Correct headlamp adjustment is a very important safety issue which is frequently underestimated. If the headlamps are set too low, the field of vision is limited during darkness. If they are too high, they dazzle and impair the view of other road users. On this page find out what requirements must be met for the correct headlamp adjustment, and how both classic and modern lighting systems can be tested.
Beamsetters fundamentally simulate the 10 m wall. The lens installed in the beamsetter box shortens the prescribed 10 m distance to 50 cm (Fig. 2 - lens to aiming screen).
The disadvantages, such as high amount of space and a suitable wall, are omitted. A beamsetter can also be flexibly used at different places within the workshop, provided the workshop floor adheres to the required tolerances.
The composition and condition of the floor are of primary importance to enable exact headlamp adjustment. That is why it also has its own standard (DIN ISO 10604) in which the "test surface" is specified precisely and the permissible tolerances listed. The graphics listed in Figure 3 clearly illustrate the requirements.
If these tolerances are not adhered to, even minor deviations have a large impact on the light distribution .
A sample calculation makes this clear:
As already mentioned, a lens is installed in the beamsetter which shortens the prescribed 10 m measuring distance to the wall to only 50 cm. A mere 5 mm measured wrongly on the aiming screen of the beamsetter thus corresponds to 10 cm difference over 10 m (ratio 10 m to 50 cm is factor 20). A vehicle with headlamps installed at a height of 60 cm has a low beam with a range of 60 meters (at 1% forward tilt = 10 cm inclination to 10 m range).
This means that the headlamp light would deviate by 60 cm. This example clearly illustrates the decisive effect that a precise test surface has on light distribution, as millimeters can decide between glare for the oncoming traffic or driving in semi-darkness!
But not only the floor conditions are important. The vehicle must also be prepared for the test.
The following points must be observed:
If the floor conditions are suitable and the vehicle has been prepared, the beamsetter still has to be aligned to the vehicle to enable exact adjustment.
The beamsetter is moved in front of the headlamp to be checked. The beamsetter box must be aligned to the middle of the headlamp or to the light source. Vertical and horizontal deviations may not exceed 3 cm. The distance between the beamsetter box and the headlamp varies depending on the manufacturer. For the
HELLA GUTMANN beamsetters
, the distance between the front edge of the beamsetter box and the headlamp may be between 30 and 70 cm, see Figure 5.
The beamsetter box is then aligned to the vehicle. Devices with a wheel-mounted base must be individually aligned for each headlamp to be checked. For beamsetter devices on rails, the beamsetter box only needs to be aligned once. Using the broad-band, laser, or mirror sight, align the beamsetter box in such a way that the sight line touches two points situated at the same height, symmetrically to the vehicle’s longitudinal axis, see Fig. 5, dashed lines.
Finally, set the "forward inclination" on the device. This corresponds to the tilt angle of the headlamp cut-off line. The forward inclination is given in % and can normally be found on the headlamp, see Fig. 6.
For example, 1% means that the low beam is at an angle of 10 cm at a range of 10 m. The aiming screen is set to the correct percentage using the scaled wheel, see Fig. 7.
Here are two tables containing the main setting dimensions for different vehicle types.
| Vehicle type: Motor vehicles, multi-lane, except agricultural or forestry tractors and working machines, or similar motor vehicles | Setting | ||
| Headlamps for low beam | Fog lamps | ||
| 1.1 | EEC (EC) / ECE as a basis for testing | Setting indicated on the vehicle | 2.0 % |
| 1.1.1 | Motor vehicles with lighting fixture according to 76 / 756 / EEC or with approval according to ECE-R 48 | ||
| 1.2 | StVZO (Road Traffic Act) as a basis for testing | ||
| 1.2.1 | Motor vehicles with initial registration as from 01/01/1990. Headlamps not higher than 1,200 mm above the road1) | ||
| 1.2.2 | Motor vehicles with initial registration up to 12/31/1989. Headlamps not higher than 1,400 mm above the road1) and motor vehicles with initial registration as from 01/01/1990. Headlamps higher than 1,200 mm but not higher than 1,400 mm above the road1) | 1.2 % | 2.0 % |
| a) | Passenger cars (also combination motor vehicles) | 1.2 % | 2.0 % |
| b) | Motor vehicles with level-regulating suspension or automatic tilt compensation of the light beam2) | 1.0 % | 2.0 % |
| c) | Trucks with loading area at the front | ||
| d) | Trucks with loading area at the back, except motor vehicles as per 1.2.2 b) | 3.0 % | 4.0 % |
| e) | Truck tractor except motor vehicles as per 1.2.2 b) | ||
| f) | Buses except motor vehicles as per 1.2.2 b) | ||
| 1.2.3 | Motor vehicles with headlamps H ≤ 1,400 mm1) | H/3 | (H/3 + 7) |
| 2.0 | Motor cycles and similar motor vehicles | ||
| 2.1 | 93 / 92 / EEC as a basis for testing | ||
| a) | 2-wheel mopeds | No requirements | |
| b) | 3-wheel scooters and 4-wheel light vehicles | ||
| c) | Motorcycles without/with sidecar | 0.5 to 2.5% | 2.0 % |
| d) | 3-wheel scooters | ||
| 2.2 | ECE-R 53 as a basis for testing | Setting indicated on the vehicle | 2.0 % |
| 2.3 | StVZO (Road Traffic Act) as a basis for testing | 1.0 % | 2.0 % |
| 3.0 | Agricultural or forestry tractors and working machines, or similar motor vehicles | ||
| 3.1 | EEC (EC) / ECE as a basis for testing | ||
| a) | Headlamp height: 500 mm < h ≤ 1,200 mm | 0.5 to 4.0% | 2.0% |
| b) | Headlamp height: 1,200 mm < h ≤ 1,500 mm | 0.5 to 6.0% | 2.0% |
| c) | Additional headlamps (on tractors equipped for front structures) H ≤ 2,800 mm | H/3 | |
| 3.2 | StVZO (Road Traffic Act) as a basis for testing | ||
| a) | Single-axle tractors or working machines with permanent low beam headlamps which indicate the required inclination of the light beam center | 2 x N | 2.0 % |
| b) | Multi-axle tractors or working machines | 1.0 % | 2.0 % |
1) Up to the highest point of the illuminating area.
2) Special features of this equipment must be observed in accordance with the manufacturer's instructions.
The device now has an optimal setting and the different light distributions can be checked and corrected if necessary.
Cover the right headlamp and align the left headlamp so that the horizontal part of the cut-off line touches Line D. Then align the headlamp laterally. The kink between the horizontal and the sloping (asymmetrical) part of the cut-off line must lie on Line B. Then align the right headlamp in the same way. In this case, the kink of the cut-off line lies on Line C.
