Serviceanleitung ML-EASY AEI02 ENG1

Service Manual ML 6, 6-R, 8, 8-R EASY
Service Manual
Wheel measurement
computer
ML EASY
© IT no.: 902.509.081 AEI:02 Page 1 of 189

Document data:
Service manual ML6/6R ML8/8R EASY ENG

EDV.No.:902 509 081
First print: 04.2004

Changes: 08.2004
Archive: Technische Redaktion auf “Mucfs01 (H) \ Dokumentation \
Papier_Dokumentation \ 1.0_Achsmeßgeräte_ML_PKW \ ML_EASY \
902509081_Serviceanleitung_ML-EASY_AEI01_ENG.doc
© Sven Hodissen Frank Gast

Beissbarth GmbH
Hanauer Straße 101 D-80993 Munich, Germany
Tel: +49 89 / 14901 – 0
Internet: www.beissbarth.com
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Contents
INTRODUCTION ................................................................................. 9
TARGET GROUP FOR THIS MANUAL .......................................................................... 9

THE AIM OF THIS MANUAL ........................................................................................ 9
PRECONDITIONS ........................................................................................................ 9
1 THE COMPLETE EQUIPMENT ................................................ 10
1.1 FUNCTIONAL DESCRIPTION ............................................................................ 10

1.1.1 ML 8 R EASY .................................................................................................................... 10
1.1.2 ML 8 EASY ........................................................................................................................ 11
1.1.3 ML 6 R EASY .................................................................................................................... 12
1.1.4 ML 6 EASY ........................................................................................................................ 13
1.2 TECHNICAL DATA ........................................................................................... 14
2 HARDWARE.................................................................................. 15
2.1 PC ................................................................................................................... 15
2.1.1 TECHNICAL DATA - HARDWARE ....................................................................................... 15
2.1.2 OPERATING SYSTEM ......................................................................................................... 15
2.1.3 CONNECTIONS REAR SIDE OF PC ..................................................................................... 16
2.1.4 DONGLE............................................................................................................................. 17
2.1.4.1 Function.......................................................................................................................... 17
2.1.4.2 Connection ..................................................................................................................... 17
2.1.4.3 Licence number .............................................................................................................. 17
2.1.4.4 Issuing licences .............................................................................................................. 17
2.1.5 THE COMMUNICATIONS PROCESSOR IN THE PC (ONLY ML 6 AND 8 EASY)...................... 18
2.1.5.1 Functional overview....................................................................................................... 18
2.1.5.2 Functional description .................................................................................................... 18
2.1.5.3 Connections.................................................................................................................... 19
2.1.5.4 Jumper ............................................................................................................................ 20
2.1.5.5 Cable............................................................................................................................... 20
2.1.5.6 Flash-EPROM ................................................................................................................ 20
2.2 CHARGING STATION (ONLY ML 6 R AND 8 R EASY) ................................... 21
2.2.1 COMPLETE COMPONENT .................................................................................................. 21
2.2.1.2 Functional diagram......................................................................................................... 22
2.2.1.4 Connections on the front ................................................................................................ 24
2.2.1.5 Connections right hand side ........................................................................................... 24
2.2.1.6 Connections at the rear................................................................................................... 24
2.2.1.7 Installation in the equipment cabinet ............................................................................. 25
2.2.2 CIRCUIT BOARD FOR THE POWER SUPPLY TO THE BATTERY CHARGER.......................... 26
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2.2.2.3 Connectors...................................................................................................................... 27
2.2.2.4 Cables ............................................................................................................................. 28
2.2.2.5 Potentiometer settings .................................................................................................... 29
2.2.3 FAN .................................................................................................................................... 32
2.2.3.1 Power supply .................................................................................................................. 32
2.2.3.2 Connector ....................................................................................................................... 32
2.2.3.3 On/Off threshold ............................................................................................................ 32
2.2.4 COMMUNICATIONS PROCESSOR ....................................................................................... 33
2.2.4.3 Connectors...................................................................................................................... 34
2.2.4.4 Jumper ............................................................................................................................ 34
2.2.4.5 Cable............................................................................................................................... 35
2.2.4.6 Power supply .................................................................................................................. 35
2.2.4.7 Flash-EPROM ................................................................................................................ 35
2.2.4.8 Changing the radio channel............................................................................................ 35
2.2.5 WIRELESS MODULE .......................................................................................................... 36
2.2.5.3 Power supply .................................................................................................................. 36
2.2.5.4 Connectors...................................................................................................................... 37
2.2.5.5 Cable............................................................................................................................... 37
2.2.5.6 Radio frequency ............................................................................................................. 37
2.2.5.7 Flash-EPROM ................................................................................................................ 37
2.2.6 THE DISTRIBUTION BOARD ............................................................................................... 38
2.2.6.3 Connectors...................................................................................................................... 39
2.2.6.4 Cable............................................................................................................................... 40
2.2.7 CHARGING SOCKETS ON THE MOBILE EQUIPMENT CABINET .......................................... 41
2.2.7.1 Pin connections .............................................................................................................. 41
2.2.7.2 Cable............................................................................................................................... 41
2.3 DISTRIBUTION BOX (ONLY ML 6 AND 8 EASY) ............................................ 42
2.3.1.3 Connections on the front ................................................................................................ 43
2.3.1.4 Connections on the left side ........................................................................................... 43
2.3.1.5 Connections on the right side ......................................................................................... 43
2.3.2 THE DISTRIBUTION BOARD ............................................................................................... 44
2.3.2.1 Connections.................................................................................................................... 44
2.3.2.2 Cables ............................................................................................................................. 45
2.4 CONNECTING CABLE....................................................................................... 46
2.4.1 FUNCTIONAL DESCRIPTION .............................................................................................. 46
2.4.2 WIRING SCHEME ............................................................................................................... 46
2.5 MEASUREMENT PODS (ML 6, 6 R, 8, 8 R EASY) .......................................... 47
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2.5.2 MEASUREMENT PROCESSOR ............................................................................................. 49
2.5.2.3 Connections.................................................................................................................... 51
2.5.2.4 Cables ............................................................................................................................. 52
2.5.2.5 DIP switch ...................................................................................................................... 54
2.5.2.6 Board layout by model - version ....................................................................................54
2.5.2.7 Flash-EPROM ................................................................................................................ 55
2.5.2.8 Reading / Duplicating the calibration values ................................................................. 55
2.5.2.9 How to swap a measurement processor ......................................................................... 55
2.5.3 CCD CAMERA ................................................................................................................... 56
2.5.3.3 Technical data / features................................................................................................. 58
2.5.3.4 Differences to the 10 degree camera .............................................................................. 58
2.5.3.5 Camera components ....................................................................................................... 59
2.5.3.6 Flash-EPROM ................................................................................................................ 60
2.5.3.7 Calibration values........................................................................................................... 61
2.5.3.7.1 Corrections .................................................................................................................. 61
2.5.3.7.2 Zero values .................................................................................................................. 62
2.5.3.7.3 Reading / Duplicating the calibration values .............................................................. 62
2.5.3.8 How to swap cameras..................................................................................................... 62
2.5.4 KEYBOARD PRINTED CIRCUIT BOARD ML 6 R AND 8 R EASY......................................... 63
2.5.4.3 Keyboard function.......................................................................................................... 64
2.5.4.4 Connections.................................................................................................................... 64
2.5.4.5 Cables ............................................................................................................................. 64
2.5.4.6 Changing the radio transmission channel....................................................................... 65
2.5.5 KEYBOARD PRINTED CIRCUIT BOARD ML 6 AND 8 EASY ..............................................66
2.5.5.3 Keyboard function.......................................................................................................... 66
2.5.5.4 Connections.................................................................................................................... 67
2.5.5.5 Cables ............................................................................................................................. 67
2.5.6 WIRELESS MODULE (ONLY ML 6 R AND 8 R EASY).......................................................68
2.5.6.3 Power supply .................................................................................................................. 68
2.5.6.4 Connections.................................................................................................................... 69
2.5.6.5 Cables ............................................................................................................................. 69
2.5.6.6 Radio frequency ............................................................................................................. 69
2.5.6.7 Flash-EPROM ................................................................................................................ 69
2.5.7 CHARGING ELECTRONICS CARD (ONLY ML 6 R AND 8 R EASY) .................................. 70
2.5.7.3 Connections.................................................................................................................... 71
2.5.7.4 Cables ............................................................................................................................. 71
2.5.7.5 Pin connections for the potentiometer............................................................................ 72
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2.5.7.6 To check and set the charging voltage ........................................................................... 72

2.5.8 BATTERY (ONLY ML 6 R AND 8 R EASY) .......................................................................73
2.5.8.1 Technical data ................................................................................................................ 73
2.5.9 MOUNTING PIN = CHARGING CONTACT (ONLY ML 6 R AND 8 R EASY)........................73
2.5.9.2 Connections.................................................................................................................... 74
2.5.9.3 Cables ............................................................................................................................. 74
2.5.9.4 Charging voltage ............................................................................................................ 74
3 SOFTWARE ................................................................................... 75
3.1 OPERATING SYSTEM SOFTWARE .................................................................... 75

3.1.1 DESCRIPTION OF THE OPERATING SYSTEM SOFTWARE ................................................... 75
3.1.2 OPERATING SYSTEM – CD................................................................................................ 76
3.1.2.1 Function.......................................................................................................................... 76
3.1.2.2 Use.................................................................................................................................. 76
3.2 USER SOFTWARE ............................................................................................. 77
3.2.1 USER SOFTWARE DESCRIPTION ........................................................................................ 77
3.2.1.1 Modular assembly of the individual programme blocks................................................ 77
3.2.1.2 Main programme ............................................................................................................ 78
3.2.1.2.1 Functional overview.................................................................................................... 78
3.2.1.2.2 Function / Tasks .......................................................................................................... 78
3.2.1.2.3 Path to the main programme ....................................................................................... 79
3.2.1.2.4 Description of the files ................................................................................................ 80
3.2.1.2.5 Main programme INI file ............................................................................................ 81
3.2.1.3 CCD Server .................................................................................................................... 84
3.2.1.3.2 Function....................................................................................................................... 84
3.2.1.3.3 Path to the programme module ................................................................................... 85
3.2.1.3.5 Programme module INI file ........................................................................................ 87
3.2.1.3.6 Service information / selecting a turntable.................................................................. 89
3.2.1.4 Demo. Server.................................................................................................................. 93
3.2.1.4.2 Function....................................................................................................................... 93
3.2.1.4.3 Path.............................................................................................................................. 94
3.2.1.4.5 INI file ......................................................................................................................... 96
3.2.1.4.6 Service information ..................................................................................................... 96
3.2.1.5 Licence server ................................................................................................................ 98
3.2.1.5.1 Function / Tasks .......................................................................................................... 98
3.2.1.5.2 Path.............................................................................................................................. 99
3.2.1.5.3 Description of the files .............................................................................................. 100
3.2.1.5.4 INI file ....................................................................................................................... 101
3.2.1.5.5 Service information ................................................................................................... 101
3.2.1.6 ILSV server .................................................................................................................. 103
3.2.1.6.1 Function / Tasks ........................................................................................................ 103
3.2.1.6.2 Path............................................................................................................................ 104
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3.2.1.6.4 INI file ....................................................................................................................... 106

3.2.1.6.5 Service information ................................................................................................... 107
3.2.1.7 Target data editor ......................................................................................................... 109
3.2.1.7.1 Function..................................................................................................................... 109
3.2.1.7.2 Path............................................................................................................................ 109
3.2.1.8 Text editor .................................................................................................................... 111
3.2.1.8.1 Function / Tasks ........................................................................................................ 111
3.2.1.8.2 Path............................................................................................................................ 111
3.2.1.8.4 INI file ....................................................................................................................... 112
3.2.1.9 System monitor ............................................................................................................ 113
3.2.1.9.1 Function / Tasks ........................................................................................................ 113
3.2.1.9.2 Path............................................................................................................................ 113
3.2.1.9.4 Operation................................................................................................................... 115
3.2.1.10 Flash - Writer ............................................................................................................. 123
3.2.1.10.1 Function................................................................................................................... 123
3.2.1.10.2 Path.......................................................................................................................... 123
3.2.1.10.3 Description of the files ............................................................................................124
3.2.1.10.4 INI file ..................................................................................................................... 124
3.2.1.10.5 Using the software................................................................................................... 125
3.2.1.10.5.1 Preparing the measurement system ......................................................................125
3.2.1.10.5.2 Programme sequence............................................................................................ 125
3.2.1.10.5.3 Toolbar ................................................................................................................. 125
3.2.1.10.5.4 Menu..................................................................................................................... 126
3.2.1.10.5.5 Settings ................................................................................................................. 126
3.2.1.10.5.6 Screens ................................................................................................................. 128
3.2.1.10.5.7 Additional information......................................................................................... 139
3.2.1.11 Databases.................................................................................................................... 143
3.2.1.11.1 Summary ................................................................................................................. 143
3.2.1.11.2 Structure .................................................................................................................. 144
3.2.2 INSTALLATION / DEINSTALLATION OF APPLICATION SOFTWARE ................................. 145
3.2.2.1 Installation.................................................................................................................... 145
3.2.2.1.1 Programme software ................................................................................................. 145
3.2.2.1.2 Target data software .................................................................................................. 146
3.2.2.2 Uninstalling user software............................................................................................ 149
3.2.2.2.1 Windows system / Software menu ............................................................................149
3.2.2.2.2 Uninstall with unwise.exe ......................................................................................... 150
3.2.3 SAVING YOUR OWN USER DATA ...................................................................................... 153
3.2.3.1 Customer data / Measurement results .......................................................................... 153
3.2.3.2 Measurement record.....................................................................................................154
3.2.4 SERVICE USER SOFTWARE .............................................................................................. 155
3.2.4.1 Version record .............................................................................................................. 155
3.2.4.2 Equipment status .......................................................................................................... 156
3.2.4.2.1 The Runtime screen................................................................................................... 156
3.2.4.2.2 General screen ........................................................................................................... 157
3.2.4.3 Direct angle measurement............................................................................................ 158
3.2.4.4 Calibration.................................................................................................................... 163
3.2.4.4.1 Function..................................................................................................................... 163
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3.2.4.4.2 Toe-in ........................................................................................................................ 164

3.2.4.4.3 Calibrating camber .................................................................................................... 174
3.2.4.4.4 Spirit level adjustment............................................................................................... 185
MAINTENANCE MANUAL ........................................................... 188
A FINAL WORD............................................................................... 188
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Introduction
Target group for this manual
This service manual is both for service technicians, who have little or no experience
in the area of wheel measurement, and for technicians, who have many years of
experience in servicing wheel measurement equipment and Beissbarth wheel
measuring computers.
The aim of this manual
The aim of this manual is to provide technical documentation intended for, and from
the point of view of, service technicians; ranging from beginners to technicians with
many years of experience.
This means that this service manual serves both as an introduction to servicing the
Beissbarth wheel measurement computers ML EASY and also as a reference book for
questions arising in practice.
To make the content as straight-forward and clear as possible, and to explain complex
technical relationships, in an understandable manner, we have tried to avoid specialist
terminology and wordy explanations in favour of clear graphics and diagrams.
Preconditions
For better understanding and take up of the contents of this manual, it would be helpful
if the reader had attended the courses or has the following knowledge:
Basic understanding of wheel measurement
How to use the wheel measurement computer ML EASY
Courses on the use and servicing of the Beissbarth wheel measurement computer
ML EASY at the Karlsfeld training centre, or at your own location.
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1 The complete equipment

1.1 Functional description
1.1.1 ML 8 R Easy
Easy: The new product line from Beissbarth.

“Easy” means easy to use, via the user interface, and standard measurement routines
from the extensive Beissbarth database of target values.
Target group:
Workshops and tyre service establishments with a lot of measurements to do, where
speed and precision are important.
Where additional measurements are desirable e.g. for crash vehicles.
ML 8 R Easy, the wheel measurement system for all types of car and commercial
vehicles, up to a maximum wheelbase of 6.5 m.
The measurement is carried out with an 8-pod system, with integrated camber-
pendulum, wireless infrared CCD measurement sensors and radio data transmission
between measurement sensors and the central equipment rack. The new camera
technology enables standard measurements, with mechanical turntables, when steering
at up to 20°.
The advantages of the wheel measurement equipment:
Robust aluminium bearers with a hardwearing plastic housing.
New CCD cameras, with an extended range for toe-in measurements and with an
integrated camber-pendulum, enable caster measurements when steering 20° with
mechanical turntables, at a distance of 6 m (optionally 18 m) with unbeatable precision
and repeatability.
• The batteries are charged via the locating pins of the measuring sensors
(wireless version).
• The precision is checked continuously.
• As required, you have a free choice between measurements guided by
the programme, quick measurements and optional measurements.
• Large, clear graphics when setting.
• Live display of the values measured.
• Free choice between 2 types of measurement record: tabular or graphical.
• Vehicle database with over 12 000 sets of target data, from more than
48 manufacturers.
• Can be updated at any time, via the Internet.
• With pictures illustrating settings, animations and videos.
• Available in over 18 languages.
• Equipment cabinet: modern, compact, functional design.
• It’s mobile and can be used at various locations.
• PC with a low temperature CPU, Windows XP Home operating system and
DVD/CD writer (combination drive).
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1.1.2 ML 8 Easy

Target group:
Workshops and tyre service establishments with a medium to high number
of measurements to do, where precision is important.
Where additional measurements are desirable e.g. for crash vehicles.
ML 8 Easy, the wheel measurement system for all types of car and commercial
The measurement is carried out with an 8-pod system, with integrated camber-pendulum,
wireless infrared CCD measurement sensors and data transmission via cable between
measurement sensors and the central equipment rack. The new camera technology
enables standard measurements, with mechanical turntables, when steering at up to 20°.
• Robust aluminium bearers with a hardwearing plastic housing.

• New CCD cameras, with an extended range for toe-in measurements and with
an integrated camber-pendulum, enable caster measurements when steering 20°
with mechanical turntables, at a distance of 6 m (optionally 18 m) with
unbeatable precision and repeatability.
• The precision is checked continuously.
48 manufacturers.
• Separate storage of measurement pods and holders, saves space and facilitates
the installation.
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1.1.3 ML 6 R Easy

Target group:
Workshops and tyre service establishments with a lot of measurements to do, where
speed and precision are important.
Inexpensive wheel measurement system is required.
ML 6 R Easy, the wheel measurement system for all types of car and commercial
The measurement is carried out with a 6-pod system, with integrated camber-pendulum,
wireless infrared CCD measurement sensors and radio data transmission between
• Robust aluminium bearers with a hardwearing plastic housing.
• The batteries are charged via the locating pins of the measuring sensors
(wireless version).
48 manufacturers.
the installation.
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1.1.4 ML 6 Easy

Target group:
Workshops and tyre service establishments with a low number of measurements to do.
Inexpensive wheel measurement system is required.
ML 6 Easy, the wheel measurement system for all types of car and commercial
The measurement is carried out with a 6 pod system, with integrated camber-pendulum,
wireless infrared CCD measurement sensors and data transmission via cable between
Robust aluminium bearers with a hardwearing plastic housing.
• As required, you have a free choice between measurements guided by the
programme, quick measurements and optional measurements.
• Free choice between 2 types of measurement record. Tabular, graphical.
48 manufacturers.
the installation.
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1.2 Technical data
Dimensions of the equipment cabinet including 17” colour monitor:

WxDxH: approx. 98x80x160cm.
Weight: approx. 80 kg Colour: RAL 7011 (grey) / RAL 5015 (blue)
Power supply: Operating temperature: +5 °C...+40 °C

100-115 V AC / 220-240 V AC Storage temperature: -20 °C...+60 °C
Frequency 50/60 Hz Temperature gradient: 20 °C / hour
Power: 0.5 kW rel. operational humidity: 10 %...90 % .(40 °C)
Fuse 3.15 A (slow blow) rel. humidity gradient: 10 % / hour
max. operational altitude: -200 m... 3000 m
(Other connections, on request.) max. transport altitude: -200 m...12000 m
Measurement options: Precision for value range

Overall toe-in ±3’ ±2°
(Front Axle + Rear Axle) ±2’ ±2°
Individual toe-in (FA+RA) ±2’ ±3°
Camber ±2’ ±2°
Wheel offset (FA) ±2’ ±2°
Driving axle angle ±4’ ±18°
Caster ±4’ ±18°
Inclination ±4’ ±20°
Toe out on turns ±4’ ±7°
Caster correction range
Additional measurement options: ±2’ ±2°
Wheel offset (RA) ±3’ ±2°
Wheel base differential ±2’ ±2°
Lateral offset left/right ±3’ ±2°
Track width differential ±3’ ±2°
Axle offset (RA)
Memory to store vehicle details: unlimited
The text displayed appears in the country language programmed.
Clamp systems: Quick clamp units: Multiquick clamp units:
Working range passenger cars 10” to 20” Working range passenger cars 10” to 23”
Turntables: 1000 kg load for cars, angle of turn – 360°,

(LxWxH) 450x450x50 mm, sliding range ±50 mm, weight 18 kg.
Sliding plates: 1000 kg load for cars, angle of turn ±10°,

(LxWxH) 450x450x50 mm, sliding range +65 <-> -50 mm, weight 17 kg.
Wireless system: Frequency range 2.4 GHz (433 MHz)

Multi-channel system (ML 8R/6R easy)
We reserve the right to make changes.
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2 Hardware
2.1 PC
2.1.1 Technical data - Hardware
Currently, the following computer is used in the ML EASY series:
Housing ATX mini tower

Motherboard C3M266
CPU VIA C3 1 GHz
RAM 256 MB-DDR PC 266
Hard disc 40 GB
Drive Floppy 3.5 inches
CD-Rom Combination BTC 48x
Graphic card On board
Sound card On board
Network card On board
2.1.2 Operating system

Operating system Windows XP Home Edition - English
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2.1.3 Connections rear side of PC
Power supply connection

On/off switch
PS/2 keyboard
PS/2 mouse
USB
COM 1 (9 way serial)
COM 2 (9 way serial)
LPT 1 (parallel Centronics)
Monitor (VGA 15 way)
Network (BNC/ RJ 45)
10/100 Mbit
COM 3 and COM 4 (optional)
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2.1.4 Dongle
IT number: 932.501.023
2.1.4.1 Function
The hardware licence number of the wheel measurement computer is stored in the dongle.
Without a dongle or, if it’s broken, you can only run in demonstration mode. No real-time
measurements are possible!
When first installed, and then at every subsequent update, this hardware licence is read
out of the dongle and compared with the supplied software licence for the installation.
The installation will only proceed and complete successfully if these two licences match.
After this, every time the wheel measurement programme starts, the dongle licence is
compared with the software licence installed on the hard disc.
The same is true every time the C key is pressed in the wheel measurement programme.
If they don’t match, no measurements are possible.
2.1.4.2 Connection
The dongle is plugged into the parallel interface LPT 1 on the rear of the computer. It is
transparent to other dongles for other programmes or for a printer and does not affect
any other hardware.
2.1.4.3 Licence number

The licence number is the same as the serial number of the equipment. It consists of
a 2 digit alphanumeric string and a 7 digit numeric string
e.g.: C0 0000102.
The alphanumeric string supplies information about the model of the wheel
measurement computer, the numeric string results from the production serial number.
C0= ML 6 R and 8 R Easy C1= ML 6 and ML 8 Easy
(wireless version) (cabled version)
2.1.4.4 Issuing licences

Licences can only be issued (= programming the serial number of the equipment into the
dongle) in the Beissbarth factory. Every licence number is only issued once. If the dongle is
lost or stolen, a replacement will be supplied which is marked as such by having 98 instead
of the first two zeroes.
For special purposes (service technicians, sales staff), instead of the two zeroes, 99 is used.
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2.1.5 The communications processor in the PC

(only ML 6 and 8 EASY)
IT number: 932.503.102
2.1.5.1 Functional overview
Conversion of the 12V

Communications control, produced by the PC power supply
when operating in cable mode into 8V for the measurement pods
ComProc
Serial data transmission
to the PC Store the 6 radioo channel numbers
2.1.5.2 Functional description

The communications processor (ComProc) controls the communication between the PC
(CCD server) and the 4 measurement pods. It coordinates the delivery of the
measurement commands, which it receives from the software measurement programme
“CCD Server”, and it returns the received measurements there.
The communications processor is connected to the PC COM 2 interface via a 9-way
serial cable.
The communications processor is connected to the 4 measurement pods via the
distribution box.
The PC power unit supplies the communications processor with 12 V.
From that, it generates the 8 V needed by the measurement pods.
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2.1.5.3 Connections
not used
Output to the distribution box
12 V power supply
via PC power supply
Serial connection
COM 2 from PC
DIP switch
not used
(used for programming, in the factory)
not used
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2.1.5.4 Jumper
1 Wireless module 2.4 GHz
(ON)
2 not used
3 not used
4 not used
Standard is all OFF
2.1.5.5 Cable
Cable
PC – distribution box; connection cable
IT no.: 932.503.121
brown cable ground
white cable + 8.00 V
green cable data
yellow cable data
2.1.5.6 Flash-EPROM
Software updates change the Flash memory (= writing new content to the EPROM
using a cable connection from a notebook, running a special software programme) by
using the “Flash-Writer” service programme.
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2.2 Charging station (only ML 6 R and 8 R EASY)

2.2.1 Complete component
IT number:
932.502.038_03
Wireless data Mains voltage for PC

transmission looped trough
Mains fuse 3.15 A
slow blow
Data transmission Charging station
via cablel Switch 110/230V
Serial data Fuse 3.15A slow blow

transmission to PC battery/connection cable
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2.2.1.2 Functional diagram
Schematic representation of the charging station ML 6R and 8R EASY

Fuse 3.15A
230V slow blow
Mains voltage to Switch Mains voltage
the PC 110/230V 110V/ 230V
230V
Fan Power supply

12V 110V/ 230V
12V
8V
Charging
socket 8V J10
Charging 5V
8V J9 Distribution
socket
circuit
board Data ComProc
Charging 8V J8
5V/ 8V 5V/ 8V
socket 8V Ground
Chargi Daten J7
ng J1 J3
socket Daten
5V 9-pole
Data 8V
serial
Data
COM 2
PC
Wireless module5V
8V
Fuse 3,15A
slow blow
Measurement pod
data
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The charging station provides the required 5.00 volt, 8.00 volt and approx. 12 volt dc
supplies. It also contains and supplies the communications processor.
Power distribution:
The mains cable is fed to the socket on the charging station. From here, it goes back to
the 110 V/230 V switch. Then, the supply is split.
1. It goes to the distribution socket, with a central on/off switch for the PC, monitor
and printer.
2. It goes to the power supply printed circuit board, inside the charger.
Power supply circuit board:
The power supply on the PCB generates the two voltages necessary of 8.00 volts and
approx. 12 volts.
Fan:
If required, the temperature-controlled fan is turned on automatically.
Communications processor:
The communications processor generates the 5.00 V required for the wireless module.
It controls, and also makes available, the connection between the CCD server and the
measurement processors in the measurement pods.
The distribution board:
The distribution board divides the supply voltage and data transmission to the
Wireless module
Batteries
Connection cable to the measurement pods
Communications processor, and to the
Power supply.
Wireless module:
The wireless module sends commands to the measurement pods and receives the real-
time measurements from them.
Power supply and data transmission to the distribution board.
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2.2.1.4 Connections on the front
Aerial connection
Fuse for 8.00 volts
3.15 A slow blow
2.2.1.5 Connections right hand side
Socket for connection cable

left hand side
Socket for connection cable
right hand side
2.2.1.6 Connections at the rear
Socket for null modem cable

Mains socket
Switch 110 V / 230 V
Socket for distribution socket
Fuse for mains voltage
3.15 A slow blow
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2.2.1.7 Installation in the equipment cabinet
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2.2.2 Circuit board for the power supply to the battery charger
IT number:
932.503.016
8V supply voltage 8V supply voltage

to the battery charger to the communications processor
Circuit
8V supply voltage
12V supply voltage
to the fan
board to the connectimg cable
The power supply board converts the 110 V / 230 V ac mains voltage into 15V dc.
From this 8.00V are derived, for
the power supply to the communications processor

charging the batteries
supplying power to the measurement pods via the connecting cable
The power supply board also supplies approx. 12 V for the temperature-controlled fan.
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2.2.2.3 Connectors
Fan
about 12 V
Mains voltage
Communications
processor 8.00 V
Distribution board
8.00 V
Fan
about 12 V
Mains voltage
Communications
processor 8.00 V
Distribution board
8.00 V
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2.2.2.4 Cables
Cable
Mains filter - power supply board IT
no. 932.503.108
pin 1 = orange wire
pin 3 = brown wire
pin 4 = purple wire
pin 6 = black wire
+8.00 V cable
Power supply – Fuse3.15 A slow blow
IT no. 932.503.111
pin 1 = white cable +8.00 V
Cable supplying the fan.
Permanently connected at the fan.
pin 1 = blue wire +12 V
pin 2 = brown cable ground
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2.2.2.5 Potentiometer settings
T adj.
potentiometer
for the fan
V adj.
Potentiometer for
8.00 V
I adj.
potentiometer
for 23 mV
Test point 1
= ground
Test point 2
Test point 3
Test point 4
Test point 5
Test point 6
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Setting
After a visual check, the settings must be carried out in the sequence specified.
After successful calibration, the potentiometers must be sealed.
1. Vadj (R8):
= Sets the supply voltage for the communications processor, the batteries and
the connecting cable.
Location: R8 (200 Ω potentiometer)

Conditions to make an adjustment: Temperature between 20 °C and 30 °C, no load.
Test point: MP2 on C6 pin 1 (+) to GND (MP1)
Vadj = + 8.00 V +0.04 V (0.25%) - 0.00 V
2. Ιadj (R11):
= Setting the operational amplifier input

(= Safety circuit to prevent the power supply being overloaded by a short-circuit
or by simultaneously charging batteries and operating in cable mode.
The power supply is only dimensioned to support either battery charging or
operation is cable mode.)
Conditions to make an adjustment: Temperature between 20 °C and 30 °C, no load.
Test point: Voltage from MP4 (pin 5) to MP3 (pin 6) on OP U2
With Ilast = 0 ∆UOp-inputs = +23 mV ± 0.5 mV
3. Tadj (R16):
= Sets the threshold at which the temperature dependent fan starts operating.

Conditions to make an adjustment: No load & fan off !
Test point: Voltage from MP5 (pin 2) to MP6 (pin 3) on OP U2, T is the
temperature of the heat-sink
Use the following table to do the setting:
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0 300,0
1 291,5 300,0
2 283,1
3 274,8
4 266,5
5 258,4
6 250,4
250,0
7 242,5
8 234,7
9 226,9
10 219,3
11 211,8
12 204,3 200,0
13 197,0
14 189,8
15 182,6
16 175,6
mV
17 168,6 150,0
18 161,8
19 155,0
20 148,4
21 141,8
22 135,3
100,0
23 129,0
24 122,7
25 116,6
26 110,5
27 104,5
28 98,6 50,0
29 92,9
30 87,2
31 81,6
32 76,1
33 70,7 0,0
34 65,4 0 10 20 30 40
35 60,3
36 55,2 T/°C
37 50,2
38 45,3
39 40,5
40 35,8
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2.2.3 Fan
IT number:
932.503.014
2.2.3.1 Power supply

The fan is supplied with approximately 12 volts.
This is supplied via the power supply board.
2.2.3.2 Connector
Cable supplying the fan.
Permanently connected at the fan.
pin 1 = blue wire +12 V
pin 2 = brown cable ground
2.2.3.3 On/Off threshold

The fan is controlled by the power supply board, which checks the temperature to turn it
on/off. That means it does not run constantly.
The threshold to turn the fan on is set on the power supply board, using potentiometer
R16 Tadj. See potentiometer settings on the power supply board too.
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2.2.4 Communications processor
IT number: 932.503.074
Communications control, Converting 8V to 5V

when using wireless transmission for the wireless module
Communications control, Earth connection
when operating with cable ComProc for the distribution card
Serial data transmission To store
to the PC the radio hannel numbers

The KomProz (communications processor) controls the communication between the PC
(CCD server) and the 4 measurement pods. It coordinates the delivery of the
measurement commands, which it receives from the software measurement programme
“CCD Server”, and it returns the received measurements there.
The communications processor is connected to the PC COM 2 interface via a 9-way
serial cable.
The communications processor is connected to the 4 measurement pods via the
distribution card and the wireless module.
The power supply supplies the communications processor with 8 V.
From that, it generates the 5 V needed by the wireless module.
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2.2.4.3 Connectors
Not used. Used

by the manufacturer to
programme new Eproms.
not used
Connector
Comms Processor/
Distribution card
pin 1 data
pin 2 +5V
pin 3 data
pin 4 ground
pin 5 +8V
pin 6 ground
pin 7
pin 8
2.2.4.4 Jumper
1 Wireless module
2.4 GHz (ON)
2 not used
3 not used
4 not used
Standard is all OFF
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2.2.4.5 Cable
Serial cable
PC (COM 2) – Comms Processor
IT no.: 932.503.114
Cable
Comms Processor -
Distribution card
IT no.: 932.503.112
pin 1 = yellow wire data wire
pin 2 = red wire +5 V
pin 3 = green wire data wire
pin 4 = brown wire ground
pin 5 = white wire +8 V
pin 7 = blue wire wireless data
pin 8 = purple wire wireless data

The power supply supplies the communications processor with 8.00 V.
From that, it generates the 5.00 V needed by the wireless module.
2.2.4.7 Flash-EPROM
Software updates change the Flash memory (= writing new content to the EPROM
using a cable connection from a notebook, running a special software programme) by
using the “Flash-Writer” service programme.
2.2.4.8 Changing the radio channel

It is possible to run up to 6 ML 6R or 8R EASY in parallel, in wireless mode.
Preconditions to do that:
Different radio frequencies must be used for communication between the measurement
pods and the communications processor, so as not to interfere with one another.
6 different radio frequencies are available for this purpose. The information about
which radio frequency each pod uses is stored in the communications processor.
The frequencies used can be displayed or changed using the “System Monitor” utility.
When changing a channel, the frequency must not only be changed in the
communications processor but also in each of the 4 measurement pods.
A combination of keys on the measurement pod’s keyboard is used to do this.
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2.2.5 Wireless module
IT number: 932.503.075
Data transmission
to the measurement pod
Wireless Communication with
the measurement pod
Data reception
from measurement pod
module

The wireless module transmits the measurement commands to the measurement pod
at 433 MHz and then receives the measurement results.

The wireless module is supplied with a voltage of 5.00 V.
This is supplied via the distribution board.
The 5.00 V is generated on the communications processor.
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2.2.5.4 Connectors
Connection to the
distribution card
pin 1: ground
pin 2: data
pin 3: + 5.00 V
pin 4: data
Connector to program the
wireless module software into
FLASH memory
Not used
Displays the status of the
wireless data transmission
2.2.5.5 Cable
Cable
Wireless module – Distribution card
IT no.: 903.503.004
pin 2 = green wire data
pin 3 = white wire + 5.00 V
pin 4 = yellow wire data
2.2.5.6 Radio frequency

The wireless module transmits at 433 MHz.
In case more than one EASY wheel measurement system is used in a workshop,
there are 6 alternative frequencies available, which are all in the area of 433 MHz.
2.2.5.7 Flash-EPROM
Software settings and/or updates are written to the Flash memory (= writing new
content to the EPROM using a cable connection from a notebook, running a special
software programme) by using the “Flash-Writer” utility.
Information about the software and the status of any errors can be read with the
“System monitor” utility.
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2.2.6 The distribution board
IT number:
932.503.107
Data transmission
to the measurement pod Looped through 8V
in back-up cable operation to charge the batteries
Data reception
from the measurement pod Looped through 8V
in back-up cable operation Distribution for cable operation
board
Looped through data, Looped through 5V
when in wireless mode for the wireless module
The distribution card splits the necessary data connections and supply voltages.
Loops the data:
in wireless mode
in cable mode
Loops the supply voltages:
+8.00 V to charge the batteries

+8.00 V for cable mode
+5.00 V for the wireless module
There are no electronic components on the printed circuit board, just copper tracks
and connectors.
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2.2.6.3 Connectors
Charging sockets
Charging sockets
Connection cable to built-in socket
Connection cable to built-in socket
Wireless module
The communications processor
Power supply
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2.2.6.4 Cable
Cable
IT no.: 932.503.004
Cable
Distribution card – built-in socket
IT no.: 932.503.109
Cable
Communications processor –
Distribution card
IT no.: 932.503.112
pin 1 = green wire data wire
pin 2
pin 3 = yellow wire data wire
pin 4 = brown wire ground for
5 V/8 V
pin 5 = red wire + 5.00 V
pin 6 =
pin 4 = purple wire wireless data
pin 4 = blue wire wireless data
Cable +8.00 V
Power supply - Distribution card
IT no.: 932.503.111
pin 1 = white wire +8.00 V
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2.2.7 Charging sockets on the mobile equipment cabinet
IT number:
932.503.097
2.2.7.1 Pin connections
Connection to the distribution

card +8.00 V
Connection to the
distribution card
ground
2.2.7.2 Cable
Cable +8.00 V
Distribution card
- Charging socket
IT no.: 932.503.100
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2.3 Distribution box (only ML 6 and 8 EASY)

IT number: 932.502.051
Looped the 8.00V

Serial data transmission
through
to/from the PC
Y-splitter; divides the data and

supply voltage between 2 outputs Complete
distribution box
1.6A slow blow fuse Loops the measurement data
for the connection cable through

The distribution box divides the serial measurement data connection, coming from
the PC, and divides the 8.00 V supply voltage, to 2 Neutrik sockets, for the connection
cable. At the same time, the 8.00 V supply for the connection cable is protected with
a 1.6 A slow blow, glass fuse.
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2.3.1.3 Connections on the front
Fuse for 8.00 volts

1.6 A slow blow
2.3.1.4 Connections on the left side
Connection
Input to the distribution box
from the PC/Comms processor
2.3.1.5 Connections on the right side
Connection
Output of the distribution box
to the measurement pod via
the connection cable
Connection
Output of the distribution box
to the measurement pod via
the connection cable
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2.3.2 The distribution board
IT number:
932.503.107
2.3.2.1 Connections
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Input
Serial from PC/
Comms processor
Output
Input
Connection cable to
8.00 V from the PC via the
built-in socket
1.6 A slow blow fuse
Output
Connection cable to
built-in socket
2.3.2.2 Cables
Cable
PC - Distribution card
connection cable
IT no.: 932.503.121
brown wire ground
white wire + 8.00 V
green wire data
yellow wire data
Input cable
Built-in socket –
Distribution card/ fuse
IT no.: 932.703.011
white wire + 8.00 V
Cable +8.00 V
Fuse 1.6 A slow blow - Distribution card
IT no.: 932.503.110
Output cable
Distribution card – built-in socket
IT no.: 932.503.109
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2.4 Connecting cable
IT number:
Set of cables: 932.401.019
4.5 m cable: 932.402.010
6.5 m cable: 932.402.011
2.4.1 Functional description

The connecting cables have the following tasks:
To deliver the supply voltage to the measurement pods
Communication / data transmission
To charge the batteries (only ML 6 and 8 R EASY)
2.4.2 Wiring scheme

There are two options to connect the measurement pods with the cables.
Two cable runs, one to the left and one to the right of the vehicle
A U-shaped cable run around the vehicle, between the 4 measurement pods.
(Not ML 6R and 8 R EASY)
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2.5 Measurement pods (ML 6, 6 R, 8, 8 R EASY)

ML 8 R EASY
A set of measurement pods: 932.501.074
Front, right pod: 932.501.050

Front, left pod: 932.501.051
Rear, left pod: 932.501.052
Rear, right pod: 932.501.053
ML 8 EASY

ML 6 R EASY

ML 6 EASY

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© IT no.: 902.509.081 AEI:02 Page 48 of 189

2.5.2 Measurement processor
IT number: 932.503.094
Select between Execute commands

wireless and wired operation from the comms processor
for the cameras and turntables
Generate 5V supply voltage
Control measurement commands
to the camera
Measure the
measurementpod voltages Measurement Receive pictures from the camera
Manage keyboard commands processor Change pictures to pixel values
Manage LED display Calculate angles from pixel values,

on the keyboard using caliration data
Transmit angular values
Power save mode to comms processor
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Keyboard Wireless module
5V Daten
M
o
u Connection Connection Interface for Connection for
for the keyboard for the w ireless programming in the the w ireless
n status LED factory module
t
i Jumper SW1
Measurement
Jumper SW2
n measurement pod not usedt
processor
position relative to
g vehicle
Connection for the charging electronics
p
i
n 5V
8V Control 8V Data 8V
5V
link Data
ca. 5V
8V
Connection cable Connection cable Built-in socket for
to built-in socket to built-in socket the electronic
turntables
Charging
Ground connection
electronics
to the measurement Battery
pod chassis
ground
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2.5.2.3 Connections
J6 keyboard
keyboard
J3
wireless status
not used
J1 factory use only
programming
J7 wireless module
S1
jumper
+
S2
charging
J2
electronics
connection cable
J5
to built-in socket
J11 turntable
camera 2
J10
mounting pin
Rear side of printed circuit board J9
camera 1
arm
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2.5.2.4 Cables
Cable
Keyboard –
Measurement processor board
Wireless status
IT no.: 932.503.008
Cable
Keyboard –
Measurement processor board
Keyboard function
IT no.: 932.503.027
Cable
IT no.:

Cable
Charging electronics –
Measurement processor
IT no.: 932.503.129
white wire = 8 V
pink wire = 5 V
red wire = Vcc = 5 V for the
measurement processor
red wire = Vir = 5 V
for the wireless module
brown wire = ground
brown wire = ground
yellow wire = Voff =
control circuit turn off
blue wire = Von =
control circuit turn on
purple wire = Vref = 4.2 V
reference voltage = protection
from complete discharge
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Cable
Measurement processor –
built-in socket (cable)
IT no.: 932.503.122
green wire = data

yellow wire = data
brown wire = ground
white wire = 8 V
yellow wire = data
green wire = data
brown wire = ground
white wire = 8 V
Cable
built-in socket (turntable)
IT no.: 932.403.028
Cable
ground – contact area Measurement processor – CCD camera
for screwed clamps Permanently installed in the camera
to the measurement Earth connection via the
processor cable screen and the clamp on
the measurement processor
Contact strip
Cable
CCD cameraIs pushed into
the socket and then locked
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2.5.2.5 DIP switch
The ML EASY angle measurement pods do not have any position buttons.
To set the position of each pod, the DIP switch SW1 on the measurement processor
board is used:
The switches are allocated as follows:
Measurement pod switch 1 switch 2 switch 3 switch 4

1 front left OFF OFF OFF OFF
2 front right ON OFF OFF OFF
3 rear left OFF ON OFF OFF
4 rear right ON ON OFF OFF
DIP switch SW2
not used
2.5.2.6 Board layout by model - version

Depending on the model
ML EASY
GTR 700
ML 5000
a resistor is soldered in as a bridge, to
configure the measurement processor.
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2.5.2.7 Flash-EPROM
Information about the software and the status of any errors can be read with
the “System monitor” utility.
2.5.2.8 Reading / Duplicating the calibration values

Each time the measurement pod is reset or turned on, the checksums are compared
between the EPROM contents in the measurement processor and in the camera.
If a difference is found, the calibration values, corrections and zero values are all copied
from the camera to the measurement processor.
That means that the camera is the master location to store the calibration information.
If there is any difference between the measurement processor memory and the camera
memory, the camera values will always be taken from the camera and written to the
measurement processor.
2.5.2.9 How to swap a measurement processor

If, during a service call, it is necessary to manually swap the measurement processor
board, no other work such as entering/reading the calibration information is required.
The correction data are automatically copied from the camera to the measurement
processor, in the background, when the measurement pod is powered up.
No further manual action is required from the service technician to do this.
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2.5.3 CCD camera
IT number: 932.501.042
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A CCD camera array, mounted at 45 degrees, is at the heart of the CCD camera.
The array has only one line of sensors and is not colour, but black & white.
Resolution 2048 pixels.
To reach the required precision, the 2048 pixels are not simply taken, rather the
difference in the light levels between the individual pixels is used.
Measurement principle:
Besides the CCD array, every CCD camera also has, underneath, an infrared
emitting diode (toe-in diode), which aims its invisible (for human eyes) infrared beam
at the neighbouring camera. This beam hits the CCD array, is evaluated by the camera
electronics and digitally passed on to the measurement processor, which puts together
a measurement image from this information.
Then, this (toe-in) diode is turned off and the second infrared transmitting diode in the
camera (for camber) is turned on. This is located in the upper area of the camera and is
attached to a moveable, vertical pendulum, which always points to the centre of the
Earth, and also focuses, via a slit, on the CCD array. The CCD beam, which hits the
CCD array, is evaluated by the camera electronics and passed, digitally, on to the
measurement processor, which then generates measurement images.
The emitting diode for camber is turned off and the emitting diode for toe-in, opposite,
is turned on again, for the next toe-in measurement.
This cycle of measurements, using one sensor (CCD array) and two measurement
pulses (Toe-in and camber) per camera, is continually repeated during the wheel
measurement, without interruption.
Depending on the attitude of the wheel and the associated attitude of the measurement
pod and it’s cameras the toe-in and camber values are produced accordingly.
Aperture angle:
The camera aperture is about +/ - 23 degrees.
It thus enables a standardised measurement of toe out on turns at 20°, simply using
the measurement pods, without the use of electronic turntables.
Previously, the cameras used by Beissbarth had +/- 10 degree aperture. The current
version doubles this by
making complete use of the 2048 pixels
reducing the distance between the lens and the CCD array
modifying the lens
Result: Double the aperture whilst maintaining the same measurement accuracy.
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2.5.3.3 Technical data / features
Digital measurement system

Combined measurement system
Toe in and camber measurement using a camera (CCD array)
With an 8 pod system the system checks its own accuracy continuously
As one CCD array (= a sensor) allows the combined measurement of toe-in &
camber, the camber values are implicitly checked for precision
Linear CCD array – measurement strip
Resolution 2048 pixels
Resolution – 2.8 minutes externally / 0.3 minutes internally
No temperature drift
Very high long term stability
(Aging not measurable – changes are only possible through external mechanical
influence e.g. knocks or dropping the measurement pod.)
Toe in can be measured over a range of +/- 23 degrees. Toe out on turns is thus
possible using the cameras, without the use of electronic turntables.
Intelligent camera = integrated micro controller (Texas Instruments)
2.5.3.4 Differences to the 10 degree camera
Double the aperture whilst maintaining the same measurement accuracy

Lowered the toe-in emitting diode by approx. 3 cm (similar effect to the
spoiler adapter)
All electronic components are now accommodated on a flexible printed circuit
Intelligent camera = integrated microprocessor
The camera electronics controls the 3 emitter powers
The data measured is digitally transmitted from the camera to the
Calibration information (previously gain, now correction values) is stored in
the camera.
The calibration information is not entered manually, but values saved in the
camera are copied to the measurement processor (Easier and removes a source
of errors, when servicing)
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2.5.3.5 Camera components

The flexible printed camera circuit (front)
The flexible printed camera circuit (rear)
Layout of the printed circuit
The CCD receiver array is mounted

diagonally in the housing. It measures 2
independent toe in and camber beams.
The CCD array receives the toe in beam
from the opposite camera and the camber
beam from the emitting diode
located above.
The toe in diode emits a beam to the

opposite measurement pod.
The camber LED emits a beam via

a pendulum focus mechanism to the CCD
array in the same camera.
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Via the slot in the camber pendulum, the

camber diode emits its infrared beam to
be focussed on the CCD array.
Cable
Ground contact area Measurement processor – CCD camera
for screwed clamps Permanently installed in the camera
on the measurement Earth connection via the
processor cable screen and the clamp
on the measurement processor
Contact strip
Cable
Measurement processor – CCD camera
Is pushed into the socket
and then locked
2.5.3.6 Flash-EPROM
Software settings and/or updates are written to the Flash memory
(= writing new content to the EPROM using a cable connection from a notebook,
running a special software programme) by using the “Flash-Writer” utility.
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2.5.3.7 Calibration values

To maintain the required high measurement accuracy, the camera must not only
be precisely mechanically installed, but must also be electronically calibrated.
In this way, there is an opportunity to use the electronic calibration to correct
measurement deviations arising from external mechanical influences.
The calibration programme is integrated into the user interface and menu driven.
In this way, not only service technicians, but also users can do the calibration.
There are 2 sorts of calibration data:
The corrections. These can only be determined in the factory and are
permanently stored in the EPROM on the camera printed circuit.
The zero vales. These are determined on the spot using the menu driven
calibration programme, when the camera is swapped, at the annual calibration or
by the service technician during a service call.
2.5.3.7.1 Corrections
The past, the 10 degree camera
With the previous camera, the 10 degrees camera, the zero point was established on
the spot by the service technician, this continues to be the case. Also, to ensure that the
linearity of the measurement results stayed constant over the entire measurement
range, at +/- 2.5 degrees the so called gain values were determined in the factory.
These were printed out in hexadecimal and stuck to the camera. The service technician
could then enter these values into the measurement processor’s EPROM using
a maintenance utility programme.
Today, the 20 degree camera
To make the most of the doubled measurement range, maintaining the precision,
i.e. linearity, the factory calibration of the gain values was substantially extended
and improved.
In the toe in range, the corrections are now measured at intervals of 5° in

the range +/- 20°, per camera. There are thus 8 correction values.
In the camber range, the corrections are now measured at intervals of 2° in

the range +/- 10°, per camera. There are thus 10 correction values.
In addition, to allow for any possible non-linear deviation between the

measurement points, a polygonal calculation is used to work out the correction.
We thus no longer talk about gain values, but talk about correction values,
which do not depend upon the angle or the range.
These values are measured in the factory and permanently stored in an EPROM on
the camera printed circuit.
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2.5.3.7.2 Zero values

With the present camera, the 20° camera, the zero points are set on the spot, either by
a service technician or by the user, using the menu driven user interface.
These zero point calibration values, in contrast to the 10° camera, are permanently
stored on an EPROM on the camera printed circuit.
2.5.3.7.3 Reading / Duplicating the calibration values

Each time the measurement pod is reset or turned on, the checksums are compared
between the EPROM contents in the measurement processor and in the camera.
If a difference is found, the calibration values, corrections and zero values will be
copied from the camera to the measurement processor.
That means that the camera is the master location to store the calibration
information.
If there is any difference between the measurement processor memory and the camera
memory, the camera values will always be taken from the camera and written to the
measurement processor.
2.5.3.8 How to swap cameras

If a camera has to be swapped, during a service call, after swapping the camera,
the service technician must only recalibrate the zero points.
The correction data is automatically copied from the camera to the measurement
processor, in the background, when the measurement pod is powered up.
No further manual action is required from the service technician to do this.
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2.5.4 Keyboard printed circuit board ML 6 R and 8 R Easy
IT number: 932.502.101
LED display
Keyboard function wireless status
Change measurement
pod radio channel
Keyboard
LED display LED display
initial condition battery condition

You use the keyboard to commission the measurement pod, to determine the wheel
run-out and to store the results.
The LEDs supply information about whether the pod is turned on, the status of
the wireless connection, the battery status and about charging.
Apart from that, via a combination of keys, you can choose between 6 different radio
transmission channels.
The commands from the keyboard are passed on to the measurement processor.
This also drives the LED display.
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2.5.4.3 Keyboard function

On key (reset)
2 Wheel run-out compensation key
3 Save key
4 Display wheel run-out compensation
5 Save indicator
6 On indicator
7 Radio Tx/Rx indicators
8 Battery indicator:
off: battery is OK
flashing: battery - low (reserve)
on: battery is charging
2.5.4.4 Connections
Connector for the cable
Wireless module -
Measurement
processor card
wireless status
Wireless module -
Measurement
processor card
keyboard function
2.5.4.5 Cables
Cable
Keyboard - Measurement
processor board
Wireless status
IT no.: 932.503.008
Cable
Keyboard - Measurement
processor board
Keyboard function
IT no.: 932.503.027
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2.5.4.6 Changing the radio transmission channel

For the simultaneous operation of up to 6 ML 6R and 8R, you can set individually set
different transmission channels in the radio frequency range of 433 MHz.
You have to make these changes to all four measurement pods in a system and also
to the communications processor in the charging station.
What to do at the measurement pod:
Switch the measurement pod on, using the R button. The green LED will illuminate.
Simultaneously, briefly press the R button and the wheel run out button (the middle button).
All of the LEDs extinguish.
(1) Press the wheel run out button (middle button) once – the pod is using transmission
channel 1. The LED beneath the wheel run out button illuminates once, to match.
(2) Press the wheel run out button (middle button) once more – the pod is using
transmission channel 2. The LED beneath the wheel run out button illuminates
twice, to match.
transmission channel 3. The LED beneath the wheel run out button illuminates 3
times, to match.
times, to match.
times, to match.
times, to match.
Press the R button to close the channel select routine.
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2.5.5 Keyboard printed circuit board ML 6 and 8 EASY
IT no.: 932.502.100
LED display
Keyboard funktion
Keyboard initial condition

You use the keyboard to commission the measurement pod, to determine the wheel
run-out and to store the results.
The LED tells you whether the equipment is turned on.
The commands from the keyboard are passed on to the measurement processor.
This also drives the LED display.
2.5.5.3 Keyboard function

1 On key (reset)
2 Wheel run-out compensation key
3 Save key
4 Display wheel run-out
compensation
5 Save indicator
6 On indicator
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2.5.5.4 Connections

Wireless module –
Measurement
processor card
keyboard function
2.5.5.5 Cables
Cable
Keyboard – Measurement
processor board
Keyboard function
IT no.: 932.503.027
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2.5.6 Wireless module (only ML 6 R and 8 R EASY)
IT number: 932.503.075
Data transmission Communication

to wireless module with the wireless module
charging station charging station
Wireless
Data reception Exchange of data
from wireless module module with the measurement
charging station processor

The wireless module transmits the measurement commands at 433 MHz to the wireless
module in the charging station and receives the results of the measurement from there.

The wireless module is supplied with a voltage of 5.00 V.
This is supplied via the measurement processor board.
The 5.00 V is generated on the communications processor.
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2.5.6.4 Connections
Connection to the
distribution card
pin 1: ground
pin 2: data
pin 3: + 5.00 V
pin 4: data
Connector to program the
wireless module software
into “FLASH” memory
Not used
Displays the status of the
wireless data transmission
2.5.6.5 Cables
Cable
IT no.:

2.5.6.6 Radio frequency

The wireless module transmits at 433 MHz.
In case more than one EASY wheel measurement system is used in a workshop,
there are 6 alternative frequencies available, which are all in the area of 433 MHz.
2.5.6.7 Flash-EPROM
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2.5.7 Charging electronics card (only ML 6 R and 8 R EASY)
IT number: 932.403.006
The battery charging electronics is supplied with +8 V from the charging contacts or
from the connection cable. If the board is supplied with voltage, the relay will close and
the battery will be charged.
If the measurement pod is commissioned in infrared mode (by initialising the pod
without a cable connection to the computer), the relay will switch and the measurement
processor will be run from the battery. The battery will discharge. Charging the battery
over night is sufficient for about 10 hours of operation.
The life expectancy of the batteries is about 5 years.
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2.5.7.3 Connections
Connection to the battery

Connection to the
Connection to the
charging contacts
2.5.7.4 Cables
Cable
Charging electronics –
Measurement processor
IT no.: 932.503.129
white wire = 8 V
pink wire = 5 V
red wire = Vcc = 5 V for the
red wire = Vir =
5 V for the wireless module
brown wire = ground
brown wire = ground
yellow wire = Vout =
control circuit turn off
blue wire = Von =
control circuit turn on
purple wire = Vref = 4.2 V
reference voltage = protection
from complete discharge
Cable
charging electronics – mounting pin
IT no.: 932.503.118
white wire = 8 V
brown wire = ground
Cable
charger electronics – battery.
Permanently connected to the battery
white wire = 5 V
brown wire = ground
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2.5.7.5 Pin connections for the potentiometer
Test point ST 5
Test point ST 6
Potentiometer P1
2.5.7.6 To check and set the charging voltage
Tools required:
Digital multimeter with a 4-digit display

Thermometer with better than 1 °C accuracy
The battery charging voltage depends upon the temperature of the environment.
When exchanging the battery charging electronics, this must be calibrated.
Procedure:
1. Replace the battery charging electronics.

2. Unplug the battery plug
3. Connect the digital multimeter between the test points ST5 and ST6.
Set the voltage from the table, using the potentiometer P1:
Room temperature Voltage [V]

[°C]
16 5.775
17 5.766
18 5.757
19 5.748
20 5.739
21 5.730
22 5.721
23 5.712
24 5.703
25 5.694
26 5.685
27 5.676
28 5.667
29 5.657
30 5.648
5. Plug the battery in.
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2.5.8 Battery (only ML 6 R and 8 R EASY)
IT number: 932.403.007
2.5.8.1 Technical data

Nickel-Cadmium battery
4.8 Volt
4 Amp hours
2.5.9 Mounting pin = charging contact (only ML 6 R and 8 R EASY)
IT number: 932.563.001
ML 6R measurement pod rear:
IT number: 932.563.001

The permanently fitted batteries in ML 8R EASY and ML 6R EASY are supplied with
the 8 V charging voltage via the mounting pin and the charging socket.
The +8 V charging voltage flows through the isolated, hollow core of the mounting pin,
the actual mounting pin provides the ground.
Advantages: The charging contacts stay clean, no additional components required.
When the measurement pod is plugged into the charging socket, battery operation is
switched off and charging begins – see the functional diagram of the charging electronics.
The green power LED extinguishes and the red charging LED illuminates.
When the measurement pod is removed from the charging socket, the red charging
LED extinguishes and the charging process stops. The measurement pod is turned off.
Press the R button on the measurement pod’s foil keyboard to reset it and power it up.
The green power LED will illuminate.
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2.5.9.2 Connections
n
thread of the mounting pin =
8 V charging voltage
ground connection, via
the frame of the
measurement pod.
2.5.9.3 Cables
brown wire = ground

white wire = 8 V
2.5.9.4 Charging voltage

The voltage on the charging socket, off load, with no measurement pod plugged in,
is 8.00 – 8.05 V.
On load, with 4 measurement pods plugged in, with new, charged up batteries,
the voltage will sink to 7.00 V. Per inserted measurement pod, the voltage will fall
in steps of 0.25 V.
On load, with 4 measurement pods plugged in, with new, half charged
batteries; the voltage will sink to 6.7 V. Per inserted measurement pod,
the voltage will fall in steps of 0.4 V.
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3 Software
3.1 Operating system software
3.1.1 Description of the operating system software
Operating system Windows XP Home Edition - English
Currently, Windows XP Home is installed

as the operating system in the PC for
ML EASY. 2 users are configured.
Administrator with
logon password admin
Beissbarth without
logon password: just hit the
Enter key.
The Administrator has complete access

to the operating system and the installed
programmes. The Beissbarth user has
restricted privileges. If new hardware or
software updates are to be installed in
the PC, please always start the PC
as Administrator.
For general information and questions on
the operating system, please refer to the
Microsoft home page and the relevant
specialist literature.
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3.1.2 Operating system – CD

3.1.2.1 Function
The original operating system CD allows you to reinstall the operating system at any time,
after a hardware change or software problems. Later on, you can also install any
necessary drivers or software from this CD.
In addition, there is a repair start mode on the CD, for emergencies.
3.1.2.2 Use
Make sure, that the BIOS setting is such that it first tries to boot from the CD
drive and only then from the hard drive. (BIOS = Basic Input Output System =
basic programme on the PC, stored in an EPROM on the PC mother board,
which controls the basic settings of the PC, before the operating system takes
over. How do you get to it? Hold the DEL (ENTF on a German keyboard) key
down whilst the memory test is running. For more information on the BIOS,
please look at the mother board manual, delivered with the equipment, or see the
relevant technical literature.).
Put the operating system CD-ROM into the CD drive.
Restart the PC.
The computer will boot with the minimal operating system stored on the CD.
Follow the instructions from the operating system’s user interface and the
operating system will be installed.
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3.2 User software

3.2.1 User software description
3.2.1.1 Modular assembly of the individual programme blocks
TDE
TED
= Targe t Data
PC
PC Editor
= Te xt Editor
Lice nce -Se rv e r

M ain programme ILSV-Se rv e r
= lice nce
= Use r inte rface = language programme
programme
Re mote control CCD-Se rv e r De mo-Se rv e r

= software re mote = me asure me nt = de monstration
control programme programme
LPT 1 COM 1 COM 2
Re ce iv e r re mote
Dongle control
optional
Charging
Communications
proce ssor station
Transmitte r
Printe r re mote
controloptional
Distribution Wire le ss
board module
M e asure me nt
re cord
Cable socke ts
Ae rial
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3.2.1.2 Main programme
3.2.1.2.1 Functional overview
ILSV-Server
CCD-Server = provides information
=provides the real-time, measured values on language modules
Demo-Server
= provides the demonstration, TDE= Target data editor
measured values
TED= Text Editor
Licence-Server Girder
= provides information on licences = remote control programme
Main programme
= user interface
3.2.1.2.2 Function / Tasks

Function / Tasks
The main programme serves as the

interface between the user and the
equipment. The user receives all of the
information. The user interface is a basic
platform to work from.
The main programme receives data from
the 4 servers:
ILSV
Licence
CCD
Demo
Software version and date programmed.

Important:
Always look at the build version.
An update may only mean a change to
the build version and not necessarily to
the programme version.
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3.2.1.2.3 Path to the main programme

Path
You can find the main programme

(= user interface) under the path:
C:\Programme\Beissbarth\WheelAligner\Aligner\
The main programme consists of
Install.log BNWeightAplm010.dll
MicrolineCCD.exe JumboAPlmr001.dll
MicrolineCCD.ini Jumbomr.dll
Unwise.exe MicrolineWeightCell.dll
Unwise.ini OCX.bat
MicrolineRuntimeCCD.htm Regsvr32.exe
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3.2.1.2.4 Description of the files

Description of the files
n The INSTALL.LOG file records the

entries and changes made to the software
when installing the main programme.
oThe Aligner.exe file is the executable
file which starts the main programme.
It is also in Autostart and will thus start
automatically and after the various servers.
pThe Aligner.INI file contains important
settings for the configuration. These can only
be changed using an editor and may not be
changed, except by a service technician.
o qThe other files are all required for the
p Windows operating system.
rThe UNWISE.EXE file is the executable
uninstall application for the main programme.
q sThe Unwise.INI file contains uninstall
instructions for the UNWISE.EXE file.
These can only be changed using an
editor and may not be changed, except by
a service technician.
n tThe NIVEAU.INI file provides information
on which COM port (3 or 4) is used to
connect an optionally available piece of
test equipment to measure tilt and on the
programme to control it.
t
r
s
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3.2.1.2.5 Main programme INI file

[General] General
BackgroundBitmap=6379663.jpg Background image
LicenceModulIdentifier=6379663 Programme execution
Language=0 Language = German
LanguageAlternative1=1 1. alternate language = English
LanguageAlternative2=1 2. alternate language = English
MeasurementMode=1 Measurement mode: Measuring = 1,
Demonstration = 0
DisplayFormatDefaultAngle=0 Display format for angles = degrees,
minutes
DisplayFormatAngle=1 Display format for lengths = millimetres
DisplayFormatLength=13 Standard display format for angles =
angular units
ViewType=0 Type of measurement display = two
dimensional
ToolTips=1 Window for button labels = active
AudioControl=0 Audio control = active
VoiceControl=0 Voice control = deactive
TurningRoutine=1 Steering routine = 20 degrees
TurningRoutineTruck=0 Steering routine =
RemoteControl=1 Remote control = active
AutomaticSteeringControl=0 Measurement routine steering robot
ShopNetwork=0 Workshop network jobs
ADRCalibrationTruck=1 Calibration distance control commercial
vehicle
MeasurementBayControlSystem=0 Measurement bay control system = off
MeasurementSummaryLook=0 Overview of the measurement record =
table
MeasurementProtocolLook=0 Measurement record = table
FullSteeringLock=0 Maximum steering lock = on
ToeOutOnTurnsDialog=0 Dialogue for manual entry of toe out on
turns
[LanguageServer] ILSV = language server
Address=localhost Address = local hard disc
Port=1096 Port address for server requests
[CCDServer] CCD = Measurement data server
[DemoServer] Demo. Server
[Protocol] Record of the measurement
Directory=C:\PROGRAMME\BEISSBARTH\ The path to the folder for measurement
WHEELALIGNER\ALIGNER\general\protocol\ records
[LastDatabases] Most recently opened database
Customer=CUSTOMERDATABASE_USER Customer database
Vehicle=VEHICLEDATABASE_USER Database of vehicles you edited yourself
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Measurement=MEASUREMENTDATABASE Database of measurement records

_USER
Fitting=FITTINGDATABASE_SHIM Shim settings database
[LicenceServer] Licence server
[MeasurementRoutines] Measurement routines
MeasurementQuality=0 Default requirements from the
measurement routine
CompleteMeasurement=39 Select measurement routine by the type
of programme
QuickMeasurement=1 Quick measurement
AutomaticMeasurement=3 Measurement with a steering robot
[Licence] Licence
PathFileName=C:\PROGRAMME\ Path for passwords to open the
BEISSBARTH\WHEELALIGNER\ALIGNER\ databases from the main programme.
general\txt\Licence.txt
[MeasurementSystemSetup] Settings for the measurement system
OutOfTolerance=600 Equipment is out of tolerance = 600” =
10’ (angular) minutes
[TargetDataValues]
MeasurementBayControlSystem Measurement bay control system
ToleranceValue=326 Tolerance = 321” = 5.5’
[DatabaseCustomer] Customer database
Name=USER Name
Path=C:\PROGRAMME\BEISSBARTH\ path to the database
WHEELALIGNER\ALIGNER\general\
File=Customer.mdb File name
Type=1 Database dependencies amongst
themselves
[DatabaseVehicle] Database of self edited vehicle
target data
Name=USER Name
Path=C:\PROGRAMME\BEISSBARTH\ path to the database
WHEELALIGNER\ALIGNER\TargetData\USE
R\
File=Vehicle.mdb File name
themselves
[DatabaseVehicleDemo] Demonstration database
Name=DEMO Name
Path=C:\PROGRAMME\BEISSBARTH\ Path to the database
WHEELALIGNER\ALIGNER\TargetData\DEM
O\
File=Demo.mdb File name
themselves
[DatabaseMeasurement] Database of measurement records
Name=USER Name
Path=C:\PROGRAMME\BEISSBARTH\ Path to the database
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WHEELALIGNER\ALIGNER\general\
File=Measurement.mdb File name
themselves
[DatabaseFitting] Shim settings database
Name=SHIM Name
Path=C:\PROGRAMME\BEISSBARTH Path to the database
\WHEELALIGNER\ALIGNER\Fittingdata\
File=Fitting.mdb File name
themselves
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3.2.1.3 CCD Server
Stand-alone programme modulel Start using auto start
Server for the main programme

CCD
Provides real-time measurements
= values currently measured on the vehicle Start before the main programme
3.2.1.3.2 Function
Function / Tasks
nThe CCD server is a stand-alone

programme module.
It is available to the main programme as a
server (server = making data available) and
n when testing, supplies the measurement data.
That means, that the CCD server is the real
measurement programme in the wheel
measurement system, and supplies the
o main programme (i.e. user interface) with
the required, real-time measurements
(= current toe-in and camber measurements
as measured from the vehicle).
For this reason, the CCD server must always
be started before the main programme.
o Software version and date programmed.
Important: Always look at the build version.
An update may only mean a change to the
build version and not necessarily to the
programme version.
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3.2.1.3.3 Path to the programme module
Path
The CCD server is under the path:
C:\Programme\Beissbarth\WHeelAligner\CCD
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nMicrolineCCD.exe is the executable

file to start the CCD server.
automatically and before the main
programme.
oThe file MicrolineCCD.INI contains
important configuration settings. These
can only be changed using an editor and
may not be changed, except by a
service technician.
pThe file
n MicrolineCCD-Runtime-xxxxxx.htm
records the programme starts and any
o errors on the CCD server.
qThe INSTALL.LOG file records the
p entries and changes made to the
software when installing the CCD server.
q rThe Jumbo files present a connection

to the optional Micro-Weight system.
r
sThe UNWISE.EXE file is the
executable uninstall application for
the CCD server.
tThe Unwise.INI file contains uninstall
s editor and may not be changed,
except by a service technician.
t uThe other files are all required for
the Windows operating system.
u
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3.2.1.3.5 Programme module INI file

[CCDCore]
Existence=1
Rbz=0 Robosterz steering robot:
0 = no function
Sht=0
[Settings] Settings
Show=1 Display CCD icon bottom right in the
task bar.
0: no display
1: display
Port=1081 Port where the CCD server makes its
information available.
TurntableType=2. Turntable selection:
0 = electronic turntables
1 = defective electronic turntables
2 = mechanical turntables
[CCDHardware]
ElectronicTurnTables=100
Sensorhead20=1
[CCDCalculation] Calculation of the measurement values
LimitOutOfTolerance=60
NrOfRechargeUnitsToMiddle=10
StabilityLimit=40
SpaceWheelplaneCCDmm=312
SpaceWheelplaneLEDmm=312
SpaceWheelaxleCCDmm=-75
SpaceWheelaxleLEDmm=-60
Wheelbasemm=2675
Trackmm=1450
2xSpaceWheelPlaneAndSensorhead=660
[CCDCalculationSensorhead10]
MaximumTurningAngleSec=28800
[CCDCalculationSensorhead20]
MaximumTurningAngleSec=79200
[CCDCalibration] Calibrating the camera
LevelTolerance=240
StabilityTimeout=4000
StabilityTolerance=180
StabilityNumberOfMeasurements=5
CamberCorrection=120
CalibrationPhaseDifferencePlausibility=30
CalibrationCamberNewZeroCorrection
Plausibility=4800
CalibrationCamberZeroCorrection
DifferencePlausibility=35000
CalibrationToeNewZeroCorrection
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Plausibility=4200
CalibrationToeNewZeroCorrection
DifferencePlausibility=35000
CalibrationSavingNecessaryBottom=35
[WC] MicroWeightSystem
ini=c:\BNet\GlobalConfig\jumbo.ini Path to its INI file
[CCDCalculationTurnTableTest] Calculation turntable test
TurnTableCheckLimit=100
TurnTableDecisionLimitOnSensorheads=600
TurnTableDecisionLimitOnTurntables=800
[CCDCom] Communication
COMNr=2
COMBaudrate=115200
COMParity=1
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3.2.1.3.6 Service information / selecting a turntable

Selecting a turntable / Service
The programme module is started automatically by Autostart and always before the
main programme, working in the background, invisible to the user. It is only visible via
the yellow programme symbol CCD in the right task bar.
If you click with the right hand mouse key on this symbol, a dialogue with the following
entries will be opened.
n nStatus and activity of the programme

oSelection between mechanical /
electronic turntables, port address as server.
o pInformation about the version of
firmware in the communications processor
p and the measurement pod.
qInformation and options for the
transmit channel.
q Only useful if the entire system is to be
changed, or if the system is cabled.
rProgramme information, version.
sHalt the measurement system, only
r as a test option for development.
tExit from the program.
If you exit from the CCD server during
the course of the main programme, you
s can not make any further measurements.
There are no longer any measurements
available. You get an error message.
t The programme can only be run in
demonstration mode.
Close the main programme, restart the
CCD server and then restart the main
programme. Now you are back in
measurement mode with real-time
measurements.
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This programme window serves to supervise the two most important

software connections:
Main program CCD server
nThis entry shows the number of

connections from the main programme
to the CCD server, for all of the time that
it has been running since the last restart.
Usually, this is 1 connection to the
main programme.
oThis entry shows the number of
n queries from the main programme to the
CCD server, for all of the time that it has
o been running since the last restart.
Usually, this will be a continually growing
number. These queries run significantly
quicker than those between the CCD
server and the measurement box.
pThis entry shows the number of
p connections to the CCD server, in real
time. Either 0 or 1 are possible here.
As soon as a measurement has been
made, only 1 is allowed.
qThis entry shows the number of
queries to the measurement hardware
(communications processor), for all of
the time that it has been running since
the last restart. Normally, this involves
a continuously growing number of queries,
which run approximately half as quickly as
q the queries between the main programme
and the CCD server.
r Should the connection to the
communications processor be completely
interrupted, the query display will
immediately freeze.
rThis entry shows the number of
queries, which failed. This should usually
be as small as possible.
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n Here, you can choose between

electronic, mechanical and defective
turntables.
The default setting is mechanical
turntables.
o Here, you can choose between 6 and

n 8 pod systems.
As long as you have an 8 pod system.
o The selectable options are thus
backwards compatible.
pThis entry shows which port the
p CCD server uses to present the real time
measurements (current toe in and camber
values measured on the vehicle) to the
main programme.
This address is set at installation and
is the same for all Beissbarth Windows
wheel measurement systems.
nInformation about
the version of software
in the communications
processor.
n
oInformation about the
version of software in the
4 measurement pods.
pInformation about
the type and variant of t
o p he measurement pod (here
ML EASY with 2 cameras)
qInformation about
the COM port, which the
communications processor
is connected to.
q Factory default:
always COM 2
r rSwitch to reload the

displayed information
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For ML EASY there are 6 transmission

channels available at frequencies around
433 MHz. This is necessary in case more
than one system is to be used simultaneously
in a workshop or at a trade fair.
n nInformation about the channels set
in the communications processor.
o Information about the transmission

channels set in the measurement pod.
pPull down menu to select one of the
o 6 transmission channels.
Factory default:
always channel 1
qButton to write the channel selected
to the EPROMs in the communications
processor and in the measurement pod.
p q
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3.2.1.4 Demo. Server
Stand-alone programme module Start using Auto Start
Provides the
demonstration measurement values Demo Start before the main programme
3.2.1.4.2 Function
Function / Tasks
nThe Demo server is a stand-alone

programme module. It is available to
the main programme as a server (server =
making data available) and supplies
n measurement data (toe in and camber)
when in demo mode. For this reason,
the Demo. server must always be started
before the main programme.
o oSoftware version and date programmed.
Important:
Always look at the build version.
the build version and not necessarily to the
programme version.
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3.2.1.4.3 Path
Path
The Demo. server is under the path:
C:\Programme\Beissbarth\WheelAligner\Demo
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Description of the file
nThe INSTALL.LOG file records

the entries and changes made to the
software when installing the Demo server.
o MicrolineDemo.exe is the
executable file to start the Demo server.
programme.
pThe file MicrolineDemo.INI contains

important configuration settings. These can
n only be changed using an editor and may
not be changed, except by a service
o technician.
p qThe UNWISE.EXE file is the executable

uninstall application for the CCD server.
q
rThe Unwise.INI file contains uninstall
r instructions for the UNWISE.EXE file.
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3.2.1.4.5 INI file

INI file
The address of the demo server used by
the main programme to request
demonstration measurement values.
This address is set at installation and is
the same for all Beissbarth Windows wheel
measurement programmes.
Display of the programme symbol,

bottom right in the task bar, if the
programme has been started.
Show=1⇒ symbol visible
Show=0⇒ symbol not visible
3.2.1.4.6 Service information

Service
n The programme is launched automatically
in Autostart.
o The programme itself works invisibly, in the
background. It is visible via the yellow
programme symbol D in the right task bar.
p If you click with the right hand mouse key
on this symbol, a dialogue with the
following entries will be opened.
q
nStatus and activity of the programme
oPort address as server
pProgramme information
qExit from the program.
If you close the Demo server whilst the
main programme is running, it is no longer
possible to switch to demonstration mode.
There are no longer any measurements
available. You get an error message.
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connections to the Demo server, for all of
the time that it has been running since the
last restart. Usually, this is 1 connection to
n the main programme.
o oThis entry shows the number of queries
from the main programme to the Demo
server, for all of the time that it has been
running since the last restart. Usually,
this will be a continually growing number.
p pThis entry shows the number of
connections to the Demo server, in real
time. Either 0 or 1 are possible here.
As soon as a measurement has been
This entry shows the software connection

port for the Demo server, which is used
by the main programme to request the
demonstration values.
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3.2.1.5 Licence server
Stand-alone programme module Start using Auto Start

Lice nce
Provides the licence Start before the main programme

Function / Tasks
nThe Licence server is a stand-alone

programme module. It is available to the
main programme as a server (server =
making data available) and supplies the
key to the hardware licence for the wheel
measurement equipment. This key is
n located in the dongle. The dongle is
plugged into the parallel port LPT1. It is
transparent to the data transmission to
the printer, which is also connected to
LPT1. The licence server accesses the
dongle via a driver.
o The Licence server must always be started
before the main programme.
Every time it is started, the main
programme asks for the licence from the
Licence server, and then every time the
C button is pressed. If the licence is not
available when requested, then you will get
an error message. The databases of target
values will be closed and measurements
only possible in Demo mode.
oSoftware version and date
programmed.
Important: Always look at the build version.
programme version.
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3.2.1.5.2 Path
Path
The Licence server is under the path:
C:\Programme\Beissbarth\Licence
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nThe INSTALL.LOG file records the

when installing the Licence server.
oLicence.exe is the executable file
to start the Licence server.
programme.
p The Licence.INI file contains important
settings for the configuration. These can
only be changed using an editor and may
n not be changed, except by a service
technician.
o qThe UNWISE.EXE file is the executable
uninstall application for the Licence server.
p rThe Unwise.INI file contains uninstall
q These can only be changed using an
r a service technician.
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3.2.1.5.4 INI file

INI file
The address of the Licence server used
licence key.
Display of the programme symbol, bottom
right in the task bar, if the programme has
been started.

Service
n The programme is launched automatically
in Autostart.
The programme itself works invisibly, in the
o background. It is visible via the yellow
programme symbol L in the right task bar.
p If you click with the right hand mouse key
following entries will be opened.
q nStatus and activity of the programme

pProgramme information
If you exit from the Licence server
during the course of the main programme,
you can not make any further
measurements with real time data. You get
an error message. The databases of target
values will be closed and measurements
only possible in Demo mode.
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connections to the server, for all of the time
that it has been running since the last
restart. Usually, this is 1 connection to the
n main programme.
from the main programme to the Licence
running since the last restart. Usually, this
p will be a continually growing number.
pThis entry shows the number of
connections to the Licence server,
in real time. Either 0 or 1 are possible
here. As soon as a request has been
This entry shows the software connection

port for the Licence server, which is used
demonstration values.
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3.2.1.6 ILSV server
Stand-alone programme module Start via Auto Startt

Server for the main programme ILSV
= provides data Start before the main programme

Function / Tasks
nThe ILSV=language server is a stand-

alone programme module. It is available to
n the main programme as a server (server =
making data available) and supplies the
various language modules. The ILSV
server must always be started before
o the main programme.
oSoftware version and date

programmed.
Important: Always look at the
build version.
the build version and not necessarily to the
programme version.
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3.2.1.6.2 Path
Path
The ILSV server is under the path:
C:\Programme\Beissbarth\Ilsv
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nIlsv.exe is the executable file to

start the ILSV server.
It is also in Autostart and will thus
start automatically and before the
main programme.
oThe file Ilsv.INI contains important
configuration settings. These can only be
changed using an editor and may not be
changed, except by a service technician.
pThe INSTALL.LOG file records the

when installing the ILSV server.
qThe UNWISE.EXE file is the executable
n uninstall application for the ILSV server.
rThe Unwise.INI file contains uninstall
o instructions for the UNWISE.EXE file.
p editor and may not be changed, except by
q
r
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Subdirectory database = database

for the language server
nThe files Ilsv.ldb and Ilsv.mdb contain

the language database for the ILSV server.
oThe INSTALL.LOG file records the
when installing the ILSV server, for the
subdirectory.
p The UNWISE.EXE file is the executable
uninstall application for the ILSV server.
n q The Unwise.INI file contains uninstall
o These can only be changed using an
p a service technician.
3.2.1.6.4 INI file

INI file
The address of the ILSV server used by

the main programme to make requests on
the language module.
The path for the language database of the
ILSV server.
Display of the programme symbol, bottom
right in the task bar, if the programme has
been started.
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Service
The programme is launched automatically

in Autostart.
The programme itself works invisibly, in the
n background. It is visible via the white
programme symbol in the right task bar.
If you click with the right hand mouse key
o following entries will be opened.
nStatus and activity of the programme
p pProgramme information
If you close the ILSV server, whilst the
main programme is running, the error
q message “Connection to language
database interrupted” will appear.

connections to the server, for all of the time
that it has been running since the last
restart. Usually, this is 1 connection to the
n main programme.

from the main programme to the ILSV
running since the last restart. Usually, this
will be a continually growing number.
p pThis entry shows the number of
connections to the ILSV server, in real time.
Either 0 or 1 are possible here. As soon
as a request has been made, only 1
is allowed.
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n This entry shows the software

connection port for the ILSV server,
n which is used by the main programme to
send requests to the language module.
o This address is set at installation and is
oEntry for the path to the language
database for the ILSV server.
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3.2.1.7 Target data editor
3.2.1.7.1 Function
Function
nThe target data editor TDE is a stand-
alone programme module.
With it, you can edit and extend the user
vehicle database, used by the main
n programme.
It is not started automatically with the other
programme modules, but when required,
via a link on the desktop, or from the Start
menu -> Programmes ->Beissbarth.
o oSoftware version and date programmed.
Important: Always look at the build
version.
programme version.
3.2.1.7.2 Path
Path
The path to the target data editor is:

C:\Programme\Beissbarth\WheelAligner\Tde
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nThe file DatabaseCipheringUR.dll is

needed by Windows.
oThe INSTALL.LOG file records the
when installing the target data editor.
pThe TDE.INI file contains important
only be changed using an editor and may
not be changed, except by a service
n technician.
qTDE.exe is the executable file
o to start the target data editor.
It is not included in Autostart.
p The target data editor TDE can be
launched via the shortcut on the desktop or
q via the Start menu -> Programmes ->
r Beissbarth.
r The UNWISE.EXE file is the executable
s uninstall application for the target data
editor TDE.
sThe Unwise.INI file contains uninstall
These can only be changed using an editor
and may not be changed, except by a
service technician.
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3.2.1.8 Text editor

Function / Tasks
nThe text editor TED is a stand-alone

programme module.
n With it, you can edit or extend the modules
in the language server.
It is not started automatically with the other
programme modules, but when required,
o via a link on the desktop, or from the Start
menu -> Programmes ->Beissbarth.
oSoftware version and date programmed.
Important: Always look at the build
version.
programme version.
3.2.1.8.2 Path
Path
The path to the text editor TED is:
C:\Programme\Beissbarth\Ted
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when installing the text editor.
oTED.exe is the executable file to start
the text editor.
The text editor can be launched via the
n shortcut on the desktop or via the Start
menu -> Programmes -> Beissbarth.
pThe TED.INI file contains important
only be changed using an editor and
may not be changed, except by a
o service technician.
qUNWISE.EXE is the executable file to
p uninstall the text editor TED.
q r The Unwise.INI file contains uninstall
r instructions for the UNWISE.EXE file.
These can only be changed using an editor
and may not be changed, except by a
service technician.
3.2.1.8.4 INI file

INI file
nThe location and address of the ILSV

language server whose language modules
are used by the text editor TED.
This address is set at installation and is the
n same for all Beissbarth Windows wheel
o
oSelection of the language used for
the text editor TED and for the language
p server ILSV.
pSelection of the application =
programme module, for which the language
module is to be edited or extended.
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3.2.1.9 System monitor

The “System Monitor” service tool
is available in 2 variants.
As a viewer for the service technician,
and as a full version for Beissbarth
development and production.
In the viewer version you can call up all
of the important status information for the
hardware and its software versions.
This utility is not integrated in the user
interface = main programme, but can be
started separately in the Beissbarth folder
on the desktop or via Windows Explorer
under the associated path, see below.
3.2.1.9.2 Path
Path
The system monitor server is

under the path:
C:\Programme\Beissbarth\WheelAligner\
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when installing the text editor.
oThe SysMonitor.exe file is the
executable file which starts the system
monitor utility.
Neither is there a start button on the
desktop or any other link available.
The SysMonitor utility can only be
launched with a double-click on the
SysMoniter.exe in Explorer.
pUNWISE.EXE is the executable file to
n uninstall the text editor TED.
o qThe Unwise.INI file contains uninstall

p These can only be changed using an
q
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3.2.1.9.4 Operation
The “System Monitor” service tool is available in 2 variants.

As a viewer for the service technician, and as a full version for Beissbarth development
and production.
In the viewer version you can call up all of the important status information for the
hardware and its software versions.
This utility is not integrated in the user interface = main programme, but can be started
separately in the Beissbarth folder on the desktop or via Windows Explorer under the
associated path, see below.
At present, this programme is only available in English.
There are 2 pages of information:
The page for “Type and Version Info”

and the “Light exposure” page
You can switch between the pages using the monitor menu.
The “Type and Version Info” page
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n nVersion of the system monitor utility

o oCOM port for the communications processor
p pTo read out the camera calibration information from the

camera memory, or the same values which were copied to
memory in the measurement processor.
q qOnly with the “full version” of the system monitor, is it
possible to write to the EPROM in the camera and in the
r measurement processor.
rRead out the EPROM contents from the measurement
processor and/or the camera.
s
sSave the EPROM contents in a file.
t tRead the information from a file, in order to then write
them to EPROM.
u
v uSelect the range to be read in. In this case, all of it.
vCancel the selection.
n nSelect a range
o oIdentify the components (here: 0 = comms processor)
p pFirmware version (e.g. KPV00.80)
q qSerial number (e.g. 00000101)
r rIT number: (e.g. 932503074/01 )
s sDate of manufacture (here: first software installation)
t tVersion (currently not used)
u u Radio channel configured
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n nSelect a range
o oIdentification of the components
(here Measurement pod 1, front, left,…)
p pFirmware version (e.g. MPV00.80)
q qSerial number (e.g. 0000115)
r rIT number (e.g. 932503094/01)
s sDate of manufacture (here: first software installation)
t tVersion (not currently used)
u uConfigured radio channel
n nSelect a range
oIdentification of the components
o (here measurement pod 1 = front left,…)
pFirmware version (e.g. CQV02.04 )
p
qSerial number (currently not used)
q
rIT number (currently not used)
r
s sDate of manufacture (currently not used)
t tVersion (e.g. CQT)
u u PLD = programmable logic device
= programmable chip (e.g. CQP06.00)
v vCalibration date
Terminology
KP Communications processor
MP Measurement processor
CQ Side to side camera
CL End to end camera
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The “Light exposure” page
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n nVersion of the system monitor utility

o oCOM port for the communications processor
pTo read out the camera calibration information from the
p camera memory, or the same values which were copied to
memory in the measurement processor.
qWith the “view version” of the system monitor, is it also
possible to write to the EPROM in the camera and in the
q measurement processor.
rRead out the EPROM contents from the measurement
r processor and/or the camera.
s sSave the EPROM contents in a file.

tRead the information from a file, in order to then write
t them to EPROM.
u uSelect the range to be read in. In this case, all of it.

v vCancel the selection.
n nSelect a range
oToe in diode, emitted power 0 for calibration
o Side to side and end to end camera (e.g. 00, 00)
p p Toe in diode, emitted power 1 for short distances

Side to side and end to end camera (e.g. 01, 01)
q q Toe in diode, emitted power 2 for medium distances
Side to side and end to end camera (e.g. 05, 05)
r r Toe in diode, emitted power 3 for large distances
Side to side and end to end camera (e.g. 0F, 0F)
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n nSelect a range
oSide to side camera toe in; exposure time of CCD array
o
pSide to side camera light intensity and time period for the
p camber LED emission
q qSide to side camera camber; exposure time of CCD array
rEnd to end camera toe in; exposure time of CCD array
r
sEnd to end camera light intensity and time period for the
s camber LED emission
t tEnd to end camera camber; exposure time of CCD array
u uSuppression threshold. Avoidance of noise in the image
due to weak infrared signals
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In this area, by choosing toe in or camber
and the corresponding measurement pod
and selecting graph
you can display a graphic representation of the infrared beam on the CCD array.
Using the entire range of pixels
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and zoomed in, onto the area around the peak.
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3.2.1.10 Flash - Writer
3.2.1.10.1 Function
This programme is a stand alone module

for service technicians.
The programme enables firmware updates
to be installed on the communications
processor (measurement box) as well as
on the measurement and camera
processors (measurement pod). To do this,
each piece of equipment must have a
version of software which is greater
than 200. To display the version of
software, in the wheel measurement
programme, use the function
“Equipment status”.
3.2.1.10.2 Path
Path
The Flash writer is under the path:
C:\Programme\Beissbarth\WheelAligner\
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nSubdirectory with the HTML screen

pages from the programme.
oFile containing the firmware images

(EPROM content = software) to be written
to the EPROMs in the communications
processor, the measurement processor
n and the camera.
o This is always in the same directory as the
FlashWriter.EXE file.
p pThis is the executable file to start the
q FlashWriter utility.
Preconditions:
Both the user interface = Aligner.exe
and the CCD-Server = CCD.exe have
r been closed.
qInitialisation file for the Flash Writer.
rLanguage DLL files for Windows.
s sInitialisation file for the application to
t uninstall the Flash Writer.
tUninstall file for the Flash Writer.
3.2.1.10.4 INI file
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3.2.1.10.5 Using the software
3.2.1.10.5.1 Preparing the measurement system
The wheel measurement programme and the CCD server must not be running.
If required, close these programmes. You can close the CCD server with a right mouse
click on the CCD server symbol in the task bar. This opens a context menu, from which
you should choose EXIT.
A firmware update is only possible when running in cable mode. You must thus connect
all of the measurement pods via cable.
3.2.1.10.5.2 Programme sequence
The firmware update is carried out in several steps. The sequence depends upon
the course of the update process, the status of the attached equipment and the
programme settings.
For each step, a page is displayed on the screen showing information about things you
are supposed to do, things currently happening, or the results of an action.
When you have carried out something requested by the programme or have seen the
results of a particular action, then you can move on to the next step or cancel the
firmware update.
3.2.1.10.5.3 Toolbar
With this function, you change to the next step. This is only possible if
nothing is happening.
This cancels the firmware update. This is only possible if nothing is
happening.
Only use this function if there’s a problem or if you are absolutely sure that
you do not want to execute the following steps.
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3.2.1.10.5.4 Menu
Menu FILE
NEXT Change to the next step

STOP Cancel the firmware update
SETTINGS... Show a dialogue screen for programme options
QUIT Close the programme
Menu VIEW
TOOLBAR Show or hide the task bar

STATUS BAR Show or hide the status bar
Menu ?
INFO… Show a dialogue screen with version and
copyright information
3.2.1.10.5.5 Settings
The settings dialogue offers the following options and settings:
Drop down menu

“Language”:
Allows the language for the
user interface to be
selected.
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Option “Do not check versions”

Usually the firmware will only be
updated if the image in the firmware
file is newer than the firmware in the
equipment. Thus, at the start, the
versions are checked to be able to
decide, which equipment can be
updated at all. This comparison can
be disabled here.
This option should only be used by
skilled users or service technicians.
See the chapter on “Additional
Information”.
Option “Use a different firmware file”:

The standard location for firmware
images is the file FlashData.xml,
which is in the same directory as the
programme file FlashWriter.exe-
If this option is selected, the file shown
in the text field at the bottom, will be
used instead.
The file is selected using the button,
which will copy it into the text field.
This option should only be used

by skilled users or service technicians.
See the chapter on “Additional
Information”.
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3.2.1.10.5.6 Screens
Preparation
This screen is displayed directly after the programme has started, or once a firmware
update has completed. It displays the tips listed in the chapter “Preparing the measurement
system”. With the change to the next step, the update of the firmware will begin.
Preparation
1. Close the wheel measurement program and the CCD-Server.

2. Connect the measurement pod to the measurement box,
with a cable.
3. Go to the next step.
Checking the attached equipment
The firmware versions of the attached equipment and the versions of the firmware
images in the FlashData.xml file are checked. Checking the version numbers may well
continue after the execution of the update for individual pieces of equipment in order to
read the versions of equipment which were not accessible before.
Checking the attached equipment
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Checking the version
Before the firmware update starts, a check is made as to which pieces of equipment can
be updated. The results of this check will be displayed here. Unreachable equipment is
either not connected or has not got any working firmware.
Checking the version
Checking the versions of each piece of equipment has produced the

following status:
Measurement box:
Communications KPVFL.0
KPVEE.00
0
processor
Sensorhead 1: Sensorhead 2:
Measurement Measurement
MPVEE.01 MPVFL.01 MPVEE.02 MPVFL.02
processor processor
Camera 1 CQVEE.01 CQVFL.01 Camera 1 CQVEE.02 CQVFL.02
Camera 2 CLVEE.01 CLVFL.01 Camera 2 CLVEE.02 CLVFL.02
Measurement Measurement
MPVEE.03 MPVFL.03 MPVEE.04 MPVFL.04
processor processor
Camera 1 CQVEE.03 CQVFL.03 Camera 1 CQVEE.04 CQVFL.04
Camera 2 CLVEE.03 CLVFL.03 Camera 2 CLVEE.04 CLVFL.04
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The symbols have the following meaning:
= The firmware is up-to-date

= There is a newer version of the firmware available.
= The equipment is unreachable, the version of the firmware could not be
determined.
= Update not possible.
If you would like to do an update now, go on, to the next step.
Please note:
A firmware update is not possible prior to software version 01.00.
The ability to update the communications processor is the precondition, that the measurement and camera processors
can also be updated.
The ability to update the measurement processor is the precondition, that the camera processors in each measurement
pod can also be updated.
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Updating the communications processor
The data transmission to the communications processor is displayed continuously and

then the results of this transmission are displayed.
Updating the communications

processor
Data is being written...
Do not make any changes to the measurement system and do not close
the program, whilst the firmware update is in progress.
Updating the communications

processor
Status of the communications

processor:
Go to the next step.
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Updating the measurement processors
All of the connected and updateable measurement processors will be updated one after
another. The data transmission to the measurement processors is continuously
displayed and, after all of the measurement processors have been updated, the results
of the data transmission will be displayed.
Under no circumstances close the programme, or make any changes

(press any keys, remove/move cables etc.) to the attached equipment,
whilst the data transmission is in progress.
Data transmission in progress is signalled by flashing all of the LEDs
on the user panel of the measurement pod.
Updating the measurement

processors
Measurement processors' data is being written...
Do not make any changes to the measurement

system and do not close the program, whilst the
firmware update is in progress.

processor
Status measurement processor 1:
Measurement processors, where the firmware update was not successful (red cross),
will be dealt with individually in the next step. Go on to the next step.
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Individual treatment of single measurement processors
If the update of an individual measurement processor has failed, it could be that

the affected measurement processor has not got any working firmware. In this case
a special procedure is required to load the firmware.
Here, you will be asked to make the corresponding preparations. Only the measurement
pod that needs updating may be connected by cable.
This page should not normally be displayed, as all measurement pods are delivered
with working firmware.
It will, however, be displayed if no measurement pods at all are connected.
Please don’t forget, after going through the special procedure for all of the affected
measurement pods, to connect all of the pods to their cables.
Individual treatment of single

measurement processors
• Connect the sensorhead to the cable.

• Remove all other sensorheads from the cable. Only the single
sensorhead, that you want to update, may be connected!
Go on to the next step.
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processor
Reconnect all sensorheads back onto the cable!
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Updating the cameras
All of the connected and updateable camera processors will be updated one after
another. The data transmission to the measurement processors is continuously
displayed and, after all of the measurement processors have been updated, the results
of the data transmission will be displayed.
Under no circumstances close the programme, or make any changes

(press any keys, remove/move cables etc.) to the attached equipment,
whilst the data transmission is in progress.
Sensorhead Camera data is being written...
the program, whilst the firmware update is in progress.
Status camera 1 Status camera 1

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Results
The results of the final version check are displayed. Unreachable equipment is either
not connected or is defective.
Results
The final check of the measurement system produced the following

results:
Measurement box:
Communications KPVFL.0
KPVEE.00
0
processor
Measurement MPVFL.0 Measurement

MPVEE.01 MPVEE.02 MPVFL.02
1
processor processor
CQVFL.0
Camera 1 CQVEE.01
1 Camera 1 CQVEE.02 CQVFL.02
CLVFL.0
Camera 2 CLVEE.01
1 Camera 2 CLVEE.02 CLVFL.02
Measurement MPVFL.0 Measurement

MPVEE.03 MPVEE.04 MPVFL.04
3
processor processor
CQVFL.0
Camera 1 CQVEE.03
3 Camera 1 CQVEE.04 CQVFL.04
CLVFL.0
Camera 2 CLVEE.03
3 Camera 2 CLVEE.04 CLVFL.04
= The firmware is up-to-date

= There is a newer version of the firmware available.
= The equipment is unreachable, the version of the firmware could not be
determined.
= Update not possible.
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Before starting the next measurement, the reset button must be pressed
on every sensorhead.
The next step will take you back to the beginning.
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Special messages and error messages
If there’s an error or a special situation, you will be presented with a special screen with
a corresponding message.
This is an overview of possible errors and problems:
“The measurement pod is not connected To update the firmware, a cable

with the cable! connection is mandatory. Before the
Please connect the measurement pod, measurement processor can be updated,
with the cable, and then move on to the a check is made whether it is connected
next step.” by cable. If that is not the case, this
message will be produced.
“The file “<Path>”, containing the The standard file is used - FlashData.xml
firmware, could not be read.” which is in the same directory as the
programme file, that is, unless another
setting has been made.
This message can appear for the

following reasons:
The file does not exist, is damaged or
is locked by another process.
The file format is invalid, that
means it does not contain any
firmware images.
“The communications processor is As long as the communications processor
unreachable”. or the measurement box is connected,
this message can be caused by the
following:
The serial interface doesn’t work or is
blocked by another application.
The communications processor
has neither a useable application,
nor a boot loader, or is defective.
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3.2.1.10.5.7 Additional information

Loading an older version
Should a firmware update not work as expected, an older version can be loaded, using
the following steps:
In the settings, choose the options “Do not check versions” and “Use a different
firmware file”, choosing a file containing the older firmware images.
Start the firmware update. As the version check has been disabled, all connected
equipment will be loaded with the older firmware.
Afterwards, remove the options set in the first point.
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Updating the boot loader
This update can only be done by a service technician as special

firmware images are required. It is only required in exceptional
circumstances.
The following steps are required to update the boot loader:
In the settings, choose the option “Use a different firmware file” and then choose the file
with the boot loader images.
Start the firmware update. During the course of the update the screens “Boot loader
update” and “Results of the boot loader update” will be displayed.
During the boot loader update it is particularly important not to

interrupt the data transmission. A failed attempt to update the boot
loader will lead to the equipment being unusable!
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Bootloader Update
The bootloader update is accomplished only if the respective equipment

can be addressed over its ID. Interrupt in no case the update procedure.
A failed update means the loss of the equipment!
If you want to start the bootloader update go to the next step.
Bootloader update
Data is being written...
Sensorhead 1
Sensorhead 2
Sensorhead 3
Sensorhead 4
Communications processor
the program, whilst the bootloader update is in progress.
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Result of the bootloader updates
Status mesurement processor 1:
Status of communications
processor:
The next step will take you back to the beginning.
Afterwards, uncheck the option “Use a different firmware file”.
Now do a normal firmware update, as, following a boot loader update, the equipment
will no longer have an application. This is visible on the measurement pods as all of
the user panel LEDs will illuminate.
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3.2.1.11 Databases
3.2.1.11.1 Summary
At least the following databases are available:
¾ Customer database
Name Customerdatabase_User
Path C:\Programme\Beissbarth\WheelAligner\Aligner\General\
database
File Customer.mdb
Type 1
¾ Personally edited vehicle target data database

Name Vehicledatabase_User
Path C:\Programme\Beissbarth\WheelAligner\Aligner\TargetData\
User\database
File Vehicle.mdb
Type 2
¾ Database of measurement records

Name Measurementdatabase_User
Path C:\Programme\Beissbarth\WheelAligner\Aligner\General\
database
File Measurement.mdb
Type 3
¾ Demonstration vehicle database

Name Demo
Demo\ Database
File Demo.mdb
Type 2
¾ Shim settings database

Name Fittingdatabase_Shim
Path C:\Programme\Beissbarth\WheelAligner\Aligner\FittingData\
Database
File Fitting.mdb
Type 4
¾ Beissbarth – target data - database

Name “Vehicle make” database
“Vehicle make”\Database
File “Vehicle make”.mdb
Type 2
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3.2.1.11.2 Structure
Customer
=Database
Type = 1
CAR DATA VEHICLE VEHICLE

Target data Customer Demonstration
=Database =Database =Database
Typ = 2 Typ = 2 Typ = 2
MEASUREMENT RECORD
Customer
=Database
Typ = 3
SHIM
Settings
= Database
Typ = 4
When creating a new customer record, this is composed of the type and sequence
of various databases, as shown above.
If more, optional, sources of target data are to be installed, then the number
of databases increases by the number of additional sources.
The target databases (Beissbarth-Target Data, VAG-Factory Data, DC-Factory Data, ... )
all exhibit the same structure.
1 database directory and 4 sub-directories:
Adjustment help, database (the actual database),
dependent target data and preparatory work.
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3.2.2 Installation / Deinstallation of application software

3.2.2.1 Installation
3.2.2.1.1 Programme software

Put the programme CD in the CD drive of
your PC. The installation programme Start the installation, by clicking on
starts automatically. “Setup & Update”. These installation
instructions can be opened, by clicking
on “Update-Instructions”. Should Acrobat
Reader (to display PDF files) not be
installed on your PC, please choose
“Acrobat Reader (English version)”.
The “Exit” button, ends the
installation process.
Should the installation not start
automatically, please run
AutoRunExec.exe from the root directory
on the CD.
Close all other programmes. Click on

“Continue” to proceed with the installation.
By clicking on “Continue” the

actual installation process begins.
Update:
At this point, the programme checks
whether there is a valid licence on the
hard disc.
If this is found, from here the installation
process will run automatically up to
the end.
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At this point, select a licence file

(Microline_ Cxnnnnnnn_nnnnn.lic).
• A licence disk belongs to the
equipment. This contains the
licence for the programme installed
on your equipment.
• You have downloaded a new
licence from our software centre
(www.beissbarth.com) and stored
this on your PC’s hard disc or on
a floppy disk.
If the installation is finished, then remove any licence diskette and restart the computer.
After the completed installation, you will

find the Beissbarth wheel measurement
system symbol in the Beissbarth folder,
on your desktop.
3.2.2.1.2 Target data software

Put the target data CD into the CD drive
of your PC. The installation programme Start the installation, by clicking on
starts automatically. “Setup & Update”. These installation
instructions can be opened, by clicking
on “Update-Instructions”. Should Acrobat
Reader (to display PDF files) not be
installed on your PC, please choose
“Acrobat Reader (English version)”.
The “Exit” button, ends the installation
process.
Should the installation not start
automatically, please run
AutoRunExec.exe from the root directory
on the CD.
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Close all other programmes. Click on

“Continue” to proceed with the
installation.
By clicking on “Continue” the actual

installation process begins.
“yes” – You will be asked to select a

licence file (see the programme
installation for more detail).
“no” – The installation will proceed with
the licence on your equipment.
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The installation programme checks all

target data on the CD for a valid licence.
During the installation, an html record
will be displayed. Apart from the serial
number of your equipment and the start
and end times, the installation of every
set of data will be recorded.
If the programme finds a valid licence,
the set of data will be entered into the
record, in green, with a comment
(installation successful).
If no valid licence is found, for a set
of data, it will appear in red with the
comment (**Not installed; invalid/no
licence found**).
When the installation is complete, this file
is saved in the directory C:\Documents
and Settings\User\Local Settings\Temp.
When sending error reports to our service
dept., please send this file too.
If the installation is finished, then remove any licence diskette and restart the computer.
© IT no.: 902.509.081 AEI:02 Page 148 of 189

3.2.2.2 Uninstalling user software

If you would like to remove the wheel measurement programme, you have 2 options.
Either you choose the uninstall menu in the operating system, or you launch the
uninstall files directly.
3.2.2.2.1 Windows system / Software menu

If you would like to work with the Beissbarth uninstall menu, click on
StartÖSettingsÖControl panelÖSoftware:
In this window, mark each Beissbarth programme and software module and then click
on the Change/Remove button.
Follow the prompts to uninstall the selected software.
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3.2.2.2.2 Uninstall with unwise.exe

If you would like to work directly with the uninstall files, use the F3 button from the
desktop, to call up the search screen.
Enter unwise.exe as the term to be searched for in the field “Search for the following
files or directories”.
Select the local, hard disc (C: or D:) in the “Search in” field.
Click on the “Search now” button:
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All of the available uninstall files “unwise.exe” for the individual programmes and target
data modules will be displayed.
Click once on the first file – it will be highlighted.
Then press the “Ctrl” and “A” keys together – all of the files will be highlighted:
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Hit the ENTER key and the uninstall process will begin.
Follow the screen prompts.
The software will be uninstalled.
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3.2.3 Saving your own user data

3.2.3.1 Customer data / Measurement results
To save customer data and measurement results, you need to save the following
directories:
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3.2.3.2 Measurement record

To save the measurement records in their complete, usual format, you need to save the
following directories:
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3.2.4 Service user software

3.2.4.1 Version record
The version record supplies information about the versions of the individual,
installed programmes and target data modules:
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3.2.4.2 Equipment status
3.2.4.2.1 The Runtime screen

The Runtime screen supplies information about run time events:
This information is intended for the development department.
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3.2.4.2.2 General screen

The General screen provides important information for the user and for
service technicians:
Here, you can see the versions of the installed user interface and the measurement
programme, the CCD server.
Further status information:
Connection PC – charging station

Connection to measuring pod 1
Connection to measuring pod via radio or cable
The status of the communications processor software and the
4 measurement pods
The charge state of the 4 pods. A charged, new battery 5.6 - 5.5 V. Flat battery,
error message battery alarm and voltage collapse at 4.7 V.
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3.2.4.3 Direct angle measurement
Inclination Toe in side

to side
Camber Toe in end

to end
Measuring angles directly makes it possible to locate faults, in the individual cameras.
Displayed information:
Displays measurements in degrees, minutes and seconds.

8 toe-in values
4 camber values
4 inclination values
3 values for transmission power between the 8 cameras
hexadecimal result of the self-test for precision
Toe in values:
Measurements can be displayed in the range of +/- 23 degrees.
Camber values:
Measurements can be displayed in the range of +/-15 degrees.
Inclination values:
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Measurements can be displayed in the range of +/-15 degrees.
Transmit power:
There are 3 levels of transmit power available:
Power level for short wheelbases,

Power level for medium distances and
Power level 3 for long distances.
If the opposite camera does not detect an infrared beam, the transmit power will be
automatically increased. If the opposite camera detects an overload (the light or infrared
beam is too bright, the information carried can not be decoded), the transmit power will
automatically be reduced. The transmit power is controlled by the camera electronics.
Hexadecimal result of the self-test for precision:
This is only possible in an 8 pod system.

A rectangle is formed with the 8 pods.
The sum of the angles in a rectangle is always 360 degrees.
The equipment adds up the angles measured by the individual cameras and either
reaches 360 degrees, or not.
Currently, the permissible deviation, before the error message “Equipment out of
tolerance” is produced in the user programme, is 10 minutes = 600 seconds.
The user can thus be sure of making accurate measurements, until this error message
appears.
The precision can only be displayed (in hexadecimal admittedly) when measuring
angles directly.
The result:
Hexadecimal, numbering system:

This numbering system consists of 16 numbers:
0,1,2,3,4,5,6,7,8,9,A,B,C,D,E,F
A = 10 decimal
B = 11 decimal
C = 12 decimal
D = 13 decimal
E = 14 decimal
F = 15 decimal
Together with zero, there are thus 16 values.
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Hexadecimal values are displayed with 4 digits.
XXXX
16° = 1 x Wert (X) =
161 = 16 x Wert (X) =
162 = 256 x Wert (X) =

163= 4096 x Wert (X) =
Ergebnis in Winkelsekunden
Example:
The hexadecimal value 3AB7
3 A B 7
7 x 160 = 7 x 1= 7
1
11 x 16 = 7 x 16 = 176
10 x 162 = 10 x 256 = 2560
3 x 163 = 3 x 4096 = 12288
15031 decimal
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Failure of a side to side toe in camera:
In 95% of all cases the emitting diode fails and not the CCD array, so the presumption
is always that the camera opposite has failed.
Thus, in our example, camera n and not camera o.
Failure of an end to end toe in camera:
In this example, we also presume that the failure is due to the emitting diode in the
opposite camera.
Thus, camera n and not camera o.
Failure of a camber camera:
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The camber camera is showing 14 degrees 21 minutes. This can only be a camera
failure, as this value can never be measured on a vehicle and is at the end of the range
of the camber camera.
This means that the failure of a camber camera is either shown by horizontal dashes,
as in the toe in camera, or by a very high measured value.
Locating the fault is much easier, when compared to the toe in camera, as the problem
is always with the shown camera.
Failure of an inclination camera:
The same is true for the inclination cameras as for the camber cameras.
They are nothing more than camber cameras turned through 90 degrees.
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3.2.4.4 Calibration
3.2.4.4.1 Function
Using the calibration routines, integrated into the main programme (user interface),
you have the following options for calibration:
1) Calibrate toe in
2) Calibrate camber
3) Calibrate spirit levels
When must you calibrate?
If you suspect, that the displayed values, from the wheel measurement
system, are not correct.
If the error message “Equipment out of tolerance” is permanently displayed.
If the wheel measurement system is due for maintenance.
(If the wheel measurement system is equipped with 8 measurement pods,

the equipment constantly checks its own measurement precision, electronically.
Any problems will then produce an error message “Equipment out of tolerance”.)
How do you calibrate?
Simply boot the wheel measurement system and wait until the user interface,
to measure the wheels, is ready.
In the button bar, click on maintenance, move the mouse over calibration and
a selection menu will pop up, where you then choose the type of calibration that
you need. Follow the instructions on the screen, for each step of the calibration.
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3.2.4.4.2 Toe-in
Click on the “Maintenance” button,

in the main window.
Next click on “Calibration”.
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Click on “calibrate toe in”.
Enter your name and the

reason for the calibration: Then
confirm with “OK”.
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Align the calibration

shaft and activate the
measurement pods.
Click on the “Next”

button.
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Align the measurement

pods as instructed.
Click on the
“Calibrate” button.

pods as instructed.
Click on the
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pods as instructed.
Click on the

pods as instructed.
Click on the
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Rotate the calibration

beam on its own axis.
Click on the
“Next” button.

pods as instructed.
Click on the
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pods as instructed.
Click on the

pods as instructed.
Click on the
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pods as instructed.
Click on the
Click on the
“Save” button.
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Click “Yes”
to save.
This message must appear!!

Otherwise, the calibration is not valid.
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Click on the
“Print” button.
Select a printer,
set the number of copies,
select “Print”.
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3.2.4.4.3 Calibrating camber
Click on the “Maintenance” button,

in the main window.
Next click on
“Calibration”.
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Click on
“calibrate camber”.
Enter your name and the

reason for the calibration: Then
confirm with “OK”.
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Align the calibration

shaft and activate the
measurement pods.
Click on the
“Next” button.
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pods as instructed.
Click on the

pods as instructed.
Click on the
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button.

pods as instructed.
Click on the
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pods as instructed.
Click on the

beam horizontally.
Yellow stays on top!!

button.
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pods as instructed.
Click on the

pods as instructed.
Click on the
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button.

pods as instructed.
Click on the
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pods as instructed.
Click on the “Calibrate”

button.
Click on the
“Save” button.
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Click “Yes”
to save.
This message must appear!!

Otherwise, the calibration is not valid.
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Click on the
“Print” button.
Select a printer,
set the number of copies,
select “Print”.
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3.2.4.4.4 Spirit level adjustment
1.1 Adjusting the spirit levels
Click on the “Maintenance”

button, in the main window.
Now, click on the

“Calibration” button.
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Now click on the

“Adjust spirit levels” button
Adjust all of the measurement pods on

the vehicle exactly to the spirit levels on
the pods….
…and then click on “Save” to save

the adjustments for the spirit level
calibration.
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Finish the spirit level adjustment

using the “Exit” button.
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Maintenance manual
Maintenance of the Beissbarth ML EASY wheel measurement system, its scope and
contents are extensively described, in the separately available
Maintenance manual ML EASY IT no.: 902.509.091
A final word
We hope that, with this service manual, we have given you a guide, where perhaps the
odd points were “new” to you.
Of course, we would be very happy if you too could contribute to the quality of our
products by sending us your ideas and suggestions.
Of course we try hard to keep you up-to-date and recommend that you download
the latest news from our software centre (registration required), on the Beissbarth
home page:
http://www.beissbarth.com
Sven Hodissen Frank Gast
Beissbarth Customer Services
Hanauer Str. 101

D-80993 Munich
Germany
eMail: service@beissbarth.com
Fax: +49 (0)89 / 14901 –240

Tel: +49 (0)89 / 14901-164
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© IT no.: 902.509.081 AEI:02 Page 189 of 189

Serviceanleitung ML-EASY AEI02 ENG1

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Service Manual ML 6, 6-R, 8, 8-R EASY

© IT no.: 902.509.081 AEI:02 Page 1 of 189

Service manual ML6/6R ML8/8R EASY ENG

First print: 04.2004

© Sven Hodissen Frank Gast

© IT no.: 902.509.081 AEI:02 Page 2 of 189

TARGET GROUP FOR THIS MANUAL .......................................................................... 9

1 THE COMPLETE EQUIPMENT ................................................ 10

1.1 FUNCTIONAL DESCRIPTION ............................................................................ 10

© IT no.: 902.509.081 AEI:02 Page 3 of 189

2.2.2.1 Functional overview....................................................................................................... 26

© IT no.: 902.509.081 AEI:02 Page 4 of 189

2.5.1.2 Functional description .................................................................................................... 48

© IT no.: 902.509.081 AEI:02 Page 5 of 189

2.5.7.6 To check and set the charging voltage ........................................................................... 72

3.1 OPERATING SYSTEM SOFTWARE .................................................................... 75

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3.2.1.6.4 INI file ....................................................................................................................... 106

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3.2.4.4.2 Toe-in ........................................................................................................................ 164

MAINTENANCE MANUAL ........................................................... 188

A FINAL WORD............................................................................... 188

© IT no.: 902.509.081 AEI:02 Page 8 of 189

Target group for this manual

The aim of this manual

© IT no.: 902.509.081 AEI:02 Page 9 of 189

1 The complete equipment

Easy: The new product line from Beissbarth.

© IT no.: 902.509.081 AEI:02 Page 10 of 189

Easy: The new product line from Beissbarth.

• Robust aluminium bearers with a hardwearing plastic housing.

© IT no.: 902.509.081 AEI:02 Page 11 of 189

Easy: The new product line from Beissbarth.

© IT no.: 902.509.081 AEI:02 Page 12 of 189

Easy: The new product line from Beissbarth.

© IT no.: 902.509.081 AEI:02 Page 13 of 189

1.2 Technical data

Dimensions of the equipment cabinet including 17” colour monitor:

Power supply: Operating temperature: +5 °C...+40 °C

Measurement options: Precision for value range

Turntables: 1000 kg load for cars, angle of turn – 360°,

Sliding plates: 1000 kg load for cars, angle of turn ±10°,

Wireless system: Frequency range 2.4 GHz (433 MHz)

© IT no.: 902.509.081 AEI:02 Page 14 of 189

Housing ATX mini tower

2.1.2 Operating system

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2.1.3 Connections rear side of PC

Power supply connection

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2.1.4.3 Licence number

2.1.4.4 Issuing licences

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2.1.5 The communications processor in the PC

2.1.5.1 Functional overview

Conversion of the 12V

2.1.5.2 Functional description

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2.2 Charging station (only ML 6 R and 8 R EASY)

2.2.1.1 Functional overview

Wireless data Mains voltage for PC

the power supply to the communications processor

+8.00 V to charge the batteries