses the turntable scales andprovides the ability to enter the resultsin the computer for viewing and print-ing. Consult an alignment specifica-tion manual or shop service manualfor manufacturers procedures andspecifications.

Toe Curve Change -- this featureallows measurement of individualwheel toe change as the suspensionsystem goes through jounce and re-bound (spring compression and ex-pansion). An excessive amount of toechange can cause premature tirewear. A large change on only one sidecan cause "bump steer", a dangerouscondition causing the vehicle to rap-idly change directions when bumpsare encountered. While there are nospecifications for the amount ofchange, a comparison of left and rightwheels can assist in diagnosing de-fective steering system components.Follow the on-screen instructions carefully.

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TIP: On cars with rack and pinion steering, a bumpsteer condition is usually created by worn rackmounting bushings that allow the entire rack to shiftwhen bumps are hit. Some GM cars (80's Camaro& Firebird) have slotted idler arm mounts to allow

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correction of toe curve change problems.

4 Wheel Steering -- this feature provides help forwheel alignment on Honda and Mazda with the 4WSoption. If one of these vehicles is selected duringentry of specifications, this help screen will appearfollowing the caster sweep to insure proper proce-dures are followed.




Setback / Vehicle Dimensions -- setback occurswhen one wheel on an axle is not even with the other.Setback problems are mostly associated with ve-hicles involved in collisions.

Setback can be measured on either the front orrear of the vehicle. On-screen instructions mustbe followed carefully. Rear setback measure-ment is automatic with the Vehicle Dimension-ing feature.

The results of setback measurements are displayedonly on the All Readings screen and are printedduring the alignment results printout. With the 8 ToeSensor models, setback is displayed on the vehicledimensions screen which also shows wheelbaseand track width dimensions. Setback can be dis-played in inches or millimeters, selectable in theUnits of Measure setup.

Front Setback



Adjustment Assistant

Adjustment Assistant Menu -- access this menufrom the front or rear readings screen by pressingsoft-key #3. There are numerous features designedto improve the efficiency and effective of the align-ment technician in performing vehicle adjustments.Menu choices are:A-Arms -- for vehicles whose caster and camberadjustments are located on the suspension A-Arm,this selection allows both angles to be correctedsimultaneously.Caster and/or camber -- several different optionsavailable to assist with these angles, including livecaster .Total toe (drag link) -- helps with vehicles having asingle toe adjuster.Shim information -- many front wheel drive carsuse a shim on the rear axle/spindle to adjust camberand/or toe. This program determines the propershim to use.Cradle adjustment -- assist with the adjustment ofthe engine cradle on many front wheel drive carsEZ Toe -- makes front toe adjustments and straightsteering wheel adjustments easier.

A-Arm Adjust -- many vehicles have adjustmentprovisions for caster and camber located on the

suspension A-Arm, either upper or lower. The ad-justments may be made with shims, eccentric cams,or slots in the frame. Both angles are easily cor-rected to specification using this screen. The firststep is telling the Sun Aligner the location of theadjustable A-Arm andwhether the correc-tions will be made onthe turntables or el-evated. Next, applythe brake pedal de-pressor (important)and follow the on-screen instructions.

Adjustment pointscan be on upper orlower control arm



Adjustment Assistant ... continued

Adjust Caster / Camber Menu -- this menucontains items to assist with angle adjustments onall types of vehicles. Choices are:Live Caster and camber -- this item can be used onthe turntables or elevated and gives live caster,camber add toe readingsCamber elevated -- usable on the front or rear, thisfunction retains the camber value after the wheelsare raised

Live Caster and Camber -- after selecting on turn-tables or elevated, a screen very similar to thestandard Front Readings display appears. The ma-jor difference is the caster reading - it is live insteadof frozen. Caster and camber can be adjusted whileviewing thisscreen, for ex-ample, casterchange wi l l beshown as a strutrod is lengthenedor shortened. Thetoe readingsshown are for ref-erence. Uponleaving this screen by pressing Enter, the standardFront Readings screen will reappear, allowing forthe final adjustment of front toe.

Elevated Camber -- for either the front or rearwheels, this feature allows thewheels to be elevated whileretaining the measured cam-ber values. This allows accu-rate correction of camber with-out vehicle weight inhibitingthe adjustment process. Thiswould be useful for tappingdown a wedge on a strut ve-hicle. The adjustment screenlooks very similar to the livecaster/camber screen above,with the exception of caster, which is frozen. Whencompleted with the adjustment, press Enter, andwhen the vehicle is lowered camber will be at speci-fication. Pressing the "Back Page" key from theAdjustment Assistant Menu will return to program tothe front or rear readings screen.



Total Toe (Drag Link) -- the steering linkage onsome trucks has a single total toe adjuster along witha drag link adjuster to correct the steering directionand straighten the steering wheel. This menu itemwill allow simple and accurate adjustments to bemade. From the Adjustment Assistant menu selectTotal toe (drag link). The technician will be promptedto choose adjust with the tie rod or the drag link byselecting soft-keys 1 or 2.

Follow the on-screen instructions. First, steer thefront wheels to equalize toe, press Enter. Next ad-just the single tie rod to specifications while observ-ing the meter, press Enter. Then, straighten and lockthe steering wheel and adjust the drag link sleeveuntil the steering direction is straight ahead, asindicated on the meter display.

Shim Adjustment -- many front wheel drive ve-hicles utilize aftermarket shims to correct rear cam-ber and/or toe. This correction is achieved by plac-ing the shim between the rear axle and the spindle.The Sun Aligner has several different aftermarketshim manufacturers available, each of which mustbe setup prior to use during the alignment program(see page 47). Consult the shim manufacturer'scatalog for detail application information.

When a vehicle that utilizes rear shims is accessedfrom the specification database the technician canuse the Sun Aligner to determine the proper shim tocorrect a rear misalignment. From the AdjustmentAssistant Menu choose "Shim Adjustment". Thechoices are then "Shim information" and "EZ Shim",a program which features the rotating, single adjust-ment shim manufactured by Specialty Products .


Total ToeAdjuster

Drag Link



Shim Information -- At this point the computer willexamine the live rear camber and toe readings,compare them to preferred specification, and calcu-late the amount of change needed. It will then recom-mend the shim needed to make this correction.

The first screen that appears is the "Rear ShimAdjustment Summary". All shim manufacturers thathave been selected in "Setup" are shown. The initialalignment reading, specification and the neededchange will be indicated along with the part numberof the shim. To view more information about place-ment of the shim, place the highlight box around thedesired manufacturer and press Enter.

The displays shown here are for Shimco andAlignTech. The screens show the part number, agraphical presentation of proper installation orienta-tion, and written instructions. After installation of theshims is completed press Enter, follow the instruc-tions, and press the "Back Page" key to move fromthe Adjustment Assistant Menu to the Rear Read-ings screen.

EZ Shim -- this program is designed by SpecialtyProducts Co. as an assistant to properly using in-stalling their EZ Shim rear camber/toe angle correc-tion product. The program automatically determineswhich one of the three colored shims is used for thevehicle, the amount of camber toe correction re-quired, and the proper indexing of the shim. Oncethe calculation is completed, a picture of the shim isdisplayed with instructions for installation. On-screeninstructions guide the operator through the steps.




Cradle Adjust -- cradle adjustment isa growing necessity for front manywheel drive vehicles. Many front wheeldrive vehicles are designed where theengine cradle also serves as the at-tachment point for the lower pivots ofthe suspension system. This assem-bly is bolted to the sub-frame as a unitfrom the bottom of the vehicle. Theassembly must be properly aligned withthe sub-frame to assure that front align-ment is maintained.

A closer look at the assembly will showthat the lower control arms are bolted tothe cradle assembly. The control arm isattached to the spindle through thelower ball joint. The strut or upper pivot

is attached to the upper end of the spindle and isattached to the upper body via the upper strut mountat the upper tower position to complete the suspen-sion steering axis.

The engine cradle can be moved side to side, chang-ing the camber and SAI angles. Prior to beginning acradle adjustment, examine the left and right cambervalues. If one side has excessive positive camberand the other side excessive negative, this vehicle isa candidate for cradle adjustment.

Vehicles with cradle adjustment potential include:Ford Taurus / Mercury Sable, Lincoln ContinentalGM "W" Body (Lumina, Grand Prix, Cutlass, Regal)Chrysler "LH" Body (Intrepid, Vision, Concorde, LHS)Honda Accord, Acura Intrepid

Consult the vehicle service manual for details onhow to loosen the engine cradle.

The Cradle Adjust screen has a graphic of the cradlewith an arrow showing the direction of needed move-ment. A meter display determines exact placement.In addition, a live caster reading is shown for refer-ence.

Camber- DecreasedSAI - IncreasedIncl'd Ang - Good

Camber- IncreasedSAI - DecreasedIncl'd Ang - Good

Cradle Shifted TowardRight Front





EZ Toe -- The EZ Toe software routine is a new and improvedmethod of setting front toe. The program calculates the amountof toe change needed on each wheel. When toe is corrected oneither wheel, the program only remembers the amount of changeneeded for that wheel (similar to the Elevated Camber adjustmentfunction), ignoring the current position of the wheel or the reactionof the opposite wheel. This allows accurate toe adjustment withthe wheels pointed in any direction (within the range of toe signals)without the use of a steering wheel holder. It is even possible tocorrect toe with the wheels turned to 10 degrees left or right, whichis helpful on cars with firewall-mounted center-point rack andpinion steering linkages. Because of the toe-change method, EZToe minimizes comebacks due to crooked steering wheels.

EZ Toe Procedure

1. Perform all alignment steps normally used to obtain alignmentreadings. Correct any misalignment in the rear as well as frontcaster and/or camber.

2. Select EZ Toe from the Adjust-ment Assistance Menu. Note: DONOT use the Steering Wheel Clampduring the EZ Toe procedure.

3. Level the vehicle steering wheeland the measuring heads. Press

Enter.

4. Steer the right wheel to adjust the position until the meter isin the green. Press Enter.

5. The next screen shows a meter indicating the amount of toechange needed for the right wheel.

6. Adjust the right tie rod until the meter needle is in the green.Press Enter after completion.

7. Follow the same procedures forthe left wheel.

8. Press Enter once the left toeadjustment is made.

9. Return to the Front Readingsscreen and recheck toe and steer-ing wheel position.



Other Soft-Key Features

Driver Complaints Menu -- this menu is accessedby toggling to the second set of soft-keys on eitherthe front or rear readings screens and pressing soft-key #4. It contains a series screens designed toassist the technician with diagnosing specificdrivability concerns. With the exception of "Advanceddiagnostic", a series of questions about the vehicle'sproblems or symptoms is presented. As the techni-cian follows the steps, suggestions are made onprobable causes. The following selections are avail-able:

Advanced diagnosticsPullUnlevel steeringVibrationTreadwear

Advanced Diagnostics -- this choice brings up aroutine that compares the measured angle readingsto specification. If out of specification, the programwill identify probable results due to misalignmentand, if SAI and Included Angle have been measured,may identify possible bent parts. See page 76 foradditional details.

Pull -- the program will ask a series of questionsregarding the vehicle pull. Select the most appropri-ate answer to move to the next test. The screen willagain ask for the most correct answer. Suggestionswill be made throughout the test to attempt to identifythe problem.




Vibration DiagnosticsThis diagnostic segment assists in locating andcorrecting vehicle vibration problems. The methodused attempts to isolate the cause of the vibration toone of three broad categories: Brakes, Engine (in-cluding drive train).

Unlevel Steering -- the program will ask a seriesof questions regarding the unlevel steering wheel.Select the most appropriate answer to move to thenext test. The screen will again ask for the mostcorrect answer. Suggestions will be made through-out the test to attempt to identify the problem.




Printer Menu -- use toggle soft-key #1 Print oneither the Front or Rear readings display to go to thePrinter Menu. The options are:Print alignment results -- prints only measuredalignment angles with specificationsPrint results (no specs) -- prints all measuredalignment angles without specificationsPrint inspection list -- prints only inspection liststhat have been filled out - no alignment angle resultsPrint all -- prints everything - alignment angles,specifications, inspection reportsSave current alignment -- usable only the Cus-tomer Database feature. Saving the alignment fromthis menu saves all alignment information to a com-puter disk. For more details, see section 5, Cus-tomer Database.

This completes the instructions on how to use the Sun Aligner software to perform a wheel alignment anddiagnose alignment related drivability problems. Keep this manual readily available as a reference whenquestions are encountered. For additional assistance, contact the local Sun Representative, or contact oneof the Sun locations worldwide using the information on the back page of this manual.

Treadwear -- there are many reasons that tireswear unevenly and wear out prematurely. Becausethe effects of having more than one problem canmake it difficult to exactly pinpoint the problem, thisguide will lead you through lists of possible causes.Use the up and down arrow keys and the "Enter" keyto select the most applicable categories or answers.



Glossary of Alignment Terms

* Ackerman Principle: An alignment principle based onvehicle tread width and wheelbase upon which turning angleis computed.* Active Suspension: A suspension system in which hydrau-lic actuators add force to the suspension system to allowcompression (Jounce) and extension (Rebound).* Alignment: The process of measuring and positioning allwheels attached to a common chassis.* Angle: Two intersecting lines that are not parallel.* Arc: Any part of a circle or a curved line.* Axial Play: Vertical movement of the wheel and tire assem-bly when inspecting a ball-joint.* Balance: This term is used to describe having equal weightdistribution about the circumference of a wheel and tireassembly.* Ball-Joint.: A chassis to knuckle connector consisting of aball and a socket. This configuration allows for simultaneousangular and rotating motion.* Bead: Steel wire forming an anchor for individual plies andrim attachment of a tire.* Bellows: a Rubber type seal which is folded to allow for atelescopic action. Normally referred to as a bellows boot.* Bias Belted: A tire construction type with overlapping pliesat 90 degrees with additional belts formed around the cir-cumference of the tire.* Bias Ply: The same type of construction is used on thisdesign as a bias belted, but without the reinforcement belt.* Body Roll: The leaning of the vehicle body while cornering.* Braking Control: Vehicle stability related to the reactionunder all stopping conditions.* Bump Steer: A directional change in steering caused byroad irregularities. As the suspension moves through jounceand rebound, changes in alignment at the front or rearwheels may alter the vehicle’s directed path.* Bushing: A component made of metal or rubber-typematerial, used to isolate interconnected moving parts.* Cam Bolt: A bolt and eccentric assembly which whenrotated will force components to change a position.* Camber: The inward or outward tilt of the wheel at the topand as viewed from the front.* Camber Roll: A change in camber brought about bysuspension changes while cornering.* Caster: The forward or rearward tilt of the steering axis atthe top and as viewed from the side.* Center Bolt: A bolt that provides centering and attachmentof an axle and spring assembly.* Centerline Steering: A centered steering wheel while thevehicle is traveling in a straight ahead course.* Chassis: All major assemblies on a vehicle includingsuspension, steering, drivetrain and frame; everything ex-cept the body.* Circumference: The total distance around a circle.* Coil Spring: Spring steel wire formed in the shape of a coil.* Compliance: The ability of an object to yield elasticallywhen a force is applied.* Concentric: Two or more components sharing a commoncenter.

* Conicity: The cone shape that a tire takes through itsnormal life when inflated and loaded.* Contact Area: The total amount of tread surface thatcontacts the road.* Control Arm: An arm that is used to attach a spindle or axleto the chassis.* Cornering: The ease at which the vehicle travels a curvedpath.* Cradle: The framework of a front wheel drive vehicle thatprovides the engine mounts as well as front suspension pivotpoints for many vehicles.* Curb Weight: The overall weight of a vehicle less passen-gers, luggage, or load.* Degree: A unit of measurement to describe an angle.* Dial Indicator: An instrument used to measure and displaylinear displacement. Measurement is displayed on a dialface and the scale is commonly graduated in thousandths.* Directional Stability: The tendency of a vehicle to maintaina directed path.* Drag Link: A tube or rod used for interconnection betweena pitman arm and tie-rod assemblies.* Dry Park Check: Inspection of chassis and steering partswith the vehicle at normal ride height. Not in the raisedposition.* Dynamic Balance: This normally refers to the balancecondition of a wheel and tire assembly in motion.* Eccentric: See cam bolt.* Feather Edge Wear Pattern: An abnormal tread wearpattern whereby one side of an individual tread rib is wornmore than the other.* Flow Control Valve: Regulates flow output from the powersteering pump. This valve is necessary because of thevariations in engine RPM and a need for consistent steeringability in all ranges from idle to highway speeds.* Foot Pound: A unit of measurement used to describe torqueforce.* Four Wheel Steering: The ability of the rear wheels to aidin steering a vehicle for improved handling and drivingcharacteristics.* Frame Angle: Used to describe a non-level frame.* Friction Ball Joint: Outer suspension pivot that does notsupport the weight of the vehicle.* Front Steer Rack and Pinion: Steering system located infront of spindle centerline.* Geometric Centerline: A line drawn between the midpointof the front axle and the midpoint of the rear axle.* Horizontal: Parallel or level with the plane of the horizon.* Hub: The assembly that houses the bearings about whichthe wheel and tire assembly rotates.* Hydraulic Pump: A power driven device generating con-stant volume and pressure.* Idler Arm: An arm and lever assembly used to support andmaintain a parallel position with a conventional steeringsystem.* Included Angle: The sum of the angles camber and SAI.* Independent Suspension: A suspension system that pro-vides an isolated mounting for each wheel to the chassis.




* Individual Toe: The angle formed by a horizontal line drawnthrough the plane of one wheel versus a centerline.* Integral Power Assist: A power assist system where thecontrol valve and all major hydraulic components are self-contained.* Intersect: The crossing point of two lines.* Jounce Travel: A suspension moving up through its travel.* Kinetic Balance: The balance condition of a rotating wheelrelated to force generated in a vertical plane.* King-Pin: A pin used to attach a spindle to an axle.* Lateral Run-Out: Side-to-side movement with a rotatingwheel or tire.* Lead: A slight tendency for a vehicle to lead away from itsdirected course.* Linkage: A series of rods or levers used to transmit motionor force.* Load Carrying Ball Joint: Outer suspension pivot thatsupports the weight of the vehicle.* Load Range: A system used to describe the service orweight limitations of a tire.* MacPherson Strut: A suspension design where spindle,shock, and spring are all one assembly.* Memory Steer: A condition where the wheels, rather thanreturning to straight ahead, tend to remember and seek aprevious position.* Millimeter: A unit of linear measurement. One millimeter isequivalent to 0.039 inches.* Minute: A unit of measurement used to describe an angle.One minute is equivalent to 1/60th of one degree.* Non-Integral Power Assist: A power assist system wherethe control valve and all major hydraulic components are notself-contained.* Offset: The lateral displacement of a wheel or axle inrespect to a centerline.* Oscillate: A motion in two directions and at a specificfrequency.* Out-of-Round: A wheel and tire irregularity in which one orboth are not concentric with its axis of rotation.* Overinflation: Inflation pressure beyond what is recom-mended.* Oversteer: A characteristic in which a vehicle has a ten-dency to turn sharper than the driver intends.* Parallelogram Steering Linkage: A steering linkage designwhere if all pivot points are connected by lines, these lineswould be parallel.* Passive Suspension: A suspension system which usessprings along with shock absorbers to allow compression(Jounce) and extension (Rebound).* Perpendicular: Being at right angles.* Pitman Arm: A steering component that provides intercon-nection between the steering gear sector shaft and thesteering linkage.* Ply Rating: A method of rating tire strength; not necessarilyindicative of the actual number of plies used.* Power steering: A steering system which incorporateshydraulics to assist in the steering of the wheels.* Pre-load: A predetermined amount of load or force appliedduring assembly to prevent unwanted play during actual

operation.* Pressure Relief Valve: Prevents power steering fluid pres-sure buildup beyond a specified point. When fluid is at themaximum desired pressure the excess is returned to thepump reservoir.* Pull: The tendency for a vehicle to steer away from itsdirected course.* Rack and Pinion Steering Gear: A steering system designthat utilizes a pinion gear meshed with a rack gear to transmitsteering forces to the spindles.* Radial Play: Any lateral movement of the wheel and tireassembly when inspecting a ball-joint or king-pin.* Radial Ply Tire: A tire construction type with alternatingplies 90 degrees to the tire bead.* Radius: The distance from the center to the outer edge ofa circle.* Rag Joint: A type of U joint constructed from a rubberizedfabric type material.* Rear Steer Rack and Pinion: Steering system located infront of spindle centerline.* Rebound: A suspension moving down through its travel.* Recirculating Ball Steering Gear: A steering gear designthat is made up of a worm shaft, ball nut, and two recirculatingball circuits.* Returnability: The tendency of the front wheels to returnback to a straight ahead position.* Road Crown: The slope of a road from its center.* Road Feel: Necessary feedback transmitted from the roadsurface up to the steering wheel.* Road Isolation: The ability of a vehicle to better separateroad irregularities from the driver and passengers.* Road Shock: An excessive amount of force transmittedfrom the road surface up to the steering wheel.* Scrub Radius: The radius formed between wheel centerlineand steering axis projected load points at the road surface.* Setback: The angle formed between a centerline and a lineperpendicular to the front axle.* Shim: Thin material of fiber or metallic makeup used to takeup clearance between two parts.* Shimmy: A violent shake or oscillation of the front wheelstransmitted up to the steering wheel.* Shock Absorber: A suspension component used to dampenspring oscillation.* Solid Axle Suspension: A suspension system consisting ofone steel or aluminum I-beam extended the width of thevehicle.* Short Arm Long Arm (SALA): An independent suspensiondesign incorporating unequal length control arm.* Spindle: A component on which a wheel and tire assemblyis mounted and rotates.* Stability: The tendency of a vehicle to maintain a directedcourse.* Stabilizer Bar: A steel bar used to minimize body roll.* Steering Arms: A steering component which providesinterconnection between the outer tie-rod and spindle.* Steering Axis Inclination: The angle formed by an imagi-nary line drawn through the steering axis versus vertical.Viewed from the front.




* Steering Gear: A mechanical device used to convert therotary motion at the steering wheel to a lateral motion.* Steering Geometry: See Alignment.* Steering Knuckle: A forged assembly which typically in-cludes: the spindle, steering arm and steering axis pivotpoints.* Steering Shaft: A tube or rod which interconnects thesteering wheel to the steering gear.* Steering Wheel Play: Any abnormal play or movement thatdoes not result in movement at the front wheels.* Strut: Any support used between two parts.* Suspension: An assembly used to support weight, absorband dampen shock, help maintain tire contact, and properwheel to chassis relationship.* Suspension Height (Ride Height): The specified distancebetween one or more points on a vehicle to the road surface.* Thrust Angle: The angle formed by thrustline and geometriccenterline.* Thrustline: Average rear toe added together and divided bytwo. The direction the rear rolls.* Tie Rod Assembly: The outer most assemblies on aparallelogram steering linkage. These assemblies are at-tached to the drag link and steering arms.* Tie Rod End: The ball and socket assembly of a tie rod.* Tie Rod Sleeve: A threaded tube that provides connectionand adjustment of a tie rod assembly.* Tire Force Variation (Radial Force Variation): A tire irregu-larity in which there is a difference in radial stiffness about thecircumference of the tire.* Tire Wear Pattern: The design developed on the treadsurface from abnormal wear.* Toe: The comparison of a horizontal line drawn throughboth wheels of the same axle.* Turning Angle: The difference in the turning angle of thefront wheels in a turn.* Torsion Bar: A spring steel bar used in place of a coil spring.Suspension is provided through its resistance to a twisting ortorque effort.* Torque Steer: The effect that acceleration or decelerationhas on the steering of the front wheels.* Tracking: The interrelated paths taken by the front and rearwheels.* Treadwidth: The dimension as measured between thecenterlines of the wheels on the same axle.* Treadwear Indicators: Ridges molded between the ribs ofthe tread that visibly indicate a worn tire.* Underinflation: Air pressure below that which is specified.* Understeer: A characteristic in which a vehicle has atendency to turn less than the driver intends.* Unit Body (Uni-Body): A design that incorporates both bodyand frame as a unit.* Vertical: Being exactly upright or plumb.* Vibration: To constantly oscillate at a specific frequency.* Waddle: The lateral movement of a vehicle usually causedby some type of tire or wheel imperfection.* Wander: The tendency of a vehicle to drift to either side ofits directed course.

* Wheel Base: The dimension as measured between thecenter of the front and rear axles.


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Customer Database


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Advanced PC Aligner Owner's ManualCustomer Database

Customer Info

The "Customer Info" selection of the Main Menuallows access to the Customer Database option andother Sun Aligner functions. Place the check boxadjacent to Files and press Enter.

Information Menu -- from the Information Menuchoices are:

Customer files -- accesses Customer Databasefunctions such as view or print records and selectionof storage drivesAlternate specifications -- allows the setup ofexternal specification databasesStore name -- enter the store information to beincluded on all printoutsDemo program -- for Sun personnel only

Customer Database

Customer Database is a Sun Aligner feature thatallows the aligner user to permanently store infor-mation about the customer, his vehicle, and theresults of the wheel alignment service. A "database"is a collection of information to be sorted and re-trieved as needed for analysis. Available informationincludes the car owner's last name, address, phonenumber; the vehicle make/model/year, VIN number,and mileage; plus the date of service along withbefore and after alignment readings. This informa-tion is stored on a computer disk drive for laterretrieval. Once retrieved, the information can bereviewed and can become the starting point for anew alignment.

Prior to saving the alignments, it is necessary tosetup the system and learn the steps to store andretrieve data during an alignment.



Customer Files Menu

From the Information Menu, select "Customer Files".Choices are:View records -- allows sorting and viewing of cus-tomer database recordsPrint records -- this selection causes a memorydump of all records sorted by last name to theprinter. Only name and address are sent to theprinter.Select drive -- specifies the drive in the computerwhere customer database records will be storedBackup -- if records are stored on the computer'shard drive, this allows a backup to be done to afloppy disk as a data security measureRestore -- any backup data from a floppy disk canbe placed onto the hard drive

View Records -- select "View Customer Records"from the Customer Files menu. A blank data sheetwill appear. Move the selector up or down the screenusing the arrow keys to sort on a variety of topics. Asearch could be on last name, phone number, orlicense plate number. At the desired topic, type in theinformation to search for. Press Enter and the com-puter will sort by that data field and bring up anyavailable records. Pressing the soft-key #1 "Next"goes to the next record in the database, pressingsoft-key #2 "Last" goes back one record. Whenviewing customer records under the Files Menu,before and after alignment readings cannot beviewed.

The process described above is also utilized whendoing a wheel alignment. When the Customer Datascreen appears, press soft-key #1 to open up ablank sheet to search for the desired records. Thisprocess is described in detail on Page 106.



Selecting the Disk Drive -- to determine which diskdrive the computer will refer to when writing orretrieving data, choose "Select database disk drive"from the Customer Files Menu. The selections areA, B, or C. Disk drives A and B are Floppy drives.These are disks which can be interchanged betweenmachines and computers. The "C" drive is a "HardDisk Drive" permanently mounted inside the com-puter. The Hard Drive contains much more storagecapacity than a floppy disk. Select the appropriatedrive letter for the computer configuration of the SunAligner. If in doubt, contact a Sun Representative.

Backup Database -- the computer system willallow the customer data to be stored onto a floppydisk drive for safe keeping or for use at anotherlocation. Information which has been backed-uponto the floppy can be reentered back into thecomputer. To backup the database simply select"Backup" from the Customer Files Menu. The com-puter will then ask you to insert a floppy disk into thedrive slot and press Enter. The computer now takesover and copies all the internal files to the floppy forstorage. After backup the computer will ask if theinternal file is to be erased to make room for moredata. If "Yes" is selected all internal data will beerased! Selecting "No" will allow more data to beadded.

NOTE: Any existing customer files on the floppy willbe overwritten. If additional diskettes are required,contact your Sun Representative or request a pre-formatted 3.5" 1.44 MB diskette from a local com-puter supplier.

Data Retrieval, Restore -- if data is to be restoredto the internal hard drive, select "Restore" at theCustomer Files menu. The screen asks you to insertthe floppy which contains the desired informationinto the floppy disk drive slot and press enter. Thestored information is then read into the computer foruse. Please note that when the data is read into thecomputer the existing file will be overwritten. Makesure that the data on the disk is that which is desiredon the computer.



Using Database During an Alignment

After choosing Begin Alignment the Customer Menuwill appear. Select "New customer" to add a newrecord. To find an existing record select "Find cus-tomer data".

Adding a New Customer Record -- when "Newcustomer" is selected a blank Customer Data pagewill appear. Using the keyboard, type in all pertinentinformation about the customer and his vehicle in thefields provided. Once completed, there are two op-tions: soft-key #3 "Save" will save only the customerinformation that is on the screen or, if inspection andalignment data is desired to be saved, press soft-key#4 to continue. The opportunity to save all informa-tion will come at the completion of all alignmentprocedures.

Finding a Customer Record -- when "Find cus-tomer data" is selected (or soft-key #1 on the Cus-tomer Data screen), a blank data screen appearswith a dark box (white cursor in it) in the First Namefield. This box is the search criteria selector. Usingthe up/down arrow keys, choose the desired field tosearch for the customer record (i.e. last name, plate#, etc.). In the field type the customer informationand press Enter. Any information in the Sun Alignerdatabase that corresponds to the search criteria willappear. If there is more than one record for thatcriteria (i.e. two people with same last name) presssoft-key #1 "Next" or to move backwards in thedatabase press soft-key #2 "Last". Notice the com-plete customer information including the date ofservice.

To continue reviewing all information associatedwith this customer record, press soft-key #4, "Ac-cept".



Vehicle Specification History -- the next screenthat appears shows the specifications from the storedalignment. This eliminates the need to reenter speci-fications, even if they were "Custom" specs. Thevehicle adjustments can be illustrated by pressingsoft-key #2. Press soft-key #4 to continue.

Inspection Menu History -- if any vehicle inspec-tions were performed and entered into the SunAligner database they can be recalled from thismenu. Highlight the desired area to examine theresults. Any items that were checked, serviced, orrecommended for replacement during this previousalignment service will be shown. Press soft-key #4to continue to the alignment readings review.

All Readings History -- this screen allows a reviewof the alignment readings as stored in the datarecord. Only the "All Readings" screen can be viewed(no meter displays). To view the initial alignmentreadings, press soft-key #2 "Initial" and press soft-key #3 "Final" to see the ending results. The dis-played values will be green or red indicating theirstatus versus manufacturers specification. Grayreadings indicate there was no specification for thatangle. This historical review can be printed by press-ing soft-key #1 "Print".

This completes the review of all information stored ina customer data record. To perform a new alignmentusing this customer and vehicle information presssoft-key #4 "Align". All customer information will beretained to streamline the alignment process.



Saving Complete Alignments

After entering new customer data, pressing the "Save"soft-key will save only the typed information (seePage 66). If all information about the alignment,including inspections and alignment readings, is tobe saved, go to the "Print" soft-key on either theFront or Rear Readings screen to enter the PrinterMenu. The final selection is "Save current align-ment". After this is highlighted, press Enter. Afterapproximately 5 seconds a beep will be heard indi-cating the alignment has been saved. This align-ment is now stored in the database for future refer-ence.

Other Information Menu Items

Store Name -- this entry places the name, address,and phone number of the shop performing the align-ments on every printout. This can be an effectivemarketing tool as customers tend to share informa-tion with friends and family.

Demo Program -- desiged for use by Sun Sales andService personnel.


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Maintenance and Service


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Advanced PC Aligner Owner's ManualMaintenance and Service

Maintaining the Sun Aligner

Maintenance of the Sun Aligner is easy and in most cases can be performed by theoperator of the machine. A daily cleaning with a mild ammoniated cleaner willmaintain the exterior. Using a silicon based spray on the head keypads will keepthem soft and pliable giving you years of use. This will help preserve the professionalappearance desired in today's automotive shop.

Periodic calibration of the measuring heads insures alignments are done withaccuracy and confidence. Using the optional Customer Calibration Kit, Sun makesbasic calibration a simple process allowing the equipment operator to quicklyperform the steps whenever necessary. The following pages assist with use of thissoftware and the calibration of the unit. When calibration software is not installed theunit will prompt entry of a "Security Code" for use only by an authorized Sun ElectricService Technician. During the head calibration, if any of the sensors has failed ormoved beyond acceptable limits the software will flag the situation and recommendservice by a qualified Sun Representative.

In the back of this guide is a troubleshooting guide designed to assist you should aproblem occur. Refer to this guide should the unit fail to operate normally.

To access all equipment maintenance functions, use the arrow keys to place thehighlight box over "Maintain Aligner" and press Enter.



Maintain Aligner Menu

This menu is the hub of all Sun Aligner service andmaintenance activities. Choices are:Calibrate -- the software that enables the measuringheads to be calibratedCheck sensors -- primarily for Sun Electric Com-pany service personnel, this allows access to mea-suring sensor direct outputDiagnose -- a series of functions for Sun ElectricCompany service personnelMaintain -- a software feature that guides the equip-ment operator through recommended periodic alignermaintenance

Customer Calibration (with optional kit)

Step 1. Calibrate Aligner -- select this item fromthe Maintain Aligner Menu and press Enter to accessthe calibration menus. Since the Sun AdvancedAligner is equipped with Preventative Maintenancesoftware, a technician identification screen appears.Any name or ID number can be entered for laterverification of the person performing the calibration.

Step 2. Calibration Menu -- select which set ofmeasuring head sensors are to be calibrated. Choicesare:Camber, SAI, and cross toe -- camber sensors arein all heads, while SAI and cross toe sensors are onlyin the front heads on 6 sensor systems and in the rearheads of 8 sensor systems. Cross toe measure thewheel angles across the front or back of the vehicle.Track toe -- each head has a toe system thatmeasures angles from the front to rear (or vice versa)of the vehicle.Calibration factors -- shows a chart of the currentfactors that are stored in memory.Calibration history -- a graphical display of calibra-tion factors for each head along with dates of service.Clear calibration factors -- resets all factors to zero.



Customer Calibration ... continued

Left Front Head and numbered side ofcalibration bar.

Figure 1. Calibration bar and standsset up on turntables (Rear View)

Step 3. Camber, SAI, and Cross Toe Calibration

A. Select whether the front or rear heads are to becalibrated. Press Enter.

B. The screen will prompt to identify which rack is tobe calibrated. Up to 3 alignment surfaces can beutilized with the Sun Aligner Series, and each mustb calibrated independently. In most shops, Rack A isthe primary alignment surface. Press Enter. Followall on-screen instructions carefully.

C. The Customer Calibration Kit includes a calibra-tion bar, approximately 6 ft. (2.5m) long and twostands that sit on the alignment rack surface. Whenperforming calibration of the front heads, place thestand on the turntables. When calibrating the rearheads, place the stands on the rear of the rack.

The bar is placed in the notches ofthe stands as shown in Figure 1.Make sure the numbered end of thebar (1, 2, 3) is on the left side.Remove the heads from the wheelclamps and mount them on the endsof the calibration bar as shown.

D. The next step is to perform runout compensationof the calibration bar. This is done by rotating the baruntil the #1 position is at 12:00, as shown by the flipindicator on the left stand.

At the #1 position, press the"Runout" button on the left headonly (Figure 2). It is not neces-sary to take runout on the righthead. The light on the runoutbutton will blink. Next rotate thebar until position #2 is at 12:00,and press the runout button onthe left head. Repeat for position#3.

E. After runout is completed thescreen will prompt to level andlock the heads. Carefully per-form this step using the levels onthe heads, then press Enter.

Runout Button

Figure 2. LeftHead Keypad



F. Calibration Check / Recalibration -- After com-pleting the runout and level/lock procedure, a screenappears to verify calibration. The screen at the righthas three columns. The first column describes thecondition of the aligner prior to calibration. The nextset is used to display the most recent calibration.The last column shows the total amount of changebetween calibrations. Should a factor exceed theusable limit, a warning will be displayed which indi-cates a possible problem and will recommend thata service technician be called. Pressing soft-key #4"X" will cancel the calibration procedure. Pressing#1 "OK" will use the new calibration factors to per-form alignments. Refer to the troubleshooting por-tion of this guide should the unit fail to work correctly.Use the Calibration Factors Menu to see the resultsof the calibration. The Sun Aligner will use thesecalibration factors to perform alignments. Simplyput, this becomes the unit's "0" reference.

G. The next screen to appear is "Calibration Notes".The reason the calibration was performed is enteredhere for future reference. This information becomesa part of the calibration history that is retained by thecomputer's memory. Select the most logical entryand press Enter.

This completes the calibration procedure for cam-ber, SAI, and cross toe.

Step 4. Track Toe Calibration -- track toe is usedto establish the vehicle's rear toe, geometric centerline, and thrust line. Track toe calibration must bedone on a vehicle using the special Track ToeFixture that is part of the Customer Calibration Kit.Place all head/clamp assemblies on the vehicle inpreparation for these steps. Each head must bedone independently. The head to be calibrated mustreside on a front wheel with the track toe systemfacing the rear.

A. Select Track Toe from the Calibration Menu.Follow the on screen instructions which assist in thecalibration step by step.





B. Choose the head to be calibrated. The head to becalibrated must be mounted to a front wheel in orderto steer when directed.

C. Choose the companion head to be used on therear wheel to act as a track toe signal receiver.

Track Toe Fixture Setup(Figure 3) -- this fixtureis included with the Cus-tomer Calibration Kit. Thekit includes the Track ToeFixture (L-shaped alumi-num piece with a stubshaft), 2 standard headlocking knobs, and onelocking knob with a longerthreaded section. The two

standard locking knobs are placed in the threadedholes on the top, both ends of the fixture. Removethe head to be calibrated from the wheel clamp.Mount the track toe fixture onto the wheel clampshaft with the larger end facing the wheel. Use theincluded knob to snug the fixture to the clamp shaft.

D. Remove the tightening knob from the head to becalibrated and place the head on the shaft of theTrack Toe Fixture. Using the long screw lockingknob going down through the top of the fixture,tighten the head onto the fixture.

E. Mount the companion head on the rear wheelopposite the head being calibrated. Make sure thereis a clear line of sight from the front to the rear. Leveland lock the companion head.

F. Following the on-screen instructions, steer thefront wheel until the reading shown is close to zero.

IMPORTANT NOTE: DO NOT move the wheel atall after this point! DO NOT remove the headfrom the fixture!




G. The software will prompt to remount the head andTrack Toe Fixture upside down. This is done byloosening the knob holding the fixture to the wheelclamp and sliding the fixture off away from the wheel,while being careful not to move the vehicle wheel.Turn the fixture with the head still securely mountedto it upside down (180 deg.) until the narrow end ofthe fixture is facing the wheel. Remount this narrowend on the clamp shaft and tighten down the knob/screw. A correct orientation at this point will have thetrack toe system of the head pointing to the rear.Make sure there is a numerical reading on screen atthis point. It may be necessary to point the fixture/head downwards slightly towards the companionreceiver head.

H. Once these steps are done, press Enter to viewthe Calibration Check / Recalibration screen to de-cide whether to accept or reject the calibration of thishead. If the New Factor or Change values are exces-sive a warning message will appear. In most casesthe calibration factors are good and it is proper topress soft-key 1, "OK".

I. The Calibration Notes screen will appear to allowentry and storage of the reason for calibration.

J. Repeat these steps for all heads in the system.The Left Front and Right Rear heads are calibratedon the vehicle's left front wheel. The Right Front andLeft Rear heads are calibrated on the vehicle's rightfront wheel. This completes the customer calibrationprocedure.

Calibration Factors

The calibration factors can be viewed at any time byselecting "Calibration factors" from the CalibrationMenu. These factors are referenced each time analignment is performed. Notice there are three setsof camber factors for the three alignment surfaces.



Calibration History Menu

The past calibrations 10 of the Sun Aligner can beviewed by selecting "Calibration history" from theCalibration Menu. It gives a graphical presentationof the calibration factors along with dates the calibra-tions were performed. Reason for calibration detailis accessed by highlighting a date and pressingEnter.

Check Sensors

These screens are primarily used by Sun Servicepersonnel in diagnosing equipment problems. Thisinformation displays the direct output of the variousmeasurement sensors used to determine the wheelalignment angles. As the operator of the equipment,it may be useful to have some knowledge of the SunAligner's built-in diagnostic capabilities.

Data Display MenuThere are two screens to view sensor outputs:

Display all sensor data -- shows a myriad of sys-tem information for advanced diagnostic capabilitiesDisplay raw values only -- a simple display of directoutput values from the measurement sensors




Display All Sensor Data -- The infor-mation available on this screen in-cludes:

Displayed values -- the alignmentangle numbers that are displayed onthe Front/Rear Meter screens. Cali-bration and runout factors are includedRaw values -- direct sensor outputsGain -- amplifier values for toe systemcircuitsRunout factors -- these values werestored when runout compensation wasperformed on each wheel. There is acamber and toe plane value given

Calibration factors -- these are the values stored inmemory from the last head calibration performedHead communication -- a status indicator of whetherthe head computer is communicating with the maincomputer in the consoleData input -- as a key on the main keyboard or anyhead keypad is pressed it will appear here.

Raw Data DisplayThis screen shows only the direct sensor outputsfrom each head. The values themselves have verylittle meaning when viewed while the heads are on avehicle. All dashes showing for a head indicates aloss of communications. A loss of any toe signal willresult in dashes appearing in the problem location.

Diagnose -- Aligner Diagnostics Menu

Contains the following tests:

Printer test -- causes the printer to begin printing itscharacter set. Be sure the printer is turned on beforebeginning this test. The printer will stop printingwhen it has completed its testing.CRT adjustment -- used to maintain the VGA Moni-tor at peak sharpness. Adjustments to the CRTshould be performed by qualified Sun Service Tech-nicians onlyHead diagnostics -- reserved for Sun Service per-sonnel



Maintain -- Preventative MaintenanceMenuWhen a Sun Aligner is equipped with theoptional Customer Calibration Kit, thesoftware has a preventative mainte-nance routine built-in that insures thealigner is kept at peak operating perfor-mance. When "Maintain" is chosen fromthe Maintenance Menu, the choices are:

Weekly maintenance -- items thatshould be addressed on a weekly basisMonthly maintenance -- items thatshould be addressed on a weekly basisMaintenance history -- shows the datesmaintenance was performedMaintenance day -- lets the softwareknow what day of the week to prompt theoperator that maintenance is due

Weekly Maintenance Checklist -- theitems listed represent the weekly choresand checks that should be made. Asimilar list is shown for Monthly Mainte-nance. The choices are Checked, Ser-vice, or Remark, depending on theoperator's input.

Maintenance History -- a listing of thedates, who the person was, and whetherit was weekly or monthly maintenance isshown. Details of the maintenance pro-cedure can be shown by highlightingany date, then press Enter.

Maintenance Day -- when a day of theweek is selected, the Sun Aligner soft-ware will automatically inform the op-erator of maintenance needed. In fact,2 days before the chosen day, the soft-ware flashes "Maintenance due in 2days", followed by "Maintenance due in1 day", and finally "Maintenance due".



User Serviceable Parts

Many parts of the Sun Aligner can be replacedwithout calling for a Service Technician.

Cable replacement (85617): Unplug the cable fromthe back of the aligner and from the head. Replacewith the new cable and check for proper operation.

Printer ribbon replacement: Remove the top coverof the printer and remove the old ribbon from itsreceptacle. Remove the protective cover from thenew ribbon and position in the receptacle. Use theprinter test function under the Maintain Aligner menuto test the printer's operation. Read the Printer'sOwners Manual for more details.

Membrane panel replacement (88029): Removethe four screws from the head cover. The membraneswitch ribbon cable is attached to printed circuitboard inside the head.

DO NOT PULL ON THE HEAD COVER WHENREMOVING. DAMAGE TO THE RIBBON CABLECONNECTOR WILL OCCUR.

Pinch the tabs on both sides of the cable connectorand pull back gently on them. Slide the cable fromthe connector. NOTE THE POSITION OF THE RIB-BON CABLE WHEN REMOVING FOR EASIER IN-STALLATION OF THE NEW MEMBRANE CABLE.Peel the old membrane from the head cover. Cleanthe head cover thoroughly with Isopropyl Alcohol.When dry, peel backing off of the new membraneswitch and place on head cover being careful not topinch the ribbon cable as it passes through the holein the cover. Place the ribbon cable back in theconnector and push the connector's tabs back in.Reinstall the head cover and test the membrane forproper operation.

Other Replacement Parts

85569 Keyboard, no decals85633 Clamp wedge grip85649 Clamp stub shaft63499 Bungi strap86477 Clamp rod extension83258 Head locking knob86159 Level - black round85617 Head interconnect cable - 33'85616 Head interconnect cable - 65'86278 Rack to head cable - straight

Sun would like to take this opportunity to Thank Youfor your purchase of a Sun Aligner and sincerelyhope it will bring you many years of profitable ser-vice.



Troubleshooting Operational Problems

Symptom

Unit fails to turn on.

Boot Up sequence not com-plete.

No screen display.

Error message displayed onboot Up.

Possible Cause

Power Supply from wall

Power cable

Blown Fuse

Program start up failure

Drive failure

Blown fuse

Video card or CRT problem

Program failure

Computer hardware problem

Suggested Repair

Check wall power supply by pluggingin a known working item.Check the power cable for correctconnection to machine.

Check cable continuity or substituteknown good cable.Check all three fuses located on back.

If fuses are blown, check for propervoltage setting, replace.

Call a qualified Technician if unit stillfails to turn on.

Switch off and turn back on. On floppysoftware units try with backup disk. Ifproblem persists call a technician.

Call for service.

Unplug unit. Check all fuses, replaceif necessary.

Call for service.

Restart unit. See above boot-up prob-lem. If problem persists call for tech-nician.

Call for service.



Symptom

Program will not advance whenusing Head or console remote.(Lock Up)

Displays Head CommunicationLoss.

Will not perform Runout.

Will not perform Caster Swing.

Camber reading does notchange and "0" Caster read-ing.

Caster Adjustment reads back-ward from expected adjust-ment.

Possible Cause

Blown Fuse

Program lockup

Computer hardware failure

Bad Head Cable

Toe PCB or computer failure

Bad head keypad

Toe PCB or computer failure

Blocked Track Toe beam

Too much total toe on frontwheels

Unequal head heights on clamp

Problem with vehicle

Head component failure

Broken Camber sensor

Bad Toe PCB.

Brake pedal depressor not usedor not holding brake secure.

Turntables seizing

Suggested Repair

Check fuses on rear of unit

Restart aligner and retry operation.call for assistance if required.

Call for service technician

Substitute know good Head cable.Use Measurement Data Displayscreen. Replace bad cable.


Use Measurement Data Display toread keyboard entry displays. Call forparts or for service to replace keypad.


Remove obstruction in toe beam path,clean lenses.

Adjust total toe to straightahead.

Adjust head heights

Switch to Manual Caster mode to com-plete, try on another car


Call for service to replace sensor


Check use of pedal depressor. Startvehicle to use power brake system.

Clean, rebuild, or replace service turn-tables




Symptom

"0" SAI reading after swing andno live Caster or A-arm assis-tance adjustment - frozen.

No Toe Readings.

No Printer operation

Machine resets or changesmenus randomly.

Possible Cause

Broken SAI Sensor

Bad Toe PCB

Blocked Toe Beam

Bad LED Transmitter

Bad Toe Receiver

Printer unplugged or not turnedon.

Printer data cable disconnectedor failed.

Program not configured correctlyfor printer or printer DIP switchesnot set properly.

Head keypad or keyboard prob-lem

Computer system problem

Suggested Repair



Remove obstruction in toe beam path,clean lenses, check for missing/cracked lenses.



Check all printer power connections.Check on/off switch. Ensure Printer is"On Line" as indicated by LED.

Check connections at printer and backof computer.

Check system configuration under Se-curity Code Word. If printer not en-abled, call for codes. Check Printersetup also for proper configuration.

Unplug each head to see if problemstops. Unplug keyboard from com-puter to see is problem stops. Re-place defective item.




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Snap-on Diagnostics420 Barclay Blvd.Lincolnshire, IL 60069(800) 225-5786

Model EEWA-109Advanced Wheel Aligner

Owner’s Manual

Form #5438

File Information: eng_nt @ c:pubs\aligners\eewa109.p65 wdc...copyright...8/99 Printed in U.S.A.

is a registered trademark of Snap-on Corporation, Kenosha, WI


model eewa-109 advanced wheel aligner owner’s...

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