Magneti Marelli 007935902020 User manual

Magneti Marelli Aftermarket Spółka z.o.o.
Plac Pod Lipami 5, 40-476 Katowice
Tel.: + 48 (032) 6036107, Fax: + 48 [phone]
e-mail: [email protected]
www.magnetimarelli-checkstar.pl
Lightning aligment device PREMIUM-digital measurement
(Biksenon, Halogen,Antifog,Laser)
Manual
007935902020

ACCEPTANCE OF THE DEVICE
At the time of delivery it is essential to check at once and
make sure you have received all the material indicated in
the shipping documents, and that the device has not
undergone damage during shipment. In this case, show the
damage to the forwarder and inform our customer service
department. Only if you proceed promptly in this way will it
be possible to obtain any missing material and
reimbursement of thedamage.
FOREWORD
This is a device designed for correct beam alignment of any
type of automobile or motor vehicle headlight.
The device must be used for this purpose only. Even the
finest of devices can function properly and ensure profitable
service only if it is used correctly and kept in the best
possible condition. For this reason, we ask you to read this
manual with care and to reread it whenever difficulties
should arise in using the device. In case of need, we
remind you that our service centers, organized in
cooperation with our retailers, are always at your disposal
for any advice you mayneed.
NOTE: the manufacturer may decide to make changes in
the device without notice, in order to adapt it to
technological advances and specific production or
installation needs. Therefore, even if the illustrationsshown
in the manual differ slightly from the device in your
possession, the safety and instructions about it are
guaranteed.
TECHNICAL DATA
Field of measurement
orientation: above and below
right and left
0 –600 mm / 10 mt (0 - 6 %)
0 –1000 mm / 10 mt (0 - 10 %)
Intensity:
0 - 240 lx (Lux/25mt)
0 - 150.000 cd (Candle)
0 –150.000 lx (Lux/1mt)
Unit of intensity measurement
Lux (a 25mt) –Kcand –Klux (a 1 mt)
Unit of orientation measurement
% - cm/10mt –degrees (°)
Height from ground of optical center
from 240 to 1450 mm
Supply voltage with internal battery
12 V
Input voltage of battery charge
100 –240 V / 50 mt (0 - 60 Hz)
Working temperature
+ 5°C - + 45°C
Width - height - length
mm
660 - 1780 - 695
Weight
kg
36
Laser product classification
Class 3R laser product
2 Laser modules in the optical box
class 3R
wave length is 635 nm
power is 5 mW
fan angle 90°
Visor laser module
class 3R
wave length is 635 nm
power is 5 mW
fan angle 130°
LASER RADIATION
AVOID DIRECT EYE EXPOSURE
CLASS 3R LASER PRODUCT

SYMBOLS USED IN THE MANUAL
Warning symbol
Read the sections preceded by this symbol with particular care, for the safety of the operator
and the device.

SYMBOLS USED ON THE DEVICE
Indicator of internal battery charge status.
When the symbol is red, the device needs to be recharged, using the battery charger
supplied with the equipment.
Indicator of state of connection with station PC.
xxxxxxNOT CONNECTED *****
Indicator of state of connection with station PC.
xxxxxx CONNECTED *****
Indicator of state of connection with station PC.
xxxxxx INVALID DATA ITEM TRANSMITTED OR RECEIVED *****
Touch key function to go back:
when you press this key the menu returns to the previous page
Touch key function to start test:
when you press MEASURE, the internal laser lights and the key changes its color to green
Real touch key function:
when you press REAL, the window opens with the REAL image projected on the internal
screen of the optical box.
Graphic touch key function:
when you press GRAPHIC, the window opens with the image reconstructed graphically of the
measurement point projected on the internal screen of the optical box.
Save touch key function:
when you press Save, the data are saved and remain available for transmission to the PC
when required.
Print touch key function:
when you press Print, the test result is printed.
Touch key function to switch the laser point on:
when you press LASER, the internal laser lights and the key changes its color to green
Class 3R laser radiation symbol, applied on the side of the optical chamber and on the
rear of the laser visor
LASER RADIATION
AVOID DIRECT EYE EXPOSURE
CLASS 3R LASER PRODUCT
LASER EMISSION POINT
This label is placed beside the emitting point of the laser, one in the visor and two in the
optical box, before use the device read the relative section

Class 3R laser WARNING:
 The risk of Class 3R laser products is limited because unintentional exposures would rarely reflect
worst-case conditions of the laser source with a large pupil and worst-case accommodation with the
entire beam energy entering the eye because of the natural aversion behaviour for exposure to bright
light for the case of visible radiation
 The risk of injury increases with exposure duration, it may be hazardous for ocular exposure for
intentional directintrabeam viewing.
 Never look directly at the laser source.
 Never aim a laser beam directly at anybody, particularly not atthe face or eyes.
 Under low ambient light conditions, dazzle or flash-blindness and afterimages may be caused by a
beam from a Class 3R laser product in the visible wavelength range. This may have indirect general
safety implications resulting from temporary disturbance of vision or from startle reactions
 Avoid reflections, e.g. by covering up or removing any reflective surfaces in the vicinity of the laser
beam.
Observe the intended use

PREPARATION OF THE DEVICE
HANDLING CRATED DEVICE
The device is packed in a special crate.
Do not stack more than five crates.
The packed weight is 40 kg.
The external dimensions are:
W: 630 mm L: 1800 mm H: 660 mm
CONTENTS OF THE PACKAGE
1 carton containing a base unit
1 column unit
1 visor
1 carton containing:
o an opticalchamber
o a batterycharger
o a package containing 4 screws and 4 washers for fastening the optical chamber to
thestructure
o manual for use andmaintenance
o conformitycertificate
o cd rom containing software for communication with a personal computer or
inspection line and thismanual.
If you receive erroneous parts, or notice shortages or damage, contact the distributor. Keep the
package, including the original packing material, in case you need to send the product for
repairs.
HOW TO ASSEMBLE THE DEVICE
Open the crate from the top.
Remove the parts taking care not to cause violent impacts and damage.
Take the column and unscrew the screw and
washer from the pivot.
Fit the column in the base taking care to center
the friction ring between them.

PREPARATION OF THE DEVICE
Replace the screw and washer centering thetwo
holes with the pins. Tighten the screw all the
way, eliminating any slack in the column and
give it another quarter turn, always taking care to
the direction oforientation.
Return the structure to the upright position,
check the correct orientation between the base
and the column and check column rotation.
Remove the optical box and fit it in from the top
of the box in the housing on the slider of the
column taking care to fit it all the way in. Fasten
the optical box to the slider using the screws
supplied, to be assembled on the bottom of the
box, as shown by the arrows in the figure.
Remove the visor from the carton, screw it onto
the support and tighten, using the hole in the
visor.

PREPARATION OF THE DEVICE
Place the device over the rails previously
installed, remove the screw and washersholding
the counterweight in the bottom section of the
column.
LEVELING THE DEVICE
Position the headlight tester in the work zone.
Check the position of the level inside the optical
box and, if it is not aligned, slightly loosen the
screw fastening the wheel and adjust the tilt
using the screw above it, then tighten the screw
fastening the wheel.

DESCRIPTION OF THE DEVICE
The headlight tester is a device that serves to test
headlights of all types, for motor vehicles, cars and
trucks ingeneral.
The device can be installed as a fixed station with
lateral movement on a track.
The column can rotate, by means of a pin installed
on a glide bearing, by about 30° to align with the
vehicle.
The optical chamber is adjustable in height by
means of slides on precise, silent, plastic runners
along a drawn aluminum column marked with a
centimeter scale for exact positioning with respect
to the headlight.
To center the
device at the light
source, the front
side is equipped of
2 laser line emitter
class 3R the wave length is 635 nm
(nanometers) and the power is 5 mW
(milliwatts) fan angle is 90° highlighted in the
picture aside, they create a cross starting from
14cm to the opticalbox
LASER RADIATION
AVOID DIRECT EYE EXPOSURE
CLASS 3R LASER PRODUCT
The control screen is equipped with an LCD
graphic color monitor that, with a few touches of
the TOUCH SCREEN, guides the operator in
performance of the test with accuracy and
simplicity.

DESCRIPTION OF THE DEVICE
The visor that facilitates the alignment of the
device to the vehicle can be
equipped with mirror or laser.
Mirror visor
Laser visor To align the device at
the vehicle, the laser
visor is equipped on a
front side laser line
emitter class 3R the wave length is 635 nm
(nanometers) and the power is 5 mW
(milliwatts) fan angle is 130° highlighted in the
pictureaside.
LASER RADIATION
AVOID DIRECT EYE EXPOSURE
CLASS 3R LASER PRODUCT

The following rules must be followed carefully to prevent damage to the operator and
device.
Read the device labels, do not cover them for any reason, and replace them immediatelyif they
should bedamaged.
The device should only be used byauthorized personnel, trained in its use.
Do not use the device in an explosive atmosphere.
The working environment should be dryand sufficientlyventilated.
When moving the device, pay attention to other people, especially children, in the vicinity.
Do not bump shelves or scaffoldings where there may be a danger of falling objects: you and
the device could bedamaged.
The storage temperature should be between -5° and +55°C.
The working temperature should be between +5° and +45°C.
Provide an adequate exhaust system for the exhaust gas, since the headlight test must be
performed with the engine of the motor vehicle running. Accidental inhalation of carbon
monoxide can cause serious damage to the organism, with a fatal outcome in some cases.
Contact our agent in your zone, who can indicate the most suitable system for your company.
Do not leave the headlight tester in the sun or in the immediate vicinity of hot objects like
heaters, radiators,etc.
Do not leave the headlight tester out in the rain or in an excessively damp place as its electronic
circuits could bedamaged.
If the headlight tester will not be used for a long period, we recommend that you cover it with its
dust cover(optional).
There is a battery in the headlight tester that could cause a fire or explosion hazard if handled
improperly. To prevent this risk to not heat or use open flames near the battery and, when
replacing it, use one with the same characteristics.
When you encounter any malfunction in use of the device, contact the retailer or send the
device to the nearest service center.
The headlight tester has to be serviced only bya authorized and trained factory technicians.
In case of parts replacements, order ORIGINAL replacement parts from a concessionaire or
authorizedretailer.
Tampering with any part of the device will invalidate the warranty.
GENERAL SAFETY RULES

PREPARATION OF THE VEHICLE
Make sure the headlights are clean and dry. If the vehicle is equipped with a headlight aligner, set in on “0”.
Eliminate anything that could affect the correct position of the vehicle: mud, snow, ice, etc. Straighten the
car wheels. Make sure the vehicle does not have any distortions of the frame. Make sure the tires are
inflated at the correct pressure. Start the engine and perform the test. In case of vehicles with pneumatic
suspension, start the engine five minutes before starting the test and proceed with the engine running.
CAUTION!
When operating in an enclosed space with the engine on it is essential to evacuate the toxic gasses
produced by combustion. We recommend using a specific fan for exhaust fumes.
WORK SURFACE
During the headlight test the floor surface must be level. If this is
not possible, the headlight tester should be positioned on a
surface with a uniform slope, in any case not exceeding 0.5%.
Do not test headlights on floors that are not perfectly regular and
level, asthe measurement might not be accurate.
CONNECTIONS
On the right side of the optical chamber is a
button for switching the device on and off,
an RS232 connector for communication and
a system for updating the software by
means of a USB port.
CAUTION!
If, when the device is switched on, the symbol for BATTERY DISCHARGED is displayed
connect the battery charger supplied to the outlet on the side of the optical chamber and let it charge for at least 12
hours; you can perform the test even with the battery charger on but the battery is not charged while the test is going
on.
PREPARATION

ALIGNMENT WITH THE LASER VISOR
Locate two details, on the front of the vehicle, that are perfectly
symmetrical between them (for example the top of the
windshield or the headlights themselves)., switch on the laser
by the button highlighted aside, turn the optical box until, when
you see the two reference points meet the laser red line.
CAUTION!
POSITIONING
Place the headlight tester in front of the right headlight of the
vehicle at a distance of about 20 cm, switch on the cross laser
by the icon on the display, align the center of the cross to
the center of the light bulb or the reference light of the beam.
Switch off the laser bythe same icon on the display
ALIGNMENT WITH THE MIRROR VISOR
Locate two details, on the front of the vehicle, that are perfectly
symmetrical between them (for example the top of the
windshield or the headlights themselves)., turn the optical
chamber until, when you look in the mirror, the two reference
points meet the black line stenciled on the mirror.
OK NO
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure
ALIGNMENT TO THE VEHICLE

PREPARATION
SWITCH THE HEADLIGHT TESTER ON with the on/off
button on the side.
Wait a few seconds for local control of the device and
loading of the process software.
- OPTIONS MENU
See the section on service and maintenance.
- APPLICATIONSMENU
Press the TOUCH button for the applications; the device
can perform two types of TEST:
- OFFICIAL
- FREE
The OFFICIAL test is enabled only when there is a
connection with the station PC, with communication in DIR
mode.
The FREE test is enabled if there is no connection with the
station PC.
SETTINGS
This menu requires the following data:
- type of vehicle being tested
 2 headlights:“automobiles”
 1 headlight:“motorcycles”
 1 headlight, low beam only: “motorbike”
- type ofheadlight
 asymmetrical
 symmetrical
- type oflight
 halogen
 xenon
- headlighttilt
 read at the top of the headlight the tilt indicated
by the manufacturer, e.g. 1.2%, set the value
using the + and -key.
- height of headlight from ground
 set the value using the + and - key.
CAUTION!
Remember that the headlight tilt must in any case comply with the law in force, which establishes that for low
beam headlights at a height above ground of up to 80 cm the tilt must be at least 1%.
For low beam headlights higher than 80 cm the tilt must be at least 1.5%.
HEADLIGHT TEST

HEADLIGHT TEST
TEST OF THE LOW BEAM HEADLIGHT
The display now shows the type of vehicle (2 headlights)
the type of headlight (low beam) and the side (right).
Switch on the RIGHT LOW BEAM headlight of the vehicle
to be tested, and press .
Wait a few second and check for the appearance of the
borderline of the luminous beam.
Now the status of the headlight is displayed (high  ,low  ,tothe
right  ,to the left  ,centered OK (dot at the center colored
green) , and the light intensity.
The position of the line at the center of the tolerance limits
with change of the color from red to green is the sign that
the headlight is correctly CENTERED.
Headlight centered
Press to proceed to control of the headlight in Real
mode.
NOTE: This screen displays the image of the luminous
beam projected on the internal screen to the optical box
and you can check the position in REAL mode.
Press to proceed to control of the next headlight.
Headlight not centered
Headlight centered

HEADLIGHT TEST
TEST OF THE HIGH BEAM HEADLIGHT
Now the device prepares to test the right high beam
headlight.
Switch on the RIGHT HIGH BEAM headlight of the vehicle
to be tested, and press.
Wait a few seconds and check for the appearance of the
maximum intensity point of the high beam.
The position of the line at the center of the tolerance limits
with change of the color from red to green is the sign that
the headlight is correctly CENTERED.
Headlight centered
Press key to proceed to control of the headlight in
Real mode.
NOTE: This screen displays the image of the luminous
beam projected on the internal screen to the optical box
and you can check the position in REAL mode.
Press to proceed to control of the next headlight.
Headlight not centered
Proceed now to the left side of the vehicle and repeat the
test sequence.
CAUTION!
When using the headlight tester in a
mobile station (on rubberized wheels),
after positioning on the left headlight
check the alignment again through the
visor.
OFFICIAL TEST: At the end of the procedure the device will
send the data to the PC via communication protocol RS232.
FREE TEST: On models with the printer incorporated, the
test results are printed when you press PRINT.

Magneti Marelli Aftermarket Spółka z.o.o.
Plac Pod Lipami 5, 40-476 Katowice
Tel.: + 48 (032) 6036107, Fax: + 48 [phone]
e-mail: [email protected]
www.magnetimarelli-checkstar.pl
SUPPLEMENTARY
INSTRUCTIONS
REPLACEMENT OF LASER VISORBATTERIES
Switch off the laser before open the visor.
Unscrew the two screws on the lid of the
laser visor and replace the 3 penlight
batteries size AA 1.5V, respecting the correct
polarity, close the visor and fasten the lid
with the screws provided.
CLEANING AND MAINTENANCE
The headlight tester has to be serviced only by a authorized and trained factory
technicians, any other intervention or modification of the device avoid the warranty.
The device does not require particular maintenance other than normal cleaning with a damp cloth
(water or normal detergent).
CAUTION!
Do not use nitro solvents
DEMOLITION AND DISPOSAL
The device is mainly composed
of steel. Other parts:
in plastic, some parts
in cardboard and paper, packing and documents
the device is painted with scratch-resistant epoxy powder.
In disposing of the device, comply with the provisions of the local authorities.
WARRANTY
In case of evident and acknowledged manufacturing defects of any product, it
will be repaired or replaced under the warranty only if the claim is made and
documented within 8 days of delivery. Returns of defective goods will be
accepted only FREIGHT PREPAID, while all returns CARRIAGE FORWARD
will be rejected. All other forms of reimbursement are excluded.
SUPPLEMENTARY
INSTRUCTIONS