Mahindra & Mahindra Ltd, A.

S, Nasik R&D ELECTRICAL

SSEER
RVVIICCEE M
MAAN
NUUAALL FFO
ORRH
HEEAAD MPP LLEEVVEELLLLIIN
DLLAAM NGG SSYYSSTTEEM
M

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:

9 The condition for best viewing pattern is called as INITIAL SETTING.

9 INITIAL SETTING: The cut-off pattern of headlamp is set at a height of 100mm
(-1%) below the headlamp center height.

9 In the factory best viewing is done under the unladen condition.

9 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

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

ª 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.

ª 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”.
ª 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

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

1.1) Headlamp with shaft 1.2) Headlamp mounting bracket

connected with motor.

2.“Headlamp Levelling Switch” mounted on Instrument panel.

Why this switch

is provided?

ª 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

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

± 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

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

± 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

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

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 0th 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).
ª Keep the vehicle at a distance of 10meter from the black screen in the dark room.
ª Mark the –1% height on the board as shown. I.e. 100mm below the Headlamp
centre height.
ª Adjust & align both LH & RH headlamps by setting the screws.
ª Check the function of system, by operating the switch 0 to 3 and observe the cut-off
pattern movement in down word direction accordingly.
ª 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

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

ªTROUBLE SHOOTING CHART FOR HEADLAMP LEVELLING SYSTEM:

Headlamp levelling system is

not functioning.
YES
Switch On the Head Lamp Low
Beam.
YES
YES
Low beam is ON but levelling Low beam and leveling system
system is not operating. both are not working.
YES YES

Check for headlamp fouling with Replace the Low beam fuse and
body parts check for any short circuit
NO
YES Check voltage between pin no 3
(+ve) and 1 (-ve) in the NO
Repair the same connector of motor 12V
YES
Check the voltage between pin
no 2 & 1in the motor connector,
it should be 10.8V (Keep switch Check the loose connections of
NO connectors at switch end.
position at “0”)

YES Check the wiring harness

Check the voltage between pin
no 3 & 2in the levelling switch YES
connector should be 12V NO
Correct the Same.

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