USE AND MAINTENANCE MANUAL HEADLIGHT ALIGNER CFl Export CF2 Export

USE OF THE "HEDLIGHT ALIGNER" Place the Headlight Aligner at a distance of 15 / 20 cm between the headlight and the optical chamber. The surface on which the vehicle is placed must be plane as possible. In case there are imperfections on the floor where you operate the headlight aligner, eliminate them by operating on the special register (7) and level (10).

Figure 1 ALIGNMENT OF THE VEHICLE You can perform it through one of the following proposed systems: 1) Mechanical alignment system (Figure 2) Place the headlight aligner in front of the vehicle and take as a reference the front badge or one of the mouldings of the bonnet; put the headlight aligner near the vehicle and place the optical group at the centre of the vehicle. Raise the optical group up to a suitable height, put the two ends of the distance keeper close to the body or to the bumper and make sure that the both knobs touch the chosen surface. Lift with the foot the pedal by inserting the couple of fixed wheels and bend the distance keeper under the optical group. Now you can move the headl ight aligner from one headlight to the other with the guarantee of its alignment with the vehicle.

Figure 2

2) Alignment system with wide range fitter (figure 3) Proceed as in the previous case. In this case you will have to aim at two symmetrical points by means of the viewer.

Figure 3 2

CHECK AND REGULATION OF THE HEADLIGHTS MAIN PROVISIONS OF THE LAW This manual refers to the use of the headlight aligner approved by the Italian Highway Code. High beam The law prescribes that the high beam must look downward in the vertical direction by an inclination of 0.5 %, corresponding to a lowering of 5 cm at the distance of 10 meters, with respect to the height from the ground of the centre of the headlight. For what concerns the horizontal direction, the law prescribes that the headlights must not converge inward. A maximum divergence of 1 30' is allowed (see figure 6). Dipped beams The demarcation line between lighted and non lighted zones must have a direction that is as horizontal as possible and a light projection with an inclination of 1 % for a headlight with its height from the ground from 0 to 80 cm, that is at 10 meters the line must be lower by 10 cm with respect to the height of the headlight from the ground (example: height of the headlight - 60 cm, height of the light beam at 10 meters= 50 cm). If the height from the ground of the headlight is between 80 and 120cm, the inclination must be of 1.5 %, that is at 10 meters the line must be lower by 15 cm with respect to the heig ht of the headlight from the ground (example: height of the headlight = 95 cm, height of the light beam at 10 meters = 80 cm). Fog lights The Law prescribes that they must have an inclination, with respect to the vertical direction, that will make the light beam landing at a maximum distance of 20 meters from the vehicle; therefore, at the distance of 10 meters it will be equal to half of the height from the ground of the centre of the projector.

CHECK AND REGULATION OF THE DIPPED BEAMS Make the alignment of the headlight aligner to the vehicle with one of two above mentioned systems and take the optical chamber in front of one of the two headlights by adjusting its height by means of the two handles (5) and by using the metric band on the upright and the reference arrow on the optical group. Adjust the horizontality of the optical chamber by using the handle (7) and the level (10).

Description of the serigraphic screen ( 13) A B C D E F G Reference scale with indication ofthc vertical deviation Movable reference line for asymmetrical headlights Reference line for headlights of vehicles used in the Anglo-Saxon countries (driving on the right hand side) Line of the position of the maximum allowed divergence for the headlight on the left of who's watching Line of the position of the maximum allowed divergence tor the headlight on the right of who's watching Centre of the light beam Lines showing the horizontal deviation

CHECK OF THE VERTICAL ORIENTATION

At this point we can proceed to the actual check. Place the horizontal line of the sliding panel on the reference 1% (height of the headlight from 0 to 80 cm) or 1.5% (height of the headlight from 80 to 120 cm) on the basis of the type of vehicle. At this point, light the dipped beams; the beam will reflect on the serigraphic screen (13). For the alignment of the dipped beams to be correct, the line of demarcation of the headlight must coincide with the horizontal line "B" and, precisely, with the horizontal line B for the symmetrical headlight and with the horizontal line "B" and inclined "C" for the asymmetrical headlight (figure 4). N.B.: The oblique line is oriented toward the right for the left-hand drive countries, toward the left for the right-hand drive countries (Anglo-Saxons and others). In the case that the dipped beam does not coincide with the above mentioned lines you must operate on the vertical adjustment screws of the headlight. In the case of projectors with external two-posit ion manual regulation, to compensate the load, you will have to make the registration with the lever in the "high headlights" position, as if the vehicle is empty. In these operations carefully observe both the concentration and the sharpness of the outline of the projection on the front panel. Both characteristics can be influenced by a lamp with detormed filament (out of the focus of the parabola) or by a non original glass or with a wrong ruling. The light concentration is also influenced by the brightness of the parabola and by the supply voltage of thc lamp holder (for example: cables with insufficient section, oxidized connections, cables with a bad isolation toward the earth, battery of the vehicle in bad conditions, etc.).

Symmetrical headlight Figure 4

Asymmetrical headlight

CHECK OF THE HORIZONTAL ORIENTATION To check the non alignment, if any, of the headlight with the longitudinal axis of the vehicle, make reference to the vertical line "G'' on the front screen of the optical chamber (figure 5). a) Asymmetrical headlight First of all, observe whether the light zone is centred on the vertical axis and the line of oblique demarcation of the lights pertectly lays on that marked on the panel. It is allowed an error of 1cm evaluated on the front reading panel (equivalent to about l 30', (see figure 6) toward the right for the right-hand drive countries and toward the left for the left-hand drive countries (Anglo-Saxons and others). If needed, you will have to operate on the headlight horizontal adjustment screws. b) Symmetrical headlight The symmetrical headlight does not have an oblique demarcation line and, therefore, the centring on the horizontal plane is more difficult to evaluate. To check its orientation it is necessary to proceed as we will explain later for the high beams.

Headlight moved to the left

Headlight moved to the right

Figure 5

Figure 6

PROCEDURE TO CHECK THE HIGH BEAMS We can face two cases: a) High beams included with the dipped beams (projectors with two lamps or projectors with two filament lamps) In this case you will only have to check if the orientation coincides with the regulation performed on the dipped beams; with well regulated headlights the nucleus of higher luminosity must be concentrated on the central point of the screen. In case there is a remarkable deviation between the point of maximum luminosity and the centre of the screen, you will have to proceed to the substitution of the lamp, because this type of defect always depends on the lamp. b) Independent high beams In this other case you will have to check both the horizontal and vertical orientations, by using the luxmeter on the high beams scale as follows: loose the screws of the headlight and, by pressing the pushbutton, search on the front panel the point where the luminosity on the meter reaches its maximum value, that will have to coincide with the centre of the cross of the horizontal line with the vertical line of the screen (for cars and lorries respectively).

CHECK OF THE LIGHT INTENSITY OF THE HEADLIGHTS (ONLY FOR MODEL CF1 EXPORT)
a) Dipped beams Position the switch on LUX TEST. With the headlight on, the needle of the luxmeter will have to move to the sector indicated by the dipped beams symbol, in the values included between 3750 lux and 90000 lux. If this does not happen you will have to: check again the alignment check the projector in its parts check the voltage at the ends of the lamp holder (by using a voltmeter) b) High beams Position the switch on LUX TEST. With the headlight on, the needle of the luxmeter will have to move to the sector indicated by the high beams symbol, in the values included between 20000 lux and 150000 lux. If this does not happen you will have to: check the state of the parabola check the voltage at the ends of the lamp holder (by using a voltmeter)

Figure 7

MAINTENANCE

Check that the rack and the pinion are lubricated. Check that the wheels are free to rotate (frictions, if any, could compromise the lateral movement). Check the efficiency of the battery of the luxmeter. If you position the switch to BATTERY TEST the needlc of the meter will point at a value; from 50 to 150 the battery is charged, otherwise, the battery needs to be substituted.

BASIC STRUCTURE

1) 2) 3) 4) 5) 6) 7)

Lower base with wheels Pedal to insert the fixed wheels Vertical uprights with rack Lifting handles Optical chamber Friction handle Level

8) 9) 10) 11) 12) 13) 14) 15)

Lux meter Knob to move the screen Serigraphic screen Viewer Label Test switch Wheel diameter 150 Pivoting wheel diameter 60

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