HAWEKA AXIS 500 User manual

Operating Instructions
Laser Wheel Aligner
(Translation of the original manual)
D-30938 Burgwedel •Kokenhorststr. 4 • Phone: +49 / 5139 / 8996-0 • Fax: +49 / 5139 / 8996-222 •
www.haweka.com • [email protected]om
GEB 001 081

Wheel Alignment AXIS500
AXIS500 Manual Instructions
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Table of contents
1 General safety precautions...........................................................................................3
1.1 Operator’s responsibility ........................................................................................... 3
1.2 Description of applied symbols ................................................................................. 3
1.3 General safety measures .......................................................................................... 4
2 Shipment.........................................................................................................................5
2.1 Dimensions and Weight ............................................................................................ 5
2.2 Information’s for general handling and storage ......................................................... 5
3 Product Description.......................................................................................................6
3.1 Agreed functionality .................................................................................................. 7
3.2 Design of laser measurement head .......................................................................... 8
3.3 Description ................................................................................................................ 9
3.4 Button assignment .................................................................................................... 9
3.5 Initiation .................................................................................................................. 10
3.6 Technical Data ........................................................................................................ 11
4 Equipment.....................................................................................................................12
4.1 Part list basic version of AXIS500 ........................................................................... 12
4.2 Accessories ............................................................................................................. 15
5 Front Wheel Alignment................................................................................................17
5.1 Preparations............................................................................................................ 17
5.2 Alignment of „Straight ahead position“ .................................................................... 18
5.3 Set-up of Toe Scales .............................................................................................. 19
5.4 Toe Measurement and Alignment ........................................................................... 20
5.5 Check of Steering Wheel Center Position............................................................... 22
5.6 Camber measurement ............................................................................................ 23
5.7 Caster and Inclination ............................................................................................. 24
5.8 Max. Steering Angle ................................................................................................ 25
5.9 Relative Steering Angle (toe out on turns) .............................................................. 26
5.10 Rim Run-Out Check ................................................................................................ 27
6 Rear Wheel Alignment.................................................................................................28
6.1 Camber Measurement of the Rear Wheels ............................................................ 28
6.2 Total Toe / Rear Axle .............................................................................................. 28
6.3 Measurement of Axle Mismatch in relation to the Frame: ....................................... 29
6.4 Axle Mismatch in relation to Vehicle’s Longitudinal Axis ......................................... 30
7 Alignment of Twin Steering Front Axles....................................................................31
7.1 Preparations............................................................................................................ 31
7.2 Reading of total toe ................................................................................................. 31
7.3 Toe Alignment of the Second Axle .......................................................................... 33

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8 Trucks with independent suspensions .....................................................................35
8.1 Measurement of Individual Toe -Trucks with Two Adjustable Toe Rods ................ 35
9 Adjustment by Run-out compensation......................................................................37
10 Checking the Wheel Alignment Clamp......................................................................39
11 Maintenance.................................................................................................................40
11.1 Maintenance ........................................................................................................... 40
11.2 Replacing the batteries in the laser housing ........................................................... 40
11.3 Replacing the batteries in the inclinometer ............................................................. 41
12 Error description .........................................................................................................42
12.1 Error description and causes .................................................................................. 42
13 Annex............................................................................................................................43
13.1 Conversion Table from Millimetres into Degrees .................................................... 43
13.2 Diagram for Determination of Axle Mismatch (optical measurement) Dia. 1 .......... 45
13.3 Diagram for Determination of Axle Mismatch (optical measurement) Dia. 2 .......... 46
13.4 Measurement report ............................................................................................... 47
14 EC-Declaration of Conformity.....................................................................................48
HAWEKA AG
Kokenhorststraße 4
Germany - 30938 Burgwedel
Tel.: +49 5139 / 8996-0
Fax: +49 5139 / 8996-222
[e-mail]
www.haweka.com
For version see page 7

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AXIS500 Manual Instructions
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1 General safety precautions
1.1 Operator’s responsibility
Laser Aligner AXIS500 has been designed and
manufactured in accordance with harmonized standards. It
is thus state of art and provides maximum security during
operation.
Structural changes of Laser Aligner require written approval
of manufacturer!
Operational safety can only be achieved, if all required
measures are carried out. It is due to the responsibility of
the operator to consider these measures and to control their
implementation.
In particular the operator has to ensure that
• the device is only used appropriately to its agreed
functionality
• the device is only used if proper functionality is provided
• complete operating instructions are provided in legible
form at point of location of device
• only suitably trained and authorized personnel operates
the device
• the personnel is regularly instructed in all aspects of
operational safety and familiar with operating
instructions and contained safety precautions
• all warning and safety precaution labels maintain
attached to the device in legible form
1.2 Description of applied symbols
These operating instructions con
tain accurate safety precautions, following symbols
have been applied for indication
This symbol indicates general risk for the device and
materials.
Warning of hazardous electric voltage
This symbol indicates risks for humans, device and
materials.

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This symbol indicates no safety concerns but
information’s for a better understanding of operating
cycles.
Symbols attached to laser measuring heads are placed close to laser beam output
opening.
Laser radiation warning
This symbol indicates that, above all, dangers to
people are to be expected.
Information sign with the laser class markings
1.3 General safety measures
Laser Aligner AXIS500 must only be operated by suitably
trained and authorized personnel that is familiar with these
operating instructions and capable of proper
implementation.
Check Laser Aligner before any operation for visual damage
and ensure proper functionality of device! In case of defect
inform manager of workshop!
Laser
CLASS 2
TYP 1
Laser devices require general considerations:
- Do never look directly into laser beam!
- Define laser beam paths accurately, use laser absorbing
means to avoid stray laser irradiation! Hazardous
reflections are particularly caused by reflecting and
shining surfaces.
- Level laser beam path above or below eye level if
possible!
- Laser beam paths should not cross operational areas. If
this is inevitable mark laser operating area significantly
and set up required warning signs.
- Switch off laser after operation!
You can find more safety precautions in:
Safety of laser products; Part 1: Equipment classification,
requirements and user’s guide (IEC 825-1:1993)
It is the responsibility of the operator to ensure proper
operation and implementation of safety precautions.

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2 Shipment
2.1 Dimensions and Weight
Length x Width x Height
120 cm x 80 cm x 90 cm
Shipment weight:
170 Kg
2.2 Information’s for general handling and storage
Avoiding damages and injuries during shipment:
• industrial trucks must be in accordance with regulations for
prevention of accidents
• shipment activities must only be carried out by suitably trained
and authorized personnel
• heavy impacts during shipment must be avoided
Keep device always dry.
This applies in particular to shipment and storage of complete
instrument cabinet.
Ensure that storage location is dry and dust free.

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3 Product Description
Laser Aligner AXIS500
Part No. 922 000 050
These operating instructions are subject to alterations.
8. revised version 2019
Illustration: HAWEKA AG / 30938 Burgwedel
This publication may not be reproduced in any form or by any means.

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3.1 Agreed functionality
• Laser Aligner AXIS500 is designed for wheel alignment of motor vehicles.
• Only for the fast measurement of the chassis geometry.
Front wheel alignment and steering axle:
- Total Toe / Single Toe
- Camber
- Caster
- KPI
- Relative steering angle
- Steering wheel centre position
Rear wheel alignment:
- Toe
- Camber
- Offset
- Out of square
• Laser Aligner AXIS500 enables measurements while in driven position. No lifting of
vehicle is required.
• Measurements can be taken fast and reliable on all types of motor vehicles ( with
specific accessories provided).
Safe operation of Laser Aligner AXIS500 cannot be ensured
if not used appropriately to its agreed functionality!
The operator-and not the manufacturer- is responsible for all
damages and injuries resulting from inappropriate use to its
agreed functionality.
Applied laser of laser measuring head is a class 2 laser. Short-
term laser beam impact ( up to 0,25 s) proves not to be harmful to
human eyes. Eye blink reflex prevents the eye from injury during
short-term, unintentional exposure to laser beam.
DO NEVER LOOK INTENTIONALLY INTO LASER BEAM!
In case of suspected eye injury through laser beam impact consult a ophthalmologist
immediately!

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3.2 Design of laser measurement head
Laser head and main components:
Laser head is free rotatable. Ensure that laser beam output opening is
directed downward to the floor after mounting of laser heads and
before switch on of diode laser.
Inclinometer
Required for camber and caster measurement during
front wheel alignment. Electronic inclinometer is
mounted on measuring head shaft.
Grab arm assembly
Part No.912e008 140
3 arm star Pro Clamp
Part No. 912e008 265
Quick-socket magnetic
fool
Part No. 913 027 007
Star grip screw M8 x 40
Part No.DU ST08040
Measuring head shaft
Part No.913 005 015
Laser head
Part No.913 001 042
Magnetic fool 100
Part No.913 027 012

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3.3 Description
The electronic inclinometer is used to record angle values on the vehicle geometry.
This device enables the camber, caster and included angle to be determined.
Angles can be measured in the horizontal and vertical plane depending on the attachment
face.
Display symbols:
Camber display
Request for value recording
Caster / KPI
Angle value display:
Upper line: Caster
Lower line: KPI
3.4 Button assignment
ON/
OFF
On / Off button
Light
Switch on background lighting for 30 seconds.
Switches between the camber measurements, caster / KPI and max. steering. The first mode is the
camber measurement, where the result of the angle is directly shown. In caster / KPI mode, LED's light
signals confirm the recorded angle changes and after the procedure has ended the display automatically
switches to the display values for caster (upper line) and KPI (lower line).The third mode is for calculating
the max. steering angle. Press the button again to switch back to the camber display.
Tara
Press this button to adjust the angle measurement to an inclined plane. The angles in both measuring
directions are thus adjusted to zero. This operating state is indicated by a symbol in the bottom right-hand
corner. Press this button again to switch back to display of the absolute angle.
Hold/
Save
Press this button to "freeze" the angles in the display. This operating state is indicated by a symbol in the
bottom left-hand corner. If the button is pressed again the display switches back to continuous display of
the measured values.
On / Off switch
Display lighting
For angle
measurement
in an
inclined plane.
Illuminated LC display
Switches between the
angle measurements
Keep angle values in
the display
LED indicator light

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Initiation
Initial operation of Laser Aligner requires following measures:
Mounting of rolls and scale holding device on mobile instrument cabinet.
Fit in fastening screws M8 x 65 from top and tighten
with nut and washer.
For each roll
4 x Carriage bolt M8
4 x Washer M8
4 x Nut M8
3 x Carriage bolt M8 x 30
3
x Washer M8
3 x
Nut M8

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3.5 Technical Data
Measuring Accuracy:
Toe < 0,5 mm
Camber
Caster
Steering
Relative steering angle +/- 15 min.
Axle mismatch +/- 1 mm
Axle torsion +/- 5 min.
Toe measurement range +/- 28 mm
Camber measurement range to 5 degrees
KPI measurement range to 18 degrees
Castor measurement range to 12 degrees
Turning plate carrying capacity 6 t / piece
Laser:
Model LG650-7 (80)
Operating voltage 3 Volt (2 x Mignon Typ AA 1,5 Volt)
Power Po 0,91 mW
Wave range
λ
650 nm
Range 20 m
Laser class 2 DIN EN 60825-1:1994-07
Electronic inclinometer:
Operating voltage 6 volt (4 x Mignon Type AA Batteries 1.5 volt)
Current input during operation 10 mA (without lighting), 60 mA (with lighting)
Closed-circuit current (unit switched off) < 10 µA
Running time with one set of batteries without lighting: approx. 50 - 60 h.
with lighting: approx. 30 h.
Specified measuring range +/- 45° for both axles
Extended measuring range +/- 90° for both axles
Accuracy of the specified measuring range 0... 10°: +/-0° 03’
10 ... 45°: +/-0° 12’
Resolution 0° 01’
Temperature range -5 to +50 °C (in use) -20 to 65 °C (storage)
Shock resistance of the sensor 3.500g
0 ... 10°: +/- 0° 03’
10 ... 45°: +/- 0° 12’

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4 Equipment
4.1 Part list basic version of AXIS500
2 pcs. Laser measuring heads with magnetic feet (100 mm) 1 pcs. Part No. 922 001 006
4 pcs. Grab arms for trucks 1 pcs. Part No. 912e008 303
1 pcs. Electronic inclinometer
Part No. 913 009 048
1 pcs. Alignment block for uneven floors
Part No. 913 010 000

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2 pcs. 20° scales 1 pcs. Part No. 913 018 000
2 pcs. Turning plates
Left and Right
1 pcs. Part No. 913 011 000
6 pcs. Magnetic feet for rear-axle measuring (315mm)
1 pcs Part No. 913 030 012
6 pcs. Magnetic feet for front-axle measuring (100 mm) with quick socket
1 pcs. Part No. 913 027 011

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2 pcs. Toe scales (min 3.110 – max. 4.440) mm
1 pcs. Part No. 913 051 000
2 pcs. Magnetic scales
1 pcs. Part No. 913 013 000
1 pcs. mobile instrument cabinet and fastening material 1 pcs Part No. 913 052 009
4 pcs. Rolls 2 pcs. holding device
for scale
Part No. for 1 piece: Part No. 912e008 212 (1 piece)
913 019 002 (brake roll)
913 019 003 (w/o brake)
1 pcs. CD Rom
1pcs. Tape measure “Test-Record”
Part No. 900 008 041 Part No. VID 922 002

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4.2 Accessories
Upgrade kit for double steering axles Part No. 922 000 002
2 pcs. Additional turning plates 2 pcs. Laser heads with magnetic feet and grab
arms for trucks
Upgrade kit for special truck wheels (Trilex / Dayton)
6 pcs. Adapters for rim run-out compensation Part No. 922 000 004
Upgrade Kit for trailer and semitrailer alignment
Scale unit with king pin and king pin adaptor incl. 6 special magnets (265 mm)
Part No. 922 000 001

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Upgrade Kit for passenger car alignment
12 passenger car adaptors, 2 measuring heads, 8 telescoping cross arms
Part No. 922 000 016

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5 Front Wheel Alignment
5.1 Preparations
• Carry out alignment on level ground.
• Remove protective caps of wheel nuts or caps
respectively.
• Clean rim between wheel nuts.
• Check tire pressure and, if necessary, adjust as
specified.
Drive vehicle onto turning plates
• Place turning plates centrally in front of the wheels.
• Fasten turning plates with bolt to avoid torsion.
• Drive vehicle on turning plates. The wheel centre
shall be positioned in the turning plate centre.
Mounting of laser measuring heads (Illustration 1)
• The magnetic feet of the 3-arm-star have to be
adjusted to the proper rim diameter. It is
recommended to fix the laser measuring head onto
a mounting stand of instrument cabinet (Illustration
1).
• Adjust magnetic cams by turning and shifting to
achieve all-over attachment of rim flange diameter
between wheel nuts.
• Put the measuring heads with the magnets onto the
rim flange. Two magnets shall be placed above the
wheel centre and one below. (Illustration 2).
Fitting of magnetic scales
• Put the front wheels in the straight ahead position by
turning the steering wheel. (Illustration 2)
• Fix the first scale on the right-hand side of the
frame, if possible in the middle (regarding
lengthwise direction).
• Switch on laser on the right-hand side.
(left hand drive vehicles, vice versa for RTA)
Pay attention to laser beam output
opening before switch on!
• Turn right-hand laser until the laser point gets visible
on the magnetic scale.
• Adjust scale with wing nut until the laser point
indicates »0«.
• Repeat the same procedure with the second scale
on the right-hand side. Now the magnetic scales
have the same length and must not be changed
again!
• Attach one of the two scales on the left-hand
side, if possible in the same place (Illustration 3). (Illustration 3)

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Front Wheel Alignment
Fitting of magnetic scales (continued)
• Switch on left-hand laser.
Pay attention to laser beam output
opening before switch on!
• Turn left-hand laser until the laser point gets
visible on the scale.
5.2 Alignment of „Straight ahead position“
• Should the laser point on the left-hand scale not
point at zero, turn steering wheel until the value
indicated on the scale is halved. Laser points on
the same value on both scales.
Example:
Indication right: 0
Indication left: 4 scale lines out
Turn steering wheel until both laser points
point
at 2 scale lines outward(Illustration 4)
Now the front wheels are in alignment with the
frame, seen in driving direction.
• Adjust magnetic scales with the wing nuts
until both laser points point at zero.
This procedure is important for all following measurements.
(Illustration 4)