HAWEKA SAD500 User manual

Operating manual
Optical Adjustment System for
ADAS
(Advanced Driver Assistance Systems)
(Translation of the original manual)
Kokenhorststrasse 4 • 30938 Burgwedel (Germany) • Tel. [phone] • Fax [phone]
www.haweka.com • inf[email protected]om
Subject to technical modifications. Text and layout protected by copyright. Reprinting and copies, including extracts, are only permitted with written authorisation.
GEB 001 182

Optical Adjustment System SAD500
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Table of Contents
1General Safety Instructions..................................................................................... 2
1.1 OPERATOR’S DUTY OF CARE ....................................................................................2
1.2 EXPLANATION OF SYMBOLS......................................................................................2
1.3 BASIC SAFETY PRECAUTIONS ................................................................................... 3
2Product Description................................................................................................. 4
2.1 AUTHORISED INTENDED USE..................................................................................... 5
2.2 TECHNICAL DATA ....................................................................................................5
3Equipment................................................................................................................. 6
3.1 PARTS LIST FOR SAD500........................................................................................6
3.2 OPTIONAL ACCESSORIES FOR SAD500 ....................................................................7
4Preparatory measures ............................................................................................. 8
4.1 ASSEMBLY OF THE CROSSHEAD................................................................................8
4.2 SETTING UP LASER MEASURING HEADS AND SCALES.................................................11
4.3 MOUNTING THE LASER MEASURING HEADS ON THE VEHICLE ...................................... 11
4.4 ALIGNING CROSSHEAD WITH THE VEHICLE ............................................................... 12
5Measuring and adjusting the ACC sensor........................................................... 14
5.1 MEASURING THE ACC SENSOR WITH REFERENCE MIRROR........................................14
5.2 MEASURING THE ACC SENSOR WITHOUT REFERENCE MIRROR..................................15
6Calibration Reflector for the Lane-Keeping Assistant........................................ 16
6.1 ASSEMBLY OF THE CALIBRATION REFLECTOR........................................................... 16
6.2 SETTING THE CALIBRATION REFLECTOR................................................................... 17
7Servicing................................................................................................................. 19
7.1 MAINTENANCE AND CARE ......................................................................................19
7.2 REPLACING THE BATTERIES IN THE LASER HOUSING.................................................. 19
8Error description.................................................................................................... 20
8.1 DESCRIPTION AND CAUSES OF ERRORS...................................................................20
9EC Declaration of Conformity............................................................................... 21
HAWEKA AG
Kokenhorststrasse 4
D-30938 Burgwedel
Tel.:[phone]
Fax:[phone]
[e-mail]
www.haweka.com 29.09.2017
Version Notes Page 4

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1 General Safety Instructions
1.1 Operator’s duty of care
Device safety can only be implemented during practical operation
if all required applicable measures have been taken.
The operator’s duty of care includes planning such measures and
checking their implementation.
In particular, the operator has to ensure that
•the optical adjustment system SAD500 (referred to in the
following only as SAD500) is only used as determined
•the SAD500 is only used in a fully functioning state and free
from defects
•the complete operating instructions are permanently available
in a readable condition at the operating location of the device
•the device is only operated by accordingly qualified and
authorised personnel
•all operating instructions and warning notices attached to the
device have not been removed and are legible
The SAD500 may only be structurally modified with written
authorisation by the manufacturer!
1.2 Explanation of symbols
These operating instructions contain specific safety instructions. The following symbols are used
for this purpose:
This symbol does not indicate a safety instruction; it labels
information provided for a better understanding of work procedures.
The symbols attached to the laser housings are mounted so that they are positioned in the
immediate vicinity of the emerging laser beam.
Warning - laser radiation
This symbol indicates potential danger, primarily to persons.
Notice with laser class marking.

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1.3 Basic safety precautions
Prior to each use of the SAD500, it must be checked for visible damage and it must be
ensured that the system is only operated when free from defects! Any defects that are
identified have to be reported to a superior immediately!
Laser product
CLASS 2
TYPE 1
Some basic instructions must be followed for all lasers:
- Never look directly into the beam!
- Define beam paths precisely, avoiding drifting laser beams!
- Dangerous reflections can be caused especially by the mirror
panels on the crosshead or other shiny surfaces. Particular
attention should therefore be paid to the position of the mirror
panels on the crosshead before switching on.
- The trajectory of the laser beam must not lie within the work
area or where people are present. If this is unavoidable, ensure
that the laser area is clearly recognisable and marked with the
stipulated warning notices.
- Turn off the laser after work is completed!
Please refer to the accident prevention regulations (VGB 93 Laser
radiation) for further safety instructions for working with lasers.
The user is independently responsible for proper operation and
compliance with safety regulations.

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2 Product Description
Optical Adjustment System SAD500
Item No. 922 000 013
Subject to technical modifications.
3. version 09/2017
Figures: HAWEKA AG / D-30938 Burgwedel
Reproduction in any form is not permitted.

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2.1 Authorised intended use
•The SAD500 has been developed in order to be able to carry out a check and for the
adjustment of an Adaptive Cruise Control sensor (ACC sensor) on commercial vehicles.
•The SAD500 is an additional module that, in combination with the wheel alignment system
AXIS500, is used to measure the ACC sensor and for aligning the calibration panel for multi-
function cameras of drive assist systems (ADAS).
•Testing and adjustment of the ACC sensor can be carried out quickly and reliably in the
“drive position” on all vehicle types (with the required accessories in each case).
The operator, and not the manufacturer of the optical adjustment system
SAD500 is responsible for all injury to persons and damage caused to property
by incorrect use!
The laser used in the laser housing is a Class 2 laser product. The laser
radiation generated is not hazardous to the eyes for short periods of exposure
(up to 0.25 s). If you should accidentally look into the laser beam for a short
period, the eye will be protected by the blink reflex.
NEVER INTENTIONALLY LOOK INTO THE LASER BEAM!
If you have reason to believe that your eyes have been damaged by the laser beam, seek the
advice of an eye specialist immediately.
2.2 Technical Data
Measuring accuracy:
Scale division in the measuring field for the ACC laser is +/- 2°.
The ACC sensor on the vehicle can be set with an accuracy of up to 10'.
Measuring range:
The distance between the ACC sensor on the vehicle and the measuring field on the crosshead has
to be exactly 100 cm!
Deviations from the stipulated measuring distance of 100 cm result in incorrect
setting values!
Laser:
Model LG650-7(80)
Input voltage 3 volts (2 x 1.5 volt AA batteries)
Radiated power Po0.91 mW
Wavelength
λ
650 nm
Operating range 20 m
Laser class 2 DIN EN 60825-1:1994-07

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3 Equipment
3.1 Parts list for SAD500
2 × scales with gripping jaws for laser measuring heads
2 × item no. 913 012 009
2 × mirrors (included in the item “measuring crosshead”)
Mirror left 1 × item no. 913 051 025
(with cover)
Mirror right 1 × item no. 913 051 026
(with cover)
1 × laser with scale
1 × item no. 913 001 053
1 × laser guide carriage
1 × item no. 913 052 132
NOTE:
(unit = case including carriage, complete laser and mirrors L+R) item no. 922 001 014

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1 × crosshead (incl. mirrors)
1 × item no. 922 001 015
1 × device storage case
1 × item no. 900e008 383
1 × operating Instructions
1 × item no. GEB 001 182
1 × CD Rom
(measurement protocol + operating manual) 1 × item no. VID 922 004
3.2 Optional accessories for SAD500
1 × adapter mirror
1 × item no. 922 001 011

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4 Preparatory measures
4.1 Assembly of the crosshead
The crosshead consists of: 2 device supports, 1 central part, 2 side elements (left and right),
2 mirrors, 1 receiving bars, 1 carriage and laser with scale.
Step 1:
Assembly of the slide rails.
The two side parts must be connected to the left and right side of the central part.
Hereby, pay attention to the correct position of the side parts.
Front
The counter beam of 0 – 17 can be seen on the left and right at the front
Rear
On the rear, all logos must be in the same direction.
(Fig.1)
(Fig.2)

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1
2
3
1
3
Step 2:
1.) Insert the fixing screws into the holes in the central part.
2.) Slide the side part with the centring pins into the central part until the pins are seated in the
fixing screws.
3.) Use an Allen key to firmly lock the fixing screws on the pins.
•Check the surfaces in the slide rails at the transition points. These must be aligned, otherwise
the carriage could jam. As necessary, release the connection and realign the elements.
•Repeat the process for the other side part.
Step 3:
1.) Slide the star grip screws through the holes in the support.
2.) Guide the device support to the side part and manually fasten to the side part by tightening the
star grip screw.
3.) Repeat the process for the second device support.
Step 4:
Using 2 bolts M8 x 50, connect
the central rod between
the device support.
For the assembly of the calibration reflector, refer to Page 16.
(Fig. 3)
(Fig.4)

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Place the laser carriage on the slide rail of the
crosshead from the front and set it into the guide
groove.(Fig.5)
Slightly release the fixing screw on the laser
housing and pull upwards.
Place the laser housing on the pin on the
carriage and then tighten the fixing screw far
enough so that the laser unit including the scale
can still be rotated on the pin. (Fig.6)
Slide each mirror with its guide bolts into the
groove on the crosshead from either side.
Observe the mirror identification
Left “L” and Right “R” to avoid
reversing the mirrors.
(Fig.6)
(Fig.5)
(Fig.7)

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4.2 Setting up laser measuring heads and scales
The wheel alignment clamps have to be
converted for the rear wheels using the
long magnetic feet (310 mm). (Fig. 8)
•Place a scale on the measuring column of the wheel
alignment clamp with the clamping jaws.
The scale points in the direction of the laser
outlet opening. (Abb.10)
•Repeat the process for the second measuring head.
4.3 Mounting the laser measuring heads on the
vehicle
Ensure that the measurement is carried out on
a level workshop floor.
•The magnetic holders on the 3-arm clamping star must
be adjusted to the correct rim diameter.
•Check the contact surfaces of the magnets
and the rim! They have to be free from dirt
and metal filings!
•Attach the measuring heads to the rim flange using the
magnets. Two magnets should be located above the
centre of the wheel and one magnet below it. (Fig. 11)
The scale can be mounted above or below the
laser housing.
(Fig. 8)
(Fig. 9)
(Fig. 11)
(Fig. 10)

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4.4 Aligning crosshead with the vehicle
The crosshead must be installed in the centre in front of the
vehicle and parallel to the rear driving axle.
Make sure that the laser with the measuring scale is
positioned at the same height on the vehicle as the
ACC sensor.
Thereby, the distance between the laser with the
measuring scale and the sensor on the vehicle
must be exactly 100 cm. (Fig. 14)
Initial alignment of the crosshead to the centre of the vehicle
is carried out using the number scale.
•Both mirrors left and right are set at the same distance on
the slide rail and, subsequently, the complete crosshead
is pushed until the mirrors each point to the laser on the
rear axle. (Fig. 12)
The two lasers on the rear vehicle axle are switched
on and pointed at the scales of the mirror covers on
the crosshead.
•The complete crosshead is now pushed to the left or right
so that the laser point points to the same line on the
scales on the mirror covers. Hereby, the mirrors must not
be displaced.(Fig. 13)
The crosshead must now be aligned parallel to the vehicle
axle.
•For this, the mirror covers are folded up.
•The complete crosshead is rotated about its imaginary
centre point until the reflecting laser beam points to the
same value on the scales on the left and right on the rear
axle.
Figure 15 shows the laser beam now on
the same line on the left and the right
scale.
•When the crosshead is aligned and,
subsequently, the distance to the
sensor, 100 cm, is rechecked.
(Fig. 12)
(Fig. 13)
(Fig. 14)
100 cm
(Fig. 15)

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•The horizontal alignment of the crosshead
on the laser housing must be checked
using the level I , readjust if required.
•The crosshead can be aligned horizontally
with the setting screws. (Fig. 16)
•Slide the guide carriage in the crosshead
sideways until the laser beam indicates on
the mirror of the radar sensor of the
vehicle.
•Use level II to align the laser housing
horizontally by rotating around the
mounting pin. (Fig. 17)
Once the crosshead and the laser housing
have been aligned, the laser beam finally has
to hit the reference mirror of the ACC sensor.
Re-align if necessary.
Assembly of the crosshead is complete
when:
the crosshead is aligned central to the centre line of the vehicle.
the crosshead is aligned parallel to the vehicle axle.
(The reflecting laser beams indicate the same values on the left and right scales of the
rear axle)
the crosshead is aligned
horizontally (level I).
The laser housing is aligned
(level II) and the laser beam hits
the mirror of the ACC sensor on
the vehicle.
The distance between the
ACC sensor on the vehicle and
the measuring scale on the laser
housing is exactly 100 cm.
(Fig. 17)
Level II
(Fig. 16)
Level I

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5 Measuring and adjusting the ACC sensor
5.1 Measuring the ACC sensor with reference mirror
•The crosshead is aligned and is in the
centre in front of the vehicle and parallel
to the vehicle driving axle.
The laser on the crosshead is
switched on and pointing directly
at the reference mirror of the
ACC sensor. (Fig. 18)
•The reflecting laser beam is projected
back at the scale on the crosshead via the
reference mirror.
•The currently set value of the ACC sensor
can now be read from the scale. (Fig. 19)
The division on the scale is as follows:
1 scale division = 0.1 degrees
•Compare the values read with the
NOMINAL values from the manufacturer
and, as necessary, the ACC sensor must
be set to the nominal values using the
adjustment screws.
(Fig. 18)
(Fig. 19)

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5.2 Measuring the ACC sensor without reference
mirror
For checking an ACC sensor without reference mirror (Fig. 21),
the optional adapter mirror 922 001 011 (Fig. 20)must be
mounted in front of the ACC sensor on the vehicle
before the check.
•The adapter mirror is suspended in
front of the ACC sensor on the vehicle
and secured with the knurled screws.
(Fig. 22 + 23)
If the adapter mirror is mounted
correctly it will rest parallel to
the radar output area of the
ACC sensor. (Fig. 24)
The laser on the crosshead is
switched on and pointing directly
at the adapter mirror of the
ACC sensor.
The reflecting laser beam is projected
back at the scale on the crosshead via the
adapter mirror.
•The currently set value of the ACC sensor
can be read from the scale. (Fig. 25)
•The division on the scale is as follows:
•1 scale division = 0.1 degrees
•Compare the values read with the
NOMINAL values from the manufacturer
and, as necessary, the ACC sensor must
be set to the nominal values using the
adjustment screws.
(Fig. 21)
(Fig. 20)
(Fig. 22)
(Fig. 23)
(Fig. 24)
(Fig. 25)

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1
2
6 Calibration Reflector for the Lane-Keeping
Assistant
6.1 Assembly of the calibration reflector
Step 1:
Using 4 star grip screws M6 x 60, attach the reflector panel to the stand.
Step 2:
Insert the stand, with the reflector panel, into the base frame.
•Tilt the reflector panel and then insert with the rear rollers.
•Subsequently, push the reflector panel to the rear and
insert the front rollers.
•Push the reflector stand and check for ease of movement.
Make sure that the running surfaces of the base
frame are always clean and free from grease and
dust.
(Fig. 26)
(Fig. 27)
(Fig. 28)

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6.2 Setting the calibration reflector
Aligning the position:
Before the lane-keeping camera of the vehicle is put in position, the calibration reflector
must be at a distance specified by the vehicle manufacturers.
•For this, the base frame of the calibration
reflector is hung into the central rod of
the previously aligned crosshead.
(Fig. 29)
The base frame of the calibration reflector
has different positions to engage.
•Depending on the type of vehicle, select
a position to engage for the specified
distance.
Aligning the height:
•The reflector stand is pushed to the
front position until the magnets rest
on the base frame. (Fig. 30)
The lower edge of the reflector panel*
must be a distance of exactly 90 cm
from the floor.
* Lower edge of the reflector panel
•Correction of the height is carried out using the setting screws of the
crosshead.
•When the crosshead has been adapted in height, it must be checked
using the level I and, as necessary, readjusted.
Also refer to Figure 16, Page 13.
(Fig. 29)
90 cm
(Fig. 30)

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Aligning horizontally:
Subsequently, the reflector panel must be aligned into a horizontal position.
•For this, the reflector stand is
put into the rear position until
the magnets rest on the base
frame. (Fig. 31)
There is a spirit level located on
the rear of the reflector.
•Using the spirit level, the
reflector panel is aligned by the
rear setting screws of the base
frame. (Fig. 32)
Thus, setting the calibration reflector is completed and calibration of the lane-keeping
camera can be carried out in accordance with the specifications from the vehicle
manufacturer.
(Fig. 31)
(Fig. 32)