MAHA MLT, MLT 3000 Original Operating Instructions

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MLT 3000

Headlight Tester

Original Operating Instructions

BA380701-en

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2

Manufacturer

Service

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BA380701-en
2018-11-20

© MAHA Maschinenbau Haldenwang GmbH & Co. KG
The reproduction, distribution and utilization of this document as well as the communication of its

contents to others without explicit authorization is prohibited. Offenders will be held liable for the
payment of damages. All rights reserved in the event of the grant of a patent, utility model or de­sign. The contents of this edition have been checked with great care. However, errors cannot be
fully excluded. Subject to technical change without notice.

MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany

Phone: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.maha.de

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MAHA SERVICE CENTER
Maybachstraße 8
87437 Kempten
Germany

Phone: [phone]
Fax: [phone]
Mail: service@maha.

de

Web: www.mahaservicecenter.de

BA380701-en

3

Contents
1

Safety .................................................................................................................... 5

2

Description ............................................................................................................ 7

3

Operation ............................................................................................................. 13

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1.1 Introduction .............................................................................................................. 5

1.2 Symbols and Signal Words ...................................................................................... 5

1.2.1 Personal Injury .......................................................................................................... 5

1.2.2 Property Damage ..................................................................................................... 5

1.2.3 Information ............................................................................................................... 5

1.3 Intended Use ........................................................................................................... 6

1.4 Requirements on Operating and Service Personnel .................................................. 6

1.5 Safety Instructions .................................................................................................... 6

2.1 Requirements for the Place of Installation ................................................................. 7

2.2 Specifications ........................................................................................................... 7

2.3 Design ..................................................................................................................... 8

2.4 Electronic Levelling ................................................................................................... 9

2.4.1 Compensation Coordinate Axes of MLT 3000 .......................................................... 9

2.4.2 Angle Symbols ....................................................................................................... 10

2.5 Definition of Technical Terms .................................................................................. 11

2.5.1 Pitch Angle ............................................................................................................. 11

2.5.2 Low Beam ............................................................................................................. 11

2.5.3 High Beam ............................................................................................................. 12

3.1 Switching On / Off .................................................................................................. 13

3.2 Aligning .................................................................................................................. 14

3.2.1 Laser Alignment Unit (Option) ................................................................................. 14

3.2.2 LED Adjustment Aid (Option) .................................................................................. 15

3.3 Light Selection Buttons .......................................................................................... 16

3.3.1 Headlight Test according to § 29 StVZO (Germany) ................................................ 16

3.3.2 Showing the Button Labels .................................................................................... 17

3.3.3 Adjusting the Pitch Angle ........................................................................................ 17

3.3.4 Choosing the Vehicle Class .................................................................................... 18

3.3.5 Browsing back through the Test Screens ............................................................... 18

3.3.6 Choosing between Left-Hand or Right Hand Traffic ................................................ 19

3.3.7 Manufacturer-Specific Test Instructions (OEM) ....................................................... 19

3.3.8 Navigating through the Test Levels ......................................................................... 21

3.4 Testing the Headlights ............................................................................................ 22

BA380701-en

4

4

Energy Management and Troubleshooting ............................................................ 41

5

Maintenance ........................................................................................................ 44

6

Disposal ............................................................................................................... 45

7

Contents of the Declaration of Conformity ............................................................. 45

3.4.1 Test Phase Indication via Light Buttons .................................................................. 22

3.4.2 Measuring .............................................................................................................. 22

3.4.3 Light Selection Buttons Disabled ............................................................................ 23

3.4.4 Adjusting: Setting the Headlights in Real Time ........................................................ 24

3.4.5 Saving the Measurement Values to PDF ................................................................. 25

3.5 Settings ................................................................................................................. 27

3.5.1 Variables ................................................................................................................ 27

3.5.2 User Settings ......................................................................................................... 29

3.5.3 Language ............................................................................................................... 30

3.5.4 Calibrating the Camera according to Directive ........................................................ 31

3.5.5 Country Specifications............................................................................................ 33

3.5.6 Settings with Password .......................................................................................... 34

3.5.7 List of Variables (Extract) ........................................................................................ 35

3.6 Interfaces and Software Updates ........................................................................... 36

3.7 EUROSYSTEM v7.50 ............................................................................................. 38

4.1 Charging the Battery .............................................................................................. 41

4.2 Battery Status ........................................................................................................ 42

4.2.1 Battery Life ............................................................................................................. 42

4.2.2 Energy Saving Function .......................................................................................... 42

4.2.3 Protection against Deep Discharge ......................................................................... 42

4.2.4 Protection against Mechanical Damage .................................................................. 42

4.2.5 Data Recording for Error Analysis ........................................................................... 43

4.3 Troubleshooting ..................................................................................................... 44

5.1 Care Instructions .................................................................................................... 44

5.2 Spare Parts ............................................................................................................ 44

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BA380701-en

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1

Safety

1.1

Introduction

1.2

Symbols and Signal Words

1.2.1

Personal Injury

DANGER

WARNING

CAUTION

1.2.2

Property Damage

NOTICE

1.2.3

Information

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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

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safety instructions are not covered by the product liability regulations.

indicates an immediate hazard which, if not avoided, will result in death or severe
personal injury.

indicates a potential hazard which, if not avoided, could result in death or severe
personal injury.

indicates a potential hazard which, if not avoided, could result in moderate or mi­nor personal injury.

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indicates a potentially harmful situation which, if not avoided, could result in dam­age to the equipment or surrounding objects.

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indicates important information notes.

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1.3

Intended Use

1.4

Requirements on Operating and Service Personnel

WARNING

1.5

Safety Instructions

NOTICE

CAUTION

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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

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manufacturer. Any infringement renders the conformity declaration invalid.

All persons employed in the operation, maintenance, installation, removal and dis­posal of the device must

• be at least 18 years old,

• be mentally and physically suited for these activities,

• be demonstrably trained and instructed in writing,

• have read and understood the operating instructions, especially the instructions

what to do in the event of defects or malfunctions,

• be on record as having been instructed in safety guidelines,

• have practical experience in working with vehicle lifts and the hazards inherent

in such equipment.

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• This device must only ever be operated within its performance limits.

• All parts of the electrical system must be protected against damp and humidity.

• 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.

Optional laser alignment unit: Never look into the laser beam (laser class 2M).
Comply with work safety and accident prevention directives (H&SW regulations) in
respect of laser radiation.

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BA380701-en

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2

Description

2.1

Requirements for the Place of Installation

2.2

Specifications

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Please observe your national guidelines and specifications.

Measuring range above hotspot 0…800 mm / 10 m (0…8 %)

Light intensity 0…125 000 cd

above pitch angle 0…300 mm / 10 m (0…3 %)
below 0…700 mm / 10 m (0…7 %)
left 0…1000 mm / 10 m (0…10 %)
right 0…1000 mm / 10 m (0…10 %)

Illuminance 0…200 lx
Measuring distance 100…500 mm
Adjustment path of lens centre above floor 240…1500 mm
Deviation of intensity ±5 %
Deviation from one axle ±5'
Compensation of ground unevenness ±3 %
Temperature +5…+40 °C
Relative humidity 20…80 %
Supply voltage 100…240 V AC, 50/60 Hz
Charging voltage / Battery voltage 24 V DC / 12 V DC
Dimensions (W x H x D) 655 x 1770 x 720 mm
Net weight / Shipping weight 65 kg / 80 kg
Prototype release number TPN100110935

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BA380701-en

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2.3

Design

A

E
B

F

C

G

D

H

A B D

G H C E F

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Mirror, with optional
laser alignment unit

Column

Display

USB port

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BA380701-en

Charging socket

Casing, with adjusting handle

Carriage, with spirit level

Battery compartment

9

2.4

Electronic Levelling

NOTICE

2.4.1

Compensation Coordinate Axes of MLT 3000

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This headlight tester comes standard with an electronic position sensor which
determines the inclination angle of the device. The software compensates possible
deviations in the X- and Z-axes while calculating the position of the headlights.

The headlight tester may be set up on uneven surfaces even if the ground
unevenness is outside the permissible tolerances, provided that the maximum
unevenness does not exceed the headlight tester’s self-levelling capacity of 3%.

After enabling the respective function, the compensation values can be checked
using a dot or cross hair laser. See section “Operation > Settings > Calibrating the
Camera according to Directive”.

This function must be enabled exclusively by authorised service technicians and is
applicable for the respective test surface only.

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BA380701-en

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2.4.2

Angle Symbols

axis active, inclination too

axis active, inclination too

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Once the adjustment of the inclination sensor has been completed, an angle sym­bol appears in the info bar to indicate the adjusted/active inclination axes.

Overview of symbols:

Both axes adjusted/active,
headlight tester ready for
operation

Both axes active, inclination
of Z- and X-axis too large,
no measurement possible

Both axes active, inclination
of X-axis too large, no
measurement possible

Both axes active, inclination
of Z-axis too large, no
measurement possible

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Z-axis active, headlight test-

er ready for operation

Z-

large, no measurement pos-

sible

X-axis active, headlight test-

er ready for operation

X-

large, no measurement pos-

sible

BA380701-en

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2.5

Definition of Technical Terms

2.5.1

Pitch Angle

2.5.2

Low Beam

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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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A

Light-dark limit

B

Inflection point

α

Yaw angle

α

Rolling angle

2.5.3

High Beam

C

Central mark

D

Hot spot

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Boundary for light distribution between ‘top dark’ and ‘bottom light’ for low­beam lights.

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.

Angle between the inflection point on the rising component of the light-dark
limit and the horizontal line for asymmetric low-beam light.

Angle between the left component of the light-dark limit and the horizontal,
usually 0°.

From the central mark, the deviation of hot-spot is specified in X and Y di-

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rections.

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

3.1

Switching On / Off



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The headlight tester is operated via touchscreen buttons. The resistive touch­screen reacts to pressure and can also be operated while wearing work gloves.

The On/Off button is on the right-hand side underneath the touchscreen.

Press to confirm Switch Off.

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3.2

Aligning

3.2.1

Laser Alignment Unit (Option)

CAUTION

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When using guide rails, position the device centrally in front of the vehicle.
Without guide rails, the device must be adjusted in front of each headlight. Please

observe your national guidelines and specifications.
The device is correctly aligned when two symmetrical reference points on the front

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of the vehicle are located on the black line of the alignment mirror.

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The optional unit is integrated into the mirror holder. The device is correctly aligned
when the laser pointer is parallel to two symmetrical reference points on the front
of the vehicle.

Observe manufacturer’s instructions according to workshop manual.

Never look into the laser beam (laser class 2M). Comply with work safety and ac­cident prevention directives (H&SW regulations) in respect of laser radiation.

The AA Mignon batteries powering the laser are located in the alignment unit and
can be easily replaced.

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3.2.2

LED Adjustment Aid (Option)

A

B

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This optional unit is integrated into the window housing (A) above the Fresnel lens.
The colour LEDs (B) pointing toward the vehicle indicate the direction of adjust­ment.

Green LED = Optimum setting

Yellow LED = Minor deviation within tolerance range

Red LED = Outside tolerance

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(corresponds to green rating in the display centre)

(corresponds to yellow direction arrows on the display)

(corresponds to red direction arrows on the display)

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3.3

Light Selection Buttons

3.3.1

Headlight Test according to § 29 StVZO (Germany)



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Headlight test according to § 29 StVZO (Germany).

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Use the OEM button for manufacturer-specific test instructions.

17

3.3.2

Showing the Button Labels

3.3.3

Adjusting the Pitch Angle

When the Info button is activated, the button labels are shown instead of the
symbols.

The pitch angle can be increased or reduced using the Arrow buttons.

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3.3.4

Choosing the Vehicle Class

3.3.5

Browsing back through the Test Screens

The Truck/Car button activates the appropriate settings for the respective vehicle
class.

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Use the Back Arrow button to browse back through the test screens one by one.

19

3.3.6

Choosing between Left-Hand or Right Hand Traffic

3.3.7

Manufacturer-Specific Test Instructions (OEM)

Left-hand/Right-hand traffic can be changed under “User Settings”. Right-hand
traffic is preset by default.

OEM area! Perform the test according to manufacturer’s instructions.

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20

Button “ALL“ makes several test levels available.

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Example: testing Volkswagen matrix headlights
OEM area! Perform the test according to manufacturer’s instructions.

21

3.3.8

Navigating through the Test Levels

Use the Play button to open the activated test levels one by one.

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3.4

Testing the Headlights

3.4.1

Test Phase Indication via Light Buttons

3.4.2

Measuring

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Green dot = Headlight tested, measurement OK
Red dot = Headlight tested, not OK
Grey dot = Headlight without evaluation

Adjusting direction:
Yellow arrow = Minor deviation within tolerance range
Red arrow = Outside tolerance

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Rating in centre = Headlight within tolerance range

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23

3.4.3

Light Selection Buttons Disabled

PA = Pitch Angle; IP = Inflection Point; I = Intensity
Yaw and Rolling angles can be additionally activated under “User Settings”.
Use the Camera button (bottom centre) to change from the Measuring menu to

the Adjusting menu.

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During measurement the light selection buttons are disabled.

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3.4.4

Adjusting: Setting the Headlights in Real Time

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Green light button = Current measurement

Use the “New vehicle” button to change back to the Main menu.

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3.4.5

Saving the Measurement Values to PDF

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Using the USB stick button, all available test values can be saved as PDF to a
USB stick. The button appears only in the Measuring and Adjusting menus and if
a USB stick has been detected by the headlight tester.

The values are saved to folder “MLT3000 Results” with date and time stamp, for
example: “Testvalues14082018_153922.pdf“.

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Overview of test results as PDF file (example)

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27

3.5

Settings

3.5.1

Variables



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Limit values as well as user and customer variables can be set directly at the
headlight tester.

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28



Grenzwerte, User- und Kundenvariablen können direkt am Gerät angepasst
werden.

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29

3.5.2

User Settings



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Quick access to all important settings.

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3.5.3

Language

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Use the flag button to open the language selection.

Choose the desired language.

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31

3.5.4

Calibrating the Camera according to Directive

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Compensation values can be checked using button “Calibrate camera according
to directive”. No password required.

Choose between Cross hair / Spot laser.

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32

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33

3.5.5

Country Specifications



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Statutory requirements, limit values and country-specific settings.
Switching back from some of the country-specific test procedures requires a

password.

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34

3.5.6

Settings with Password

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The disabled (greyed out) menu items can be accessed only by entering a service
technician password.

Adjustment of the headlight tester is permitted exclusively with the following
calibration equipment approved by MAHA and must be performed by an
authorised service technician.

VP 990175 Laser calibration device with spot laser, model LK1
(no longer available)

VP 990471 Laser calibration device with cross hair laser, model LK2

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35

3.5.7

List of Variables (Extract)

No.

User variables

Default

Min

Max

Customer variables

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3.0 Percentage 0 / Degrees 1 0 0 1

4.0 Lux 0 / Candela 1 0 0 1

6.0 Target value Pitch angle Car 11 0 50

6.1 Target value Pitch angle HGV 30 0 50

8.0 Switch-off time of display in minutes 10 2 1200

10.1 RHT/LHT button enabled 1 / disabled 0 0 0 1

11.0 OEM in main menu enabled 1 0 1

12.0.1 Output yaw/rolling angle on display 0 0 1

1.0 Customer header line 1 0 20

1.0 Customer header line 2 0 20

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3.6

Interfaces and Software Updates

USB

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Software updates are normally performed using a USB stick (FAT32). Procedure:
1 Download the current software version from the MAHA homepage.

www.maha.de/downloads.htm

2 Open the ZIP file by double-clicking.
3 Select the MAHA folder with preset folder structure

and copy it to a USB stick.
4 Connect the USB stick containing the software update to the USB port outside

at the casing. Start installation in the Service menu (see Fig. below).

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





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38

3.7

EUROSYSTEM v7.50

Please wait until the software has been installed and restarted.

Interfaces for connecting a computer:

• RS232 as cable connection (round connector, see section “Energy Manage-

ment and Troubleshooting > Charging the Battery”)

• Wireless connection via Bluetooth, order number: VZ 990312

• These interfaces can be used for establishing a connection to MAHA’s EU-

ROSYSTEM software, which is included with the cable or Bluetooth module. Al-

ternatively, the headlight tester can also be integrated into a EUROSYSTEM

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test lane.

After the connection has been estab­lished, the yellow indicator lamp is ON.

A Bluetooth symbol appears in the info
bar of the headlight tester.

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39

Set variables using System / Settings /
Section, Lanes, External Devices.

• Variable 1: 100

(standalone device only)

• Variable 25: 1

• Variable 26: COM port

Reboot EUROSYSTEM.

Test devices are connected automati­cally.

After the measurement has been start­ed, all measured values are transferred
to EUROSYSTEM.

The connection to the MLT 3000 is re­tained until EUROSYSTEM is quit.

Select menu item <Display measure­ment values>.

Select menu item <Light tester>.

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40

An overview of the measured values
appears.

Select the desired measurement.
In this example: second level with dy­namic high-beam and motorway light.

The selected measurement data is dis­played in detail.

Graphic representation of headlight ad­justment in EUROSYSTEM:

Use the camera button on the
MLT 3000 display to switch over to
headlight adjustment. EUROSYSTEM
shows the coordinates, the measured
values and the headlight image in real
time.

The headlight pattern graphics can be
updated manually using the <F6> but­ton.

The image transmission can be com­pletely disabled via soft DIP.

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41

4

Energy Management and Troubleshooting

4.1

Charging the Battery

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The plug of the charger is inserted into the round (Neutrik) connector on the un-

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derside of the housing (see Fig.).

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The charging process normally takes 11 hours. Full battery capacity is achieved
when the battery voltage has exceeded 14.00 V during charging.

The battery indicator in the top left-hand corner of the touchscreen corresponds
approximately to the actual charging level.

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42

4.2

Battery Status

4.2.1

Battery Life

4.2.2

Energy Saving Function

4.2.3

Protection against Deep Discharge

4.2.4

Protection against Mechanical Damage

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The battery has a rated capacity of 9500mAh and can provide up to 20 hours of
continuous workshop operation at an optimum environmental temperature of
20°C.

After 10 minutes of no activity, the display switches off. By tapping the touch­screen, the device is immediately ready for operation.
After 120 minutes of no activity, the unit switches off completely and then needs
to be switched back on manually.
These standard settings can be customised in the user variables.

To protect the battery from deep discharge, the unit switches off beyond 10.8V
battery voltage.

In the event that the device is set into motion while the charger is connected, the
following image is displayed and accompanied by an audible alert:
(Alert must be enabled, see section “Operation > Settings > User Settings”.)

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43

4.2.5

Data Recording for Error Analysis

USB

The data records of the battery status allow for an optimum analysis in problem
cases.

A USB stick is needed for data recording. Records with a duration of more than
2 h can be saved by setting variable 9.0 accordingly.

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4.3

Troubleshooting

5

Maintenance

5.1

Care Instructions

NOTICE

5.2

Spare Parts

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This message may appear after updating older software versions. Acknowledge
with “Wait”.

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• The equipment must be periodically cleaned.

• Do not use high pressure and steam jet cleaners nor caustic cleaning agents.

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Regular care and maintenance is the key condition for functionality and long life
expectancy of the equipment!

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To ensure safe and reliable operation, only use original spare parts supplied by the

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equipment manufacturer.

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45

6

Disposal

7

Contents of the Declaration of Conformity

MAHA Maschinenbau Haldenwang GmbH & Co. KG

Model:
Designation:
Directives:
Standards:

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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]

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Email: [e-mail]

Alternatively, you may take the equipment to a specialised waste management
plant to ensure that all components and operating liquids are properly disposed

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of.

herewith declares as a manufacturer its sole responsibility to ensure that the
product named hereafter meets the safety and health regulations both in design
and construction required by the EC directives stated below.
This declaration becomes void if any change is made to the product that was not

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discussed and approved by named company beforehand.

=== Ende der Liste für Textmarke Inhalt ===

MLT 3000 / SEP Comfort

Headlight Tester

2014/30/EU; 2014/35/EU

DIN EN ISO 12100:2010; DIN EN 60204-1;
DIN EN 61000-6-3, DIN EN 61000-6-4

BA380701-en