Part 1
32 01 99 (503) Kinematics diagnosis system and environmentBMW KDS (Beissbarth)
Table of contents
1. Foreword
1.1 Objective
1.2 Further development of the BMW kinematics diagnosis system
1.3 Technical data
1.4 Delivery specification
1.5 Required accessories
1.6 Advisable accessories
2. Measuring options with the BMW KDS
2.1 Front Axle
2.2 Rear Axle
2.3 Other measuring options
3. System description
3.1 BMW KDS 1, based on the ML4000 from Beissbarth
3.2 Computer
3.3 Graphics pad
3.4 Equipment cabinet
3.5 Remote display
3.6 Measuring pickup with image sensor (CCD camera)
3.7 BMW quick-release brackets
3.8 Rotational / sliding supports
3.9 Sensor tips
3.10 Spoiler adapter
3.11 Quick-clamping units
3.12 Retaining claws
4. Work bay
4.1 Environment
4.2 Prerequisite for measurement
4.3 Measuring tolerance
4.4 Levelling of measuring point
5. Chassis-specific terms
5.1 Toe difference angle
5.2 Camber
5.3 Toe
5.4 Castor
5.5 Geometrical driving axis / symmetrical axis
5.6 Wheel offset angle
5.7 Kingpin offset / kingpin radius
6. Wheel suspension
6.1 Rigid axle
6.2 Independent suspension
7. Wheel alignment / procedure
7.1 Measuring options
7.2 Preparatory work:
7.3 Incoming / outgoing wheel alignment
7.4 Printout of the data
8. Special features
8.1 Wheel alignment with non-selective access
8.2 System setting
9. Comparison, BMW KDS (Bosch - Beissbarth)
10. Change in operation (menu)
10.1 Master key with display
10.2 Summary operating instructions
10.3 Display support
11. Software updates / nominal data
11.1 Preconditions
11.2 Procedure (Beissbarth)
11.3 Procedure (Bosch)
12. Creating, copying and editing nominal data
12.1 Copying
12.2 Creating
13.3 Editing
13. Special functions
13.1 Customer button for printer protocol
13.2 Adjustment options
13.3 Turntable test
13.4 Viewing and deleting customer entries from the database
14. Internal program change
15. Error
15.1 Tire fault
15.2 Front axle fault
15.3 Rear axle fault
1 Preface
1.1 Objective
The complexity of wheel alignment as a topic has increased. This BMW Service Technology document is therefore intended to achieve several objectives:
- Compiling guidelines for working with the BMW KDS.
- Getting to grips with the technology of wheel alignment on modern vehicles and clarifying any questions that arise.
- Transparency and clarification of different terminology.
- Clarification of fault causes from the past, so that these can be avoided in future after studying this paper.
- Prerequisites for safe dealings with BMW KDS.
1.2 Further development of the BMW kinematics diagnosis system
- The BMW kinematics diagnosis system (KDS) forms an integral element of systems-based philosophy in relation to automotive technology. This provides the peace of mind of being able to work rationally and in a BMW-compliant manner, and the certainty of being prepared for future technological developments. With regard to precision and performance in the area of wheel alignment and chassis adjustment, BMW has done the best it can with what is technologically feasible: The BMW kinematics diagnosis system (KDS).
- The BMW kinematics diagnosis system from Beissbarth is more than just a further development of conventional axle alignment equipment. It sets new dimensions in terms of precision, performance, speed and handling. Guarantees for the perfection upon which BMW customers count in their dealings with BMW Service.
- Ride comfort, driving safety and tire wear depend to a large extent on perfect interaction with vehicle kinematics. BMW is constantly delivering new generations of chassis and suspension to the market, each of which is superior and/or even closer to perfection than its predecessor. That means that there are fewer kinematic adjustment points on the chassis and suspension and even tighter specified tolerances with regard to wheel alignment and adjustment.
- Through the use of the multilink rear axle and the E36, the previously recommended electronic wheel alignment equipment was no longer suitable for BMW chassis alignment checks. This related to the measuring procedure as well as to the measuring accuracy. The generation of equipment approved with the introduction of the E36 range is still able today to satisfy all the requirements imposed on modern wheel alignment equipment, including the use of the latest computer technology.
- For wheel alignment purposes, only the BMW kinematics diagnosis systems from Beissbarth and Bosch may be used.
1.3 Technical data
1. Display - 17 inch graphics screen with high-resolution graphics (640x480 pixels with 256 colors)
2. Teletext - in each programmed national language
3. Wheel sizes - 12"...20"
4. Vehicle memory capacity - unlimited
5. Turntables - Load-carrying capacity 1000 kg, angle of rotation ± 360°, 450 x 450 x 50mm (L x B x H), sliding range ± 50 mm, weight 18 kg
6. Sliding supports - Load-carrying capacity 1000 kg, angle of rotation ± 10°, 450 x 450 x 50mm (L x B x H), sliding range ± 65 mm, weight 17 kg
7. Electrical connection - 100...115 V / 220...240 V 50/60 Hz, 0,5 kw (other connections on request)
1.4 Delivery specification
1 PC display element with graphics screen, graphics panel, equipment cabinet, small or large including automatic charging station, DIN-A4 dot matrix printer
4 Pickup with CCD camera technology and infrared data transfer, with installed voltage supply
1 Wiring harness (comprising 4 cables)
1 Brake tensioner
1 Steering wheel lock
2 Electronic precision turntable supports with integrated sensor and without approach ramp
2 Sliding supports without approach ramp
4 BMW quick-release units comprising a locating bell housing P8-68 and quick-release bracket P267 01, incl. coated retaining claws
1 Operating instructions for BMW KDS (8 languages)
1 BMW software and the BMW nominal vehicle data with adjustment images as well as texts for measurement preparations
1.5 Required accessories
2 Locking rods for positioning the vehicle
1 Set of sandbags for specified loading
1.6 Advisable accessories
4 Quick-clamping units
2 Set of collision plates
1 Remote control / display
1 Transport carriage (for ballast pockets, turntables and sliding plates, and 4 quick-release brackets)
2 Measuring options with the BMW KDS
2.1 Front axle
- Toe-in (individual wheel and total toe-in relative to the geometrical driving axis)
- Camber (when driving straight ahead)
- Wheel offset (relative to the left front wheel)
- After-run, steering axis inclination and toe difference angle
2.2 Rear axle
- Toe-in (individual wheel and total toe-in relative to the central plane of the vehicle's longitudinal axis --> previously known as the symmetrical axis)
- Geometrical driving axis
- Camber
2.3 Other measuring options
- Wheel offset, rear
- Wheelbase difference
- Lateral offset, right
- Lateral offset, left
- Track width difference
- Axial offset
3. System description
3.1 BMW KDS 1, based on the ML 4000 from Beissbarth
The KDS 1 is available without surcharge in a choice of two design versions:
1. Mobile workstation
2. Mobile compact cabinet
The larger workstation provides a small storage space for accessories, whereas the compact cabinet is mobile and is ideal for confined working areas. Both versions are available as a wireless measuring system (infrared). In terms of measuring technology, the only difference between these two systems is in their handling and their upgrade options. In both these versions, the four pickups are stored in integrated inserts with battery charge points. Following the automatic charging process, the accumulators on the pickups deliver enough power for 10 hours of continuous operation.
3.2 Computer
- KDS system 1 comprises tried-and-tested and thoroughly reliable industrial components. The computer is an IBM-compatible 32-bit Intel processor with CD drive, of the kind commonly used in the PC sector.
3.3 Graphics pad
- All functions are depicted graphically on a "Symbol" pad. The pad is protected beneath a Plexiglass panel. This is easy to replace whenever major design changes are required. The user interface has no membrane and is therefore safely protected against damage. The main functions are enabled by clicking the symbol with the sensor probe.
3.4 Equipment cabinet
- The PC with graphics monitor and pull-out operating pad, mountings for the pickups, the remote control and the DIN-A4 printer are integrated on the workstation. The charging station is located in the cabinet and can also be connected to the pickups and remote control unit by plug-in cables (operation with simultaneous charging of the accumulators / rechargeable batteries).
3.5 Remote display
A wireless remote display unit can be provided on request. The remote control buttons are only enabled during the measurement and setting process (not in response to customer input, choice of vehicle, processing of nominal data etc.). The following displays are supported by the remote display facility:
- Measured value with nominal/actual variance comparison and tolerance bar
- Touchscreen icon for touch-sensitive routines
- Live overview of toe-in / camber values with nominal / actual comparison
- Rims, lateral runout compensation
3.6 Measuring pickup with image sensors (CCD cameras)
Each of the measuring pickups is equipped with two image sensors and its own processor for wireless infrared transmission with integrated accumulators for automatic measurement. Advantages:
- No temperature deviation
- Very high measuring resolution (theoretically, toe-in could be measured in seconds of an angle).
- Single toe-in range of more than ± 9 degrees relative to constant screen display of toe-in during the replacement of track rod ends
- Exact system precision, i.e. with measurements on the vehicle following rim lateral runout compensation: an accuracy of 2 minutes of angle for toe-in and camber
3.7 BMW quick-release brackets
- BMW quick-release brackets for precise mounting of measuring pickups and measurement without compensation of lateral runout on rims.
- Note: Quick-release brackets potentially available,, e.g. from older F1600 or ML-3000 models, must not be used with the BMW KDS.
3.8 Rotational / sliding supports
- Electronic precision turntables (rotational supports) for the front wheels with integrated sensor (360 degrees all-round measuring range)
- Robust sliding supports for the rear wheels with a swivelling / rotating upper plate.
- Accessories: Cover for aluminium rotational supports / turntables
3.9 Sensor probes
- From April 1993, a new BMW light-alloy wheel (styling No. 18) has been available as a BMW optional accessory. During vehicle alignment checks on these wheels, new sensor probes are required for the quick release mountings on the recommended wheel alignment equipment.
- On recent deliveries of KDS 1, the new sensor probes are included in the delivery specification (order number: BS 90 19 11).
3.10 Spoiler adapters
- On vehicles with very deep spoilers, it is possible for the measuring beam between the measuring pickups to get interrupted. This is particularly true of the transverse front axle.
- In this case, the spoiler adapter acts as a connecting member between the measuring device holder and the measuring pickup. This causes the measuring pickup to be located 50 mm lower, thereby enabling the measuring beam to pass freely below the spoiler.
3.11 Quick-release mountings
- Quick-release mountings for the wheel alignment of other vehicles with compensation of lateral runout on rims.
- Wheel rims without sensor bore holes (wheel rims for BMW vehicles made my other manufacturers)
3.12 Retaining claws
- The versatile retaining claws and the rubberized retaining claws enable an extremely wide and varied range of clamping variants to be used for the measuring equipment holder, even on exotic, i.e. extremely unusual, light-alloy rims.
4. Work bay
4.1 Environment
Description:
All the vehicle hoists currently recommended by BMW (cf. Workshop Equipment - Planning Documentation, issue 11) for wheel alignment equipment comply with the requirements for BMW KDS.
The BMW KDS does not impose great demands on its installation location. The device can be used over inspection pits or on vehicle hoists (i.e. workshop ramps).
Prerequisites:
- Wheel alignment pits
- Telescopic mast vehicle hoists with lowering facility
- 2-stamp vehicle hoists with lowering facility
- Repair statuses with lowering facility
- One measuring station (approx. 4.5 m x 7.0 m).
- The rotational supports ('turntables') must be bolted to the vehicle hoist
The locating surfaces for rotational and sliding plates must not exceed the maximum difference in height described below:
- from left to right ± 0.5 mm
- from front to back ± 1.0 mm
- diagonally ± 1,0 mm.
Note:
A height difference between turntables of ± 2 mm from left to right gives rise to a measuring error with camber of 4,8°.
For comparison: The camber tolerance on the E36 is ± 10'. Tire tread difference or different inflation pressures give rise to measuring errors on the same magnitude.
4.2 Prerequisites for the wheel alignment check
During the wheel alignment check, the front and rear wheels need to be standing on the rotational and sliding supports to enable all wheel suspension points during the touch-sensitive routine and the adjusting procedure to remain free of torsional stresses. This demonstrates the need for the rotational and sliding supports for the various wheel bases and track widths on the candidate vehicle for the wheel alignment check to be relocated.
4.3 Measuring tolerance
The full range of measuring tolerance are system tolerances. That means that the total of all individual tolerances yields the value identified in the argumenter. Example - camber: Quick-release bracket + measuring pickup + computer = 1' with a measuring range of ± 3° (all BMW vehicles lie within this measuring range).
4.4 Measuring station levelling
The manufacturers of BMW KDS (Beissbarth / Bosch) are able to check the alignment of the measuring station to the required level of precision, using levelling devices to do so. Bars or hose-type water scales are not suitable. Vehicle hoists must be under load when being levelled to ensure that due account is taken of the uneven deflection in vehicle rails.
Important!
A specialist operator must be involved in the setup work on each vehicle hoist (a member of the manufacturer's Service Product Support staff).