HEADLIGHT SYSTEMS

CORRECT AIMING
MADE EASY

www.hella.com/techworld
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 TABLE OF CONTENTS | 3

Headlight system aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Aiming with a 10-metre wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Aiming with the beam setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Measuring method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Headlight aiming site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sample calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vehicle test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting up the beam setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Set the forward inclination of the cut-off line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking headlamp aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting the "glare-free high beam cut-off line" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Photoelectric light measuring device (Incident Light Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Aligning the beam setter to the vehicle's longitudinal axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Levelling with a point laser on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Levelling with a line laser on the beam setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test spectrum headlamp aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

HEADLIGHT SYSTEM AIMING

Since asymmetric light distribution appeared on the market These circumstances were also ultimately among the factors
in 1957, there have also been statutory provisions for aiming responsible for the development of beam setters. Such devices
headlights. enable the light distribution to be checked quicker and more
flexibly.
Headlights were first aimed at the so-called "10-metre wall". That
means a vehicle is driven to a distance of 10 m in front of a light- The following pages describe the measuring methods, the legal
coloured wall, which has certain markings on it. The headlights are basis and the most important stages involved in headlamp aiming.
then checked or adjusted on the basis of these markings.

This has remained the statutory test method until today and is still
used particularly for checking agricultural or specialist vehicles.
One of the disadvantages of this method is that you need a
relatively, large, light-coloured and free wall, and a corresponding
amount of space to go with it. Neither of these were, or are,
exactly easy to find in a garage.
 4 | HEADLIGHT SYSTEMS

AIMING WITH A 10-METRE WALL

General As already mentioned, this method is still mainly used today for vehicles where the upper
edge of the headlights is higher than 140 cm above the ground. The vehicle is driven on
to a level surface, which does not have to be horizontal, to a distance of 10 metres from a
vertical, light-coloured wall.

B A C

e
D
H

90°
10 m

The following lines have to be marked on the wall.

Line A Extend the longitudinal axis of the vehicle to the test wall and mark it with a vertical line.

Line B and C Measure the distance X of the vehicle headlight (centre to centre) and mark it on the wall
symmetrically to Line A.

Line D Draw this line at a distance ‘e’ below Line H.

For headlights
H
„e“ = cm
3
For fog lights
H
„e“ = + 7 cm
3

Line H Measure the height of the centre of the headlights above the ground draw the line on the
test wall parallel to the ground.

Please ensure that specific national regulations are always observed

 10-METRE WALL | 5

AIMING WITH A 10-METRE WALL

Adjusting the headlights Cover the right headlight and align the left headlight so that the horizontal part of the cut-
off line touches Line D. Then align the headlight laterally. The bend between the horizontal
and the sloping (asymmetrical) part of the cut-off line must lie on Line B. Then align the
right headlight in the same way. In this case, the bend of the cut-off line lies on Line C.

Please ensure that specific national regulations are always observed

 6 | 10-METRE WALL

AIMING WITH THE BEAM SETTER

Measuring method Beam setters generally simulate the 10 m wall. The lens installed in the beam setter box
shortens the prescribed 10 m distance to 50 cm
(Fig. 2 - lens to test screen).

2
1 3

1 Fresnel lens 2 Screen

3 Scaled wheel 4 Photo diode

2

Measuring method The disadvantages, such as storage space and a suitable wall, are omitted. A beam setter
can also be flexibly used at different places within the garage, provided the garage floor
adheres to the required tolerances.

Headlight aiming site The composition and condition of the floor are of primary importance to enable exact
headlight aiming. 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 diagram 3 clearly illustrate the requirements.

Please ensure that specific national regulations are always observed

 BEAM SETTER | 7

AIMING WITH THE BEAM SETTER

Sample calculation If these tolerances are not adhered to, even minor deviations have a large impact on light
distribution.

A sample calculation makes it clear:

As already mentioned, a lens is installed in the beam setter which shortens the
prescribed 10 m measuring distance to the wall to only 50 cm. A mere 5 mm error in the
measurment on the test screen of the beam setter thus corresponds to 10 cm difference
over 10 m (ratio 10 m to 50 cm is factor 20). A vehicle with headlights installed at a height
of 60 cm has a dipped headlight with a range of 60 metres (at 1% forward tilt = 10 cm
inclination to 10 m range).

This means the light projected by the headlight would deviate by 60 cm! This example
clearly illustrates the decisive effect that a precise test surface has on light distribution, as
the difference between glare or driving in semi-darkness is measured in millimetres!

Please ensure that specific national regulations are always observed

 8 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Vehicle test Not only the floor conditions are important. The vehicle must also have been prepared for
the test. The following points must be observed.

 Test the headlight function.

 Check the cover lenses for damage from stones, scratches and for dullness.
 The tyres must have the prescribed air pressure.
 Check the vehicle with a person on the driver's seat or a weight of 75 kg, which is
otherwise not loaded.
 No load is required for trucks and other multi-lane vehicles.
 Single-lane vehicles and single-axle traction or working machines (with seat cart or
trailer) should be checked with a person on the driver's seat or a 75 kg load.
 In the case of vehicles with hydraulic or air suspension, manufacturers' instructions
must be heeded.
 If automatic correction of the headlights or an infinite or multi-stage setting fixture is
available, follow the manufacturer's instructions. In this case, various function tests,
depending on the manufacturer, must be carried out.
 A diagnosis tester is required for adjusting various vehicles with automatic headlight
range adjustment, since the control unit has to be in “basic mode” during adjustment.
If the cut-off line is set correctly, this value is set as the new control value, Fig. 4.

Opel/Vauxhall Signum 3.2i V6

Home Basic setting/Headlight range adjustment

Basic setting
Exit program
Basic setting Xenon headlights

Basic setting light power modules

Please ensure that specific national regulations are always observed

 BEAM SETTER | 9

AIMING WITH THE BEAM SETTER

Setting up the beam setter If the floor conditions are acceptable and the vehicle has been checked, the beam setter
still has to be aligned to enable exact adjustment.

The beam setter is moved in front of the headlight to be checked. The beam setter
box must be aligned to the middle of the headlight or to the light source. Vertical and
horizontal deviations may not exceed 3 cm. The distance between the beam setter box
and the headlight varies depending on the manufacturer. In the case of HELLA devices, the
distance from the front edge of the beam setter box to the headlight should be between 30
and 70 cm, Fig. 5.

The beam setter box is then aligned to the vehicle. Devices with a wheel-mounted base
must be individually aligned for each headlight to be checked. Beam setter devices on rails
only need to be aligned once. Using the broad-band, laser or mirror sight, align the beam
setter box in such a way that the sight line touches two points situated at the same height,
symmetrically to the vehicle’s longitudinal axis, Fig. 5, dashed lines.

Please ensure that specific national regulations are always observed

10 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Set the forward inclination of the Finally, set the "forward inclination" on the device. This corresponds to the angle of
cut-off line inclination of the headlight cut-off line. The forward inclination is given in % and can
normally be found on the headlight, Fig. 6.

For example, 1% means that the dipped headlight is at an angle of 10 cm at a range of

10 m. The test screen is set to the correct percentage using the scaled wheel, Fig. 7.

Please ensure that specific national regulations are always observed

 BEAM SETTER | 11

AIMING WITH THE BEAM SETTER

Adjustment table
Below you will find two tables containing the main setting dimensions for different vehicle types, Fig. 8.

Setting
Vehicle type:
Multi-lane vehicles with the exception of agricultural or forestry tractors and working machines
Headlights for low beam Fog light

1.1 EEC / ECE as a basis for testing

1.1.1 Motor vehicles with lighting fixture according to 76 / 756 / EEC or with approval according to ECE-R 48
Setting indicated on the
1.2 StVZO (Road Traffic Act) as a basis for testing 2.0 %
vehicle
1.2.1 Motor vehicles with initial registration as from 01.01.1990. Headlights not higher than 1200 mm above the
road1)
1.2.2 Motor vehicles with initial registration up to 31.12.1989. Headlights not higher than 1400 mm above the
road1) and motor vehicles with initial registration as from 01.01.1990. Headlights higher than 1200 mm 1.2 % 2.0 %
but not higher than 1400 mm above the road1)
a) Cars (and 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 for vehicles
e) Semi-trailer truck 3.0 % 4.0 %
according to 1.2.2 b)
f) Buses and coaches
1.2.3 Motor vehicles with headlights H ≥ 1400 mm1) H/3 (H/3 + 7)
2. Motor cycles and similar motor vehicles
2.1 93 / 92 / EEC as a basis for testing
a) 2-wheel small capacity vehicles
No requirements
b) 3-wheel small capacity vehicles and 4-wheel light vehicles
c) Motorcyles without/with sidecar
0.5 to 2.5 % 2.0 %
d) 3-wheel small capacity vehicles
2.2 ECE-R 53 as a basis for testing Setting indicated on the
2.0 %
vehicle
2.3 StVZO (Road Traffic Act) as a basis for testing 1.0 % 2.0 %
3 Agricultural or forestry tractors or similar motor vehicles
3.1 EEC / ECE as a basis for testing
a) Headlight height: 500 mm < h ≤ 1200 mm 0.5 to 4.0 % 2.0 %
b) Headlight height: 1200 mm < h ≤ 1500 mm 0.5 to 6.0 % 2.0 %
c) Additional headlights (on tractors equipped for front loading) H ≤ 2800 mm H/3
3.2 StVZO (Road Traffic Act) as a basis for testing
a) Single-axle tractors or working machines with permanently dipped headlights which indicate the required
2xN 2.0 %
inclination of the light beam centre
b) Multi-axle tractors or working machines 1.0 % 2.0 %
1)
Up to the highest point of the beamed area.
2)
Special features of these facilities must be observed in accordance with the manufacturer's instructions.

Please ensure that specific national regulations are always observed

12 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Checking headlamp aiming

The device now has an optimal setting and the different light distributions can be set.

a) Headlights with symmetrically dipped b) Headlights with asymmetrically c) Fog light d) Special headlights for high beam
headlight dipped headlight (e.g. auxiliary driving lamps)

Dipped headlight Dipped headlight Fog light High beam

Align the device according to point 4.0. Align the device according to point 4.0.

Set the scaled wheel according to the Set the scaled wheel according to the
adjustment table (observe point 4). adjustment table.

High beam Bi-Xenon dipped headlight

Align SEG according to point 4.0. Set the Align device according to point 4.0. Set the
scaled wheel according to the adjustment scaled wheel according to the adjustment
table. table (observe point 4).

Turn on the dipped headlight: Turn on the dipped headlight: Turn on the fog lamp: Turn on the main beam:
The cut-off line must run as horizontally In the case of headlights with The cut-off line must run as horizontally The light beam centre of the main beam
as possible along the dividing line over asymmetrically dipped headlights, the as possible along the dividing line over must be on the central marking, correct if
the whole width of the screen. Correct cut-off line must touch the dividing line on the whole width of the screen. Correct the necessary using the adjustment option.
the headlamp aiming if necessary using the test surface. The bend point between headlight aiming if necessary using the
adjustment screws. the left and right sloping part of the cut-off adjustment options. In the case of separate main beam
line must run vertically through the central modules (e.g. in combination with
Turn on the main beam: marking (upper cross). The bright core of Bi-Xenon headlights), the main
The light beam centre of the main beam the light beam must be situated to the right beam should be aimed according to
must lie on the central marking, correct if of the vertical line running through the manufacturers' instructions, since
necessary with the adjustment screws. central marking. For easier determination different settings are possible in this
of the left headlight half of the bend point case.
If the same adjustability is used for both (viewed from a driving direction), cover and
the main beam and dipped headlights, then uncover again several times. Then
recheck the dipped headlight. recheck the dipped headlight.

Main beam: In accordance with the

prescribed setting of the dipped
headlight's cut-off line, the middle of
the light beam must lie on the centre
marking (upper cross).

Please ensure that specific national regulations are always observed

 BEAM SETTER | 13

AIMING WITH THE BEAM SETTER

Adjusting the "glare-free high beam cut- Some manufacturers have also been offering so-called "main beam assistants" for some
off line" time now as an optional feature. A camera installed in the windscreen recognises when a
vehicle is approaching or driving in front of your car and automatically switches the main
beam to low. In addition, there is also the so-called "glare-free high beam cut-off line".
This high beam system produces a very special light distribution on the road. Detailed
information about this system can be found in the HELLA Online Portal "TECH WORLD".

In contrast to a normal high beam that is displayed on the test screen as an oval spot of
light, the shape of the glare-free high beam cut-off line tends to be square, Fig. 9.

8 9

Normal high beam distribution Glare-free high beam cut-off line

(left headlight)

In order to adjust the main beam function, a menu needs to be called up using a diagnosis
tester. The headlights are moved into a certain position and the glare-free high beam
cut-off line is activated. Now the vertical line of the light distribution (red circle) must be
adjusted exactly to the central marking of the test screen. In the case of the glare-free
high beam cut-off line, correct adjustment is absolutely essential as otherwise other road
users may be exposed to extreme glare.

Photoelectric light measuring device After adjusting the headlights, the incident light meter can be used to check whether the
(Incident Light Meter) highest permissible glare value of the dipped headlight has been exceeded. Today's beam
setters are generally equipped with a digital incident light meter, Fig. 10.

Please ensure that specific national regulations are always observed

14 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Photoelectric light measuring device Max. glare

(Incident Light Meter)
≤ 1.0 lux for halogen light
≤ 1.3 lux for Xenon light

10

If the glare has been clearly exceeded, the headlight must be replaced so as not to blind
other road users.

Aligning the beam setter to the vehicle's As already mentioned, the condition of the floor is of primary importance to enable exact
longitudinal axis headlight aiming. That is also the reason for the low tolerance values. But what should be
done if the aiming device and the vehicle are standing on surfaces which are not on the
same level? An example to make this clear.

In many garages, the first two metres, measured from the outside wall to the middle
of the interior, form a horizontal surface. After that, there is a second, slightly sloped
area which extends to the water drain channel in the middle of the garage. This area is
where the lifting ramp or work-position is situated. If, therefore, a vehicle is driven on to
the work-position and the headlight aiming device is situated on the afore-mentioned
horizontal surface, the longitudinal axes of the aiming device and the vehicle are not
parallel to each other. That inevitably leads to wrong measurements.

On the following pages, we will show you two ways of solving this problem step by step.
However, this requires an aiming device on which the inclination of the longitudinal axis of
the beam setter box can be adjusted, e.g. by an eccentric axis, Fig. 11.

11

Please ensure that specific national regulations are always observed

 BEAM SETTER | 15

AIMING WITH THE BEAM SETTER

Levelling with a point laser on 1. A laser pointer and a tripod with adjustable inclination is used for this aiming option,
the rear axle Fig 12. The laser pointer should still be able to generate a small dot at a distance of 5 m.

12

2. Set up the tripod just behind the back wheel and parallel to the body, Fig 13. The
assembly height of the laser is determined by the position of the beam setter box. It
should be as low as possible.

13

Please ensure that specific national regulations are always observed

16 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Levelling with a point laser on 3. Switch on the laser. Hold a folding yardstick vertically, exactly over the middle of the
the rear axle back wheel rim to the wheel contact area so that the laser dot can be seen. In this case,
the value is at 42 cm, Fig 14.

14

4. Repeat the procedure for the front axle. If the values differ from each other, the height of
the stand must be changed using the adjusting screws until the same value (42 cm) is
attained on both axles. The laser now simulates the longitudinal axis of the vehicle.

5. Set up the beam setter so that the laser dot can be seen in the middle of the lens, Fig 15.

15

Please ensure that specific national regulations are always observed

 BEAM SETTER | 17

AIMING WITH THE BEAM SETTER

Levelling with a point laser on 6. Turn the scaled wheel to "0", Fig. 16.
the rear axle

16

7. Depending on the inclination of the ground, the laser dot can be seen above or below the
dashed cut-off line. Using the eccentric axis (Fig. 17) change the inclination of the beam
setter box until the laser dot is situated exactly on the cut-off line, Fig. 18.

17 18

Please ensure that specific national regulations are always observed

18 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Levelling with a point laser on 8. The longitudinal axes of the vehicle and the beam setter are now situated on the
the rear axle same level (Fig 19). When this requirement is met, an exact measurement of the right
headlight can be made. This procedure must also be carried out on the other side of the
vehicle for the left headlight.

19

Levelling with a line laser on 9. With this aiming method, a line laser is attached to the beam setter, Fig 20. With this
the beam setter laser, the magnetic plate is firmly attached to the beam setter box. The actual laser is
held to the plate by means of a magnet and is therefore movable. The laser must be
equipped with a spirit level to enable adjustment of the inclination

20

Please ensure that specific national regulations are always observed

 BEAM SETTER | 19

AIMING WITH THE BEAM SETTER

Levelling with a line laser on 10. The longitudinal axes of the line laser must now be aligned parallel to the longitudinal
the beam setter axes of the beam setter box. This occurs using the fitted spirit levels of the laser and
the beam setter box, Fig. 21 and 22.

21 22

11. The laser beam should be on the same level as the middle of the lens (arrow marking
at the front of the beam setter box). As the picture clearly shows, the laser beam runs
through the arrow point, Fig. 23.

23

Please ensure that specific national regulations are always observed

20 | BEAM SETTER

AIMING WITH THE BEAM SETTER

Levelling with a line laser on 12. Similar to levelling with the point laser, the aiming device is now set to the vehicle.
the beam setter Using a yardstick, the values are then read at the front and rear axle, Fig. 24.

24

13. If the values differ, the same value has to be set on both axles by adjusting the
eccentric axis. In Fig. 25, it is 42 cm.

25

Please ensure that specific national regulations are always observed

 BEAM SETTER | 21

AIMING WITH THE BEAM SETTER

Levelling with a line laser on 14. The longitudinal axes of the vehicle and the beam setter are now situated on the
the beam setter same level. When this requirement is met, an exact measurement can then be made.
This procedure must also be carried out on the other side of the vehicle for the left
headlight.

The two methods for aligning the aiming device to the vehicle show that with relatively
little effort, different levels on the ground can be balanced out.

Please ensure that specific national regulations are always observed

22 | TEST SPECTRUM HEADLAMP AIMING

Test spectrum headlamp aiming

Visual + technical inspection

Visual inspection Technical inspection

Cover lens Reflector Mechanics Electrics / electronics

Scratches Coating Loose fitting Faulty bulb

Milky glass effect Broken bracket Corroded contacts

Brittleness Faulty adjustment mechanism Faulty lamp holding fixture

Test with SEG

Headlight adjustment Light measurement

Low beam: High beam:

cut-off line centre of light focus Glare low beam: Luminous intensity high beam:
halogen < = 1.2 lux/ halogen 48–240 lux/
Xenon < = 1.3 lux Xenon 70–180 lux

Prescribed range is not Difference between

High beam function is not used
reached/ Higher value dazzles right + left headlight: no
optimally/poor illumination of
glare from oncoming traffic/ oncoming traffic homogeneous illumination of
the road
road ahead not well illuminated the road

Additional turnover: Show your customers the drastic effects the faults can have
on their road safety and how you can eliminate the faults.

Please ensure that specific national regulations are always observed

NOTES | 23
HELLA KGaA Hueck & Co. HELLA Australia Pty. Ltd.
Rixbecker Straße 75 54-76 Southern Road
59552 Lippstadt, Germany P.O. Box 89
Tel.: +49 2941 38-0 Mentone, Victoria 3194 Australia
Fax: +49 2941 38-7133 Telephone (3) 95819333
Internet: www.hella.com Telefax (3) 95811741
Internet: www.hella.com.au
HELLA Limited
Wildmere Industrial Estate
Banbury, Oxon OX16 3JU
Tel.: (01295) 225600
Fax: 0800 7832571
E-mail: hella.sales@hella.com
Website: www.hella.co.uk

© HELLA KGaA Hueck & Co., Lippstadt

9Z2 999 134-308 J00679/AA/07.13/1.0
Printed in Germany

Subject to technical and price modifications.