[Federal Register Volume 63, Number 218 (Thursday, November 12, 1998)]
[Proposed Rules]
[Pages 63258-63276]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 98-29921]


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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.
    (c) Titles will be used for subparagraphs and higher level 
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,
    (c) revising S5.5.10(c) and S5.510(d),
    (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 * * *
    (c) A motorcycle headlamp may be wired to allow either its upper 
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.
    (c) When activated in a steady-burning state, headlamps shall not 
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.
    (c) Each headlamp and beam contributor to which S7.2.1(a) applies 
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
    (c) One half of any headlighting system specified in S7.4 or S7.5 
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.
    (c) When the headlamps are secured, the aim will not be disturbed 
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.
    (c) The lowest intensity at any test point shall be not less than 
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
    (c) Figure 28;
    (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;
    (c) Show no deterioration regarding haze when evaluated visually, 
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.
    (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'' and the upper beam headlamp 
lens shall be permanently marked with the letter ``U''.
    (c) The lens of each replaceable light source headlamp shall bear 
permanent marking in front of each replaceable light source with which 
it is equipped that states the HB Type or the bulb marking/designation 
provided in compliance with Section VIII of Appendix A or Section VI of 
Appendix B of part 564 of this chapter.
    S7.5.4  Aimability. The system shall be aimable in accordance with 
the requirements of S8. Headlamps designed to conform to the external 
mechanical aiming requirements of S8.3 shall have no mechanism that 
allows adjustment of an individual light source, or, if there are two 
light sources, independent adjustment of each reflector.
    S7.5.5  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.
    S7.5.6  Replacement lens-reflector units. Each lens reflector unit 
manufactured as replacement equipment shall be designed to conform to 
the requirements of S7.5.1 when any replaceable light source 
appropriate for such unit is inserted in it.
    S7.5.7  Other performance requirements. Each headlamp shall meet 
the requirements of S7.4.8 and S7.4.9, except that the sentence in 
S7.4.9 granting exceptions to the corrosion, dust and humidity test 
requirements for sealed headlamps does not apply.
    S7.5.8  Incorporation of non-headlamp light sources. A replaceable 
bulb headlamp may incorporate replaceable light sources that are used 
for purposes other than headlighting.
    S7.6  Replaceable light sources. Each replaceable light source 
shall be designed to conform to the dimensions and electrical 
specifications furnished with respect to it pursuant to part 564 of 
this chapter, and shall conform to the following requirements:
    S7.6.1  Color. When the replaceable light source of any complying 
headlamp

[[Page 63268]]

is replaced with a complying light source having a compatible base, the 
color of the light produced by the headlamp shall remain white as 
specified in SAE J578 JUN95.
    S7.6.2  Test of luminous flux and power. The measurements of 
maximum power and luminous flux that are submitted in compliance with 
Appendix A or Appendix B of part 564 of this chapter, shall be made 
with the direct current test voltage regulated within one quarter of 
one percent. The test voltage shall be 12.8v. The measurement of 
luminous flux shall be in accordance with the Illuminating Engineering 
Society of North America, LM 45; IES Approved Method for Electrical and 
Photometric Measurements of General Service Incandescent Filament Lamps 
(April 1980). The replaceable light source shall be seasoned before 
such measurement.
    (a) For a light source with a resistive element type filament, 
seasoning of the light source shall be made in accordance with 
paragraph 3.8 of SAE Standard J1383 DEC96 Performance Requirements for 
Motor Vehicle Headlamps. The measurement of luminous flux shall be made 
with the black cap installed on Type HB1, Type HB2, Type HB4, and Type 
HB5 light sources, and on any other replaceable light source so 
designed, and shall be made with the electrical conductor and light 
source base shrouded with an opaque white colored cover, except for the 
portion normally located within the interior of the lamp housing. The 
measurement of luminous flux for Type HB3 and Type HB4 shall be made 
with the base covered with the white cover shown in the drawings for 
Types HB3 and HB4 filed in Docket No. NHTSA 98-3397. The white covers 
are used to eliminate the likelihood of incorrect lumens measurement 
that will occur should the reflectance of the light source base and 
electrical connector be low.
    (b) For a light source using excited gas mixtures as a filament or 
discharge arc, seasoning of the light source system, including any 
ballast required for its operation, shall be made in accordance with 
paragraph 4.0 of SAE Recommended Practice J2009 FEB93 Discharge Forward 
Lighting Systems. With the test voltage applied to the ballast input 
terminals, the measurement of luminous flux shall be made with the 
black cap installed, if so designed, and shall be made with the base 
covered with an opaque white colored cover, except for the portion 
normally located within the interior of the lamp housing.
    S7.6.3  Test of seal airtightness. The capsule, lead wires and/or 
terminals, and seal on each Type HB1, Type HB3, Type HB4, and Type HB5 
light source, and on any other replaceable light source which uses a 
seal, shall be installed in a pressure chamber as shown in Figure 25 so 
as to provide an airtight seal. The diameter of the aperture in Figure 
25 on a replaceable light source (other than an HB Type) shall be that 
dimension furnished for such light source in compliance with Section 
IV.B of Appendix A or Section III.B of Appendix B of part 564 of this 
chapter. An airtight seal exists when no air bubbles appear on the low 
pressure (connector) side after the light source has been immersed in 
water for one minute while inserted in a cylindrical aperture specified 
for the light source, and subjected to an air pressure of 70kPa (10 
P.S.I.G.) on the glass capsule side.
    7.6.4  Deflection resistance requirement. After the force 
deflection test conducted in accordance with S7.6.5, the permanent 
deflection of the glass envelope shall not exceed 0.13 mm (0.005 in) in 
the direction of the applied force.
    S7.6.5  Deflection test. With the light source rigidly mounted in a 
fixture in a manner indicated in Figure 8, a force of 17.8  
0.4N (4.0  0.1 lb) is applied at a distance ``A'' from the 
reference plane perpendicular to the longitudinal axis of the glass 
capsule and parallel to the smallest dimension of the pressed glass 
capsule seal. The force shall be applied (using a rod with a hard 
rubber tip with a minimum spherical radius of 1 mm (0.039 in) radially 
to the surface of the glass capsule in four locations in a plane 
parallel to the reference plane and spaced at a distance ``A'' from 
that plane. These force applications shall be spaced 90 degrees apart 
starting at the point perpendicular to the smallest dimension of the 
pressed seal of the glass capsule. The bulb deflection shall be 
measured at the glass capsule surface at 180 degrees opposite to the 
force application. Distance `A' for a replaceable light source other 
than an HB Type shall be the dimension provided in accordance with 
Appendix A of part 564 of this chapter.
    7.6.6  Rated laboratory life of discharge type light sources. The 
``rated laboratory life'' that is submitted in compliance with Appendix 
B of Part 564 of this chapter shall be determined in accordance with 
paragraphs 4.3 and 4.9 of SAE Recommended Practice J2009 FEB93 Forward 
Discharge Lighting Systems for light sources that use excited gas 
mixtures as a filament or discharge arc.
    7.6.7  Marking requirements for light sources. The base of each HB 
Type shall be marked with its HB Type designation. If other than an HB 
Type, the light source shall be marked with the bulb marking 
designation specified for it in compliance with Appendix A or Appendix 
B of part 564 of this chapter. Each replaceable light source shall also 
be marked with the symbol DOT and with a name or trademark in 
accordance with S7.2.
    7.6.8  Marking requirements for ballast devices. If a ballast is 
required for light source operation, each ballast shall bear the 
following permanent markings:
    (a) Name or logo of ballast manufacturer;
    (b) Ballast part number or unique identification;
    (c) Part number or other unique identification of the light source 
for which the ballast is designed;
    (d) Rated laboratory life of the light source/ballast combination, 
if the information for the light source has been filed in Appendix B of 
part 564 of this chapter;
    (e) A warning that ballast output voltage presents the potential 
for severe electrical shock that could lead to permanent injury or 
death;
    (f) Ballast output power in watts and output voltage in volts DC or 
root mean squared volts AC; and
    (g) The symbol `DOT'.
    S7.7  Special wiring requirements.
    S7.7.1  Headlamp beam switching. Each vehicle shall have a means of 
switching between lower and upper beams designed and located so that it 
may be operated conveniently by a simple movement of the driver's hand 
or foot. The switch shall complete the circuit for one beam before 
opening the circuit for the other beam to avoid transient points in 
which neither beam is powered. A blue or green upper beam indicator 
light shall be provided, with a minimum area equivalent to that of a 
4.75 mm (3/16 in) diameter circle, plainly visible to drivers of all 
heights under normal driving conditions when headlamps are required.
    S7.7.2  Semi-automatic headlamp beam switching. As an alternative 
to S7.7.1, a vehicle may be equipped with semi-automatic means of 
switching between lower and upper beams that conforms to SAE 
Recommended Practice J565 JUN89, Semi-Automatic Headlamp Beam Switching 
Devices.
    S7.7.3  Prohibition against simultaneous upper and lower beam use. 
Except as provided in S7.7.4, the wiring harness or connector assembly 
of each headlamp system shall be designed so that only those light 
sources intended for meeting lower beam photometrics are energized when 
the beam selector

[[Page 63269]]

switch is in the lower beam position, and that only those light sources 
intended for meeting upper beam photometrics are energized when the 
beam selector switch is in the upper beam position. Except as provided 
in S7.7.4, the lower and upper beams shall not be energized 
simultaneously except momentarily for temporary signaling purposes or 
during switching between beams.
    S7.7.4  Exceptions to simultaneous beam prohibition.
    S7.7.4(a) On a motor vehicle equipped with a headlighting system 
designed to conform to the photometric requirements of Figure 15-1 or 
15-2, the lower beam lamps may be wired to remain activated when the 
upper beam lamps are activated.
    (b) On a motor vehicle equipped with an Integral Beam headlighting 
system meeting the photometric requirements of S7.4.1.1(b), the lower 
beam headlamps shall be wired to remain permanently activated when the 
upper beam headlamps are activated.
    (c) On a motor vehicle equipped with a headlighting system designed 
to conform to the requirements of Figure 17-1 or 17-2, a lower beam 
light source may be wired to remain activated when an upper beam light 
source is activated if the lower beam light source contributes to 
compliance of the headlighting system with the upper beam requirements 
of Figure 17-1 or 17-2.
    (d) Lower beam headlamps may be wired to activate upon failure of 
an upper beam headlamp, regardless of the position of the beam selector 
switch.
    S7.7.5  Flashing. Headlamps and side marker lamps may be wired to 
flash for signaling purposes;
    S7.7.6  Motorcycle headlamp beam modulation. A motorcycle headlamp 
may be wired to allow either its upper beam or its lower beam, but not 
both, to modulate between a higher intensity and a lower intensity in 
accordance with S7.3.4.
    S8.  Headlamp aimability performance requirements.
    S8.0 The following is a table of contents for headlamp aimability 
performance requirements:

S8.1  General requirements
S8.2  Aiming reference features
S8.3  Headlamp mounting and aiming mechanism
S8.4  External mechanical aiming
S8.5  On-vehicle mechanical aiming (VHAD)
S8.6  Visual/optical aiming
S8.7  Replacement headlamps

    S8.1  General requirements. When a headlamp system is installed on 
a motor vehicle, it shall be aimable with at least one of the 
following: an externally applied mechanical aiming device, as specified 
in S8.4; an on-vehicle mechanical headlamp aiming device installed by 
the vehicle or lamp manufacturer, as specified in S8.5; or by visual/
optical means, as specified in S8.6. All of the headlamps within the 
system shall be aimable by the same means. An auxiliary vertical VHAD 
complying with S8.5 may be used on a headlamp complying with S8.6.
    S8.2  Aiming reference features
    (a) Each headlamp or beam contributor that is not visually/
optically aimable in accordance with S8.6 of this standard shall be 
equipped with fiducial marks, aiming pads, or similar references of 
sufficient detail and accuracy, for determination of an appropriate 
vehicle plane to be used with the photometric procedures of SAE J1383 
DEC96 for correct alignment with the photometer axis when being tested 
for photometric compliance, and to serve for the aiming reference when 
the headlamp or beam contributor is installed on a motor vehicle. The 
fiducial marks, aiming pads, or similar references are protrusions, 
bubble vials, holes, indentations, ridges, scribed lines, or other 
readily identifiable marks established and described by the vehicle or 
headlamp manufacturer.
    (b) Each motor vehicle manufactured on and after September 1, 1998, 
shall be equipped with headlamps or beam contributors which have a mark 
or markings that are visible from the front of the headlamp when 
installed on the vehicle to identify the optical axis of the headlamp 
to assure proper horizontal and vertical alignment of the aiming screen 
or optical aiming equipment. The manufacturer is free to choose the 
design of the mark or markings. The mark or markings may be on the 
interior or exterior of the lens or indicated by a mark or central 
structure on the interior or exterior of the headlamp. Examples of such 
marks include, but are not limited to: dots, circles or trademarks with 
an obvious center; marks on the periphery of the lens which can be 
converged accurately to the optical center; pointed bulb tips or 
circular light shields clearly visible through unfluted lenses if they 
coincide with the optical center. The shape of a round or rectangular 
headlamp intrinsically marks the center if its lens surface is 
symmetric about its beam axis.
    (c) Each headlamp that is visually/optically aimable in accordance 
with S8.6 of this standard shall be marked in accordance with S8.6.6.
    S8.3  Headlamp mounting and aiming mechanism. Except as provided in 
this paragraph, each headlamp shall be installed on a motor vehicle 
with a mounting and aiming mechanism that allows aim inspection and 
adjustment of both vertical and horizontal aim, and is accessible for 
those purposes without removal of any vehicle parts, except for 
protective covers removable without the use of tools.
    S8.3.1  Cross-axis sensitivity.
    (a) When installed on the vehicle, adjustment of one aim axis 
through its full on-vehicle range shall not cause the aim of the other 
axis to deviate more than 0.76 degree.
    (b) If the performance specified in S8.3.1(a) is not achievable, 
the labeling requirements of S8.5.3(c) apply, except that if the aiming 
mechanism is not a VHAD, the requirements specific to VHADs are not 
applicable, and the instructions shall be specific to the aiming 
mechanism installed.
    (c) A visually/optically aimable headlamp that has a lower beam 
shall not have a horizontal adjustment mechanism unless such mechanism 
meets the on-vehicle aiming requirements of S8.4 of this standard.
    S8.3.2  Aim adjustment range.
    (a) When a headlamp system is tested in a laboratory, the range of 
its vertical aim shall not be less than 4 degrees from the 
nominal correct aim position for the intended vehicle application. When 
installed on a motor vehicle, the range of vertical aim shall be not 
less than the full range of pitch of the vehicle on which the headlamp 
system is installed. The installed range of static pitch angle shall as 
a minimum be determined from unloaded vehicle weight to gross vehicle 
weight rating, and incorporate pitch angle effects from maximum trailer 
or trunk loadings, the full range of tire intermix sizes and 
suspensions recommended and/or installed by the vehicle manufacturer, 
and the anticipated effects of variable passenger loading. The vertical 
aim adjustment mechanism shall be continuously adjustable over the full 
range.
    (b) When a headlamp system is tested in a laboratory, the range of 
its horizontal aim shall be not less than 2.5 degrees from 
the nominal correct aim position for the intended vehicle application.
    S8.3.3  Mechanisms with independent reflector movement. If the 
headlamp is aimed by moving the reflector relative to the lens and 
headlamp housing, or vice versa, it shall:
    (a) allow movement of the headlamp system, when tested in the 
laboratory, to be not less than the full range of pitch on the vehicle 
on which the headlamp system is installed and for the horizontal aim 
range limits of S8.3.2(b),

[[Page 63270]]

    (b) conform with the photometrics applicable to it with the lens at 
any position relative to the reflector within the range limits as 
specified in S8.3.3(a)
    (c) be exempted from the 4 degree vertical aim range 
for laboratory testing of S8.3.2(a), and
    (d) be exempted from the 2.5 degree horizontal aim 
range of S8.3.2(b) if it is visually/optically aimable and has fixed 
horizontal aim.
    S8.4  External Mechanical aiming. Each headlamp system that is 
capable of being mechanically aimed by externally applied headlamp 
aiming devices shall be mechanically aimable using the equipment 
specified in SAE Standard J602 DEC89 Headlamp Aiming Device for 
Mechanically Aimable Headlamp Units without the removal of any 
ornamental trim rings, covers, wipers or other vehicle parts. The 
torque deflection test of S8.4.1 assures that headlamps designed for 
external aiming are mounted to the vehicle in a manner sufficiently 
rigid to prevent aiming errors as a consequence of the weight of the 
headlamp aiming device. The inward force test limits the influence of 
aerodynamic forces on headlamp aim.
    S8.4.1  Torque deflection test. The aim of the headlamps in each 
headlamp system that is designed to use such external aiming devices, 
shall not deviate more than 0.30 degree when a torque of 2.25 N-m (20 
in-lb), applied about a horizontal axis in the aiming reference plane, 
is removed from the headlamp in its design operating position. The 
downward force used to create the torque shall be applied parallel to 
the aiming reference plane, through the aiming pads, and displaced 
forward using a lever arm that is perpendicular to the aiming reference 
plane and originates at the center of the aiming pad pattern (see 
Figures 4-1 and 4-3). For headlamps using the aiming pad locations of 
Group l, the distance between the point of application of force and the 
aiming reference plane shall be not less than 168.3 mm (6.625 in.) plus 
the distance from the aiming reference plane to the secondary plane, if 
used (see S8.3.4(a)). For headlamps using the aiming pad locations of 
Group II, the distance between the point of application of force and 
the aiming reference plane shall be not less than 167.9 mm (6.609 in) 
plus the distance from the aiming reference plane to the secondary 
plane, if used. For headlamps using the nonadjustable Headlamp Aiming 
Device Locating Plates for the 146 mm diameter, the 176 mm diameter, 
and the 92x150 mm sealed beam units, the distance between the point of 
application of force and the aiming plane shall, respectively, be not 
less than 177.4 mm (6.984 in), 176.2 mm (6.937 in), and 193.7 mm (7.625 
in). For types A, B, C, D, E, F, G and H sealed beam headlamps the 
force shall be applied using the appropriate deflectometer described in 
SAE J1383 DEC96.
    S8.4.2  Inward force test. When a headlamp is installed on a motor 
vehicle, its aim in any direction shall not change by more than 0.30 
degree nor shall the lamp recede more than 2.5 mm (0.1 in) after being 
subjected to an inward force of 222N (50 lb) applied evenly to the lens 
parallel to the optical axis.
    S8.4.3  Corrosion test. The mounting and aiming mechanism of each 
headlamp system shall be subjected to a salt spray (fog) test in 
accordance with ASTM B117-73 Method of Salt Spray (Fog) Testing for a 
period of 50 hours, consisting of two successive 25-hour periods of 24 
hours exposure followed by 1 hour of drying. At the end of 50 hours, 
the headlamp system shall be capable of meeting any of the applicable 
requirements of S8.
    S8.4.4  Lens marking for use of adjustable aimer locating plate. 
Each headlamp system which is designed to use the type of Headlamp 
Aiming Device Locating Plates which uses adjustable length legs for the 
100 x 165 mm unit and the 142 x 200 mm unit shall meet the requirements 
of S8.4.4 (a) and (b).
    (a) The lens shall have three aiming pads which meet the 
requirements of Figure 4, Dimensional Specifications for Location of 
Aiming Pads on Replaceable Bulb Headlamp Units. The aiming pads need 
not be centered at the geometric center of the lens, or on the optical 
axis. Except as provided in subparagraph S8.4.4(b), a whole number, 
which represents the distance in tenths of an inch (i.e., 0.3 inch = 3) 
from the aiming reference plane to the respective aiming pads which are 
not in contact with that plane, shall be inscribed adjacent to each 
respective aiming pad on the lens. The height of these numbers shall be 
not less than 4 mm (0.157 in). If there is interference between the 
plane and the area of the lens between the aiming pads, the whole 
number represents the distance to a secondary plane. The secondary 
plane shall be located parallel to the aiming reference plane and as 
close to the lens as possible without causing interference.
    (b) If the most forward aiming pad is the lower inboard aiming pad, 
then the dimensions may be placed anywhere on the lens. The dimension 
for the outboard aiming pad (Dimension F in Figure 4) shall be followed 
by the letter ``H'' and the dimension for the center aiming pad shall 
be followed by the letter ``V.'' The dimensions shall be expressed in 
tenths of an inch.
    S8.4.5  Nonadjustable aimer locating plate. Each headlamp may be 
designed to use the nonadjustable Headlamp Aiming Device Locating Plate 
for the 100 x 165 mm unit, the 142 x 200 mm unit, the 146 mm diameter 
unit, the 178 mm diameter unit, or the 92 x 150 mm unit of SAE J602 
DEC89 and incorporate lens mounted aiming pads or other aimimg plane 
locators as specified for those units in Figures 27, 21, 22, 25 or 23 
respectively in SAE J1383 DEC96. If so designed, no additional lens 
marking is necessary to designate the type of plate or dimensions.
    S8.5  On-vehicle mechanical aiming (VHAD). Each headlamp system 
that is capable of being aimed by mechanical equipment installed on the 
vehicle shall include a Vehicle Headlamp Aiming Device (VHAD), 
providing for headlamp aim inspection and adjustment in both the 
vertical and horizontal axes, that conforms to the following 
requirements:
    S8.5.1  Vertical aim. The VHAD shall include the necessary 
references and scales relative to the horizontal plane to assure 
correct vertical aim for photometry and aiming purposes. An off-vehicle 
measurement of the angle of the plane of the ground is permitted. In 
addition, an equal number of graduations from the ``0'' position 
representing angular changes in the axis in the upward and downward 
directions shall be provided.
    (a) Each graduation shall represent a change in the vertical 
position of the mechanical axis not larger than 0.19 degree (2.54 mm at 
7.61 m ( 1 in. at 25 ft)) to provide for variations in aim at least 1.2 
degrees above and below the horizontal, and have an accuracy relative 
to the zero mark of less than 0.1 degree.
    (b) The VHAD shall be marked to indicate headlamp aim movement in 
the upward and downward directions.
    (c) Each graduation shall indicate a linear movement of the scale 
indicator of not less than 1.27 mm (0.05 in) if a direct reading analog 
indicator is used. If a remote reading indicator is provided, it shall 
represent the actual aim movement in a clear, understandable format.
    (d) The vertical indicator shall perform through a minimum range of 
1.2 degrees.
    (e) Means shall be provided in the VHAD for compensating for 
deviations in floor slope less than 1.2 degrees from the horizontal 
that would affect the correct positioning of the headlamp for vertical 
aim.

[[Page 63271]]

    (f) The graduations shall be legible under an illumination level 
not greater than 30 foot-candles, measured at the top of the 
graduation, by an observer having 20/20 vision (Snellen), and shall 
permit aim adjustment to within 0.19 degree (25.4 mm at 7.61 m (1 in. 
at 25 ft)).
    S8.5.2  Horizontal aim. The VHAD shall include references and 
scales relative to the longitudinal axis of the vehicle necessary to 
assure correct horizontal aim for photometry and aiming purposes. An 
``0'' mark shall be used to indicate alignment of the headlamps 
relative to the longitudinal axis of the vehicle. In addition, an equal 
number of graduations from the ``0'' position representing equal 
angular changes in the axis relative to the vehicle axis shall be 
provided.
    (a) Each graduation shall represent a change in the horizontal 
position of the mechanical axis not greater than 0.38 degree (51 mm at 
7.61 m (2 in. at 25 ft)) to provide for variations in aim at least 0.76 
degree (102 mm at 7.61 m (4 in. at 25 ft.)) to the left and right of 
the longitudinal axis of the vehicle, and shall have an accuracy 
relative to the zero mark of less than 0.1 degree.
    (b) The VHAD shall be marked to indicate headlamp aim movement in 
the left and right directions.
    (c) The graduations shall be legible under an illumination level 
not greater than 30 foot-candles, measured at the top of the 
graduation, by an observer having 20/20 vision (Snellen), and shall 
permit aim adjustment to within 0.38 degree (51 mm at 7.61 m (2 in. at 
25 ft.)).
    (d) The horizontal indicator shall perform through a minimum range 
of 0.76 degree (102 mm at 7.61 m (4 in. at 25 ft.)); 
however, the indicator itself shall be capable of recalibration over a 
movement of 2.5 degrees relative to the longitudinal axis 
of the vehicle to accommodate any adjustment necessary for 
recalibrating the indicator after vehicle repair from accident damage.
    S8.5.3  Aiming labels and instructions.
    (a) The instructions for properly aiming the headlighting system 
using the VHAD shall be provided on a label permanently affixed to the 
vehicle adjacent to the VHAD, or in the vehicle operator's manual. The 
instructions shall advise that the headlighting system is properly 
aimed if the appropriate vertical plane (as defined by the vehicle 
manufacturer) is perpendicular to both the longitudinal axis of the 
vehicle, and a horizontal plane when the vehicle is on a horizontal 
surface, and the VHAD is set at ``O'' vertical and ``O'' horizontal.
    (b) Should a remote indicator or a remote indicator and adjuster be 
provided, the instructions shall be placed in the operator's manual, 
and may also be placed on a label adjacent to the VHAD.
    (c) Should the mechanism not meet the requirements of S8.3.1, a 
cautionary label shall be placed adjacent to the mechanism stating the 
caution and including either the reason for the caution or the 
corrective action necessary. Each such label shall also refer the 
reader to the vehicle operator's manual for complete instructions. Each 
such vehicle shall be equipped with an operator's manual containing the 
complete instructions appropriate for the mechanism installed.
    S8.5.4  Fixed VHAD calibration. Each headlamp equipped with a VHAD 
that is manufactured for use on motor vehicles manufactured on or after 
September 1, 1998, shall be manufactured with the geometry of the VHAD 
devices permanently aligned with the beam pattern.
    S8.5.5  Testing the VHAD.
    S8.5.5.1  The headlamp assembly (the headlamp(s) and the VHAD(s)) 
shall be mounted on a level goniometer, aligned to a photometer located 
not less than 18.3 m (60 ft) from the VHAD assembly. The assembly shall 
be mechanically aimed using the VHAD in accordance with the 
manufacturer's instructions as provided with the vehicle on which the 
VHAD is intended to be used. A \1/4\ degree re-aim is permitted in any 
direction at any test point to allow for variations in readings between 
laboratories. The test shall be conducted in accordance with the 
photometry test procedures of paragraphs 5.1 and 5.1.4 of SAE J1383 
DEC96. Under these conditions the mounted headlamp assembly shall be 
designed to conform to the photometric requirements appropriate for the 
headlamp system under test.
    S8.5.5.2  When tested in accordance with S8.5.5.1, with any 
complying replacement headlamp unit(s) or complying light sources 
intended for use in the system under test, the VHAD and headlamp system 
shall be designed to conform to the photometric performance 
requirements appropriate for the system under test.
    S8.5.5.3  With the same VHAD and associated headlamp(s) (or 
headlamp assembly) rigidly mounted in a headlamp test fixture, each 
graduation on the horizontal and vertical aim scales shall be checked 
and any variation from the correct aim shall not exceed 0.2 
degree, and 0.1 degree respectively.
    S8.5.5.4  The calibration of the VHAD shall be maintained under the 
following test conditions. The aimer shall be adjusted before each of 
the following tests to assure that the indicators are centered at 0 
with the aiming plane horizontal and vertical and with the scale on the 
device set at 0.
    (a) The VHAD and an unlighted headlamp assembly shall be stabilized 
at -7 3 degrees C (20 5 degrees F) in a 
circulating air environmental test chamber. After a period of 30 
minutes, when measured at that soak temperature, the variation from 
correct horizontal or vertical aim shall not exceed 0.2 
degree, and 0.1 degree, respectively.
    (b) The VHAD, and the headlamp assembly with it highest wattage 
filament (or combination of filaments intended to be used 
simultaneously) energized at its design voltage, shall then be 
stabilized at 38 3 degrees C (100 5 degrees F) 
in a circulating air environmental test chamber. After a period of 30 
minutes, when measured at that soak temperature, the variation from 
correct horizontal and vertical aim shall not exceed 0.2 
degree, and 0.1 degree, respectively.
    (c) The VHAD and an unlighted headlamp assembly shall then be 
placed in a circulating air environmental test chamber and exposed to a 
temperature of 60 3 degrees C (140 5 degrees F) 
for 24 hours, followed by a temperature of -40 5 degrees C 
(-40 3 degrees F) for 24 hours and then permitted to return 
to room temperature, after which the VHAD and headlamp assembly shall 
show no damage which would impair its ability to perform as specified 
herein. The variation from correct horizontal or vertical aim shall not 
exceed 0.2 degree, and 0.1 degree, 
respectively.
    S8.5.5.5  The same VHAD and headlamp assembly shall then be tested 
according to the corrosion test procedure of S8.5.3.
    S8.5.5.6  The same VHAD and headlamp assembly shall then be tested 
for photometric compliance as specified in S8.5.5.1 and S8.5.5.2.
    S8.6  Visual/optical aiming. Each visually/optically aimable 
headlamp shall be designed to conform to the following requirements:
    S8.6.1  Vertical aim, lower beam. Each lower beam headlamp shall 
have a cutoff in the beam pattern. It may be either on the left side or 
the right side of the optical axis, but once chosen for a particular 
headlamp system's design, the side chosen for the cutoff shall not be 
changed for any headlamps intended to be used as replacements for those 
system's headlamps.
    S8.6.1.1  Vertical position of cutoff: The headlamp shall be aimed 
vertically

[[Page 63272]]

so that the cutoff is on the left side, at 0.4 degree down from the H-H 
line, or on the right side, at the H-H line.
    S8.6.1.2  Vertical gradient: The gradient of the cutoff measured at 
either 2.5 degrees L or 2.0 degrees R shall be not less than 0.13 based 
on the procedure of S8.5.1.5.
    S8.6.1.3  Horizontal position of the cutoff: The width shall be not 
less than two degrees, with not less than two degrees of its actual 
width centered at either 2.5 degrees L, or 2.0 degrees R.
    S8.6.1.4  Maximum inclination of cutoff: The vertical location of 
the highest gradient at the ends of the minimum width shall be within 
0.2 degree of the vertical location of the maximum gradient 
measured at the appropriate vertical line (at either 2.5 degrees L for 
a left-side cutoff, or 2.0 degrees R for a right-side cutoff.)
    S8.6.1.5  Measuring the cutoff parameter:
    (a) The headlamp shall be mounted on a fixture which simulates its 
actual design location on any vehicle for which the headlamp is 
intended. The fixture, with the headlamp installed shall be attached to 
the goniometer table in such a way that the fixture alignment axes are 
coincident with the goniometer axes. The headlamp shall be energized at 
the specified test voltage.
    (b) The headlamp beam pattern shall be aimed with the cutoff at the 
H-H axis. There shall be no adjustment, shimming, or modification of 
the horizontal axis of the headlamp or test fixture, unless the 
headlamp is equipped with a VHAD. In this case the VHAD shall be 
adjusted to zero.
    (c) A vertical scan of the beam pattern shall be conducted for a 
headlamp with a left-side gradient by aligning the goniometer on a 
vertical line at 2.5 degrees L and scanning from 1.5 degrees U to 1.5 
degrees D. For a headlamp with a right-side gradient, a vertical scan 
of the beam pattern shall be conducted by aligning the goniometer on a 
vertical line at 2.0 degrees R and scanning from 1.5 degrees U to 1.5 
degrees D.
    (d) Determine the maximum gradient within the range of the scan by 
using the formula: G = log E()-log E(+0.1), where 
``G'' is the gradient, ``E'' is illumination and ``'' is 
vertical angular position. The maximum value of the gradient ``G'' 
determines the vertical angular location of the cutoff. Perform 
vertical scans at 1.0 degree L and R of the measurement point of the 
maximum gradient to determine the inclination.
    S8.6.2  Horizontal aim, lower beam. There shall be no adjustment of 
horizontal aim unless the headlamp is equipped with a horizontal VHAD. 
If the headlamp has a VHAD, it shall be set to zero.
    S8.6.3  Vertical aim, upper beam.
    (a) If the upper beam is combined in a headlamp with a lower beam, 
the vertical aim of the upper beam shall not be changed from the aim 
set using the procedures of S8.6.1 and S8.6.2 used for the lower beam.
    (b) If the upper beam is not combined in a headlamp with a lower 
beam, the vertical aim of the upper beam shall be adjusted so that the 
maximum beam intensity is located on the H-H axis.
    S8.6.4  Horizontal aim, upper beam.
    (a) If the upper beam is combined in a headlamp with a lower beam, 
the horizontal aim of the upper beam shall not be changed from the aim 
set using the procedures of S8.6.1 and S8.6.2 used for the lower beam.
    (b) If the upper beam is not combined in a headlamp with the lower 
beam and has fixed horizontal aim or has a horizontal VHAD, then the 
headlamp shall be mounted on a fixture which simulates its actual 
design location on any vehicle for which the headlamp is intended. The 
fixture, with the headlamp installed shall be attached to the 
goniometer table in such a way that the fixture alignment axes are 
coincident with the goniometer axes. The headlamp shall be energized at 
12.8 V 20 mV. There shall be no adjustment, shimming, or 
modification of the horizontal axis of the headlamp or test fixture, 
unless the headlamp is equipped with a VHAD. In this case the VHAD 
shall be adjusted to zero.
    (c) If the upper beam is not combined in a headlamp with a lower 
beam, and it does not have a VHAD, the horizontal aim of the upper beam 
shall be adjusted so that the maximum beam intensity is located on the 
V-V axis.
    S8.6.5  Photometric Requirements and Measurement:
    (a) Instead of being designed to conform to the photometric 
requirements of Figures 15-1, 17-1, 27-1 or 28-1, a visually/optically 
aimable headlamp shall be designed to conform to the requirements of 
Figures 15-2, 17-2, 27-2 or 28-2 when tested in accordance with S8.6.5 
(b) and SAE J575 JUN92, with the distance from the photometer to the 
headlamp no less than 18.3 m (60 ft).
    (b) If the lower beam has a left side cutoff, reaim the headlamp 
vertically to place the maximum gradient found in S8.5 at 0.4 degree 
below the H-H line. For a headlamp with a lower beam right side cutoff, 
place the maximum gradient found in S8.5 at the H-H line. For an upper 
beam, the headlamp would already be aimed at the end of the procedure 
found in S8.5. A 0.25 degree reaim is permitted in any direction at any 
test point.
    S8.6.6  Marking.
    S8.6.6.1  Headlamp optical axis mark. There shall be a mark or 
markings identifying the optical axis of the headlamp visible from the 
front of the headlamp when installed on the vehicle, to assure proper 
horizontal and vertical alignment of the aiming screen or optical 
aiming equipment with the headlamp being aimed. The manufacturer is 
free to choose the design of the mark or markings. The mark or markings 
may be on the interior or exterior of the lens or indicated by a mark 
or central structure on the interior or exterior of the headlamp.
    S8.6.6.2  Visual/optical aimability identification marks.
    (a) The lens of a lower beam headlamp shall be marked ``VOL'' if 
the headlamp is intended to be visually/optically aimed using the left 
side of the lower beam pattern.
    (b) The lens of a lower beam headlamp shall be marked ``VOR'' if 
the headlamp is intended to be visually/optically aimed using the right 
side of the lower beam pattern.
    (c) The lens of each sealed beam or integral beam headlamp shall be 
marked ``VOR'' if the headlamp is of a type that was manufactured 
before March 1, 1997, and if such headlamp type has been redesigned 
since then to be visually/optically aimable.
    (d) The lens of a headlamp that is solely an upper beam headlamp 
and intended to be visually/optically aimed using the upper beam shall 
be marked ``VO''.
    (e) Each letter used in marking according to this paragraph shall 
be not less than 3 mm. (0.118 in) high.
    S8.7  Replacement headlamps.
    S8.7.1  If a headlamp using visual/optical aim or a VHAD is offered 
as a replacement for a headlamp using external mechanical aim, it shall 
have the same pattern of aiming pads as the original headlamp.
    S8.7.2  A headlamp using visual/optical aim may be offered as a 
replacement for a headlamp using a VHAD only if the replacement 
headlamp has a horizontal VHAD complying with S8.5.
    S8.7.3  A headlamp using a VHAD may be offered as a replacement for 
a headlamp using visual/optical aim.
    S9.  Headlamp performance test procedures.
    S9.0  The following is a table of contents of the test procedures 
for headlamp performance.

S9.1  Photometry.
S9.2  Abrasion.

[[Page 63273]]

S9.3  Chemical resistance.
S9.4  Corrosion.
S9.5  Dust.
S9.6  Temperature and internal heat tests.
S9.7  Humidity.
S9.8  Vibration.
S9.9  Sealing.
S9.10  Chemical and corrosion resistance of reflectors of 
replaceable lens headlamps

    S9.1  Photometry. Each headlamp to which S9 applies shall be tested 
according to the test procedures of Paragraphs 5.1 and 5.1.4 of SAE 
Standard J1383 DEC96 and the applicable photometric requirements 
specified in S7.4 or S7.5, after each test specified in S9.2, S9.3, 
S9.5, S9.6.1, S9.6.2, S9.7, and S9.10.1 and S9.10.2, if applicable. A 
1/4 degree reaim is permitted in any direction at any test point.
    S9.2  Abrasion.
    S9.2.1  A headlamp shall be mounted in the abrasion test fixture in 
the manner indicated in Figure 5 with the lens facing upward.
    S9.2.2  An abrading pad meeting the requirements in S9.2.2 (c)(1) 
through (c)(4) shall be cycled back and forth (1 cycle) for 11 cycles 
at 100 mm  20 mm (4  0.8 in) per second over at 
least 80 percent of the lens surface, including all the area between 
the upper and lower aiming pads, but not including lens trim rings and 
edges.
    S9.2.3(a) The abrading pad shall be not less than 25 mm 
 1 mm (1.0  .04 in) wide, constructed of 0000 
steel wool, and rubber cemented to a rigid base shaped to the same 
vertical contour of the lens. The ``grain'' of the pad shall be 
perpendicular to the direction of motion.
    (b) The abrading pad support shall be equal in size to the pad and 
the center of the support surface shall be within  2 mm 
(.08 in) of parallel to the lens surface.
    (c) The density of the abrading pad shall be such that when the pad 
is mounted to its support and is resting unweighted on the lens, the 
base of the pad shall be no closer than 3.2 mm (.125 in) to the lens at 
its closest point.
    (d) When mounted on its support and resting on the lens of the test 
headlamp, the abrading pad shall then be weighted such that a pad 
pressure of 14  1 kPpa (2.0  .15 psi) exists at 
the center and perpendicular to the face of the lens.
    S9.2.4  A pivot shall be used if it is required to follow the 
contour of the lens.
    S9.2.5  Unused steel wool shall be used for each test.
    S9.3  Chemical resistance.
    S9.3.1  The entire exterior lens surface of the headlamp in the 
headlamp test fixture and top surface of the lens-reflector joint shall 
be wiped once to the left and once to the right with a 150 mm (6 in) 
square soft cotton cloth (with pressure equally applied) which has been 
saturated once in a container with 60 ml (2 oz) of a test fluid as 
listed in S9.3.2. The lamp shall be wiped within 5 seconds after 
removal of the cloth from the test fluid.
    S9.3.2  The test fluids are:
    (a) ASTM Reference Fuel C, which is composed of Isooctane 50 
percent volume and Toluene 50 percent volume. ASTM Reference Fuel C 
must be used as specified in OSHA Standard 29 CFR 1910.106--Handling 
storage and use of flammable combustible liquids.
    (b) Tar remover (consisting by volume of 45 percent xylene and 55 
percent petroleum base mineral spirits).
    (c) Power steering fluid (as specified by the vehicle manufacturer 
for use in the motor vehicle on which the headlamp is intended to be 
installed).
    (d) Windshield washer fluid consisting of 0.5 percent 
monoethanolamine with the remainder 50 percent concentration of 
methanol/distilled water by volume.
    (e) Antifreeze (50 percent concentration of ethylene glycol/
distilled water by volume).
    S9.3.3  After the headlamp has been wiped with the test fluid, it 
shall be stored in its designed operating attitude for 48 hours at a 
temperature of 73 degrees F  7 degrees (23 degrees C 
 4 degrees) and a relative humidity of 30 10 
percent. At the end of the 48-hour period, the headlamp shall be wiped 
clean with a soft dry cotton cloth and visually inspected.
    S9.4  Corrosion.
    (a) Prior to exposure, each terminal between the headlamp and its 
connector shall be tested with apparatus shown in Figure 11. The power 
source shall be set to provide 12.8 volts and the resistance shall be 
set to produce 10 amperes at each terminal and recorded. In the case of 
replaceable light source headlamps, the procedure may be performed with 
the light source removed from the headlamp. If necessary, holes may be 
made in the connector body or bulb base for access to the terminal. 
Such holes shall be plugged during the test procedure of paragraph (b) 
below, and reopened for the procedure of paragraph (c), below.
    (b) The headlamp with connector attached to the terminals (but the 
rest of the apparatus of Figure 11 removed), unfixtured and in its 
designed operating attitude with all drain holes, breathing devices or 
other designed openings in their normal operating positions, shall be 
subjected to a salt spray (fog) test in accordance with ASTM B117-73, 
Method of Salt Spray (Fog) Testing, for 240 hours, consisting of ten 
successive 24-hour periods. During each period, the headlamp shall be 
mounted in the middle of the chamber and exposed for 23 hours to the 
salt spray. The spray shall not be activated during the 24th hour. The 
replaceable light source shall be removed from the headlamp and from 
the test chamber during the one hour of salt spray deactivation and 
reinserted for the start of the next test period, at the end of the 
first and last three 23-hour periods of salt spray exposure, and at the 
end of any two of the fourth through seventh 23-hour periods of salt-
spray exposure. The test chamber shall be closed at all times except 
for a maximum of 2 minutes which is allowed for removal or replacement 
of the replaceable light source during each period. After the ten 
periods, the lens reflector unit without the bulb shall be immersed in 
deionized water for 5 minutes, then secured and allowed to dry by 
natural convection only.
    (c) Using the voltage, resistance and pretest set up of 
subparagraph (a) the current in each terminal test circuit shall be 
measured after the salt spray exposure test conducted in subparagraph 
(b).
    S9.5  Dust. The headlamp, mounted on a headlamp test fixture, with 
all drain holes, breathing devices or other designed openings in their 
normal operating positions, shall be positioned within a cubical box, 
with inside measurements of 900 mm (35.4 in) on each side or larger if 
required for adequate wall clearance, i.e., a distance of at least 150 
mm (5.9 in) between the headlamp and any wall of the box. The box shall 
contain 4.5 kg (9.9 lb) of fine powdered cement which conforms to the 
ASTM C150-77 specification for Portland Cement. Every 15 minutes, the 
cement shall be agitated by compressed air or fan blower(s) by 
projecting blasts of air for a two-second period in a downward 
direction so that the cement is diffused as uniformly as possible 
throughout the entire box. This test shall be continued for five hours 
after which the exterior surfaces of the headlamp shall be wiped clean.
    S9.6  Temperature and internal heat tests. A headlamp with one or 
more replaceable light sources shall be tested according to S9.6.1 and 
S9.6.2. Tests shall be made with all filaments lighted at design 
voltage that are intended to be used simultaneously in the headlamp and 
which in combination draw the highest total wattage. These include but 
are not limited to filaments used for turn signal lamps, fog lamps, 
parking lamps, and headlamp lower beams

[[Page 63274]]

lighted with upper beams when the wiring harness is so connected on the 
vehicle. If a turn signal is included in the headlamp assembly, it 
shall be operated at 90 flashes a minute with a 752 percent 
current ``on time.'' If the lamp produces both the upper and lower 
beam, it shall be tested in both the upper beam mode and the lower beam 
mode under the conditions above described, except for a headlamp with a 
single Type HB1 or HB2 light source.
    S9.6.1  Temperature cycle. A headlamp, mounted on a headlamp test 
fixture, shall be subjected to 10 complete consecutive cycles having 
the thermal cycle profile shown in Figure 6. During the hot cycle, the 
lamp, shall be energized commencing at point ``A'' of Figure 6 and de-
energized at point ``B.'' Separate or single test chambers may be used 
to generate the environment of Figure 6. All drain holes, breathing 
devices or other openings or vents of the headlamps shall be in their 
normal operating positions.
    S9.6.2  Internal Heat Test.
    (a) The headlamp lens surface that would normally be exposed to 
road dirt shall be uniformly sprayed with any appropriate mixture of 
dust and water or other materials to reduce the photometric output at 
the H-V test point of the upper beam (or the 1/2D-1 1/2R test point of 
the lower beam as appropriate) to 252 percent of the output 
originally measured in the photometric test conducted pursuant to 
S7.4.2 or S7.5.2, as applicable. A headlamp with a single light source 
having two filaments shall be tested on the upper beam only. Such 
reduction shall be determined under the same conditions as that of the 
original photometric measurement.
    (b) After the photometric output of the lamp has been reduced as 
specified in 9.6.(a), the lamp and its mounting hardware shall be 
mounted in an environmental chamber in a manner similar to that 
indicated in Figure 7 ``Dirt/Ambient Test Setup.'' The headlamp shall 
be soaked for one hour at a temperature of 35 + 4-0 degrees C (95 + 7-0 
degrees F) and then the lamp shall be energized according to S8.6 for 
one hour in a still air condition, allowing the temperature to rise 
from the soak temperature.
    (c) The lamp shall be returned to a room ambient temperature of 23 
+ 4-0 degrees C (73 + 7-0 degrees F) and a relative humidity of 30 
 10 percent and allowed to stabilize to the room ambient 
temperature. The lens shall then be cleaned.
    S9.7  Humidity.
    (a) The test fixture consists of a horizontal steel plate to which 
three threaded steel or aluminum rods of nominal 13 mm (0.5 in) 
diameter are screwed vertically behind the headlamp. The headlamp 
assembly is clamped to the vertical rods, which are behind the 
headlamp. All attachments to the headlamp assembly are made behind the 
lens and vents or openings, and are not within 51 mm (2 in) laterally 
of a vent inlet or outlet.
    (b) The mounted headlamp assembly is oriented in its design 
operating position, and is placed in a controlled environment at a 
temperature of 38+4-0 degrees C (100+7-0 degrees F) with a relative 
humidity of not less than 90 percent. All drain holes, breathing 
devices, and other openings are in their normal operation positions for 
all phases of the humidity test. The headlamp shall be subjected to 24 
consecutive 3-hour test cycles. In each cycle, it shall be energized 
for l hour at design voltage with the highest combination of filament 
wattages that are intended to be used, and then de-energized for 2 
hours. If the headlamp incorporates a turn signal, it shall flash at 90 
flashes per minute with a 752 percent current ``on-time.''
    (c) Within 3 minutes after the completion of the 24th cycle, the 
air flow test will begin. The following shall occur: the mounted 
assembly shall be removed, placed in an insulating box and covered with 
foam material so that there is no visible air space around the 
assembly; the box shall be closed, taken to the air flow test chamber, 
and placed within it. Inside the chamber, the assembly with respect to 
the air flow, shall be oriented in its design operating position. The 
assembly is positioned in the chamber so that the center of the lens is 
in the center of the opening of the air flow entry duct during the 
test. The headlamp has at least 75 mm (3 in) clearance on all sides, 
and at least 100 mm (4 in) to the entry and exit ducts at the closest 
points. If vent tubes are used which extend below the lamp body, the 75 
mm (3 in) are measured from the bottom of the vent tube or its 
protection. The temperature of the chamber is 23+4-0 degrees C (73+7-0 
degrees F) with a relative humidity of 30+10-0 percent. The headlamp is 
not energized.
    (d) Before the test specified in S9.7(e) the uniformity of the air 
flow in the empty test chamber at a plane 100 mm (4 in) downstream of 
the air entry duct shall have been measured over a 100 mm (4 in) square 
grid. The uniformity of air flow at each grid point is 10 
percent of the average air flow specified in S9.7(e) of this paragraph.
    (e) The mounted assembly in the chamber shall be exposed, for 1 
hour to an average air flow of 100+0-10 m/min (330+0-30 ft/min) as 
measured with an air velocity measuring probe having an accuracy of 
3 percent in the 100 m/min (330 ft/min) range. The average 
air flow is the average of the velocity recorded at six points around 
the perimeter of the lens. The six points are determined as follows: at 
the center of the lens, construct a horizontal plane. The first two 
points are located in the plane, 25 mm (1 in) outward from the 
intersection of the plane and each edge of the lens. Then, trisect the 
distance between these two points and construct longitudinal vertical 
planes at the two intermediate locations formed by the trisection. The 
four remaining points are located in the vertical planes, 25 mm (1 in) 
above the top edge of the lens, and 25 mm (1 in) below the bottom edge 
of the lens.
    (f) After one hour, the headlamp is removed and inspected for 
moisture.
    S9.8  Vibration. A vibration test shall be conducted in accordance 
with the procedures of SAE J2139 JAN94 Tests for Lighting Devices and 
Components Used on Vehicles 2032 mm or More in Overall Width, and the 
following: the table on the adapter plate shall be of sufficient size 
to completely contain the test fixture base with no overhang. The 
vibration shall be applied in the vertical axis of the headlamp system 
as mounted on the vehicle. The filament shall not be energized.
    S9.9  Sealing. An unfixtured headlamp in its design mounting 
position shall be placed in water at a temperature of 60 3 
degrees C (176 5 degrees F) for 1 hour. The headlamp shall 
be energized in its highest wattage mode, with the test voltage at 12.8 
0.1 V. during immersion. The lamp shall then be de-
energized and immediately submerged in its design mounting position 
into water at 0 +3-0 degrees C (32 +5-0 degrees F). The water shall be 
in a pressurized vessel, and the pressure shall be increased to 70 kPa 
(10 psi), upon placing the lamp in the water. The lamp shall remain in 
the pressurized vessel for a period of 30 minutes. This entire 
procedure shall be repeated for four cycles. Then the lamp shall be 
inspected for any signs of water on its interior. During the high 
temperature portion of the cycles, the lamp shall be observed for signs 
of air escaping from its interior. If any water occurs on the interior 
or air escapes, the lamp is not a sealed lamp.
    S9.10  Chemical and corrosion resistance of reflectors of 
replaceable lens headlamps.
    S9.10.1  Chemical resistance.
    (a) With the headlamp in the headlamp test fixture and the lens 
removed, the entire surface of the reflector that receives light from a

[[Page 63275]]

headlamp light source shall be wiped once to the left and once to the 
right with a 150 mm (6 in) square soft cotton cloth (with pressure 
equally applied) which has been saturated once in a container with 60 
ml (2 oz) of one of the test fluids listed in S9.10.1(b). The lamp 
shall be wiped within 5 seconds after removal of the cloth from the 
test fluid.
    (b) The test fluids are tar remover (consisting by volume of 45 
percent xylene and 55 percent petroleum base mineral spirits); mineral 
spirits; and fluids other than water contained in the manufacturer's 
instructions for cleaning the reflector.
    (c) After the headlamp has been wiped with the test fluid, it shall 
be stored in its designed operating attitude for 48 hours at a 
temperature of 23 degrees C  4 degrees (73 degrees F 
 7 degrees) and a relative humidity of 30  10 
percent. At the end of the 48-hour period, the headlamp shall be wiped 
clean with a soft dry cotton cloth and visually inspected.
    S9.10.2  Corrosion.
    (a) The headlamp with the lens removed, unfixtured and in its 
designed operating attitude with all drain holes, breathing devices or 
other designed openings in their normal operating positions, shall be 
subjected to a salt spray (fog) test in accordance with ASTM B117-73, 
Method of Salt Spray (Fog) Testing, for 24 hours, while mounted in the 
middle of the chamber.
    (b) Afterwards, the headlamp shall be stored in its designed 
operating attitude for 48 hours at a temperature of 23 degrees C 
 4 degrees (73 degrees F  7 degrees) and a 
relative humidity of 30  10 percent and allowed to dry by 
natural convection only. At the end of the 48-hour period, the 
reflector shall be cleaned according to the instructions supplied with 
the headlamp manufacturer's replacement lens, and inspected. The lens 
and seal shall then be attached according to these instructions and the 
headlamp tested for photometric performance.
    S10.  Headlamp concealment devices.
    S10.1  While the headlamp is illuminated, its fully-opened headlamp 
concealment device shall remain fully opened should any loss of power 
to or within the headlamp concealment device occur.
    S10.2  Whenever any malfunction occurs in a component that controls 
or conducts power for the actuation of the headlamp concealment device 
shall be capable of being fully opened by a means not requiring the use 
of any tools. Thereafter, the headlamp concealment device must remain 
fully opened until intentionally closed.
    S10.3  Except for malfunctions covered by S10.2, each headlamp 
concealment device shall be capable of being fully opened and the 
headlamps illuminated by actuation of a single switch, lever, or 
similar mechanism, including a mechanism that is automatically actuated 
by a change in ambient light conditions.
    S10.4  Each headlamp concealment device shall be installed so that 
the headlamp may be mounted, aimed, and adjusted without removing any 
component of the device, other than components of the headlamp 
assembly.
    S10.5  Except for cases of malfunction covered by S10.2, each 
headlamp concealment device shall, within an ambient temperature range 
of -29 degrees C to +49 degrees C (-20 degrees F to +120 degrees F), be 
capable of being fully opened in not more than 3 seconds after the 
actuation of the headlighting control.
    S11.  Photometric test of DRL. A lamp that is wired in accordance 
with S5.5.11, shall be tested for compliance with S5.5.11(a)(1) in 
accordance with the test method specified for photometric testing in 
SAE Standard J575 JUN92 when a test voltage of 12.8V 20 mV 
is applied to the input terminals of the lamp switch module or voltage-
reducing equipment, whichever is closer to the electrical source on the 
vehicle. The test distance from the lamp to the photometer shall be not 
less than 18.3 m (60 ft), if the lamp is optically combined with a 
headlamp, or is a separate lamp, and not less than 3 m (9.75 ft), if 
the lamp is optically combined with a lamp, other than a headlamp, that 
is required by this standard.

[[Page 63276]]

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BILLING CODE 4910-59-C

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[Insert Figure 11 ]
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BILLING CODE 4910-59-P

    Issued on: November 4, 1998.
James R. Hackney,
Acting Associate Administrator for Safety Performance Standards.
[FR Doc. 98-29921 Filed 11-10-98; 8:45 am]
BILLING CODE 4910-59-P