[Federal Register Volume 61, Number 244 (Wednesday, December 18, 1996)]
[Notices]
[Pages 66745-66746]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-32029]


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DEPARTMENT OF TRANSPORTATION
[Docket No. 96-124; Notice 1]


Philips Lighting Company, U.S.A.; Receipt of Application for 
Decision of Inconsequential Noncompliance

    Philips Lighting Company (PLC) has determined that certain of its 
Model 9004 replacement halogen headlamp bulbs fail to comply with the 
requirements of 49 CFR 571.108, Federal Motor Vehicle Safety Standard 
(FMVSS) 108, ``Lamps, Reflective Devices and Associated Equipment,'' 
and has filed an appropriate report pursuant to 49 CFR part 573 
``Defect and Noncompliance Information Report.'' PLC has also applied 
to be exempted from the notification and remedy requirements of 49 
U.S.C. 30118(d) and 30120(h) on the basis that the noncompliance is 
inconsequential to motor vehicle safety.
    This notice of receipt of an application is published under 49 
U.S.C. 30118(d) and 30120(h) and does not represent any agency decision 
or other exercise of judgment concerning the merits of the application.
    Paragraph S5.1.1 of FMVSS No. 108 states in part that lamps, 
reflective devices, and associated equipment specified in Tables I and 
III and S7, as applicable, shall be designed to conform to the SAE 
Standards or Recommended Practices referenced in those tables. Table I 
applies to multipurpose passenger vehicles, trucks, trailers, and 
buses, 80 or more inches in overall width. Table III applies to 
passenger cars and motorcycles, and to multipurpose passenger vehicles 
trucks, trailers, and buses, less than 80 inches in overall width.
    PLC's description of the noncompliance follows:
    Some lamps have dimensions that do not comply with FMVSS No. 108 
Figures 3-1, 3-3 and 3-8 of FMVSS No. 108. Some lamps do not comply 
with Paragraph S9 of FMVSS 108 ``Deflection test for replaceable light 
sources.'' The noncompliance is caused by process variations at the 
supplier's manufacturing site. The dimensional noncompliance and the 
bulb deflection noncompliance are described in Exhibits ``A'' and ``B'' 
of the application. These exhibits reflect the results of test data 
identifying several deviations from the FMVSS No. 108 specification.
    PLC supported its application for inconsequential noncompliance 
with the following:
    ``Dimension K Low, Figure 3-1: The ``K'' low dimension defines the 
location of the low[er] beam filament within the lamp. In a random test 
sample, two lamps were found whose measurements

[[Page 66746]]

on this point were outside of the requirement by .002'' and .005'' 
respectively. This small deviation from the minimum limit is not 
material to any safety issue based upon PLC's experience with 
measurement of completed headlamp assemblies, which demonstrates that a 
deviation of this type and magnitude, will not affect safety. In fact, 
the condition is detectable only under precise testing conditions and 
is not even detectable by visual examination. The most likely 
consequence of the discrepancy--a problem with headlamp aim/beam 
quality--is more likely to be affected by other conditions, such as 
foreign debris (which can accumulate on seating plane surfaces during 
installation), automobile loading (a full trunk can significantly 
affect automobile alignment and alter headlamp aim), dirty headlamp 
lenses or weathering of headlamp lenses than by the failure to comply 
precisely with the standard. This may explain why PLC has not received 
any complaints from end users or state inspection agencies concerning 
conditions related to this deviation from the standard.
    ``Dimension V, Figure 3-1: This dimension defines the length of the 
9004 replacement lamp electrical terminals (pins). The terminals on 
some test lamps were found to be slightly below the minimum length 
requirement. However, all test lamps functioned properly and made good 
electrical contact with the automobile lighting system connectors. The 
electrical connectors locked in place as designed and no difficulty was 
encountered with installation or electrical operation. This 
noncompliance does not affect lamp operation or performance (i.e., aim 
or beam quality) and is thus inconsequential and not safety-related. 
Again, PLC has not received any complaints from any party concerning 
conditions related to this deviation from the standard.
    ``Dimension F, Figure 3-3: The ``F'' dimension defines the location 
of the terminal cavity in relation to the centerline of the lamp. Some 
test lamps had terminal cavities that were from .002'' to .012'' below 
the minimum specification for location. The cavity size (opening) is 
within specification limits in all respects. The automobile lighting 
system electrical connector fits into the cavity freely and locks in 
place as designed. This noncompliance does not affect headlamp system 
performance in any way (i.e., aim or beam quality), and PLC has not 
received any complaints from any party concerning conditions related to 
this deviation from the standard. Thus this deviation also has no 
adverse effect on safety and is inconsequential.
    ``Dimension J, Figure 3-3: This dimension defines the location of 
the lower electrical terminals (pins) in relation to the lamp 
centerline. One of the test lamps measured slightly above the upper 
specification limit for this characteristic. Since the ``R'' dimension 
and ``S'' dimension on the same lamp are within limits, the 
noncompliance could be related to measurement error or handling damage. 
However, all test lamps functioned properly and made good electrical 
contact with the automobile lighting system connectors. The electrical 
connectors locked in place as designed and no difficulty was 
encountered with installation or electrical operation. This 
noncompliance also does not affect lamp operation or performance (i.e., 
aim or beam quality), and PLC has not received any complaints from any 
party concerning conditions related to this deviation from the 
standard. This deviation also has no adverse effect on safety and is 
inconsequential.
    ``Bulb Deflection, Figure 3-8: PLC understands that the bulb 
deflection criteria for the 9004 replacement headlamp bulb are included 
in the FMVSS No. 108 to ensure that bulbs which are handled by 
automated or robotic insertion equipment are strong enough to withstand 
the stresses that such equipment may put on the bulb. PLC agrees that 
deflection criteria for bulbs inserted by automated/robotic equipment 
are necessary and the criteria defined by FMVSS No. 108 are reasonable 
for bulbs that are inserted by automated/robotic equipment. However, 
because PLC currently furnishes 9004 replacement headlamp bulbs for 
aftermarket use only, all 9004 replacement bulbs that PLC furnishes are 
installed by human beings. Manual insertion of the 9004 replacement 
bulb does not pose a risk that permanent deflection will result because 
of the much lower forces that are exerted on the bulb when robotic 
insertion is not involved.''
    ``When inserting a replacement bulb into the headlamp housing the 
glass bulb is placed through an opening in the back of the reflector 
which is approximately two times larger than the bulb diameter. During 
manual insertion, little to no force is placed on the glass bulb. Force 
during manual insertion is placed on the plastic base and not the glass 
bulb. Nor are there other sources of stress that can cause deflection 
of the bulb. Common road hazards such as large potholes cannot cause 
sufficient force to equal that required to permanently deflect the bulb 
(which is also called a ``burner'') * * *. While the bulb is in the 
headlamp housing, unacceptable permanent deflection can be caused only 
by force equal to that which would be experienced in a high speed 
collision. No bulbs exhibited deflection or distortion prior to the 
test or after manual insertion, confirming that this noncompliance is 
inconsequential and does not constitute a potential safety hazard for 
bulbs furnished to the aftermarket. PLC has not received any complaints 
from any party concerning conditions related to this deviation from the 
standard.''
    SAE Tolerances: PLC notes that the 1996 edition of the Society of 
Automotive Engineers (SAE) Ground Vehicle Lighting Standards Manual, 
specifically HS-34, provides for greater dimensional tolerances than 
those contained in FMVSS No. 108. At least two of those tolerances are 
relevant to PLC's Petition for Exemption, as they involve two of the 
dimensions for which PLC's 9004 replacement bulbs do not comply with 
FMVSS No. 108:

------------------------------------------------------------------------
            Dimension             FMVSS No. 108 Tol.       SAE Tol.     
------------------------------------------------------------------------
V (Fig. 3-1)....................  +/- 0.10 mm.......  +/- 0.50 mm.      
F (Fig. 3-3)....................  +/- 0.10 mm.......  +/- 0.15 mm''.    
------------------------------------------------------------------------

    Interested persons are invited to submit written data, views, and 
arguments on the application of PLC, described above. Comments should 
refer to the docket number and be submitted to: Docket Section, 
National Highway Traffic Safety Administration, Room 5109, 400 Seventh 
Street, SW, Washington, D.C., 20590. It is requested but not required 
that six copies be submitted.
    All comments received before the close of business on the closing 
date indicated below will be considered. The application and supporting 
materials, and all comments received after the closing date, will also 
be filed and will be considered to the extent possible. When the 
application is granted or denied, the notice will be published in the 
Federal Register pursuant to the authority indicated below.
    Comment closing date: January 17, 1997.

(49 U.S.C. 30118 and 30120, delegations of authority at 49 CFR 1.50 
and 501.8)

    Issued on: December 11, 1996.
L. Robert Shelton,
Associate Administrator for Safety Performance Standards.
[FR Doc. 96-32029 Filed 12-17-96; 8:45 am]
BILLING CODE 4910-59-P