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HEADLAMP ADJUSTER NOTES, REQUIREMENTS, INFORMATION, ETC.

Headlamp adjusting devices are used to check the gradient of the low-beam cut-off, e.g. 1% = 10cm / 10m. The units listed below all comply with the guidelines of the German traffic code (StVZO) dated 25 September 81 in force in Germany and have been granted type approval by the TUV. They may also be used for ellipsoidal headlamps and xenon lamps. In Europe, headlamps are adjusted according to the low-beam cut-off. In the USA, an adjusting device is usually used which is placed on the 3 bumps on the lens when so equipped. The headlamps are then adjusted via bitable levels. The headlamp setting (specified gradient of the low-beam cut-off with respect to the center axis of the headlamp) is adjusted by moving the collector screen (stated in cm per 10m range, e.g. 10cm / 10m). It is aligned with the longitudinal vehicle axis using a mirror with aiming line. A new lighting technology was introduced with model W202/W210. The low-beam reflectors used in this model achieve uniform light dispersion over the entire surface of the lamp. The fanning of the light cone begins right at the lens (in conventional headlamps with 2 filament bulbs [Bilux, H4], the light is strongly focused at ranges close to the headlamp). For the conventional lamps, a distance of approx. 300mmm between the adjuster and the headlamp is recommended (greater distances are still acceptable). For the new lamps, it is absolutely essential to maintain a distance of between 200 and 300mm. Vehicles with xenon lights (gas discharge) feature automatic headlamp range adjustment. But the headlamp adjusting devices are still used to check the function of the headlamp range adjustment (different load states should produce no change in the position of the low-beam cut-off). Following headlamp replacement axle of accident repairs, or to compensate for the vehicle- and headlamp specific tolerances, a headlamp aimer is to be used to check the headlamp setting at a defined vehicle load and adjusted if necessary (see WIS) and the "zero position" is entered using the hand-held tester (HHT/SDS). QUALITY ASSURANCE: The new lamp technology also places much stricter demands on the floor level of the adjustment bay. In the direct vicinity of the vehicle, the floor level must not vary by more than max. 1.5mm. In the direct vicinity of the headlamp adjuster location, the floor variation must not be greater than ± 0.5 mm. This requirement may necessitate alterations to tiled floors and also demands increased work in the construction of new workshops. Furthermore, because of this requirement it is advisable to reserve one workbay specifically for headlamp adjustment work. The levelness of the floor should be initially ensured by using a precision leveling instrument (transit) during installation and should be checked at regular intervals, e.g. whenever the adjustment device is calibrated. Handle the device with care and protect it against external damage. Use a cover to prevent soiling. The accuracy of the headlamp adjusting devices can only be checked with precision instruments, (e.g. special leveling instruments) by trained personnel. The manufacturers recommend an inspection interval of approx. 12 months combined with a check of the floor level. Discuss procedures with the Manufacturer/supplier. Avoid shipping the device away for testing. If there is doubt concerning the accuracy of the aimer, it may be necessary to consider the "wall test method". The gradient of the low-beam cut-off is 1% for headlamps where the top edge of the reflector is < 135 cm above the floor. Therefore if the headlamp is 10m (5m) away from the wall, the low-beam cut-off must be 10 cm (5cm) below the height of the center of the headlamp (performed where the floor is known to be level).