MAHA MLT Series User manual

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MLT 1000 MB
Headlight Tester
Original Operating Instructions
BA380801_001-en
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Contents
1
Safety ....................................................................................................................4
1.1 Introduction..............................................................................................................4
1.2 Intended Use ...........................................................................................................4
1.3 Safety Instructions....................................................................................................4
2
Description ............................................................................................................5
2.1 Requirements for the Place of Installation .................................................................5
2.2 Specifications...........................................................................................................5
2.3 Equipment Overview ................................................................................................6
2.4 Projection Screen.....................................................................................................7
2.5 Setting Wheel...........................................................................................................8
2.6 Definition of Technical Terms....................................................................................9
2.6.1 Pitch Angle...............................................................................................................9
2.6.2 Low Beam ...............................................................................................................9
2.6.3 High Beam.............................................................................................................10
3
Operation.............................................................................................................11
3.1 Positioning the Vehicle ...........................................................................................11
3.2 Using the Colour Filter ............................................................................................12
3.3 Setting the Headlights ............................................................................................13
3.4 Measuring the Luminous Intensity / Illuminance ......................................................14
3.4.1 Low Beam .............................................................................................................14
3.4.2 High Beam.............................................................................................................14
4
Maintenance ........................................................................................................15
4.1 Installing the Cover Hood .......................................................................................15
4.2 Cleaning.................................................................................................................15
5
Disposal...............................................................................................................15
6
Inspection Equipment Monitoring..........................................................................16
6.1 Vertical and Horizontal Alignment of Headlight Tester .............................................16
6.1.1 Vertical Alignment...................................................................................................17
6.1.2 Horizontal Alignment ..............................................................................................18
6.2 Laser Calibration Set ..............................................................................................19
6.3 Laser Positions.......................................................................................................19
6.4 Checking the Precision of the Laser Calibration Set................................................20
6.5 Mechanical Inspection............................................................................................21
6.6 Adjusting the Pointer Position.................................................................................22
6.6.1 Adjusting the Projection Area..................................................................................25

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6.6.2 Calibration of the Luminous Intensity ......................................................................26
6.7 Inspection Certificates (Inspection Interval: Annually)...............................................27
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1
Safety
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1.1
Introduction
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Thoroughly read this manual before operating the equipment and comply with the
instructions. Always display the manual in a conspicuous location.
Personal injury and property damage incurred due to non-compliance with these
safety instructions are not covered by the product liability regulations.
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1.2
Intended Use
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This device only serves to check and adjust the alignment of vehicle headlights.
This device cannot be modified without the express, written consent of the
manufacturer. Any infringement renders the conformity declaration invalid.
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1.3
Safety Instructions
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•This device must only ever be operated within its performance limits.
•All service work must be performed by service technicians employed by the
manufacturer or by authorized service partners.
•Never expose the lens to direct sunlight. The bundling of light may cause fire
damage inside the housing.
•Only ever clean the lens with a soft cloth and a glass cleaning agent.
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Description
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2.1
Requirements for the Place of Installation
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Please observe your national guidelines and specifications.
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2.2
Specifications
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Measuring range
below 0…600 mm / 10 m (0…6 %)
left 0…1000 mm / 10 m (0…10 %)
right 0…1000 mm / 10 m (0…10 %)
Height of luminous centre 240…2000 mm
Measuring distance 100…500 mm
Intensity
Luminous intensity 0…40 000 cd (Candela)
Illuminance 0…64 lx (Lux)
Operating range
Temperature +5…+40 °C
Relative humidity 20…80 %
Dimensions (W x H x D) 655 x 2240 x 720 mm
Weight 65 kg
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2.3
Equipment Overview
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A
Column The column envelopes a precision profile which carries the
slide rails. The counterweight which can be used to set the
housing to the desired test height is located in the interior of
the column (automatic locking).
B
Carriage The carriage can be moved on two rails perpendicular to
the vehicle’s approach direction.
C
Knob for Fol-
ding Mirror
The projection screen in the housing can be observed in
the folding mirror.
A
C D E F
B

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D
Viewing Win-
dow
The projection screen in the housing can be viewed
through the viewing window.
E
Light Measure-
ment Unit
The luminous intensity or illuminance of the headlights can
be checked using the light measurement unit.
When performing a light measurement, the colour filter
must be removed.
F
Setting Dial Use the setting dial to move the projection screen up and
down in the housing to achieve the desired inclination val-
ue.
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2.4
Projection Screen
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The projection screen is based on the test condition that the distance between
headlight and test surface is 10 m.
Use the folding mirror or the viewing window to observe the projection screen in
the housing on which the headlight beam is reproduced.
The image on the projection screen is displayed 20 times smaller than the original.
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A
Dividing line = Reference axis for light-dark border of low beam
B1
Tolerance mark (left) for inflection point of asymmetrical European low
beams
B2
Tolerance mark (right) for inflection point of asymmetrical European low
beams
C
Central mark = Elementary point for setting the high beams
D
The outlined corners indicate the size of the test surface which is binding
based on the directives for vehicle headlight settings (e.g. in Germany).
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2.5
Setting Wheel
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Use the setting wheel to move the projection screen up or down in the housing.
As the inclination of the headlight hot spot in relation to the driving surface is
usually expressed in percentage, the setting wheel has a percentage (%) dial.
The inclination values (light-dark border of the vehicle headlights) can be set from
0 to -6 % using the dial.
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2.6
Definition of Technical Terms
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2.6.1
Pitch Angle
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Angle of inclination of light-dark limit against the test surface.
The inclination of headlight lighting bundle against the test surface is expressed as
a percentage, using 10 m as a reference parameter:
X 100
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2.6.2
Low Beam
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A
Light-dark limit
Boundary for light distribution between ‘top dark’ and ‘bottom light’ for low-
beam lights.
B
Inflection point
Synonymous with the light-dark limit for asymmetric low-beam lighting. The
deviation of the inflection point is expressed in %. 10 meters is used as the
reference dimension.
α
Yaw angle
Angle between the inflection point on the rising component of the light-dark
limit and the horizontal line for asymmetric low-beam light.
α
Rolling angle
Angle between the left component of the light-dark limit and the horizontal,
usually 0°.
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2.6.3
High Beam
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C
Central mark
From the central mark, the deviation of hot-spot is specified in X and Y di-
rections.
D
Hot spot
Center of light beam for high-beam. The deviation of hot spot from central
mark is expressed in %.10 meters is used as the reference dimension.
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3
Operation
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3.1
Positioning the Vehicle
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•An adhesive film is stuck to the floor at a right angle to the guide rails as an
approach marking (see fig.). Length: 7 m (+2 m, -0.3 m), recommended length
for testing transporters and commercial vehicles: 9 m.
NOTE:
It is advisable to apply the approach marking with paint on floors with a non-
slip coating.
•Position the vehicle’s left front wheel at the start of the approach marking.
Drive along the approach marking and precisely maintain the distance from
the left front wheel while doing so. Park the vehicle once the measuring dis-
tance (100 to 500 mm) has been reached.
NOTE:
The position of the left rear wheel does not have to be taken into
consideration. It varies due to differences in track width, mixed tyres, the rear
axle angle, etc.
In the case of right-hand drive vehicles, carry out the procedure for the right
front wheel with the approach marking back-to-front.
•A mirror (not included in the scope of delivery) can be used to help with posi-
tioning.
•Slide the headlight tester in front of the headlight to be adjusted.
A
Headlight tester
B
Guide rails
C
Approach marking
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7 m (+2 m; -0,3 m)
A
B
C

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3.2
Using the Colour Filter
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The “Orange” colour filter (Lee 105) has the
LED1
marking.
The colour filter must be removed when measuring the intensity (luminous intensity
/ illuminance).
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3.3
Setting the Headlights
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1 Switch on the headlights.
2 Set the projection screen to the required inclination value using the setting
dial.
3 The headlights should be tested individually, the other(s) should be turned off
or covered if necessary.
4 Observe the projection screen. If the headlight setting is checked through the
folding mirror, note that all screen markings are displayed mirror-inverted.
5 Adjust the headlights until they match the applicable statutory directives.
Example: When setting the low beam, the dividing line is the reference line for the
inclination point of the light-dark border.
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3.4
Measuring the Luminous Intensity / Illuminance
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The luminous intensity or illuminance of the dipped beam and full beam are
displayed in lux (lx) and kilocandelas (kCd) with the light measuring equipment.
Observe the following to maintain correct values:
•The colour filter must be removed for the light measurement
•The headlight tester must be aligned to the headlight
•The headlights must be adjusted correctly
•The vehicle battery must be fully charged
•Leave the vehicle engine running at a medium rotational speed
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3.4.1
Low Beam
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1 Switch on the low beams.
2 Position the toggle switch to low beam position (upwards).
3 Set the projection screen using the dial so that the dividing line lies on the
light-dark border.
4 Read the value: The incoming light is extrapolated to 25 m and can be read
off the upper scale.
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3.4.2
High Beam
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1 Switch on the low beams.
2 Set the projection screen using the dial so that the dividing line lies on the
light-dark border of the low beams.
3 Switch on the high beams.
4 Position the toggle switch to high beam position (downwards).
5 Read the value: The incoming light is extrapolated to 25 m and can be read
off the lower scale.
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4
Maintenance
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4.1
Installing the Cover Hood
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Attach the supplied cover hood when the tester is not being used. The hood is
used to protect against sunlight and other environmental influences.
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4.2
Cleaning
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This headlight tester is an optical measuring device and must therefore be handled
accordingly (i.e. with care).
The lens needs to be wiped regularly with a clean cloth and commercial glass
cleaner. In all other respects, this is a zero-maintenance device.
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5
Disposal
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If you want to dispose of the equipment, please contact your MAHA dealer or the
following address, indicating equipment type, date of purchase and serial number:
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
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Alternatively, you may take the equipment to a specialised waste management
plant to ensure that all components and operating liquids are properly disposed
of.
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16
BA380801_001-en
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6
Inspection Equipment Monitoring
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6.1
Vertical and Horizontal Alignment of Headlight Tester
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•Align the laser beam parallel to the approach marking.
•Slide the headlight tester so that the centre of the lens is in the laser beam.
•Precisely place the setting wheel’s pointer into the zero position.
•If it does not match the centre cross on the rear panel of the headlight tester,
correct the vertical / horizontal alignment (see below).
A
Headlight tester
C
Laser
E
Setting wheel
B
Approach marking
D
Laser beam
F
Centre cross
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D
A
C
B
E F

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BA380801_001-en
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6.1.1
Vertical Alignment
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•Loosen the fixing screws with an Allen key WAF 5.
•Adjust the column position.
•Carefully tighten the fixing screws at intervals.
•Check that they match the centre cross again.
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•After vertical alignment, close the openings of the fixing screws using seal la-
bels to prevent unauthorised changes.
When performing maintenance, the seals can be destroyed and replaced by
new ones (part #+ 54 2694).
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BA380801_001-en
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6.1.2
Horizontal Alignment
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•Loosen the fixing screw (a) with an Allen key WAF 5.
•Adjust the tappet’s setting screw (b) with an open-ended wrench WAF 27.
•Carefully tighten the setting screw and fixing screw.
•Check that they match the centre cross again.
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a
b

19
BA380801_001-en
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6.2
Laser Calibration Set
A
Prism
D
Circle spirit level
B
Battery housing
E
Base plate
C
Adjustment screws
F
Alignment rail
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6.3
Laser Positions
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1:
X = 0.0 %
Y = 0.0 %
2:
X = +2.0 %
Y = 0.0 %
3:
X = 0.0 %
Y = 2.0 %

20
BA380801_001-en
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Never stare into the laser beam. Wear safety goggles. Observe occupa-
tional safety and accident prevention regulations for laser radiation.
Precise measurements can only be taken if the measuring station is absolutely
level. The base surface for the vehicle and the light tester must form a horizontal
plane (for tolerances, see below).
The laser beam calibration unit allows the measurement accuracy of the headlight
tester to be checked and corrected as needed on site.
Accuracy of the measuring equipment .......................................................±2 mm / 10 m
Permissible unevenness of light tester base surface......................... max. 1 mm / 1 m
Permissible unevenness of vehicle base surface.....................................................
....................................................... see country-specific road traffic licensing regulations
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6.4
Checking the Precision of the Laser Calibration Set
1 Mount the laser calibration set on the tripod and position it in front of a screen
at a distance of 10 m (± 0.5 cm).
2 Use the spirit level to align the laser unit and then switch on the laser.
3 Rotate the laser 180° around its axis in the basic position in the prism
(position 1, no setting angle).
The laser point on the screen must always remain in the same place and must
not perform any rotation (± 1 mm).
4 Move the laser to position 1 and mark the laser point on the screen.
5 Move the laser to position 2 and mark the new position.
The new laser point (position 2) on the screen must be 20 cm (± 4 mm) to the
right. This corresponds to an angle of 2%.
6 Move the laser back to position 1.
7 Use the adjustment screw to move the laser to position 3.
8 Mark the new laser point on the screen.
The new laser point (position 3) on the screen must be 20 cm (± 4 mm) verti-
cally below the original setting (pos. 1). This corresponds to an angle of 2%.
9 Dismount the laser calibration set.
If the laser point changes position when it rotates around its axis or the distances
between the various positions are different to those specified, the calibration set is
faulty and must not be used for calibration. The calibration set needs to be rea-
ligned by the manufacturer.
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