A

REPORT ON
PRACTICAL TRAINING
TAKAN AT
ASHOK LEYLAND
ON
WHEEL ALIGNMENT

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

Submitted to:
Deptt. of` Mechanical Engg.
Govt. Engineering College, Ajmer

35

Submitted by:
RAVI KR. AGARWAL
B.TECH IV YEAR
R.N.:- 07ME58

CONTENTS
S. N.
1

2
3
4
5
6
7
8
9

TITLE
Acknowledgement
Declaration
History of Ashok Leyland
Introduction to Alwar plant
Ashok Leyland departments
Certificate and quality policies
Energy power resources
Ashok Leyland products
Wheel Alignment

35

PAGE
NO.
3
4
5
7
9
15
18
19
21

ACKNOWLEDGEMENT
I wish to acknowledge indebtedness to Mr. A.K. Chopra (GM, Ashok
Leyland Alwar), Mr. Ramesh Kumar Yadav (Div. Manager HR, Ashok
Leyland Alwar), Mr. Ashok Kumar (AGM, Production Department,
Ashok Leyland Alwar), for giving me an opportunity to take my training
in Ashok Leyland, alwar. For their support motivation and Guidance in
throughout my training session.
I also pay thanks to Mr. Moulishankar sir and all the engineers,
supervisors, and workers without whom this training would not have been
a successful one.
Last but not the least-I thank to all the people who directly or
indirectly
Supported in this endeavor.

35

DECLARATION
I RAVI KUMAR AGARWAL Student of Govt. Engg. College
Ajmer Here by declare that all the information of in this report is based
on my experience and study during training.
I further declare that all the information and facts furnished
in this report are based on my intensive research and findings. They
are original in nature.
Date: -

Ravi kr. Agarwal

Govt. Engg. College,
Ajmer

35

History of Ashok Leyland:

Ashok Leyland was urge for self reliance industry felt by Indias
first Prime Minister Pt. Jawaharlal Lal Nehru, persuaded Mr.
Raghunandan charan, an industrialist to enter automotive manufacture. In
1948,Ashok motors was set up but was then in Madras, for the assembly
of Austin cars after that in 1955 companys name and luck changed by
equity participation by British company Leyland and Ashok motors get a
new brand ASHOK LEYLAND the manufacture of commercial
vehicles. Since Ashok Leyland has been a foremost existence in Indias
commercial vehicle industrial. With a convention of technological
leadership achieved by tie ups and collaboration with international
technology leading organization through enthusiastic in-house research
and development it set up its existence in Indian and Foreign market.
Admittance to global
technology and equipment enabled the company to set first with
technology in full Air-brakes, Power-Steering, and Rear engine buses etc;
Ashok Leyland pioneered all these concepts. Responding to the operating
conditions and practice in the country, the company made its vehicle
strong over engineering then with extra metallic Muscles
Ashok Leyland vehicles have built repute for reliability and
austerity. The 5, 00,000 Vehicles put on the roads have considerably
eased the additional pressure placed on road transportation in independent
India.
Ashok Leyland buses are used by four for out of five most
populated states as there state transportation corporation Vehicles.
Some of them like double decker and vestibule buses are unique
models tram Ashok Leyland trailer made for high density routs. The
companys products are inherent to Indian lives Ashok Leyland
dominates in city passenger transportation with specialized high capacity
buses such as the double decker and vestibule bus for which the company
is the only Indian source.

35

Ashok Leyland supplies a host of modern special purpose to India

defense sector. This includes stallion 4x4s forming the back bone of
Indian armys logistics operations, now being assembled within the
defense sector through a technology transfer agreement. The stallions left
an indelible mark for reliability during the Kargil conflict. When India
and Pakistan open there common gate at baga, Ashok Leyland buses was
the choice for this prestigious cross border passenger service.
Ashok Leyland has maintained its technology even as it offers the
most comprehensive range of model configurations in its class, offering
the costumers the closest fit with his unique requirements. A pioneer in
alternate fuels, Ashok Leyland made Indias first CNG powered buses in
1997. In 2002, India entered another frontier technology Ashok Leyland
developed Indias first hybrid electric bus in a partnership with the Govt.
sector.
In 1987, the overseas holding by land rover Leyland international
holdings limited was taken over by a joint venture between the Hindu
group, the known residential Indian transport group and IVECO. (Since
July 2006, Hinduja group is 100% holder of LRLIH)
In the journey towards global standard of quality of Ashok Leyland
reached a major milestone in 1993, when it becomes the first Indian
history to win the ISO-9002 certification. The more comprehensive ISO9001 certification came in 1994, QS-9000 in 1998 and ISO-14001
certification for all vehicles manufacturing units
In 2002.It has also become the first Indian auto company to receive
the latest ISOTS-16949 corporate certification (in July 2006) which is
specified to the auto industry.

35

INTRODUCTION OF ASHOK LEYLAND ALWAR PLANT

Ashok Leyland, Alwar plant is one of the production unit of Ashok
Leyland Ltd. Alwar city situated in west north in Rajasthan and is very
near to Delhi, The capital of India. Alwar comes in NCR (National capital
region) also it is located at M.I.A (Matasya industrial area) Alwar.
This plant was established in 1982 and has completed his 25 years
successfully. This plant is known for his high productivity. It is basically
an assembly plant where the chassis is assembled.
Ashok Leyland, Alwar is worlds largest CNG vehicles producing
plant. CNG (compressed natural gas) is used as an alternate fuel to diesel
and is very less polluting. The pollution of CNG vehicles is less than even
EURO-IV vehicles which is known for its lesser pollution value.
The total covered area of Alwar plant is 352 acres. And fencing is
done around 161 acres of area. The plant comprises of 4 shops called
shop-I, shop-II, shop-V and shop-VII. The plant has three gates; One
main gate one for entering the goods carries and the third for the products
going out of the plant for sale.
There is an administrative office, one P&A department block,
department-offices, a medical centre, a canteen, a news paper reading
room and library, a training centre and systems department, RSO yard
and the construction is going on for new stores. The over view of alwar
plant is

The plant is inaugurated on 22-08-1982.

The total land area is 352.09 acres.
Fenced area is 161.52 acres.

35

WORK SHOP: - In alwar plant the various workshops are

SHOP-1 Chassis assembly takes place in the line by old
assembly method and the PDI (pre delivery inspection) is
carried.

SHOP-2 Chassis assembly takes place on conveyor line

which is newly installed in the plant.

SHOP-5 Bus body manufacturing takes place on the

conveyor line which is newly installed in the plant.

SHOP-7 Pre inspection delivery of chassis takes place in

this shop which is newly installed in the plant.

LAYOUT: - The various parameter of the company are

SHOPS AREA AND DISCRIPTION
4 shops
140x100
14000 sq mt each
Shop office area
274.5 sq
meters in each shop.
Shop no 1 : Assembly activity
Shop no 2 : Chassis assembly shop
Shop no 5 : Bus body manufacturing
shop
Shop no 7 :
Pre delivery inspection
(PDI)
35

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

MAIN ADMN. BLOCK

Main admin block Office space of 297 sq meters
which include following sectors
Manufacturing managers office
Purchase department
Systems department
Reception and office service
Finance department

PERSONNEL AND ADMN. BLOCK

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

ASHOK LEYLAND DEPARTMENTS

PRODUCTION DEPARTMENT:
This department handles all the plan work for production. This
department is responsible for all the production and its process going at
assembly line and also the PDI (pre delivery inspection)
They deal with all the workers to get the work output from them for
production. They decide which model is to be assembled according to the
availability of material and demand of production.
35

 PERSONNEL AND ADMINISTRATION

DEPARTMENT:
This department has to perform the no. of functions such as all
kind of recruitments like executives, managers and workers. They
conduct various types of tests and interviews for vacancy lying in the
organization or at demand of managers.
They also take care of medical facility, canteen facility,
library and security too. They are also responsible for the discipline in the
plant. Mainly they deal with all the personal behaviors of employees.
They arrange seminars and other motivating events for the employees.
They also conduct cultural events and get together, in which they include
the family members of the employees for giving a change from routine
work.
They also record all individual working record in
organization. They deal the relations with other organizations and
institutes. This department is known as human resource department in
other organization.

QUALITY CONTROL DEPARTMENT:

This department is responsible for the quality of products and parts
whatever they sell or purchase. The quality checking is done in three
processes, which are given as follows:
1. Incoming material inspection
2. In process inspection
3. Final inspection
There is a GR & D (goods receipt and dispatch) section, which
receives goods, and QC department inspect them and ensure the quality
as per the recommended standards and then send them to store.

35

For in process inspection they use one chassis card in which the
worker check whether all things has been done which he had to do and
then do his signature in the card. This is known as self certification.
When the chassis become off track to the assembly line then the
chassis goes for a road test. The defects and shortcomings in the
chassis are noted such as noise, smoke, driving control etc. then an
inspection of chassis takes place at PDI and then all the defects are
noted and are rectified. After that the chassis is passed to sales
department by QC department.

PPC DEPARTMEPPNT:
Production planning and control department is known as PPC
department. This department control GR & D section and storerooms.
They receive the goods coming from the factories. Then according to
the vouchers, counting of parts is done. They prepare a daily report of
goods receive and send it to finance department for further procedure.
They allot part number for the parts and parts are arranged
according to the part number in the store room. They keep all the
records of store room. Monthly counting of parts is also done.
PPC department does whole of the material planning for
production. Also they make available all the material required for the
production at the time of production at all the stages. Two bin
system is being used here for the supply of material at all the stages.
This is like there will be two bins at a stage and, as one becomes
empty that will be replaced by a bin full of the material.

35

UNIT PLANNING DEPARTMENT:

This department basically does the planning work. They are given
the project of some new units to be prepared in the plant for which
they plan the appropriate place for installation of the new unit, the
approximate duration of completion of project, cost estimation and
benefits of the installation of new unit.
Presently they are taking care of new rear axle assembly conveyor
line project being installed in shop-2, paint booth for body painting of
foton bus in shop-5.

PRODUCTION SERVICES DEPARTMENT:

This department is also known as maintenance department. They
are responsible to provide the services required for the production and
also for the maintenance of all the equipments being used. They
rectify the problem occurred in the equipment at the time of break
down of some equipment. For example the equipments are bolt
tightening machine, impact wrench, forklift, overhead crane,
conveyor, compressor, generator and electricity, oil filling machine,
greasing machine, pneumatic devices, lightning devices and fans etc.
They do regular checking and maintenance. A formal calling
system is being used. Whenever the maintenance is required at
assembly line or some break down occurs in machine, a person press
the button and the maintenance department will be informed by the
system. Then the person from maintenance section will come at the
location and will solve the problem.
They also take care of horticulture in the plant. This makes the
beauty of the plant and makes the plant environment friendly green
plant.
They are responsible for those instrument and services provided
by them to achieving the production.
35

PURCHASE DEPARTMENT:
Raw material is very important for the production. Purchase
department purchases all the raw materials from various dealers and
companies. They decide which material should be bought from which
company.
They also look at the cost of material to be purchased and the
transportation charges. It is better if the material is coming from a
place nearer to the plant because the transportation cost will be
reduced.
They also the firm to sell the scrap items of iron, wood etc. the
tender will be given who ever will pay more.
They also hire the contractors from the market by tendering to
manage many works in plant like material unloading, transportation,
and construction.

FINANCE DEPARTMENT
This department takes care of all financial things of plant. They
keep record of all the salaries and alliance of the employees, the money
spent on purchasing the things for plant, the money earned by the sale of
products and other financial activities. They prepare monthly and annual
budget of the plant.
Also they monitor the attendance of employees by an electronic
card punching attendance system. All the employees are provided with an
electronic card, which is punched in the card-punching machine at the
time of entering the plant and at the time of leaving the plant. The
machine will note the time of punching and thus the department gets the
data.

35

SALES AND MARKETING DEPARTMENT:

Products are made in the plant and they need to be sold for the
customers. This department takes care of all the marketing activities.
After the product is passed from QC department, sales and marketing
department keeps all the products at R.S.O (regional sales office) with
safety. The vehicle is kept in the RSO after fitting the heat guards,
warning triangles, RUPD (rear under protection device) and canopy as
per the government rule. Then at demand and requirement the products
are sent to the dealers.
They look at the demand of product in the market and the
customers feedback about the product. They also provide the training for
servicing of the product.
They send their report that in what amount market has demand to
production department so that they can decide the amount of production
that they can.

PDI (PRE DELIVERY INSPECTION):

It comes under the production department but it has its much utility
that it has an important role in the production.
The vehicle coming from assembly line is not perfect in quality. It
has many defects. So the chassis is inspected, faults are arrested in this
section and all the defects and faults are noted. The chassis comes into
PDI section after road testing.
Then all the defects and faults found in the chassis are
rectified using necessary tools and items. Then the chassis is painted in
paint booth and if there is any dent on the chassis FES then it is removed.
And finally passed to sales department. The chassis passed from PDI is
fault free
and prefect in quality.
Painting of the chassis is also done under this department.
35

GR&D (Goods Receive and Dispatch):

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

Certificates and quality policy of ashok Leyland

In the journey towards global standard of quality of Ashok Leyland
reached a major milestone in 1993, when it becomes the first
Indian history to win the ISO-9002 certification.
The more comprehensive ISO-9001 certification came in 1994,
QS-9000 in 1998
ISO-14001 certification for all vehicles manufacturing units in
2002.
It has also become the first Indian auto company to receive the
latest ISOTS-16949 corporate certification (in July 2006) which
is specified to the auto industry.

35

QUALITY POLICIES
It is the objective of Ashok Leylands quality policy to achieve
customer satisfaction by meeting the customer expectations in relation to
the product and services offered by the company.
Towards this objective, the quality policy of Ashok Leyland is;
To make continuous improvements in the products manufactured
by the company.
Give uninterrupted quality services offered to the customer
To enhance employee potential to contribute to quality by
improving the knowledge and skills of the employee as appropriate
to their functions.
To induce in vendors, commitment to continue improvement to
meet quality standards.
To make good relation with the customer by providing regular
service to vehicle by their service centre.
Get feedback from the customer to improve the quality of product
and customer satisfaction.
Increasing the research and development centre to achieving
quality standards and quality goal of the organization.

35

ENVIRONMENTAL POLICY:
Tech development
Industrialization
Population growth
More production
More automobiles
More food required
Any type of activity that is performed or any type of product that is
manufactured has an effect on the surrounding or environment.
At Ashok Leyland are committed to preserving the environment
through a comprehensive environmental policy and a proactive approach
in planning and executing our manufacturing and service activities.
We are concerned about the earth our children will inherit. Thats why
we make sure our vehicles consume less fuel and pollute less. This
concern is reflected in the manufacturing systems, the various processes,
energy conservation measure and conscious greening indicatives of the
company.
A system is employed to control or minimize the adverse impact on
the environment is environment management system (EMS).

Objective of Ashok Leyland environment policy are:

To adhere to all applicable environment legislations and
regulations.
To adopt pollution preventive techniques in design &
manufacturing of our products.
To conserve all such resources such as power, oil, gas, water,
compressed air etc. and optimizes their uses through scientific
methods.
To provide a clean working environment to our employees,
contractors, and neighbors.
Commit to comply with all relevant legal and other
requirements.
35

 Continuously strive to minimize waste generation by all

possible ways and to reuse and recycle same through a time
bound action plan.

SAFETY AND HEALTH POLICY

3

INTENTION
AND
MANAGEMENT

COMMITMENT

OF

THE

TOP

Ashok Leyland affirms that all its employees irrespective of the cadre
or rank need to be safe guarded against any person injuries or damage to
the properties during working period. That the management recognize the
principle that accident prevention contributes in the long run to all
process
and development of the organization.
Towards this objective, Ashok Leyland is committed to:
Implementing all practical safety measures like safe working
and environmental condition.
Carrying out a systematic critical appraisal of all potential
hazards involving personal, plant service and operating
methods.
Following strictly safety rules and regulation incorporated in
the factories act and rules.
Maintaining safe and health education program for employee
with specific emphasis on creating safety and health
awareness.
Welcoming useful and constructive suggestions and ideas in
regard to safety and health.

ENERGY POWER RESOURSES

The power is being received from Jaipur Vidyut Vitran Nigam
limited of 33KVA line which is stepped down to 11KVA at main
receiving station. Each shop has got further step down transformer to
bring down the voltage to 440 Volts.
35

The plant has SKL Diesel generator of 1100KVA kept in generator

house. Total diesel storing capacity of the generator house is 133KL. The
generator output Voltage is 11KV.

LEYLAND PRODUCTS
From 18 seated mini buses used by schools and corporate to 82
seated to double Decker buses from 7.5 ton to 49 ton in haulage vehicles,
from numerous special vehicle applications to diesel engines for
industrial, marine and genset applications.
Ashok Leyland offers a wide range of products. Though timely
innovations the company has created new products and application
segments, there by expanding the market. From eggs to steel, from
flowers to carswhat doesnt moves Ashok Leyland vehicles?
Ashok Leyland have made and sold product like roadways buses,
CNG buses, Defense trucks Vestibule buses, luxury buses, Rear engine
buses, School buses, Tripper and Dumper, Vehicles for fire brigade.
The bus run on Delhi-Lahore route is also made by Ashok Leyland.
Apart from these Ashok Leyland makes the engines which are
being used for Generators, marine and industrial applications. Ashok
Leyland makes three kinds of engines-Al engines, Iveco engine; Mostly
hino engines are being used.

35

3516 TRUCK
TRUCK

3116 TRUCK
BUS

SLF CNG
BUS

4018 TRUCK

CHEETAH BUS

1611

VIKING

ULE A/C & NON A/C BUS

35

35

DYNAMIC SPACE TECHNOLOGY

ALADIN 3 ALIGNER

35

Specifications:
Designed for the alignment of trucks-buses.
4 Measuring Heads, 6 CCD Sensors
Main Features:
Designed for the alignment of trucks-buses.
4 Measuring Heads, 6 CCD Sensor
Bluetooth System data transmission
Windows XP, Different Languages,
15 Monitor, Pentium PC, Ink-Jet Printer,
0.01 degree data display
Steering angles measured automatically and directly by the sensors, no
need for electronic turntables

Measurement:
A camera unit (sometimes called a "head") is attached to a
specially designed clamp which holds on to a wheel. There are usually
four camera units in a wheel alignment system (a camera unit for each
wheel). The camera units communicate their physical positioning with
respect to other camera units to a central computer which calculates and
displays how much the camber, toe and caster are misaligned.
Often with alignment equipment, these "heads" can be a large
precision reflector. In this case, the alignment "tower" contains the
cameras as well as arrays of LEDs. This system flashes one array of
LEDs for each reflector whilst a camera centrally located in the LED
array "looks for" an image of the reflectors patterned face. These cameras
perform the same function as the other style of alignment equipment, yet
alleviate numerous issues prone to relocating a heavy precision camera
assembly on each vehicle serviced.

Necessity:
Wheel alignment is part of standard automobile maintenance that
consists of adjusting the angles of the wheels so that they are set to the
vehicle maker's specification. The purpose of these adjustments is to
reduce tire wear, and to ensure that vehicle travel is straight and true
(without "pulling" to one side). Alignment angles can also be altered
beyond the maker's specifications to obtain a specific handling
characteristic.
35

EXPERIMENTAL DATA

35

STUDY OF WHEEL ALIGNMENT

Wheel Alignment should be checked whenever new tires are installed,
suspension components installed, when the vehicle has encountered a
major road hazard or curb and any time unusual tire wear patterns appear.
Wheel Alignment is the Measurement of complex suspension angles and
the adjustment of a variety of suspension components. It is a suspensiontuning tool which greatly influences the vehicle's handling and tire wear.
Wheel alignment consists of adjusting the angles of the wheels so that
they are parallel to each other and perpendicular to the ground, thus
maximizing tire life and ensures straight and true tracking along a straight
and level road.
The primary static suspension angles that need to be measured and
adjusted are caster, camber, toe and thrust angle.
The following are definitions Conditions and Possible Causes of each
angle and its influence on a vehicle and its tires.
Wheel Alignment: Abstract of These Fundamental Elements

WHEEL ALIGNMENT

CASTER

CAMBER

TOE

35

THRUST

CASTER:
Caster is the angle between an imaginary line drawn
through the upper and lower steering pivots and a line
perpendicular to the road surface (viewed from side of
vehicle).
If the top of the line tilts rearward, the vehicle
is said to have POSITIVE caster. If the top of the line
tilts forward, the vehicle is said to have NEGATIVE caster.
Positive caster can also be defined as when the
spindle is tipped so that the pivot support centerline
intersects the road surface at a point in front of the
Initial tire contact. Negative caster would then be the
center line intersection to the road surface behind the
initial tire contact.

Purpose:
The King Pin is usually set so that tire contact
point with the ground is behind the intersection
point between the steering axis and the ground

This forces the tire to always go ahead.

This improves Straight-Ahead Drivability,

and improves Handling/Steering Return.

Characteristics:
Larger Caster Angle -

Merit: Better Straight-Ahead Drivability Tire contact point Caster Trail

Intersection point Better Steering Wheel Return
with the ground between steering
Demerit: - Heavier Steering
35

Camber Angle
The camber angle will affect the wear on the inner
or outer edge of the tire. Camber is the inclination
of the centerline of the wheel from the vertical as
viewed from the front of the vehicle. Camber angle
is measured in positive or negative degrees.
Positive camber is the outward tilt of the top of the
tire. Negative camber is the inward tilt of the tire at
the top. If a tire was absolutely vertical, the degree
of camber would be zero. Unlike the caster angle,
camber will change with vehicle load and ride height.
With the weight of the driver in the vehicle

Purpose:
1. Improve Steering Control Performance
(Which is related with King Pin Offset?)
2. Improve Cornering Performance.

Characteristics:
Larger Positive Angle (King Pin Offset is smaller)

Merit:Better Handling Control

Better Handling/Steering Return

Demerit:Reduced Cornering Capacity *

Larger Negative Angle (King Pin Offset is larger)

Merit: - Better Initial Handling Response

Better Cornering Capacity

Demerit: - Reduced Handling Control

(Cornering Capacity Safety on Cornering Speed or Radius)
35

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

35

Toe-In and Toe-Out

Toe is the difference between the leading edge (or
front) and trailing edge (or rear) of the tires. Toe-in is
the measurement in fractions of an inch, millimeters or
decimal of degrees that the tires are closer together in
the front than they are in the back. Toe-out is the same

A < B = Toe-

In
A > B = Toeout

measurement, except the tires are further apart in the

front than in the rear.
Some manufacturers measure the angular change
from straight-ahead in degrees. Slight toe-in is preferred
to toe-out on most vehicles because steering is
aligned while the vehicle is stationary, is moving, linkage
components flex causing a change in
alignment angles. The usual tendency is for the tires to turn outward
while the vehicle is in motion, so most vehicles are
designed with a static toe-in setting.

35

Purpose:By setting the most appropriate Toe condition

with the correct Camber condition, driving
performance is well arranged to:
1. Improve Straight Drivability.
2. Improve Handling Response.

The Case:
According to the Camber condition, the Toe-In or Toe-Out settings are
adapted as follows to:
avoid irregular wear, and
balance side forces by Camber and by Toe for high speed driving
performance.

35

Scrub Radius
Scrub Radius is the distance between the extended centerline
of the steering axis and the centerline of the tire where the
tread contacts the road. This distance must be exactly the
same from side to side or the vehicle will pull strongly.
If the steering centerline is inboard of the tire centerline, the
scrub radius is positive. If the steering centerline is outboard
of the tire centerline, the scrub radius is negative.
Rear-wheel drive cars and trucks generally have a positive scrub
radius while FWD cars usually have zero or a negative scrub radius
because they have a higher Steering Axis Inclination (SAI), angle.
Using different wheels other than stock can alter the scrub radius.

35

TOOLS USING IN WHEEL ALIGNMENT FOR

3116 MODEL TRUCK
Space Aladin 3 Aligner (Bluetooth)
Running plot
Numetic gun
Torque ranch
Jack
Wooden block
Sockets
Pressure gauge
Other tools

35

Wheel Aligning Process

Remove cover from the equipment
Switch on the UPS, CPU and monitor
Fix the running plot with the base by studs
Bring the assembled chassis on running plot
Inflate all 12 tires to 40 psi
Remove the running plot stud
Enter the chassis number, vehicle type, etc. in the log book.

Axle 1:
Mount the sensor bracket on the 1st front axle and the rear axle
2
Mount the front sensor on the 1st front axle and rear sensor on
the rear axle 2
Raise the 1st front axle and 2nd rear axle using jack.
Rotate the wheel and keep the knob on the bottom direction
and tighten the knob
Press centre button in the sensor and loosen the knob
Rotate the wheel and keep the knob on the up direction and
tighten the knob
Press centre button in the sensor.
See the monitor it shows stop and the wheel direction shows
up.
Lower the jack and remove the jack.

Follow the steps 1 to 6 on four

35 wheels

 The monitor shows all four wheels in up direction

Press F4 to show next step
Level all four sensor and the monitor shows level position of
each sensor
After leveling the sensors the monitor shows stop and goes to
next step
Steer the steering and place the steering box in green column
as shown in the monitor
And make steering position in centre as shown in the monitor
The monitor shows thrust angle reading.

Correction of Thrust Angle

Loosen all the 2nd axle U bolt nut
Place wooden piece (3"x18") in the 1st and 2nd rear
axle.
Place the jack in between the wooden piece.
Rise the jack up to the reading shows 0 00' in the
monitor.
Tighten all the U bolts in 2nd rear axle.
Remove the jack and wooden box
See the readings in the monitor it should show in the
range -0 05' to +0 05'
Torque all U bolt nuts to 375lbft
Press F4 to go to next step.
The monitor shows the 1st front axle toe reading

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Correction of Toe
The toe reading shows in the monitor
Loosen the pinch bolt in the track rod
Adjust the track rod by rotating it should in the range
of 0.00mm to +2.00mm.
Tighten the pinch bolt using gun.
Press F4 to go to next step.

Axle 2:
The monitor shows the second position in the screen
Retain the 1st axle sensor position
Remove the sensor with bracket from 2nd rear axle
Mount the sensor with bracket in the 1st rear axle
Follow the steps from 1 to 6 on two wheels in the 1st rear axle
Press F4 to go to next step.
The monitor shows Scrub angle reading.

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Correction of Scrub Angle

Loosen all the 1st front axle U bolt nut
Place wooden box in the 1st and 2nd rear axle.
Place the jack in between the wooden box.
Rise the jack up to the reading shows 0 00' in the monitor.
Tighten all the U bolts in 2nd rear axle.
Remove the jack and wooden box
See the readings in the monitor it should show in the
range -0 02' to +0 02'
Torque all U bolt nuts to 375lbft.
Press F4 to go to next step.

Axle 3:
The monitor shows the third position in the screen
Retain the 1st rear axle sensor position
Remove the sensor with bracket from 1st front axle
Mount the sensor with bracket in the 2nd front axle
Follow the steps from 1 to 6 on two wheels in the 1st rear axle.
Press F4 to go to next step.
The monitor shows the 2nd front axle toe position

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Axle 4:
The monitor shows the fourth position in the screen
Retain the 1st rear axle sensor position
Remove the sensor with bracket from 2nd front axle
Mount the sensor with bracket in the 1st front axle
Follow the steps from 1 to 6 on two wheels in the 1st rear axle.
Press F4 to go to next step.
Steer the steering and place the steering box in green column
as shown in the monitor
And make steering position in centre as shown in the monitor

NOTE
Run-out: Rotate the any one side wheel in any
direction to 180 and push the center button of camera.
rotate once again wheel to 180 and push button.
Keep steering always in centre position
Always level first front axle cameras
Use locking device as steering, brakes when needed.
Always lock running plot in the starting of wheel
alignment
Apply torque wrench (345 lbft) after tightening U-bolts.
Use hand brake when lifting rear axles.
There should not be present any objects between
sensor heads.

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