Federal Motor Vehicle Safety Standards Lamps, Reflective Devices, and Associated Equipment

Federal RegisterNov 12, 1998

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DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration

49 CFR Part 571

[Docket No. NHTSA 98-4673; Notice 1]

RIN 2127-AG87

Federal Motor Vehicle Safety Standards Lamps, Reflective Devices,

and Associated Equipment

AGENCY: National Highway Traffic Safety Administration (NHTSA), DOT.

ACTION: Notice of proposed rulemaking.

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SUMMARY: This document proposes to amend the Federal motor vehicle

safety standard on lighting to reorganize the sections relating to

headlighting. A notice proposing reorganization of the sections

relating to other lamps is planned for later in 1998. This action is

taken to remove inconsistencies and to facilitate reference to the

standard in an effort to improve its comprehensibility.

DATES: Comments are due on the proposal February 10, 1999.

ADDRESSES: Comments should refer to the docket number and notice

number, and be submitted to: Docket Management, Room PL-401, 400

Seventh Street, S.W., Washington, D.C. 20590 (Docket hours are from

10:00 a.m. to 5:00 p.m.)

FOR FURTHER INFORMATION CONTACT: Patrick Boyd, Office of Safety

Performance Standards (202-366-6346).

SUPPLEMENTARY INFORMATION:

I. The Reason for This Rulemaking

Federal Motor Vehicle Safety Standard No. 108 specifies performance

requirements for lamps, reflective devices and associated equipment on

new motor vehicles, as well as their location. The standard also covers

replacement lighting equipment. Its present version represents 31 years

of accumulated amendments and the incorporation of numerous industry

consensus standards. In many cases, the incorporated versions are no

longer in print. Requirements concerning a particular lighting device

are sometimes found at different places within the standard or are

partially contained in SAE standards which are themselves incorporated

by reference. As printed at 49 CFR 571.108, revised as of October 1,

1997, Standard No. 108 occupies 73 pages, by far the longest of the

Federal motor vehicle safety standards. The agency responds to

approximately 150 letters annually from domestic and foreign

manufacturers of vehicles and equipment, state agencies, vehicle

owners, and inventors of lighting devices asking for interpretations of

Standard No. 108, and even more inquiries by telephone. The agency

believes that this heavy demand may be due in part to difficulties that

interested parties may have in finding the applicable provisions in the

standard and in gaining confidence that they are aware of all

requirements.

Therefore, NHTSA has decided to issue two notices proposing

amendments intended to make the standard easier to understand. The

amendments are not intended to change the requirements of the standard,

except in a few minor instances which will be clearly identified in

this preamble and the preamble of the second proposal. This NPRM

proposes amendments to only those sections of Standard No. 108 applying

to headlamp systems. Revised regulatory language for other lamps will

be proposed for amendment in a future notice. The principal change in

the organization of headlamp requirements is the elimination of the

separate section devoted to sealed beam headlamps. They are treated in

this proposal as a type of integral beam headlamp which have additional

requirements to assure interchangeability.

II Drafting Guidelines

The following drafting guidelines have been followed in this

proposal and will be followed in the subsequent proposal to the extent

possible where the agency believes that adherence to them improves the

clarity of the standard:

[[Page 63259]]

(a) All requirements directly affecting a specific type of lamp or

reflector will be consolidated in the same section to avoid scattered

requirements. Requirements common to more than one lamp or reflector

will be repeated in each lamp or reflector section if they are brief,

or they will be referenced in subsequent sections if they are too

lengthy.

(b) Lighting requirements should be contained within the text of

Standard No. 108 rather than incorporated by reference. Users should be

relieved of the burden of searching incorporated SAE standards for the

possibility of additional requirements. Ideally, the required

performance of a lamp or reflector would be described fully within the

text of Standard No. 108, but the details of the test method would be

specified by incorporation of industry standard test methods developed

by SAE and other consensus bodies. In other instances where lighting

requirements are unavoidably established by incorporation of an

industry standard, the citation should include mention of the types of

requirements found in the standard. A reader of Standard No. 108 should

be able to determine at least the existence of all lighting

requirements without prior knowledge of the content of industry

standards incorporated by reference.

paragraphs. Subparagraph titles will form an index to this lengthy

standard in the manner of the proposed interim index of headlamp

requirements attached to S7. Paragraph names will impose a logical

order on the requirements that will assist writers of future amendments

in preserving the value of the index and assist readers in locating

provisions of interest.

(d) In general, the existing wording of requirements will be

preserved to avoid unintended effects on regulatory burdens, but the

desire for clarity will call for occasional edits. A review of past

interpretation letters will be used to identify particular instances

where editing may be beneficial.

(e) References to SAE standards will be updated to current versions

unless a revision would result in significant burden without

compensatory safety benefits or unless NHTSA believes that the older

version is better for motor vehicle safety.

(f) Two different numbering systems are used within the existing

paragraphs of the standard. In the most frequently used system, letters

and numbers follow a prescribed hierarchy. This has led to some

unwieldy constructions where it is difficult to identify and cite a

specific requirement. For example, in the requirements for replaceable

bulb headlamp systems, Standard No. 108 presently contains a paragraph

S7.5(d)(2)(i)(A)(1). The second system is similar to SAE practice in

which subparagraphs are given numbers. For example, the subparagraphs

of S7.8.5 are S7.8.5.1, S7.8.5.2, and S7.8.5.3 rather than S7.8.5(a),

(b), and (c). Even in this instance, the first system is followed

thereafter in these subparagraphs, such as S7.8.5.2(a)(1)(i). One way

to address the problem is to rewrite and simplify the text to minimize

the number of subparagraphs, which NHTSA has done. After this point,

the clearest system appears to be one that uses a numerical hierarchy

for all paragraphs above the lowest level and reserves the lowest level

for letters (e.g., S7.4.1.1(a)). The NPRM contains no subparagraphs

beyond this initial alphabetical level.

(g) References to past effective dates of provisions will be

eliminated. They have been kept until now as a guide to compliance with

replacement equipment specifications.

III. Amendments Proposed for Specific Parts of Standard No. 108

S4 Definitions. The definition of ``integral beam headlamp'' would

be expanded to include sealed beam headlamps. The definitions of both

integral and ``replaceable bulb headlamps'' would be edited to state

expressly that headlamps that are visually/optically aimable or that

incorporate a vehicle headlamp aiming device may be designed for

removable lenses. The definition of ``replaceable light source

headlamps'' would be amended to delete an unnecessary restriction on

the number of light sources in a headlamp of that type.

Definitions of ``two-headlamp systems'' and ``four-headlamp systems

would be added.

S7 Headlighting requirements. All subparagraphs and most of the

lower level paragraphs in S7 would be given titles, and the provisions

of the proposed regulatory language would be rearranged as required to

conform to the structure imposed by the paragraph titles. An index of

all headlamp provisions now contained in Paragraphs 7, 8, 9 and 10 of

the present standard has been added. When the rest of Standard No. 108

is reorganized, this partial index would become part of an index of the

whole standard to be located at the beginning.

S7.1. The mounting location requirements of Tables II and IV would

be added to the text of the standard. The language prohibiting grills,

covers and other headlamp obscurations would be moved from S7.8.5 to

this paragraph. References to past effective dates would be eliminated.

S7.2. This paragraph would be devoted to general requirements

involving headlamp lens marking and replaceable lenses. Present

S7.2.1(d), dealing with photometric test procedure, would be moved to

S7.4.2 and S7.5.2 where other photometric test requirements are

contained. The text of S5.8.2 and S5.8.11, dealing with replacement

lenses and lens marking of certain replacement headlamps, would be

moved to S7.2.

S7.3. The present S7.3 specifying sealed beam headlamp performance

would be eliminated. Sealed beam headlamps would be regulated as a type

of integral beam headlamp with photometric limitations in some

instances to preserve their interchangeability. In many four headlamp

systems, the upper beam is produced by the combined operation of the

upper beam lamp and one or more filaments in the lower beam lamp. The

standard recognizes several photometry options developed for sealed

beam headlamps in which the dual headlamps of each side of a vehicle

combine their light output in different ways to achieve an upper beam.

Manufacturers would be required to continue the use of the present beam

patterns for the various types of interchangeable sealed beam headlamps

so that the intended upper beam pattern is maintained when the consumer

replaces a single lamp. Systems using only two headlamps do not pose a

similar concern. Accordingly, no extra limitations would be placed on

sealed beam headlamps in two headlamp systems.

Present S7.9 containing motorcycle headlamp requirements would be

moved to S7.3 with several amendments. The incorporation by reference

of SAE J584 would continue to be the source of several requirements for

motorcycle headlamps, but a parenthetical note would be added telling

the reader what types of requirements are to be found in SAE J584. The

incorporated version of SAE J584 would remain that of 1964 because the

agency concluded in a recent rulemaking (61 FR 6616) that it would be

inappropriate to use the 1993 version of the standard in its entirety.

Instead, only the photometric performance and the aiming method of the

newer version of J584 were included. The reference in the present text

to SAE J566 1960 would be eliminated by including its brief provisions

directly in S7.3.

[[Page 63260]]

S7.4. The present requirements for integral beam lamps would be

used also to regulate sealed beam headlamps with a few special

provisions. Since integral beam headlamps are those without replaceable

light sources, sealed beam headlamps are simply a category of integral

beam headlamps designed to interchangeability standards rather than

particular to a given vehicle model. Paragraph S7.4 would restrict

standard sealed beam headlamps, designated by SAE types, to the beam

patterns presently specified for those types and to the visually/

optically aimable version of those beam patterns. However, the

visually/optically aimable versions would be required to retain the

aiming pads specified by the SAE standards for the attachment of

external aimers. This would be required because it is necessary to

mount external aimers on both sides of a vehicle even if only one

headlamp requires external aiming.

References to SAE J1383, regarding specifications of sealed beam

headlamp types and photometric test procedure, have been updated to the

DEC96 version. The incorporated provisions of the updated SAE J1383

appear to be substantially identical to those of the presently cited

APR85 version, except with respect to photometric performance in the

region of the beam pattern above 10 degrees up. The latest SAE revision

measures only the area 45 degrees to the right and left of the driver

(rather than +/-90 degrees), and small regions of brightness exceeding

the regional maximum of 175 cd. would be permitted if confined to a 2-

degree conical angle. This requirement protects drivers from annoying

reflections of headlamp light in rain and snow, while recognizing that

stray light beams of insignificant breadth do not pose a problem.

Paragraph S7.4.2 of the proposed revision would adopt the approach

taken by SAE J1383 DEC96 to the beam pattern above 10 degrees.

The photometric requirements for lamps comprised of multiple beam

contributors, presently in S7.4(a)(3), would be restated in terms of

beam contributors per beam rather than beam contributors per vehicle to

improve clarity. Present S7.4(b) and (c) would be combined in S7.4.5

and simplified in expression. The provision that visually/optically

aimable headlamps and headlamps with VHADs may be designed with

replaceable lenses has been moved into S7.4 and S7.5 rather than being

conveyed only by the definitions of integral beam and replaceable bulb

headlamps. In this way, the definitions are provided only to clarify

the terms used in the requirements, not to become additional sources of

regulatory provisions where they may escape the user's notice.

Currently Standard No. 108 requires the lower beam in a four-lamp

headlighting system to be provided by the uppermost lamp (if the lamps

are arranged vertically), or outermost (if they are arranged

horizontally). This presupposes that the two headlamps on a side share

a common vertical or horizontal axis. With the advent of projector beam

headlamps, there may be no common axis of light sources within a

headlamp.

The proposed language of S7.4.5 and S7.5.3 establishes that the

most important safety aspect of headlamp arrangement is the marking of

the full width of the vehicle by the operation of the lower beam. It

would set a priority of outermost over uppermost for lower beam

headlamps, reflectors or light sources, and it would permit

arrangements in which the uppermost headlamps are upper beams as long

as the outermost headlamps are lower beams. It would permit the

arrangement of upper and lower beams in a two headlamp system to be

based on either the locations of the outer lighted edges of separate

upper and lower beam reflectors or the position of the light sources.

Only where the outer edges of headlamps or headlamp reflectors or light

sources in a two headlamp system are arranged exactly vertically (i.e.,

in the same vertical longitudinal plane) would the lower beam be

required to be the uppermost lamp.

The proposed language of S7.4.5 and S7.5.3 also anticipates future

headlamp designs with an array of light sources or remote light sources

with multiple light paths to the headlamp reflector. It would require

only that the outermost light source be activated on the lower beam to

mark the full width of the vehicle, rather than to ``provide'' the

lower beam, and it would view the outermost light path of a remote

light source as equivalent to the outermost light source of a

conventional design in regard to marking vehicle width.

Proposed S7.4.8.8 Exposure resistance would apply to plastic

material for headlamp lenses the requirements of SAE J576 JUL91 Plastic

materials for use in optical parts such as lenses and reflectors of

motor vehicle lighting devices, which would be incorporated by

reference. This amendment would clarify the agency's intent that

Standard No. 108 and SAE J576 JUL91 require the same level of haze

resistance for materials for headlamp lenses, namely that they show no

deterioration in a visual inspection after a three-year outdoor

exposure test. The amendment would supersede a statement in a previous

interpretation (sent on December 7, 1994, to Brian J. Williams)

applying a 30 percent haze limit after the outdoor exposure test to

plastic materials for headlamp lenses. The statement was a literal

interpretation of the word ``lamp'' in S5.1.2. However, the reasons for

the agency's establishment in 1975 of the 30 percent haze limit for

material for ``lamp'' lenses were applicable only for signal and

license plate lamps. In 1975, the only lamps known to use plastic

materials were signal lamps and license plate lamps. Headlamps at that

time were required to be sealed beams with glass lenses.

By way of explanation, originally, Standard No. 108 cited SAE J576b

(1966) which required that ``exposed samples, when compared with the

unexposed control samples, shall not show . . . haze.'' The requirement

referred to an inspection with the naked eye of plastic samples after

outdoor exposure tests in Florida and Arizona. In 1974, General

Electric (GE) petitioned the agency to relax the haze requirement for

signal lamp lenses, but not for reflex reflectors. GE provided a large

body of data on various signal lamps with a degree of surface haze

representative of highly weathered polycarbonate plastic lenses without

protective coatings. It concluded that haze did not make signal lamps

less visible, although it altered the distribution of light output

among the photometric test points for the various lamps and could

actually have the effect of causing the lamp to appear larger. The

agency agreed with GE and amended the standard to include as an

exception to J576 (which was updated to J576c May 1970 at that time)

the following:

After the outdoor exposure test, the haze and loss of surface

luster of plastic materials used for lamp lenses shall not be

greater than 30 percent as measured by ASTM 1003-61 * * *.

The reason given by the agency for proposing the amendment (39 FR

35179) was:

In GE's view, deglossing to haze levels of 50 percent does not

appear to significantly affect the overall photometric performance

and signaling effectiveness of the lamp. The effect of haze is to

scatter light from the point of maximum intensity to the wider angle

test points, resulting in a diminution of light output at the

former, and an increase at the latter. In accordance with GE's test

data and suggestion, the NHTSA is proposing that haze levels should

not exceed 30 percent. [italic added]

NHTSA believes that it is clear from the original petition that the

only lenses to which a haze limit as high as 30 percent should apply

were those on

[[Page 63261]]

signal and license plate lamps. To repeat, at the time of that

rulemaking, all headlamps manufactured for sale in the United States

were sealed beams with glass lenses. None of the information and

assertions in GE's petition pertained to lenses for headlamps, and the

agency's stated conclusion in that rulemaking about the effect of haze

on lamp lenses shows that haze is antithetical to the objectives of

headlamp design. Headlamps are designed to maintain a difficult balance

between providing enough light to guide the driver and limiting light

that causes glare for other drivers. A hazed headlamp lens both

diminishes the light needed by the driver and simultaneously increases

the glare to other drivers. While the effect of haze is insignificant

for signal lamps, the same is not true for headlamps.

When Standard No. 108 was amended to allow plastic headlamp lenses,

the lenses were required to demonstrate resistance to abrasion.

Compliance was achieved through coatings. In a 1993 NPRM (58 FR 13042)

proposing a haze limit of 7 percent for reflex reflector material,

NHTSA asked for comments on whether all abrasion-resistant coatings

also prevented haze on headlamp lenses exceeding 7 percent (the

approximate equivalent of haze just discernable to the naked eye). Ford

Motor Company commented that, in its experience with plastic headlamp

lenses, all such coatings would prevent haze exceeding 7 percent. NHTSA

is concerned that some contemporary hard coatings may no longer provide

this level of haze protection though capable of providing sufficient

abrasion resistance. A final rule based on this proposal would

successfully address this possibility.

The provision of J576 allowing a 25-percent reduction in luminous

transmittance of plastic material as a result of outdoor exposure is

specifically excluded from application to headlamp lenses in SAE J1383

Performance Requirements for Motor Vehicle Headlamps, but that part of

SAE J1383 has not been incorporated in Standard No. 108. The agency

agrees with SAE that the 25-percent loss in transmittance permitted by

SAE J576 is another provision suitable for signal lamp lenses rather

than headlamp lenses, but it would prefer to adopt a more appropriate

transmittance-loss limit for headlamp lens material rather than simply

to eliminate the reference. The agency believes that suitable hard

coatings which protect against abrasion and haze currently limit

transmittance loss to much less than 25 percent.

Accordingly, NHTSA asks readers to comment on the actual

performance of coated plastic samples of current headlamp lens

materials in the J576 outdoor exposure tests.

Paragraph S5.1.2 contains other potential ambiguities that will be

addressed when the requirements for signal lamps and reflex reflectors

are reorganized in a future notice. For example, the measured haze

limits for reflex reflectors and signal lamps are listed in paragraphs

introduced as exceptions to J576 JUL91. However, the haze limits are

the same as those in J576 JUL91; the exception is that Standard No. 108

cites a more recent update of the ASTM haze measurement method than

does J576 JUL91.

The reference to SAE J580 Sealed Beam Headlamp Assembly would be

eliminated from the present S7.4(g) and the remaining text designated

S7.4.9. The SAE canceled SAE J580 in 1992 and its pertinent provisions

were moved to SAE J1383. However, the connector resistance test of SAE

J580, which was referenced in S7.4(g), was rejected by SAE for

inclusion in J1383. The rationale given by SAE was that the connector

resistance is not important because the photometric performance

requirement assures correct current flow at the headlamp terminal and

connector, and the resistance requirement would not permit the use of

stainless steel and other higher resistance material for terminals. The

agency agrees that the design resistance of a new headlamp terminal and

connector is not important if it provides complying photometric

performance, but it believes that Standard No. 108 should continue to

require that the resistance of terminals not be subject to significant

degradation as a consequence of corrosion. Therefore, the corrosion

resistance requirement for terminals of S7.4(h)(3) would be retained in

S7.4.8.3. A new Figure 11, illustrating the measurement of current flow

at headlamp terminals, would be added to Standard No. 108 and

referenced in S9.4 of the new text to eliminate a reference to a figure

in SAE J580.

S7.5. The present text concerning replaceable bulb headlamps is

very difficult to follow, due in part to the need for many paragraphs

and the lack of paragraph titles. The proposed text is extensively

rewritten to parallel the simpler organization of S7.4. Paragraph S7.5

would be renamed ``Replaceable light source headlamps'' because

replaceable light sources other than incandescent bulbs have been

permitted. The adoption of the proposed text would have no effect on

the requirements for replaceable light source headlamps with one

exception.

The present text requires a lens marking for replaceable bulb

headlamps identifying the type of replaceable light source, unless it

uses a type HB1 bulb. The exception for type HB1 bulbs has been removed

from the proposed text. At an earlier time when only one or two types

of bulbs were in use, it may have been acceptable to designate one type

with the absence of a mark. But it no longer appears to be a reasonable

practice, now that a large number of types of replaceable light sources

are in use. The agency believes that type HB1 bulbs are not used on

vehicles in current production, and therefore no burdens would be

imposed by the change. However, if future vehicles were to be produced

using type HB1 bulbs, their headlamps would require the same kind of

marking as required for all other types of replaceable light sources.

The purpose of the mark is to assist the vehicle owner in choosing the

correct light source with which to repair a burned out headlamp.

Finally, a headlamp system using replaceable light sources would be

allowed to combine them with fixed light sources (such as high

intensity discharge sources (HIDs)), while adhering to the same beam

patterns and requirements of replaceable light source headlamps.

S7.6. The present S7.6 on combination headlighting systems would be

eliminated. Its purpose was to address headlamps combining HID light

sources and replaceable bulbs. Formerly, HID light sources were

permitted only in the form of integral beam headlamps (which are

integrated from the 12.8 volt receptical inward), so that their use in

combination with a replaceable bulb created a distinct class of

headlamp. Now, HID light sources may be used in a replaceable form, and

the resulting headlamps are simply the replaceable light source

headlamps covered in S7.5. Paragraph S7.5 would also be amended to

recognize a headlamp system using standardized replaceable light

sources (e.g., HB3, HB4) combined with fixed light sources which need

not be standardized, including high voltage HID light sources.

The text presently contained in S7.7 Replaceable light sources

would be moved to S7.6. The text would be given paragraph titles and

arranged in a different order but otherwise remain unchanged. The

present S9 Deflection test for replaceable light sources would be moved

to S7.6.3 to make the light source section self-contained.

[[Page 63262]]

S7.7. The special wiring requirement paragraphs pertaining to

headlamp systems would be moved from S5.5 to S7.7 in the interest of

consolidating the headlamp requirements. The brief manual headlamp beam

switching requirements of J564a would be written directly in the text

rather than continuing to be incorporated by reference to a 1964

document. A switch without ``dead spots'' as expressed in the 1964

standard is clarified as a switch of the make-before-break type.

The agency proposes to update SAE J565 Semi-automatic headlamp beam

switching from the 1969 version to the most recent revision of 1989. It

is unknown if the update would impose new burdens, but it seems

unlikely that a 1969 standard continues to have relevance in the area

of automatic controls which has since been revolutionized by electronic

technology. In the case of SAE J565 JUN89, it would not be necessary to

place its requirements directly in Standard No. 108 because it

represents a self-contained treatment of a distinct wiring option which

is sufficiently identified by its title.

The language of S7.7.4 would be amended to add an exception to the

prohibition in S7.7.3 against simultaneous activation of upper and

lower headlamp beams. The purpose of this requirement is to prevent

glare. Ford Motor Company wrote NHTSA asking for an interpretation that

this provision would not apply to its Auto Low Beam backup system,

intended for a two-headlamp system. Under Ford's system, if an upper

beam fails, the lamp automatically switches to the lower beam for use

as a reserve upper beam headlamp. The agency has informed Ford that the

extinction of an upper beam results in a noncomplying headlamp system,

and that there is no prohibition against use of the remaining beam in

the headlamp to supplement the other headlamp. Because of the potential

for glare, however, the agency has not extended this interpretation to

the converse, that is, allowing an upper beam to substitute for a lower

beam when the lower beam has become inoperative. In NHTSA's view, this

would be an instance in which a manufacturer ``made inoperative'' the

glare protection provisions of Standard No. 108, within the meaning of

49 U.S.C. 30122. A reduced intensity upper beam is a possible solution

as a backup for an extinguished lower beam but NHTSA would not propose

to permit it until researching the glare issue.

The rest of the provisions are unchanged, except for paragraph

titles and some rearrangement of sentence order. S5.5.10 (b) and (c)

were repeated in S7.7.5 and S7.7.6, rather than moved, because S5.5.10

seen in its entirety is an important example of agency policy on

flashing lamps--namely, that no required or auxiliary lamps other than

those listed in S5.5.10 are permitted to flash.

S8. The text of the present S8 would be moved to S9 (vacated by the

move of the light source deflection test to S7.6), and the new S8 would

be dedicated to the present text of S7.8 Aimability performance

requirements. With the recent addition of a visual/optical aim option,

the aimability material has become much lengthier than other areas of

the standard. Further, the subject is sufficiently self-contained to

form a complete entity. The reduction of paragraph levels accomplished

by the move and the increased use of paragraph titles in the proposed

text would improve clarity.

S8.2. This paragraph would be the same as the present S7.8.1 with

the addition of a title and an updated reference to SAE J1383,

consistent with references in the proposed S7 text.

S8.3. This paragraph would contain the present text of S7.8.2

through S7.8.4, with paragraph titles and some reordering of paragraph

levels. Part of the present S7.8.5 would be included as an introductory

sentence in S8, and the part dealing with headlamp covers and

obstructions would be moved to general installation requirements that

would be contained in S7.1.

S8.4. Paragraph S8.3 would contain the present text of S7.8.5.1 on

external aim, reducing by two the levels of paragraph numbering. The

reference to SAE J602 would be updated to the DEC89 version which

includes specifications for an additional 92 x 150 mm locating plate

for the external headlamp aiming device, permitting deletion of Figure

16. A sentence informing the reader of the purpose of the torque

deflection and inward force tests would be added. The text of S8.3.1

would be amended to define that the torque value specified in the test

is that measured with respect to a horizontal axis in the aiming

reference plane. The present omission of a torque reference axis was

the subject of an interpretation (letter to Tolley, June 8, 1995). A

sentence would also be added stating that sealed beam headlamp mounts

would be tested with the standard deflectometers and adaptors specified

in SAE J1383 DEC96. In addition, paragraph titles would be added.

S8.5. The text of S7.8.5.2 on vehicle headlamp aiming devices

(VHADs) would be moved to S8.4 unchanged except for the order of a few

phrases and shorter paragraph numbers.

S8.6. The text of S7.8.5.3 on visual/optical aim, added in 1997,

would be moved to S8.5 with references to SAE J1383 and J575 updated.

S8.7. This would be a new paragraph setting aiming system

requirements for replacement headlamps. It assures that all

combinations of original and replacement headlamps are aimable.

S9. The agency considered the alternative of citing various SAE

headlamp test procedures rather than maintaining detailed test

procedures in Standard No. 108. However, the alternative was not

consistent with the goal of making the present requirements of the

standard more accessible to the reader. Some of the SAE test procedures

require reference to multiple SAE standards which does not favor

accessability. Also, the applicable SAE test procedures are not

identical to the procedures of the standard.

Some of the differences in test procedures are clearly significant.

For example, the SAE abrasion test is a test of materials, while the

abrasion test of Standard No. 108 is a test of headlamps. Also, the SAE

corrosion test does not include tests of the reflector and electrical

connector as does Standard No. 108. Other SAE test procedures contain

differences whose effects are uncertain, such as differences in the

amount of light blockage during the internal heat test and differences

in the humidity cycle and soak time in the humidity test. While there

may be merit in adopting some test procedures in the most current SAE

form, the changes would be considered for technical reasons, rather

than to reduce the size of paragraphs in the standard. Since the

clarity of Standard No. 108 would suffer from references to the SAE

test procedures accompanied by exceptions, the present brief test

procedures are retained in the text of paragraph S9.

A new Figure 11, illustrating the measurement of current flow at

headlamp terminals, would be included in Standard No. 108 and

referenced in S9.4 of the new text to eliminate a reference to a figure

in obsolete SAE J580.

Standard No. 108 has maintained a reference to the 1970 version of

SAE J575 for the vibration test because the agency believed the

vibration test of later versions of SAE J575 was insufficient. However,

it is undesirable to cite two versions of an SAE standard, especially

when one is so old that it may be hard to locate. The current SAE

standard for tests of heavy truck lamps, SAE J2139 JAN94, uses the same

vibration test as the 1970 SAE J575.

[[Page 63263]]

Therefore, SAE J2139 JAN94 would be substituted for SAE 575e to

describe the vibration test of S9.8.

S10. The general requirements in the present text of S10 concerning

simultaneous aim photometry tests of integral beam headlamps would be

moved to S7.4.4, and the material particular to type F sealed beams

would be eliminated. The present text of S12 on headlamp concealment

devices would be redesignated as S10 so that all headlamp material

would appear in contiguous sections.

S11. The title of S11 would be changed to clarify that it pertains

to daytime running lights (DRLs) rather than to headlamps. It should be

moved into a section devoted to DRLs when the requirements for other

lamps are reorganized.

Request for Comments

Interested persons are invited to submit comments on the proposal.

It is requested but not required that 10 copies be submitted.

All comments must not exceed 15 pages in length (49 CFR 553.21).

Necessary attachments may be appended to these submissions without

regard to the 15-page limit. This limitation is intended to encourage

commenters to detail their primary arguments in a concise fashion.

If a commenter wishes to submit certain information under a claim

of confidentiality, three copies of the complete submission, including

purportedly confidential business information, should be submitted to

the Chief Counsel, NHTSA, at the street address given above, and seven

copies from which the purportedly confidential information has been

deleted should be submitted to the Docket Section. A request for

confidentiality should be accompanied by a cover letter setting forth

the information specified in the agency's confidential business

information regulation, 49 CFR part 512.

All comments received before the close of business on the comment

closing date indicated above for the proposal will be considered, and

will be available for examination in the docket at the above address

both before and after that date. To the extent possible, comments filed

after the closing date will also be considered. Comments received too

late for consideration in regard to the final rule will be considered

as suggestions for further rulemaking action. Comments on the proposal

will be available to inspection in the docket. NHTSA will continue to

file relevant information as it becomes available in the docket after

the closing date and it is recommended that interested persons continue

to examine the docket for new material.

Those persons desiring to be notified upon receipt of their

comments in the rules docket should enclose a self-addressed stamped

postcard in the envelope with their comments. Upon receiving the

comments, the docket supervisor will return the postcard by mail.

Effective Date: Since the purpose of the amendments is to clarify

existing requirements, the agency believes that a final rule would not

impose any additional burden with one exception. The amended language

regarding haze resistance of plastic headlamp lens material would

supersede a December 1994 interpretation and may cause some headlamp

manufacturers to reinstate the coating materials and products generally

in use before that time. Therefore, the proposed amendment would become

effective 180 days after publication, to allow time for potential

production changes for plastic headlamp lenses.

Rulemaking Analyses

Executive Order 12866 and DOT Regulatory Policies and Procedures

This rulemaking actions was not reviewed under Executive Order

12866. It has been determined that the rulemaking action is not

significant under Department of Transportation regulatory policies and

procedures. The effect of the rulemaking action would be to clarify

existing requirements. It would not impose any additional burden upon

any person, except that a truck or multipurpose passenger vehicle

equipped with a four-lamp headlamp system in which the lamps are

arranged vertically would have to switch the relative positions of the

lamps on vehicles manufactured on and after September 1, 2000. Impacts

of the proposed rule are, therefore, so minimal as not to warrant

preparation of a full regulatory evaluation.

Regulatory Flexibility Act

The agency has also considered the impacts of this rulemaking

action in relation to the Regulatory Flexibility Act (5 U.S.C. Sec. 601

et seq. I certify that this rulemaking action will not have a

significant economic impact upon a substantial number of small

entities.

The following is NHTSA's statement providing the factual basis for

the certification (5 U.S.C. Sec. 605(b)). The final rule affects

manufacturers of motor vehicles and motor vehicle headlamps. According

to the size standards of the Small Business Association (at 13 CFR Part

121.601), manufacturers of lamps and reflective devices would be

considered manufacturers of ``Motor Vehicle Parts and Accessories''

(SIC Code 3714). The size standard for SIC Code 3714 is 750 employees

or fewer. The size standard for manufacturers of ``Motor Vehicles and

Passenger Car Bodies'' (SIC Code 3711) is 1,000 employees or fewer.

This NPRM would have no significant economic impact of a small business

in these industries because, if made final, the rule would make no

substantive change to requirements currently specified in Standard No.

108.

Further, small organizations and governmental jurisdictions will

not be significantly affected as no price increases are expected as a

result of this rulemaking. Accordingly, no Regulatory Flexibility

Analysis has been prepared.

Executive Order 12612 (Federalism)

This action has been analyzed in accordance with the principles and

criteria contained in Executive Order 12612 on ``Federalism.'' It has

been determined that the rulemaking action does not have sufficient

federalism implications to warrant the preparation of a Federalism

Assessment.

National Environmental Policy Act

NHTSA has analyzed this rulemaking action for purposes of the

National Environmental Policy Act. The rulemaking action would not have

a significant effect upon the environment as it does not affect the

present method of manufacturing motor vehicle lighting equipment.

Civil Justice Reform

This rule would not have any retroactive effect. Under section

103(d) of the National Traffic and Motor Vehicle Safety Act (15 U.S.C.

1392(d)), whenever a Federal motor vehicle safety standard is in

effect, a state may not adopt or maintain a safety standard applicable

to the same aspect of performance which is not identical to the Federal

standard. Section 105 of the Act (15 U.S.C. 1394) sets forth a

procedure for judicial review of final rules establishing, amending, or

revoking Federal motor vehicle safety standards. That section does not

require submission of a petition for reconsideration or other

administrative proceedings before parties may file suit in court.

List of Subjects in 49 CFR Part 571

Imports, Motor vehicle safety, Motor vehicles.

[[Page 63264]]

PART 571--FEDERAL MOTOR VEHICLE SAFETY STANDARDS

In consideration of the foregoing, it is proposed that 49 CFR Part

571 be amended as follows:

1. The authority citation would continue to read as follows:

Authority: 49 U.S.C. 322, 30111, 30115, 30117, and 30166;

delegation of authority at 49 CFR 1.50.

Sec. 571.108 [Amended]

2. Section 571.108 would be amended by:

(a) adding two new definitions, ``Four-headlamp system'' and ``Two-

headlamp system,'' in alphabetical order to S4,

(b) revising the definitions of ``Integral beam headlamp'' and

``Replaceable bulb headlamp,'' in S4,

(d) removing S7 through S12.5,

(e) adding new S7 through S11,

(f) removing Figures 11 through 14, 16, 18, 21 and 22; and

(g) adding new Figure 11, to read as follows:

Sec. 571.108 Standard No. 108; Lamps, reflective devices, and

associated equipment.

* * * * *

S4. Definitions.

* * * * *

Four-headlamp system means a headlamp system with two independent

headlamps on each side of a vehicle which may be used singly or in

combination to provide lower and upper beams.

* * * * *

Integral Beam Headlamp means a headlamp (including a sealed beam

headlamp listed in SAE J1383 DEC96 but not a replaceable bulb headlamp)

comprising an integral and indivisible optical assembly including lens,

reflector, and light source, except that a visually/optically aimable

headlamp or one incorporating a vehicle headlamp aiming device may have

a lens designed to be replaceable.

* * * * *

Replaceable bulb headlamp means a headlamp comprising a bonded lens

reflector assembly and one or two replaceable headlamp light sources,

except that a visually/optically aimable headlamp or one incorporating

a vehicle headlamp aiming device may have a lens designed to be

replaceable.

* * * * *

Two-headlamp system means a headlamp system with one headlamp on

each side of a vehicle, each of which provides a lower and upper beam.

* * * * *

S5.5.10 * * *

beam or its lower beam, but not both, to modulate from a higher

intensity to a lower intensity in accordance with S7.3;

(d) All other lamps, including all lamps not required by this

standard, shall be wired to be steady burning.

* * * * *

S7. Headlamp and replaceable light source requirements.

S7.0 Table of Contents. The following is a table of contents of the

requirements for headlamps and replaceable light sources.

S7.1 General Installation Requirements

S7.2 Lens Marking and Replacement Lens Requirements

S7.3 Motorcycle Headlamps

S7.4 Integral Beam Headlamp Systems

S7.5 Replaceable Light Source Headlamp Systems

S7.6 Replaceable Light Sources

S7.7 Special Wiring Requirements

S7.1 General installation requirements.

(a) Each passenger car, multipurpose passenger vehicle, truck, and

bus shall be equipped with a headlighting system designed to conform to

the requirements of S7.4 or S7.5. The headlamps shall be mounted on the

front of the vehicle symmetrically disposed about its vertical

centerline, with each lower beam headlamp at the same height and as far

apart as practicable, and with each upper beam headlamp at the same

height. With the vehicle at curb weight, the center of each headlamp

shall be not less than 560 mm (22 in) and not more than 1370 mm (54 in)

above the road surface.

(b) Each motorcycle shall be equipped with a headlighting system

designed to conform with the requirements of S7.3. A single headlamp

shall be mounted on the front vertical centerline of the motorcycle, or

if two headlamps are used, they shall be symmetrically disposed about

its vertical centerline. With the vehicle at curb weight, the center of

each headlamp shall be not less than 560 mm (22 in) and not more than

1370 mm (54 in) above the road surface.

have any styling ornament or other feature, such as a translucent cover

or grill, in front of the lens. Headlamp wipers may be used in front of

the lens, provided that the headlamp system is designed to conform with

all applicable photometric requirements with the wiper stopped in any

position in front of the lens.

S7.2 Lens marking and replacement lens requirements.

S7.2.1 Lens marking requirements.

(a) The lens of each original and replacement equipment headlamp

and of each original equipment and replacement equipment beam

contributor, and each replacement headlamp lens, shall be marked with

the symbol ``DOT,'' either horizontally or vertically, which shall

constitute the certification required by 49 U.S.C. 30115.

(b) Each headlamp lens and each beam contributor to which S7.2.1(a)

applies shall be marked with the name and/or trademark registered with

the U.S. Patent and Trademark Office of the manufacturer of such

headlamp, replacement lens or beam contributor, or of its importer, or

of any manufacturer of a vehicle equipped with such headlamp or beam

contributor. Each replacement headlamp lens shall also be marked with

the manufacturer and the part or trade number of the headlamp for which

it is intended. Nothing in this paragraph shall be construed to

authorize the marking of any such name and/or trademark by one who is

not the owner, unless the owner has consented to it.

shall be marked with its voltage and with its part or trade number.

(d) Headlamps designed to interchange with types C and D sealed

beam headlamps, specified by SAE Standard J1383 DEC96, may be marked

``1'' and ``2'' rather than ``1C1'' and ``2C1'', respectively and

``TOP'' or ``2'' rather than ``2D1''.

S7.2.2 Replacement lens requirements.

(a) A replacement lens for a headlamp that is not required to have

a bonded lens shall be provided with a replacement seal in a package

that includes instructions for the removal and replacement of the lens,

the cleaning of the reflector, and the sealing of the replacement lens

to the reflector assembly.

(b) Each replacement headlamp lens when installed on a headlamp

with a replacement seal, according to the lens manufacturer's

instructions, shall not cause the headlamp to fail to comply with any

of the requirements of this standard.

S7.3 Motorcycle headlamps. Each motorcycle shall be equipped with

a headlighting system designed to conform to the following

requirements.

S7.3.1 Photometric requirements and applicable SAE standard. Each

motorcycle may be equipped with--

(a) A headlighting system designed to conform to SAE Standard J584

Motorcycle Headlamps April 1964 (which includes requirements for

[[Page 63265]]

photometry, focus, color and resistance to vibration, moisture, dust

and corrosion) using the photometric specifications of Figure 32 and

the upper beam aimability specifications of S7.3.2 rather than the SAE

J584 photometry requirements, or

(b) If manufactured on or before September 1, 2000, a headlighting

system designed to conform to SAE Standard J584 April 1964; or

which provides both a full upper beam and full lower beam. Where more

than one lamp must be used, the lamps shall be mounted vertically, with

the lower beam as high as practicable. When installed on a motorcycle,

such half systems need not meet the aiming requirements of S8.

S7.3.2 Aimability.

S7.3.2.1 Photoelectric aim using upper beam. The upper beam of a

multiple beam headlamp designed to conform to the photometric

requirements of Figure 32 shall be aimed photoelectrically during the

photometric test in the manner prescribed in SAE Standard J584 OCT93,

Motorcycle Headlamps.

S7.3.2.2 Headlamp mounting. Headlamps and headlamp mountings shall

be so designed and constructed that:

(a) The axis of the light beams may be adjusted to the left, right,

up or down from the designed setting, the amount of adjustability to be

determined by practical operating conditions and the type of equipment.

(b) The adjustments may be conveniently made by one person with

tools ordinarily available.

under ordinary conditions of service.

S7.3.3 Motorcycle headlamp modulation system.

S7.3.3.1 A headlamp on a motorcycle may be wired to modulate

either the upper beam or the lower beam from its maximum intensity to a

lesser intensity, provided that:

(a) The rate of modulation shall be 24040 cycles per

minute.

(b) The headlamp shall be operated at maximum power for 50 to 70

percent of each cycle.

17 percent of the maximum intensity measured at the same point.

(d) The modulator switch shall be wired in the power lead of the

beam filament being modulated and not in the ground side of the

circuit.

(e) Means shall be provided so that both the lower beam and upper

beam remain operable in the event of a modulator failure.

(f) The system shall include a sensor mounted with the axis of its

sensing element perpendicular to a horizontal plane. Headlamp

modulation shall cease whenever the level of light emitted by a

tungsten filament light operating at 3000 degrees Kelvin is either less

than 270 lux (25 foot-candles) of direct light for upward pointing

sensors or less than 60 lux (5.6 foot-candles) of reflected light for

downward-pointing sensors. The light is measured by a silicon cell type

light meter that is located at the sensor and pointing in the same

direction as the sensor. A Kodak Gray Card (Kodak R-27) is placed at

ground level to simulate the road surface in testing downward pointing

sensors.

(g) When tested in accordance with the test profile shown in Figure

9, the voltage drop across the modulator when the lamp is on at all

test conditions for 12-volt systems and 6-volt systems shall not be

greater than 0.45 volt. The modulator shall meet all the provisions of

the standard after completion of the test profile shown in Figure 9.

(h) Means shall be provided so that both the lower and upper beam

function at design voltage when the headlamp control switch is in

either the lower or upper beam position when the modulator is off.

S7.3.3.2(a) Each motorcycle headlamp modulator not intended as

original equipment shall comply with S7.3.3.1(a) through (g) when

connected to a headlamp of the maximum rated power and a headlamp of

the minimum rated power, and shall provide means so that the modulated

beam functions at design voltage when the modulator is off.

(b) Instructions, with a diagram, shall be provided for mounting

the light sensor including location on the motorcycle, distance above

the road surface, and orientation with respect to the light.

S7.3.4 Marking. (a) Each replaceable bulb headlamp that is

designed to meet the photometric requirements of S7.3.1(a) or S7.3.2(a)

and that is equipped with a light source other than a replaceable light

source meeting the requirements of S7.7, shall have the word

``motorcycle'' permanently marked on the lens in characters not less

than 3 mm (o.114 in) in height.

(b) Each motorcycle headlamp modulator not intended as original

equipment, or its container, shall be labeled with the maximum wattage,

and the minimum wattage appropriate for its use.

S7.4 Integral beam headlamp systems. An integral beam headlamp

system shall be designed to conform to the following requirements:

S7.4.1 Photometric requirements. The system shall provide in total

not more than two upper beams and two lower beams. The color of any

headlamp beam shall be white as specified in SAE J578 JUN95.

S7.4.1.1 Four-headlamp systems. Except as provided in S7.4.1.1(d),

each upper beam headlamp and each lower beam headlamp in a four-

headlamp system shall be designed to conform to the photometrics

specified in its respective column of one of the following:

(a) Figure 15, or

(b) Figure 15 except that the upper beam test value at 2.5 D-V and

2.5 D-12R and 12L, shall apply to the lower beam headlamp and not to

the upper beam headlamp, and the upper beam test point value at 1.5D-9R

and 9L shall be 1000, or

(d) Headlamps designed to interchange with types A, C and G sealed

beam headlamps shall conform to the photometrics of Figure 28 only;

headlamps designed to interchange with type F sealed beam headlamps

shall conform to the photometrics of Figure 15 only; headlamps designed

to interchange with type J sealed beam headlamps shall conform to the

photometric specification of S7.4.1.3, and type 55x135 sealed beam

headlamps shall conform to the photometric specification of

S7.4.1.1(b). The cited types of sealed beam headlamps are those

specified by SAE Standard J1383 DEC96 Performance Requirements for

Motor Vehicle Headlamps.

(e) Headlamp systems using the photometry of Figures 15-1 or 28-1

shall comply with the mechanical aim requirements of S8.3 or S8.4.

S7.4.1.2 Two-headlamp systems. (a) Each headlamp shall be designed

to conform to the photometrics of either Figure 17 or Figure 27.

(b) Headlamp systems using the photometry of Figures 17-1 or 27-1

shall comply with the mechanical aim requirements of S8.3 or S8.4.

S7.4.1.3 Headlamp systems using lamps comprised of multiple beam

contributors. In a headlamp system in which there is more than one beam

contributor providing each lower beam, and/or more than one beam

contributor providing each upper beam, each beam contributor in the

system shall be designed to meet only the photometric performance

requirements of Figure 15 based upon the following mathematical

expression: conforming test point value = (Figure 15 test point value)/

total

[[Page 63266]]

number of beam contributors for each lower or upper beam, as

appropriate). The system shall be designed to use the Vehicle Headlamp

Aiming Device (VHAD) as specified in S8.4.

S7.4.2 Photometric test procedure. Each integral beam headlamp

system shall be designed to conform to the applicable photometric

performance requirements of S7.4.1 (rather than Table 3 of SAE J1383

DEC96) when tested in accordance with the test procedures of Paragraphs

5.1 and 5.1.4 of SAE Standard J1383 DEC96. Unless stated otherwise, a

tolerance of +/-\1/4\ degree is permitted during photometric

performance tests for any headlamp or beam contributor. The test points

10U-90U shall be measured in a horizontal range 45R to 45L from the

normally exposed surface of the lens face. Luminous intensities in this

upper region may exceed the limits contained in S7.4.1 if they are

confined within a 2-degree conical angle and do not exceed 438 cd. The

term ``aiming plane'' means ``aiming reference plane,'' or an

appropriate vertical plane defined by the manufacturer as required in

S8.1.

S7.4.3 Assemblies allowing simultaneous aim of multiple lamps. A

headlamp or beam contributor designed to meet S7.4.1.1 or 7.4.1.3, and

S8.3, except a type A, C or G sealed beam headlamp, may be mounted in

an assembly to permit simultaneous aiming of the beam(s) contributors,

provided that with any complying contributor the assembly complete with

all lamps meets the appropriate photometric requirements when tested in

accordance with S7.4.4.

S7.4.4 Photometric test procedure for simultaneous aim assemblies.

The assembly used for simultaneously aiming more than one integral beam

headlamp, at each side of a vehicle, shall be placed on a test fixture

on a goniometer located not less than 18.3 m (60 ft) from the

photometer. The assembly shall be aimed by centering the geometric

center of the lower beam lens(es) on the photometer axis and by

aligning the photometer axis to be perpendicular to the aiming

reference plane or appropriate vertical plane defined by the

manufacturer of any lower beam contributor. Photometric compliance of a

lower beam shall be determined with all lower beam contributors

illuminated and in accordance with the test procedures of paragraphs

5.1 and 5.1.4 of SAE Standard J1383 DEC96 using the test points and

photometric requirements of Figure 15. The assembly shall then be moved

in a plane parallel to the established aiming plane of the lower beam

until the assembly is located with the geometric center of the upper

lens(es) on the photometer axis. Photometric compliance for an upper

beam shall now be determined using the figure and procedure specified

for the lower beam. During photometric testing, a \1/4\ degree reaim is

permitted in any direction at any test point.

S7.4.5 Arrangement and marking of upper and lower beams.

(a) The reflector with the most outboard lighted edge or the most

outboard light source within a headlamp in a two-headlamp system, or

the most outboard headlamp in a four-headlamp system shall provide all

or part of the lower beam. If the light sources or the outboard lighted

edges of reflectors or headlamps are arranged along the same vertical

longitudinal plane, the upper light source, reflector or headlamp shall

provide all or part of the lower beam. For purposes of this paragraph,

the location within the headlamp reflector of the light path from a

remote light source shall be considered the location of the light

source.

(b) In a four-headlamp system, the lower beam headlamp lens shall

be permanently marked with the letter ``L'' or the number ``2'' before

the type designation letter of types A, C and G sealed beam headlamps,

and the upper beam headlamp lens shall be permanently marked with the

letter ``U'' or the number ``1'' before the type designation letter of

types A, C and G sealed beam headlamps.

S7.4.6 Aimability. The system shall be aimable in accordance with

the requirements of S8. A system that incorporates any headlamp or beam

contributor that does not have a VHAD as an integral and indivisible

part of the headlamp or beam contributor shall be designed so that the

appropriate photometrics are met when any correctly aimed and

photometrically conforming headlamp or beam contributor is removed from

its mounting and aiming mechanism, and is replaced without reaim by any

conforming headlamp or beam contributor of the same type. A visually/

optically aimable sealed beam headlamp interchangeable with a

mechanically aimable sealed beam headlamp shall be manufactured with

the aiming pads specified for it in SAE J1383 DEC96.

S7.4.7 Replaceable lenses. Headlamps that are visually/optically

aimable in accordance with S8.5 or that incorporate a vehicle headlamp

aiming device conforming to S8.4 may be designed to have a replaceable

lens.

S7.4.8 Other performance requirements. When tested according to

any of the procedures indicated in S9, each headlamp or beam

contributor shall meet the appropriate requirement:

S7.4.8.1 Abrasion. After an abrasion test conducted in accordance

with S9.2, the headlamp shall meet the photometric requirements

applicable to the headlamp system under test.

S7.4.8.2 Chemical resistance. After the chemical resistance tests

of S9.3 and S9.10.1, the headlamp shall have no surface deterioration,

coating delamination, fractures, deterioration of bonding or sealing

materials, color bleeding or color pickup visible without

magnification, and the headlamp shall meet the photometric requirements

applicable to the headlamp system under test.

S7.4.8.3 Corrosion resistance. After a corrosion test conducted in

accordance with S9.4, there shall be no evidence of external or

internal corrosion or rust visible without magnification. After a

corrosion test conducted in accordance with S9.10.2, there shall be no

evidence of corrosion or rust visible without magnification on any part

of the headlamp reflector that receives light from a headlamp light

source, on any metal light or heat shield assembly, or on a metal

reflector of any other lamp not sealed from the headlamp reflector.

Loss of adhesion of any applied coating shall not occur more than 3.2

mm (0.125 in.) from any sharp edge on the inside or outside. Corrosion

may occur on terminals only if the current produced during the test of

S9.4(c) is not less than 9.7 amperes.

S7.4.8.4 Dust resistance. After a dust test conducted in

accordance with S9.5, the headlamp shall meet the photometric

requirements applicable to the headlamp system under test.

S7.4.8.5 Heat resistance. The headlamp shall first meet the

requirements of S7.4.8.5(a) and then those of S7.4.8.5(b).

(a) After a temperature cycle test conducted in accordance with

S9.6.1, the headlamp shall show no evidence of delamination, fractures,

entry of moisture or deterioration of bonding material, color bleeding,

warpage or deformation visible without magnification or lens warpage

greater than 3 mm (0.118 in) measured parallel to the optical axis at

the point of intersection of the axis of each light source with the

exterior surface of the lens, and it shall meet the photometric

requirements applicable to the headlamp system under test.

(b) After an internal heat test conducted in accordance with

S9.6.2, there shall be no lens warpage greater than 3 mm (0.118 in)

when measured parallel to the optical axis at the point of intersection

of the axis of each light

[[Page 63267]]

source with the exterior surface of the lens, and it shall meet the

photometric requirements applicable to the headlamp system under test.

S7.4.8.6 Humidity resistance. After a humidity test conducted in

accordance with S9.7, the inside of the headlamp shall show no evidence

of delamination or moisture, fogging or condensation visible without

magnification.

S7.4.8.7 Vibration resistance. After a vibration test conducted in

accordance with S9.8, there shall be no evidence of loose or broken

parts, other than filaments, visible without magnification.

S7.4.8.8 Exposure resistance. After a three-year outdoor exposure

test conducted in accordance with SAE J576 JUL91, plastic materials

used for headlamp lenses shall:

(a) Have no loss of luminous transmittance of more than 25 percent

of the luminous transmittance of the unexposed control sample when

tested according to ASTM E 308-66 using CIE Illuminant A (2856K);

(b) Continue to conform to the color specification of achromatic

lens material contained in SAE J578 JUN95 for samples having the

thickness of the headlamp lens or greater;

and

(d) Show no physical changes affecting performance such as color

bleeding, delamination, crazing or cracking when compared visually to

unexposed samples.

S7.4.9 Exceptions to other performance requirements. A headlamp

with a glass lens need not meet the abrasion resistance test (S9.2). A

headlamp with a nonreplaceable lens need not meet the chemical and

corrosion resistance test of reflectors (S9.10). A headlamp with a

nonreplaceable glass lens need not meet the chemical resistance test

(S9.3). A headlamp with a glass lens and a non-plastic reflector need

not meet the internal heat test of S9.6.2. A headlamp of sealed design

as verified in S9.9 (sealing) need not meet the dust, humidity or

corrosion resistance requirements of S7.4.8, except that it must meet

the corrosion resistance requirement for terminals in S7.4.8.3.

S7.4.10 Incorporation of non-headlamp light sources. An integral

beam headlamp may incorporate replaceable light sources that are used

for purposes other than headlighting.

S7.5 Replaceable light source headlamp systems. Each replaceable

light source headlamp system shall use replaceable light sources

complying with S7.6, or a combination at each side of fixed light

sources and complying replaceable light sources, and it shall be

designed to conform to the following requirements:

S7.5.1 Photometric requirements. The system shall provide in total

not more than two upper beams and two lower beams and shall incorporate

not more than two replaceable light sources in each headlamp of a two-

headlamp system nor more than one replaceable light source in each

headlamp of a four-headlamp system. The color of the emanating light

produced by a headlamp shall be white as specified in SAE J578 JUN95.

The photometric performance specified in S7.5.1.1 and S7.5.1.2

(depicted in Figure 26) shall be obtained using any complying

replaceable light source of the type intended for use in such system.

S7.5.1.1 Four-headlamp systems. Each upper beam headlamp and each

lower beam headlamp of a four-headlamp system shall be designed to

conform to the photometrics of one of the following:

(a) Figure 15, or

(b) Figures 15 or 27 if the system uses only light sources of types

HB1 or HB5.

S7.5.1.2 Two-headlamp systems. Each headlamp in a two-headlamp

system shall be designed to conform to the photometrics of one of the

following:

(a) Figure 17, or

(b) Figures 17 or 27 if the system uses only light sources of types

HB1 or HB5.

S7.5.2 Photometric test procedure. Each replaceable light source

headlamp system shall be designed to conform to the applicable

photometric performance requirements of S7.5.1 (rather than Table 3 of

SAE J1383 DEC96) when tested in accordance with the test procedures of

Paragraphs 5.1 and 5.1.4 of SAE Standard J1383 DEC96. Unless stated

otherwise, a tolerance of \1/4\ degree is permitted during

photometric performance tests for any headlamp. The test points 10U-90U

shall be measured in a horizontal range 45R to 45L from the normally

exposed surface of the lens face. Luminous intensities in this upper

region may exceed the limits contained in S7.5.1 if they are confined

within a 2-degree conical angle and do not exceed 438 cd. The term

``aiming plane'' means ``aiming reference plane,'' or an appropriate

vertical plane defined by the manufacturer as required in S8.1.

S7.5.3 Arrangement and marking of upper and lower beams.