Part 1
32 01 99 (503) Kinematic Diagnosis System and environmentBMW KDS (Beissbarth)
Table of contents
1. Foreword
1.1 Objectives
1.2 Further development of the BMW Kinematic Diagnosis System
1.3 Technical data
1.4 Scope of delivery
1.5 Accessories required
1.6 Accessories recommended
2. Measuring options using the BMW Kinematic Diagnosis System
2.1 Front axle
2.2 Rear axle
2.3 Other measuring options
3. System description
3.1 BMW Kinematic Diagnosis System 1, based on the Beissbarth ML4000
3.2 Computer
3.3 Graphical tablet
3.4 Equipment cabinet
3.5 Remote display
3.6 Measuring sensors with CCD camera
3.7 BMW Quick-acting clamp
3.8 Rotating / sliding plates
3.9 Sensor pins
3.10 Spoiler adapter
3.11 Quick-clamping units
3.12 Retainers
4. Workstation
4.1 Environment
4.2 Preconditions for alignment
4.3 Measuring tolerance
4.4 Levelling the measuring station
5. Chassis-related terms
5.1 Toe-differential angle
5.2 Camber
5.3 Toe-in
5.4 Castor
5.5 Geometrical drive axis / symmetrical axis
5.6 Wheel displacement angle
5.7 Kingpin offset
6. Wheel suspension
6.1 Rigid axle suspension
6.2 Independent wheel suspension
7. Wheel alignment / procedure
7.1 Measuring options
7.2 Preparatory work
7.3 Initial / final measurement
7.4 Printing out the data
8. Special features
8.1 Free wheel alignment
8.2 System settings
9. BMW Kinematic Diagnosis System comparison (Bosch - Beissbarth)
10. Control modification (menu)
10.1 Remote control with display
10.2 Brief operating instructions
10.3 Display support
11. Updating the software / setpoint data
11.1 Requirements
11.2 Procedure (Beissbarth)
11.3 Procedure (Bosch)
12. Creating, copying and editing setpoint data
12.1 Copying
12.2 Creating
12.3 Editing
13. Special functions
13.1 Customer-specific printer report header
13.2 Adjusting options
13.3 Rotating plate test
13.4 Viewing and deleting customer entries from database
14. Modifications within program
15. Faults
15.1 Tire faults
15.2 Front axle faults
15.3 Rear axle faults
1. Foreword
1.1 Objectives
Wheel alignment has become an increasingly complex subject. The aim of this BMW Service Technology bulletin, therefore, is to achieve several objectives:
- Creation of guidelines for working with the BMW Kinematic Diagnosis System (KDS).
- Familiarization with wheel alignment technology for current vehicles and clarifying any questions which arise in this connection.
- Transparency and clarification of different terms.
- Clarification of the causes of errors in the past, such that they can be avoided after reading this document.
- Creation of conditions for dealing safely with the BMW KDS.
1.2 Further development of the BMW Kinematic Diagnosis System
- The BMW Kinematic Diagnosis System is an integrated part of automotive system concepts.
It ensures that work is carried out in a particularly rational manner which is appropriate for BMW requirements, such that you can also be certain of being prepared for future technological developments. As far as precision and performance in wheel alignment and tuning is concerned, BMW, together with leading manufacturers, has made the best of what is technically feasible: the BMW Kinematic Diagnosis System.
- The BMW Kinematic Diagnosis System manufactured by Beissbarth is more than just the further development of conventional wheel alignment equipment. It sets new standards in precision, performance, speed and handling. It is a guarantor for the perfection which BMW service customers rely on.
- Ride comfort, road safety and tire wear depend to a large extent on the perfect interplay of the vehicle's kinematic functions. BMW is constantly launching new generations of chassis which are even better than their predecessors. This is why there are fewer kinematics system adjusting points and narrower tolerances when measuring and tuning the chassis.
- With the use of the multi-link rear suspension and the E36, the electronic wheel alignment devices are no longer suitable for BMW wheel alignment purposes. This applies to both the measuring procedure and measuring precision. The generation of equipment which was approved with the E36 series still fulfils all the requirements placed on a modern wheel alignment device, including the use of the latest computer technology.
- Only BMW Kinematic Diagnosis Systems manufactured by Beissarth and Bosch may be used for wheel alignment.
1.3 Technical Data
1. Display - 17" graphic screen with high resolution graphics (640x480 pixels with 256 colors)
2. On-screen text - in the appropriate national language
3. Wheel dimensions - 12"...20"
4. Vehicle memory locations - unlimited
5. Rotating plates - Loadbearing capacity 1000 kg, angle of rotation ± 360°, 450 x 450 x 50 mm (L x W x H), sliding range ± 50 mm, weight 18 kg
6. Sliding plates - Loadbearing capacity 1000 kg, angle of rotation ± 10°, 450 x 450 x 50mm (L x W 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 Scope of delivery
1 PC display device with graphic screen, graphical tablet, small or large equipment cabinet including automatic charging station, DIN A4 dot matrix printer
4 Measuring sensors with CCD camera technology and infrared data transmission with built-in power supply
1 Cable set (comprising 4 cables)
1 Brake clamping device
1 Steering lock device
2 Electronic precision rotating plates with integrated sensor without access ramps
2 Sliding plates without access ramps
4 BMW quick-clamping units, comprising a P8-68 locating bell and P267 01 quick-acting clamp including coated holding claws
1 Operating instructions for BMW KDS (8 languages)
1 BMW software and the BMW vehicle setpoint data with setting screens as well as text for the measurement preparations
1.5 Accessories required
2 Locating rods for positioning the vehicle
1 Set of sand bags for the prescribed loading
1.6 Accessories recommended
4 Quick-clamping units
2 Sets of access ramps
1 Remote control / display
1 Trolley (for ballast bags, rotating and sliding plates and 4 quick-acting clamps)
2. Measuring options using the BMW Kinematic Diagnosis System
2.1 Front axle
- Toe-in (single and total toe-in in relation to the geometrical drive axis)
- Camber (with steering wheel pointing straight ahead)
- Wheel displacement (in relation to the left-hand front wheel)
- Castor, kingpin inclination and toe-differential angle
2.2 Rear axle
- Toe-in (single and total toe-in in relation to the longitudinal center plane of the vehicle --> previously called symmetrical axis)
- Geometrical drive axis
- Camber
2.3 Other measuring options
- Rear wheel displacement
- Wheelbase difference
- Lateral displacement on right
- Lateral displacement on left
- Track difference
- Axial displacement
3. System description
3.1 BMW Kinematic Diagnosis System 1, based on the Beissbarth ML4000
The KDS 1 is available in two different designs at no extra charge:
1. Mobile workstation
2. Mobile compact cabinet
The larger workstation offers a small storage area for accessories, whilst the compact cabinet is mobile and ideal for restricted working areas. Both variants can be supplied as a cableless measuring system (infrared).
From the point of view of measuring technology, there is only a difference in the handling and equipping of the system. For both designs, the four measuring sensors are stored in integrated inserts with rechargeable battery charging points. When automatically charged over night, the measuring sensor batteries provide enough power for 10 hours of continuous use.
3.2 Computer
- The KDS 1 system comprises tested and reliable industrial components. The computer is an IBM-compatible, 32-bit Intel processor with CD ROM drive to the industry standard.
3.3 Graphical tablet
- All functions are shown in graphical form on a "pictogram" panel. The panel is protected by a plexiglass cover. It can easily be replaced if more extensive design modifications are necessary. The operator interface has no membrane and is thus protected against damage. The main functions are activated by clicking the icon with the digital pen.
3.4 Equipment cabinet
- The PC with graphic monitor and removable operating panel, supports for the measuring sensors, the remote control and the A4 printer are integrated into the workstation. The charging station is located in the cabinet and can also be connected to the measuring sensors and the remote control using the plug-in cables (operating while simultaneously charging the batteries).
3.5 Remote display
A cableless remote display can be supplied on request. The remote control keys are only active during measuring and adjustment (not for customer data input, or if selecting a vehicle or editing the setpoint data etc.). The following displays are supported by the remote control:
- Measured value with setpoint / actual comparison and tolerance bar
- Steering graphics for steering routines
- Live overview of the track / camber values with a setpoint / actual comparison
- Rim run-out compensation
3.6 Measuring sensors with CCD camera
The measuring sensors are each equipped for automatic measurement with two CCD cameras and their own processor for the cableless infrared transmission of data with integrated batteries. Benefits:
- No temperature deviation
- Very high measuring resolution (the track could theoretically be measured in angular seconds)
- Single track range of more than ± 9 degrees for the constant display of toe-in when changing the tie-rod ends
- Exact system accuracy, i.e. when carrying out measurements at the vehicle following rim run-out compensation, the toe-in and camber measurements are accurate to 2 angular minutes
3.7 BMW Quick-acting clamp
- BMW quick-acting clamp for holding the measuring sensors precisely in position and measuring without rim run-out compensation.
- Note: Any existing quick-acting clamps, e.g. from older F1600s or ML-3000s, must not be used on the BMW KDS.
3.8 Rotating / sliding plates
- Electronic precision rotating plates for the front wheels with integrated sensor (360 degree measuring range)
- Stable sliding plates for the rear wheels with a swivelling / rotating top plate
- Accessories: Cover hood for aluminium rotating plates
3.9 Sensor pins
- A new BMW light alloy wheel (styling no. 18) has been available as optional equipment from April 1993. When measurements are being made on vehicles with these wheels, new sensor pins are required for the quick-acting clamps of the recommended wheel alignment equipment.
- The new sensor pins are included in the scope of supply for new deliveries of KDS 1 (order number: BS 90 19 11).
3.10 Spoiler adapter
- In the case of vehicles with very low spoilers, the sensor beam may be broken by the spoiler between the measuring sensors. This primarily occurs in front of the front axle.
- The spoiler adapter is used here as a connecting element between the measuring equipment clamp and the measuring sensor. Thanks to the adapter, the sensors are placed 50 mm lower, thus allowing the sensor beam to move freely below the spoiler.
3.11 Quick-clamping units
- Quick-clamping units for wheel alignment on non-BMW vehicles with rim run-out compensation.
- Rims without sensors boreholes (rims for BMW vehicles from other manufacturers)
3.12 Retainers
- The most varied clamping options for the measuring equipment are possible thanks to the versatile retainers and the rubber-coated thrust pieces, even on exotic light-alloy rims.
4. Workstation
4.1 Environment
Description:
All lifting platforms currently recommended by BMW (see Workshop Equipment Planning documentation, Issue 11) for wheel alignment meet the requirements for the BMW KDS.
No particular requirements have to be met in respect of the location at which the BMW KDS is used. The measuring device can be installed over working pits or on lifting platforms.
Requirements:
- Wheel alignment pits
- Pillar-type lifts with set-down device
- 2 plunger-type lifting platforms with set-down device
- Repair stands with set-down device
- One measuring area (approx. 4.5 m x 7.0 m).
- The rotating plates must be pinned to the platform
The support surfaces for the rotating and sliding plates may only display the following maximum height difference:
- from left to right ± 0.5 mm
- from front to back ± 1.0 mm
- diagonally ± 1.0 mm.
Note:
A difference in the height of the rotary plates of ± 2 mm from left to right results in a measuring error of 4.8° in the camber.
As a comparison: The camber tolerance on the E36 is ± 10'. The tire tread difference or varying tire pressure cause measuring errors of the same magnitude.
4.2 Preconditions for alignment
When carrying out the wheel alignment, the front and rear wheels must be centered on the rotating and sliding plates in order that all wheel suspensions remain free of tension during the steering routine and adjustment work. As a result, the rotating and sliding plates for the relevant wheel bases and track widths of the vehicle to be aligned must be moved.
4.3 Measuring tolerance
All measuring tolerances are system tolerances. This means that the sum of all individual tolerances gives the value shown in the example. Example of camber: Quick-acting clamp + measuring sensor + computer = 1' at a measuring range of ± 3° (all BMW vehicles are within this measuring range).
4.4 Levelling the measuring station
The manufacturers of the BMW KDS (Beissbarth / Bosch) are able to measure the measuring area to the required accuracy using levelling devices. Any "normal" water level is not suitable for this. Lifting platforms must be levelled under load so that the uneven deflection in the travel rails is taken into account.
Important:
Adjustment work for the lifting platform concerned must be executed by a specialist (manufacturer's after-sales service).
5. Chassis-related terms
5.1 Toe-differential angle
- The toe-differential angle (a) is the angular position of the internal wheel on the curve in relation to the external wheel on the curve when driving round bends. The steering is designed such that the angular position of the wheels in relation to each other changes as the steering angle increases.
- In ideal cases, the wheel axes meet at point D in any steering position (except for straight ahead).
5.2 Camber
- The camber is the angle of inclination of the wheel in relation to the vertical.
5.3 Toe-in
- The toe-in is the reduction in the distance between the front of the wheels and the rear. The toe-in prevents the wheels from moving apart whilst driving (wobbling and grinding).
5.4 Castor
- The castor is the kingpin angle seen from the side in the opposite direction of travel. The line through the center of the spring strut mount and control arm ball joint corresponds to the kingpin.
5.5 Geometrical drive axis / symmetrical axis
- (1) The geometrical drive axis is the line bisecting the angle of the overall rear wheel toe.
The measurements of the front wheels relate to this axis.
- (2) The symmetrical axis represents the center line through the front and rear axes.