Home

Print Page   Diagnostic Engine Tester Hermann Electronics/Pierburg Instruments Model:___________________ Serial No._______________ Software version:__________   Use  new in shop  already in use for longer period Operating hours _______________ (if equipped with operating hours meter ) Measurement display includes measurements from chassis dynamometer yes no Maintenance contract yes no yes no Trigger clip orange closing force yes no kV clip blue closing force yes no Oil temp. Temp. reading identical to room temperature yes no Current clip Nom. Closed, reading 0 A ± 1 digit jump act._______A Pressure sensor Nom. No pressure, reading 0.1 bar ± 1 digit jump yes no Printer   Function good poor     Legibility good poor Ignition oscilloscope display, continous display ( with and without adapter ) Engine idling Screen display, see instructions for good pattern yes no   Measurements identical with table yes no Simulate misfires, caution on vehicles with lambda control < 10 seconds Engine idling Misfires are correctly displayed yes no Idle speed rises approx. 3000 rp, missfires are correctly displayed yes no   Misfires are correctly displayed under acceleration yes no Meas. values Graphic display identical with table yes no Engine idle quality (smooth-running) display (with or without adapter) Simulate misfires, caution on vehicles with lambda control < 10 seconds Engine idling Misfires are correctly displayed yes no Meas. values Graphic display identical with table yes no Compression test display (with or without adapter) Remove spark plug from one cyl., route to ground in spark plug connector. Cylinder without compression is correctly displayed Graphic display yes no   Current table yes no Engine trigger setting display (with or without adapter) Idle speed rises approx. 3000 rpm Rpm display stable yes no Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic )  SUBJECT                                   - 6 1) Electronic units with Screen Dealer Code:________________ Dealer City and State:________________________________ Equipment Manufacturer/Model:____________________ Serial Number:___________________ Use  new in shop  already in use for longer period Operating hours _______________ (if equipped with operating hours meter ) PMC contract yes no Last inspected on_______________________ MB Software Version______________________ Mfr.Software Version_____________________ When setting up for the first time: get the unit manufacturer (or lift manufacturer) to check the lift/rack for equal height using a transit leveling unit (see DCAG data sheet checklist -8, -8.1). Reading Permissible digit jumps ± 1 digit act._______________ digits   Sensor on vehicle not actuated   Measuring facility Conditions good poor Measuring accuracy Check sensor, see -6.1 Printer Actuate printer Function good poor     Legibility good poor Turntables Secured on ramps   yes no   Easy to move under load yes no Sliding platforms Secured on ramps   yes no   Easy to move under load yes no Inspected by: Date: _____________________ Signature:   Next inspection:_____________

WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic ) by Manufacturer Testing on the vehicle  SUBJECT                                - 6.1   NO. Subject   1) Aligner: John Bean V6 or V7   2) Aligner: Beissbarth, microline 4001   3) Aligner: Beissbarth, microline 4601   4) Aligner: Hunter HTA-MB     Legend:     FAHRACHSWINKEL AUF NULL STELLEN = SET LONGITUDINAL AXIS TO ZERO 1. Messung = 1st measurement STURZ VORNE LINKS = CAMBER FRONT LEFT   STURZ VORNE RECHTS = CAMBER FRONT RIGHT   SPUR VORNE LINKS = TOE-IN FRONT LEFT   SPUR VORNE RECHTS = TOE-IN FRONT RIGHT   HR = RR   HL = RL   VR = FR   VL = FL   Fahrtrichtung = Forward   DIFFERENZ = DIFFERENCE   2.Messung = 2nd measurement   STURZ HINTEN LINKS = CAMBER REAR LEFT   STURZ HINTEN RECHTS = CAMBER REAR RIGHT   SPUR HINTEN LINKS = TOE-IN REAR LEFT   SPUR HINTEN RECHTS = TOE-IN REAR RIGHT

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic ) by Manufacturer Testing on the vehicle  SUBJECT                                - 6.1 1) Checking sensors by switching them on vehicle   John Bean, Visualiner V6 or V7 Drive vehicle onto turntables and sliding platforms. Remove arresting pins in platforms. Install brake pedal tensioner. Attach sensors opposite to direction of forward motion. FL RR, FR RL, RR FL, and RL FR. Switch on unit Key 4 Key3 Red key Center front wheels Actual readings. 1st  measurement Set longitudinal axis angle to zero. Sensors in zero position. Enter toe-in   and camber readings for front wheels. 2nd measurement Move sensors to direction of forward motion. Sensors in zero position.   Enter toe-in and camber readings for rear wheels. Camber readings from 1st and 2nd measurements If signs are different, add values. If signs are same, subtract smaller value from larger. Toe-in readings from 1st and 2nd measurements: If signs are different, subtract smaller value from larger. If signs are same, add values. The differences should not be greater than > 4 + 1 digit. If they are greater, the equipment must be readjusted, adjustment instructions. Counter-measurement must be repeated on the vehicle following each adjustment. Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic ) by Manufacturer Testing on the vehicle  SUBJECT                                - 6.1 2) Checking sensors by switching them on vehicle   Beissbarth, microline 4001 Drive vehicle onto turntables and sliding platforms. Remove arresting pins in platforms. Install brake pedal tensioner. Attach sensors. Switch on unit. Testbed Monitoring System (MKS) display appears. Click red dot. Click on MKS red dot. Determine position of sensors ( FL = no.4, FR = no.3, RL = no.2, RR = no.1). press C key to start new measuring and click monitor symbol. 1st  measurement Adjust longitudinal axis angle to zero. Sensors in zero position. Enter toe-in   and camber readings. 2nd measurement Switch sensors diagonally RR FL, RL FR, FR RL and FL RR.   Sensors in zero position. Enter toe-in and camber readings. Camber readings from 1st and 2nd measurements If signs are different, add values. If signs are same, subtract smaller value from larger. Toe-in readings from 1st and 2nd measurements: If signs are different, subtract smaller value from larger. If signs are same, add values. The differences should not be greater than > 4 + 1 digit. If they are greater, the equipment must be readjusted, adjustment instructions. Counter-measurement must be repeated on the vehicle following each adjustment. Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic ) by Manufacturer Testing on the vehicle  SUBJECT                                - 6.1 3) Checking sensors by switching them on vehicle   Beissbarth, microline 4601 Drive vehicle onto turntables and sliding platforms. Remove arresting pins in platforms. Install brake pedal tensioner. Attach sensors opposite to direction of forward motion. Switch on unit F4 F9. 1st  measurement Adjust longitudinal axis angle to zero. Sensors in zero position. Enter toe-in   and camber readings. 2nd measurement Switch sensors diagonally RR FL, RL FR, FR RL and FL RR.   Press R key on each sensor F1 Start new measuring operation   F9 Sensors in zero position Enter toe-in and camber readings. Camber readings from 1st and 2nd measurements If signs are different, add values. If signs are same, subtract smaller value from larger. Toe-in readings from 1st and 2nd measurements: If signs are different, subtract smaller value from larger. If signs are same, add values. The differences should not be greater than > 4 + 1 digit. If they are greater, the equipment must be readjusted, adjustment instructions. Counter-measurement must be repeated on the vehicle following each adjustment. Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ALIGNMENT CONSOLE UNIT ( electronic ) by Manufacturer Testing on the vehicle  SUBJECT                                - 6.1 5) Checking sensors by switching them on vehicle   Hunter HTA - MB Drive vehicle onto turntables and sliding platforms. Remove arresting pins in platforms. Install brake pedal tensioner. Attach sensors opposite to direction of forward motion. Switch on unit 2 x K4 K3 Quick measurement. 1st  measurement Adjust longitudinal axis angle to zero. with steering wheel Sensors in   zero position Enter camber and toe-in readings. 2nd measurement Attach sensors in direction of forward motion. Enter camber and toe-in   readings. Compare camber readings from 1st and 2nd measurements If signs are different, add values. If signs are same, subtract smaller value from larger. Compare toe-in readings from 1st and 2nd measurements: If signs are different, subtract smaller value. If signs are same, add values. The differences should not be greater than > 4 + 1 digit. If they are greater, the equipment must be readjusted, adjustment instructions. Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 Quick CLAMP ADAPTERS (MB Special Tool: 124 589 01 31 00)  SUBJECT                                - 6.3 For use with Wheel (chassis) Alignment Units Dealer Code:________________ Dealer City and State:________________________________ Use  new in shop  already in use for longer period Drive vehicle onto turntables and sliding platforms. Do not remove arresting pins in platforms. Attach universal mounts with sensors to front wheels and to right rear wheel. Attach MB Quick Clamp Adapters one after another to left rear wheel. Set spirit level to zero position and enter left rear camber / toe-in readings. 1st  measurement Evaluation Compare readings with one another. Permissible difference between readings 3` + 1`. If readings with the same value ± 2 digit jumps are obtained with two or more MB Quick Clamp Adapters, they are okay. If this accuracy is not obtained, a second measurement is necessary. The readings must be reproducible in comparison to the first measurement. If the deviation in readings is confirmed, the MB Quick Clamp Adapter(s) must be repaired. 2nd measurement Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 ANGLE or SPOILER ADAPTERS (for vehicles with front spoilers)  SUBJECT                                - 6.4 Dealer Code:________________ Dealer City and State:________________________________ Checking parallelism of angle adapters for chassis alignment on vehicle. The parallelism is assessed in pairs by means of the rear left and rear right toe-in and camber readings. Drive vehicle onto turntables and sliding platforms. Attach sensors with the Quick Clamps. Evaluation: The differences must not be greater than > 4` + 1 digit. If they are greater, then the adapter(s) must be repaired or replaced. Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 LIFT or RACK (for WHEEL ALIGNMENT)  SUBJECT                                   - 8 Lift or Rack Platform (4-post type or scissors-type) Dealer Code:____________________ Dealer City and State:___________________________ Equipment Manufacturer/Model:_________________ Serial No.________________________ Use  new in shop  already in use for longer period Indicator lights *) Nom. on with ramps lowered completely yes no   Nom. on with ramps lifted and leveled yes no Safety *) Light barriers/switch strips Indicator lights on yes no Electrical system Alignment Console unit permanently wired yes no PMC contract   yes no Measuring point Site conditions good poor Turntables Secured on ramps yes no   Easy to move under load yes no Sliding platforms Secured on ramps yes no   Easy to move under load yes no When first setting up or adjusting lifting platforms and when first setting up chassis alignment units, the wheel contact surfaces of the runways should be checked for equal height by the supplier with a transit (leveling unit) with a mind-size vehicle on the lift or rack. Runways completely lowered FL _______________ mm FR _______________ mm Difference _______________ mm RL _______________ mm RR _______________ mm Difference _______________ mm FL _______________ mm RR _______________ mm Difference _______________ mm FR _______________ mm RL _______________ mm Difference _______________ mm Runways lifted and leveled FL _______________ mm FR _______________ mm Difference _______________ mm RL _______________ mm RR _______________ mm Difference _______________ mm FL _______________ mm RR _______________ mm Difference _______________ mm FR _______________ mm RL _______________ mm Difference _______________ mm Permissible height difference between wheel contact surfaces   1mm Lifting platform ( scissors-type or 4-column etc.) Runway level correction (runways from completely lowered to lifted)   This uses the camber sensors of the aligner to check the runway level. Drive vehicle onto turntables and sliding platforms, install brake pedal tensioner, remove pins in platforms, attach sensors to vehicle, enter camber readings ( see operating instructions). Runways completely lowered Runways raised and leveled Camber FL _____________ Camber FL ____________ Difference _______________ Camber FR _____________ Camber FR ____________ Difference _______________ Camber RL _____________ Camber RL ____________ Difference _______________ Camper RR _____________ Camber RR ____________ Difference _______________ Permissible differences 2' + 1 digit jump. If differences are too great, repeat test once. The readings must be reproducible within ± 1 digit jump. If not, readjust runways. Remarks/notes: Testbed Monitoring System: Q,q2, -8.1 Scissors lifting platforms H, 00 (1), -6 Inspected by: Date: _____________________ Signature:   Next inspection:_____________

WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC	HOME
	CHAPTER                               Q
	GROUP                                  q2
MKS-MEASUREMENT CONTROL/MONITORING SYSTEM (Chassis TESTBED MONITORING SYSTEM)	SUBJECT                                - 8.1

General
	MKS offers the convenience of quickly and accurately establishing, e.g. prior to each
	chassis alignment operation, whether the systems has suffered any measurement
	accuracy. This is done by attaching precision supports for the measuring sensors
	at the front and rear of the runways on each side of the rack.
	MKS is a tool for the continuous quality assurance of the chassis alignment workplace
	by the user.
	MKS can only be installed an chassis alignment lifts/racks with runways above floor level.
	MKS is not suitable nor is it to be used for performing adjustment and leveling work on the
	lift/rack.

Prerequisites for MKS
	The runways of the lift/rack must be leveled to the same height 1 mm, when loaded,
	in all operating ranges (this must be performed by the manufacturer during the initial
	installation or during the annual calibration).
	The camber and toe-in sensors of the chassis alignment system must be properly
	adjusted according to the manufacturer's specifications (performed by the alignment
	console supplier during initial installation).

MKS Installation
	Following installation of the lift/rack and leveling of the runways by the lift supplier and
	installation of the alignment console by its supplier (including adjustment of the sensors
	on the adjustment device), the MKS should be installed by its supplier in the presence of
	the operator (dealer personnel). This includes provision of documenting the reference
	values via the transit measurements.
	The runways of the lift/rack are lowered completely. This is the start and finish position
	for all chassis alignment operations. The sensors are inserted into the MKS brackets
	at the sides of the runways, adjusted to the zero position with the aid of a spirit level fixed
	with clamping screws.
	Drive a mid-range car onto the turntable and sliding platforms. Remove the arresting pins
	from the turntables and sliding platforms or unlock the sliding platforms.
	The camber and toe-in reading displayed on the MKS screen are reference values. On
	computer - aided systems these can be set to zero after entering the password. Password
	information can be obtained from the manufacturer of the equipment.
	The reference values on non - computer - aided systems cannot be set to zero, and must
	therefore be noted or printed out for comparison purposes.

Use of the MKS
	If the MKS screen displays toe-in and camber readings > 5' + 1 digit jump before an
	alignment operation, then the entire system must be checked ( sensors inserted into the
	MKS brackets at the sides of the runways, runway lowered completely and loaded with
	a vehicle).
	In computer - aided systems with special MKS display, Impermissible reference value
	deviations are automatically marked in red. On systems without the special MKS display,
	the noted basic reference values must be compared with the current MKS values to
	assess the accuracy of the system.

Checking chassis alignment systems after impermissible MKS deviations:

METHOD 1:
Lift/rack Platform
	Runway level comparison ( bottom to top ) with
	sensor on the vehicle, q2, -8, 2 (comparison of
	camber readings between runways completely
	lowered and lifted and leveled).
	For camber reading deviations ( > 2' + 1 digit ) the
	runways must be adjusted by the supplier
	( using a transit ).
	For < 2' + 1 digit (i.e. OK), the MKS deviation is
	probably due to the aligner.

Aligner Console
	Check toe-in and camber sensors by repositioning
	them on the vehicle, q2, -6.1, 1-3.
	For differences > 4' + 1 digit, adjust the aligner
	according to the deviations, adjustment
	instructions and on-screen user guidance.

METHOD 2:
	Check the sensors of the alignment console with
	the calibration device ( included with the aligner
	console package ) and adjust if necessary. If
	this falls to reveal significant deviations at the
	sensors, then the MKS deviation is probably due
	the lift/rack ( after adjusting the sensors call up the
	MKS values again if necessary ). The lift/rack
	should only be checked and adjusted by supplier.

Print Page   WORKSSHOP EQUIPMENT DaimlerChrysler AG + MBUSA LLC HOME CHAPTER                               Q GROUP                                  q2 DISTRONIC ADJUSTING DEVICE (MBUSA Special Tool: 900 589 07 21 00)  SUBJECT                                 - 14 Dealer Code:____________________ Dealer City and State:___________________________ Manufacturer/Model______________________ In use since:___________________________ Inventory No.:_____________________________ Device no.:___________________________ Function test with testing device: Set up device as per operating Instructions. Install adjustment device. Connect     plug on spiral cable to vehicle cigarette lighter. Check position of baser beam.     Laser beam position Light spot within tolerance ( see operating instructions ) yes no       Raise centering bracket on testing device. Turn adjustment device through 180 °     Laser beam position. Light spot with tolerance ( see operating instructions ) yes no       If the light spots is outside the tolerance, the adjustment device must calibrated.     Follow operating instruction for repair/calibration service.           Leak Test on Vacuum Bell Place vacuum bell on test surface and draw vacuum to 500 mbar using a     vacuum pump.           Specification: Vacuum to hold constant for approx. 30 sec yes no       If the vacuum is not constant, the entire adjustment device must be sent to the manufacturer for repair. Follow instruction in the operating instruction for repair/calibration service. Remarks: Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   Wheel Balancing Machine, stationary Model:__________________ Serial No._______________ Manufacturer:__________________ Use new in shop already in use for longer period Display analog digital monitor Check display accuracy Caution: Switch OFF residual imbalance suppression, see operating instructions 1. Balance light alloy wheel to zero in both planes Outer/inner plane Nom. Imbalance value deviation < 5 grams Outer/inner plane Nom. Imbalance value position 180 ° < 5° 2. Attach known auxiliary weight, e.g. 30 grams, in outer plane first then in inner plane Imbalance value Act. Outer plane_______________g good poor Imbalance value Act. Outer plane_______________° good poor Imbalance value Act. Outer plane_______________g good poor Imbalance value Act. Outer plane_______________° good poor Check clamp driveshaft     balance wheel to zero in both planes. Loosen wheel on mounting flange and turn approx. 180°. Shaft and mounting flange should not turn. Tighten wheel. Outer/inner plane Nom. Imbalance value deviation < 5 grams   Act. Outer plane_______________g good poor   Act. Outer plane_______________g good poor Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Print Page   Torque Wrench Measuring and click-type torque wrenches Model:__________________ Serial No._______________ Manufacturer:__________________ Measuring range:__________to__________Nm click-type or measuring -type Visual inspections: External condition ( damage / corrosion ) good poor Legibility of scale markings and digits ( scale markings straight / sharp edged) good poor Condition of hex. drive for socket good poor       Function tests on click - type torque wrenches:           Audiable test on reaching preset specified torque good poor Self-holding function to torque adjustment good poor Ease of specific torque setting good poor       Function tests on measuring-type torque wrenches:           Ease of needle movement (friction) and self-holding of maximum. indicator good poor       Test unit model:______________________ Last calibration:______________________ Testing of measurement accuracy: End-of-range value____________Nm, thereof 20%__________NM, and 60%_____________NM Normal room temperature for torque wrenches, test instruments and the environment ( approx. 20 ± 5° C). Increase force application quickly up to approx. 80 % of test value. Then slow down and gradually add more force until wrench releases or test value is reached ( within approx. 1-4 seconds). Perform at least two trial releases. Maximum deviation for click-type torque wrenches ± 4% and for "measuring-type torque wrenches" ± 6% of the test value. Spec.value e.g.   20%:_________Nm Spec. range ± 4% (± 6%) from_______to_______Nm Spec.value e.g.   60%:_________Nm Spec. range ± 4% (± 6%) from_______to_______Nm Spec.value e.g. 100%:_________Nm Spec. range ± 4% (± 6%) from_______to_______Nm Spec. value ± 4% or ± &%, gives the spec. range within which all measured actual values must lie. Transfer these calculated specified ranges into the following chart. Calculated Specified Range Charts Spec. e.g. 20% .................Nm Actual values Within spec.range yes / no Spec. range from _________to______NM 1st measurement Nm     2nd measurement Nm     3rd measurement Nm     4th measurement Nm     5th measurement Nm     Spec. e.g. 60% .................Nm Actual values Within spec.range yes / no Spec. range from _________to______NM 1st measurement Nm     2nd measurement Nm     3rd measurement Nm     4th measurement Nm     5th measurement Nm     Spec. e.g. 100% .................Nm Actual values Within spec.range yes / no Spec. range from _________to______NM 1st measurement Nm     2nd measurement Nm     3rd measurement Nm     4th measurement Nm     5th measurement Nm     Inspected by: Date: _____________________ Signature:   Next inspection:_____________

Painting Facility (Spray Booth)

No.	Action	Designation of parts and assemblies	Perform ________ .5	approx. ______ 1	every _____ 3	..... ____ 6	months ______ 12	Notes:
1	Replace	Floor filters  (paint separator mats)	X					Urgent filter replacement, e.g. if nominal cabin pressure can no longer be set.
2		Rolling doors	X					e.g. with high- pressure cleaner
3	Maintenance	Walls	X					e.g. with high- pressure cleaner
4		Floor	X					e.g. with high- pressure cleaner
5	Replace	Prefilters		X				Observe pressure gauge or indicator light
6	Replace	Post filters		X				Observe pressure gauge or indicator light
7		Compressed-air  regulator with oil and  water separator		X				Clean filters and replace if necessary
8		Seals on gates  and doors		X				Clean, replace damaged seals
9		Weather grating			X			Clean gratings on air inlet and outlet ducts
10	Maintenance	Electric motors				X		Clean cooling air gratings
11		V-bells				X		Check for wear. Adjust or replace as necessary
12		Servomotors on the air flaps				X		Check for ease of movement
13	Replace	Ceiling fans					X	Observe pressure gauge or indicator light
14		Fans					X	Clean, remove paint residues. Rectify cause of soiling (e.g. replace floor filters). Balance fans if necessary.
15		machine room, air inlet and outlet ducts					X	Remove paint residues, vacuum
16		Cabin lighting					X	Remove paint residues, vacuum
17	Maintenance	Door drive system, bearings					X	Clean and grease (with silicone-free grease)
18		Air flaps					X	Clean, remove paint residues. Rectify cause of soiling (e.g. replace floor filters). Balance fans if necessary.
19		heat exchangers					X	Clean by specialist company.
20		Oil or gas burners					X	Cleaning and setting of nominal emissions values by specialist company.