[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]]
[GRAPHIC] [TIFF OMITTED] TP12NO98.000
BILLING CODE 4910-59-C
* * * * *
[Insert Figure 11 ]
* * * * *
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
