Mahindra & Mahindra Ltd, A.S, Nasik R&D ELECTRICAL

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1 SERVIICE MANUAL FOR HEADLAMP LEVELLIING SYSTEM BOLERO-MODELS SYSTEM DESCRIPTION: When Vehicle is fully or either partially loaded, it will have inclination toward upward from front side disturbing Headlamp aiming, to bring the aiming (Lowbeam) back to its original position we can use this system. This head light setting provides the best possible visibility to the driver. Headlamp aiming can be adjusted from driver seat with the help of switch provided on the instrument panel. This switch is having four positions marked as 0,1,2 & 3; position of switch i.e. 0 to 3 is decided according to the loading condition of vehicle, which is explained in detail in coming points. WORKING: The condition for best viewing pattern is called as INITIAL SETTING. INITIAL SETTING: The cut-off pattern of headlamp is set at a height of 100mm (-1%) below the headlamp center height. In the factory best viewing is done under the unladen condition. However when vehicle is either fully or partially loaded, it will have inclination toward upwards disturbing the initial setting. The motorized arrangement with switch will enable the headlamp to restore the initial setting. Following are the details of adjustment of switch at various load conditions for respective switch position. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 1 of 7

PLEASE SELECT THE SWITCH POSITION AS PER FOLLOWING TABLE FOR M-1 CATEGORY VEHICLES Switch Position Vehicle loading condition 0 Driver / Driver with Front passenger.

2 PLEASE SELECT THE SWITCH POSITION AS PER FOLLOWING TABLE FOR M-1 CATEGORY VEHICLES Switch Position Vehicle loading condition 0 Driver / Driver with Front passenger. 1 Driver + Front passenger + Rear seat occupied 2 All seats occupied 3 All seats occupied with luggage or Driver with full luggage at extreme rear side. PLEASE SELECT THE SWITCH POSITION AS PER FOLLOWING TABLE FOR N-1 CATEGORY VEHICLES Switch Position Vehicle loading condition 0 Driver / Driver with Front passenger. 1 All seats occupied with luggage or Driver with full luggage at extreme rear side. SYSTEM PARTS: Headlamp levelling system consists of 1.Headlamp assembly with motor & 2.Control switch on I.P. 1. Headlamp assembly with motor. As shown in the photographs 1.1 & 1.2 the headlamp with shaft gets engaged with motor-which is fixed in the headlamp-mounting bracket. The motor operates on supply voltage (+ve), ground (-ve) & signal pin. The voltage applied to the signal pin decides the shaft travel of motor. Motor use to move the lamp assembly. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 2 of 7

Headlamp Levelling Switch mounted on Instrument

Switch is nothing but a variable potentiometer

It gives the variable voltage to signal pin of

3 1.1) Headlamp with shaft connected 1.2) Headlamp mounting bracket with motor. 2. Headlamp Levelling Switch mounted on Instrument panel. Why this switch is provided? Switch is nothing but a variable potentiometer marked with 0 to3 positions. It gives the variable voltage to signal pin of motor; which decides the position of shaft travel & headlamp aiming is controlled. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 3 of 7

Connect the electrical connections of motor & headlamp. 3.

4 MOUNTING OF MOTORISED HEADLAMP: 1.Mount the Headlamp bracket. 4-MOUNTING POSITION SAME AS EXISTING. The longer-screw of Headlamp has to be engaged with this motor. 2.Connect the electrical connections of motor & headlamp. 3.Insert the Headlamp & engage the longer screw with motor by rotating the screw 2/3 rounds. 3-POSITIONS OF HEADLAMP SETTIING SAME AS EXISTING. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 4 of 7

HEADLAMP ALIGNMENT : We can align the headlamp by two methods. (1) USING THE AIMING INSTRUMENT (2) IN THE DARK ROOM 1.HEADLAMP ALIGNMENT USING THE AIMING INSTRUMENT.

c) The headlamp aiming instrument height should be in the centreline of headlamp. Fig (1) 1. Bring the aiming instrument in front of headlamp as shown in above diagram. 2.

5 HEADLAMP ALIGNMENT : We can align the headlamp by two methods. (1) USING THE AIMING INSTRUMENT (2) IN THE DARK ROOM 1.HEADLAMP ALIGNMENT USING THE AIMING INSTRUMENT. Ensure that the: a) Vehicle & headlamp aiming equipment placed on the same Level surface. b) Check All four tyre pressures as per specification. c) The headlamp aiming instrument height should be in the centreline of headlamp. Fig (1) 1. Bring the aiming instrument in front of headlamp as shown in above diagram. 2.Switch ON Headlamp low beam. 3.Keep the levelling switch in 0 position. 4.Observe the demarcation between light & dark zone. This demarcation line should coincide with horizontal line at an angle of 15 Deg. on LH side. VIEW IN THE AIMING NSTRUMENT. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 5 of 7

6 4.If the low beam does not coincide with the lines on the screen at 15 Deg adjust the setting screws to the set pattern at a required height with the help of star head Screwdriver. 5.Repeat the above procedure for other headlamp. 6.For RHD vehicles the oblique line at 15deg will be oriented towards LH side, and for LHD vehicles the same will be oriented towards RH side. 7.Check the system function by moving the switch position from 0 to 3,accordingly Cut-off pattern will move down word & at 0 th position the cut-off will come at original 1% setting. 8.If the beam pattern is moving with the switch operation that means the system is OK. 9.After setting both (RH & LH) Headlamp cut-off pattern, fit the bezel. (There should not be any fouling between Headlamp & Bezel) 2.HEADLAMP ALIGNMENT IN THE DARK ROOM: Ensure that the: a) Vehicle & black screen/ board both are placed on the same Level surface. b) Check All four tyre pressures as per specification. c) Headlamp levelling switch position is on zero (0). Keep the vehicle at a distance of 10meter from the black screen in the dark room. Mark the 1% height on the board as shown. I.e. 100mm below the Headlamp centre height. Adjust & align both LH & RH headlamps by setting the screws. Check the function of system, by operating the switch 0 to 3 and observe the cut-off pattern movement in down word direction accordingly. At zero position of switch the cut-off should come at 1% height on screen. Fig (2) h(cm):is the height 100mm below the HL-centre height i.e. 1% setting of cut-off pattern. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 6 of 7

7 TROUBLE SHOOTING CHART FOR HEADLAMP LEVELLING SYSTEM: Headlamp levelling system is not functioning. Switch On the Head Lamp Low Beam. Low beam is ON but levelling system is not operating. Check for headlamp fouling with body parts Low beam and leveling system both are not working. Replace the Low beam fuse and check for any short circuit Repair the same Check voltage between pin no 3 (+ve) and 1 (-ve) in the connector of motor 12V Check the voltage between pin no 2 & 1in the motor connector, it should be 10.8V (Keep switch position at 0 ) Check the loose connections of connectors at switch end. Check the wiring harness Check the voltage between pin no 3 & 2in the levelling switch connector should be 12V Correct the Same. HEADLAMP LEVELLING SYSTEM SERVICE MANUAL Page 7 of 7

Color Applicability/Trim Level. Hardware Bag Contents Item # Quantity Reqd. Description

Color Applicability/Trim Level. Hardware Bag Contents Item # Quantity Reqd. Description Document # 2291 (TMS) Posted 1/30/04 SCION xb 2004-2005 FOG LIGHT Section I Installation Preparation Part Number: 08590-52820 Section I Installation Preparation Kit Contents Item # Quantity Reqd. Description