96-17299. Federal Motor Vehicle Safety Standards; Lamps, Reflective Devices and Associated Equipment

[Federal Register Volume 61, Number 133 (Wednesday, July 10, 1996)]
[Proposed Rules]
[Pages 36334-36346]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-17299]


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DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration

49 CFR Part 571

[Docket No. 95-28; Notice 8]
RIN 2127-AF73


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 Standard No. 108, the Federal 
motor vehicle safety standard on lighting, to afford an option to 
existing headlamp aiming specifications which is intended to improve 
the objectivity and accuracy of motor vehicle headlamp aim when 
headlamps are aimed visually and/or optically. The proposal reflects 
the consensus of NHTSA's Advisory Committee on Regulatory Negotiation 
concerning the improvement of headlamp aimability performance and 
visual/optical headlamp aiming. The Committee was composed of 
representatives of government, industry, and consumer interest groups.

DATES: Comments are due October 8, 1996.


[[Page 36335]]


ADDRESSES: Comments should refer to Docket No. 95-28; Notice 8 and must 
be submitted to: Docket Section, Room 5109, 400 Seventh Street, SW, 
Washington, DC 20590. (Docket hours are from 9:30 a.m. to 4:00 p.m.). 
Do not send originals of comments to any person named below.

FOR FURTHER INFORMATION CONTACT: (NHTSA Advisory Committee 
representative) Steve Kratzke, Office of Safety Performance Standards, 
NHTSA (Phone: [phone]; FAX: [phone]); (technical information) 
Rich Van Iderstine, Office of Safety Performance Standards, NHTSA 
(Phone: [phone]; FAX: [phone]); (legal information) Taylor 
Vinson, Office of Chief Counsel, NHTSA (Phone: [phone]; FAX: 202-
366-3820).

SUPPLEMENTARY INFORMATION:

Background

    On June 9, 1995, at 60 FR 30506, the National Highway Traffic 
Safety Administration (NHTSA) published a notice of intent to establish 
an advisory committee (``the Committee'') for regulatory negotiation to 
develop recommended specifications for altering the lower beam patterns 
of Federal Motor Vehicle Safety Standard No. 108 Lamps, Reflective 
Devices and Associated Equipment to be more sharply defined. Such a 
pattern would facilitate visual aimability of headlamps. The notice 
requested comment on membership, the interests affected by the 
rulemaking, the issues the Committee should address, and the procedures 
it should follow. The notice also announced that NHTSA had procured the 
services of the Federal Mediation and Conciliation Service to 
facilitate the negotiations. The reader is referred to the notice of 
June 9, 1995, for further information on these issues.
    On the basis of comments received to the notice, NHTSA determined 
that establishing an advisory committee on this subject would be 
advantageous and in the public interest. In accordance with Section 
9(c) of the Federal Advisory Committee Act, 5 U.S.C. App. I sec. 9(c), 
NHTSA prepared a Charter for the establishment of a Negotiated 
Rulemaking Advisory Committee. On April 17, 1995, the Office of 
Management and Budget approved the Department's Advisory Committee Plan 
for FY 1995 which included this advisory committee, and on July 6, 
1995, the Secretary approved the Charter, authorizing the Committee to 
begin negotiating the recommended changes.

Membership

    In addition to a representative from NHTSA, the Committee consisted 
of representatives from the following organizations:

Advocates for Highway and Auto Safety
American Association of Motor Vehicle Administrators
American Association of State Highway and Transportation Officials
American Automobile Manufacturers Association
Association of International Automobile Manufacturers, Inc.
Automotive Service Association
Groupe de Travail ``Bruxelles 1952''
Hopkins Manufacturing Corporation
Japanese Automobile Standards Internationalization Center
Liaison Committee for the Manufacturers of Automobile Equipment and 
Spare Parts
National Automobile Dealers Association
National Committee on Uniform Traffic Control Devices
Society of Automotive Engineers, Road Illumination Devices Standards 
Committee
Traffic Control Materials Division, 3M Corporation
Wagner Lighting Division of Cooper Industries

    In accordance with the directives for negotiated rulemaking, these 
participants represent all ``interests'' identified by NHTSA as 
affected by a final rule on headlamp aimability: the consumer; Federal 
and State governments; American, European, and Asian manufacturers of 
motor vehicles and headlamps; the automobile service industry; and 
manufacturers of headlamp aiming equipment and traffic control devices.

Meetings

    Utilizing the services of the Federal Mediation and Conciliation 
Service (FMCS) as facilitators/mediators, NHTSA convened the first 
Committee on July 25, 1995. The Committee held an additional series of 
meetings in September, October, and November 1995, and in January, 
March, April, and May 1996. Under the direction of the FMCS mediators 
the Committee received training in the interest-based negotiation 
process. The Committee used the interest-based negotiation process to 
fulfill its charter. At its final meeting prior to publication, on May 
29, 1996, the Committee reached a consensus on the rationale and 
proposed regulatory text for this NPRM. The Committee meetings were 
open to the public, and NHTSA placed the minutes into a public docket 
(Docket No. 95-28).

NHTSA's Perspective of Headlamp Aimability

    At its simplest expression, proper aim is required to ensure that 
headlamps installed on motor vehicles fulfill the functions intended by 
their designers. There are three principal methods of aiming headlamps. 
The first is visual: project the beam upon a vertical surface and 
adjust the headlamp as determined by an observer; the second is 
optical: project the beam into a device that is placed in front of the 
headlamp and adjust the headlamp until the beam conforms to the 
parameters of the device; the third is mechanical: without activation 
of the headlamp, determine proper aim through the use of equipment 
external to the headlamp. Mechanical aim was introduced in 1955 by the 
automotive industry in response to aiming concerns expressed by the 
states. These concerns were related to visual and optical and involved 
ease of use, repeatability, and accuracy of aim.
    A constant requirement of Standard No. 108 from its effective date 
on January 1, 1968, has been the ability of motor vehicle headlamps to 
be mechanically aimed. Mechanical aiming was necessary because visual/
optical aim of the lower beam pattern in use in the United States was 
difficult. Sealed beam headlamps, the only type of headlamps permitted 
until 1983, are required to have one of four aiming-pad patterns on the 
lens. These patterns consist of three raised aiming pads arranged as a 
triangle at specified points on the lens which provide a precise 
interface between the headlamp and a mechanical aiming device attached 
to the headlamp during the aiming verification process. The mechanical 
aiming device provides information so that the aiming planes of the 
headlamps, defined by the three aiming pads, can be adjusted to be 
parallel with each other and perpendicular to the road surface. Because 
a headlamp's beam pattern is designed to be correctly aimed when the 
aiming plane is oriented as stated, the beam pattern can be aimed 
without the need for illuminating the headlamp.
    With the advent of replaceable bulb headlamps in 1983, restrictions 
on the size and shape of headlamps were no longer required, and two 
additional configurations of mechanical aiming pads were permitted. 
This necessitated new adapters and also adjustable adapters for 
mechanical aiming devices used with replaceable bulb headlamps. 
Initially, NHTSA required that vehicles with replaceable bulb headlamps 
also be equipped with aim adapters until the adapters could be supplied 
to the service industry. However, this design

[[Page 36336]]

freedom resulted in a proliferation of headlamp aimer adapters, adding 
complexity and error to the previously simple and accurate process of 
mechanical headlamp aim. In addition, headlamps became smaller, and it 
became increasingly difficult for the traditional type of mechanical 
aiming device to measure aim.
    In response to this problem, since June 8, 1989, NHTSA has allowed 
a method of mechanical aim that is no longer dependent upon an external 
applied mechanical aiming device but one which is accomplished by 
mechanical aiming equipment on the vehicle itself. NHTSA terms this a 
``vehicle headlamp aiming device'' or ``VHAD''. A VHAD is equipment 
installed on the vehicle which is used for determining headlamp aim 
mechanically. In its most common form, these are bubble vials on the 
headlamp housing which have a closely specified geometric (mechanical) 
relationship to a beam's vertical location. When the bubble is within a 
specific area indicated on the housing, the headlamp's vertical aim is 
correct. A similar mechanical reference marking system is used for 
correct horizontal aim. One attractive feature of VHADs is that they 
provide a simple way for anyone to determine proper aim and to correct 
misaim. But, in the event of damage involving the headlamp, VHADs may 
have to be replaced, with recalibration by a person other than the 
vehicle manufacturer who initially installed them. NHTSA believes, and 
the Committee concurred, that distributors, dealers, and service 
facilities do not have the ability to recalibrate replacement equipment 
to the same accuracy as the manufacturer. VHADs add to vehicle costs, 
and not all vehicles are equipped with them; therefore visual aim and 
optical aim remain important.
    As NHTSA understands it, state inspection stations and private 
repair shops are less likely today to use mechanical aiming devices 
and, for the most part, choose to aim headlamps either visually or with 
optical aimers. Given the lack of sharply defined visual cues in the 
lower beam pattern in headlamps that are designed to conform to 
Standard No. 108, aiming visually or with an optical aiming device 
yields variable results. As a consequence, there are increasing numbers 
of misaimed headlamps in the nation's vehicle fleet, with a higher risk 
of glare and inadequate illumination of the roadway including traffic 
control devices.
    When NHTSA published a general notice asking for candidates for 
regulatory negotiation, the American Automobile Manufacturers 
Association (AAMA) identified headlamp aimability as its first choice. 
NHTSA agreed with this recommendation. The NPRM that is published today 
is the result of negotiated rulemaking. The anticipated result is a 
final rule that specifies an option to mechanical aiming for easy, 
accurate headlamp aiming.

The Process Followed by the Committee and Its Recommendations

    As part of the interest-based negotiation process, the Committee 
first defined issues for the regulatory negotiation. The Committee then 
identified its interests and finally reached consensus on criteria for 
the regulatory standards.
    The Committee used the interest-based process to identify the basic 
issue as ``what standard will permit the visual/optical aiming of lower 
beam headlamps''. Subsequently the visual/optical aimability of the 
upper beam was added.
    The Committee-defined interests were divided into three main 
themes: ``Safety'', ``Service Sector and Manufacturer Needs'', and 
``Visual/Optical''. A summary of each issue is as follows:
    A. Safety: Any method of ensuring visual and or optical aim of low 
beam headlamps that involves the proposed adoption of a new Federal 
standard for lower beam headlamp photometry must not degrade , and 
desirably will enhance, the safety performance of the existing traffic 
control nighttime driving environment. A visually/optically aimable 
headlamp beam pattern shall ensure adequate driver control and 
avoidance of hazardous features (pedestrians, roadside objects, etc.), 
in the nighttime driving environment, without creating disabling glare.
    B. Service Sector and Manufacturing Needs: Implementation of a 
visual aim standard must consider the following service sector 
(dealers, repair garages, service stations, state inspection stations, 
body shops) and manufacturing (vehicles, headlamps, and aiming 
equipment) needs: simplicity, user friendliness, repeatability, 
reliability, cost effectiveness, equipment, compatible aiming methods.
    C. Visual/Optical: The development of the aiming standard should 
consider other established aiming standards.
    The Committee then developed six criteria as critical for the 
development of a consensus standard for visual/optical aim. These 
criteria are:
    1. Accuracy: proper placement of beam pattern.
    2. Repeatability: repeatable aimability.
    3. Simplicity: performable by operators of varying skill levels.
    4. Reasonable cost: no unreasonable costs for manufacturers, the 
service and inspection industry, or consumers.
    5. Critical beam characteristics: preservation of beam 
characteristics for driver control, avoidance of road hazards and 
pedestrians, detection and legibility of traffic control devices, and 
restriction of disabling glare.
    6. Ambient light conditions: achievement of acceptable aim within a 
range of ambient light conditions at manufacturer and service 
facilities.
    The Committee then determined that the new visual/optical aim 
standard should be an option to current mechanical and VHAD aim 
specifications in Standard No. 108, and usable with all headlamps: 
sealed beam, integral beam, replaceable bulb, and combination-type 
headlamps. Therefore, the Committee developed an outline to be used by 
NHTSA for the NPRM.
    To achieve its goals, the Committee decided that:
    A. the lower beam pattern must have a wider illumination,
    B. a horizontal visual cue must be added to either the left or 
right side of the lower beam,
    C. the basic characteristics of the lower beam pattern must not be 
changed,
    D. all lenses for visually/optically aimable headlamps must be 
marked to ensure that persons aiming the headlamps know that the 
headlamp can be correctly aimed using a visual or optical aiming 
procedure, and
    E. existing requirements for VHADs must be amended to add a 
specification currently missing which results in aim error.

Proposed Requirements and Their Rationales

    The Committee recommends and NHTSA proposes that the visually/
optically aimable lower beam of a headlamp meet the following criteria:
    A. Vertical Aim of Lower Beam. A visual cue (cutoff) is required in 
the lower beam pattern to permit accurate aiming. The cutoff marks a 
transition between the areas of higher and lower luminous intensities. 
The cutoff in the lower beam pattern is a horizontal line composed of 
maximum vertical logarithmic gradients of the illumination of the 
aiming screen.
    Vertical aim requires both a laboratory specification for headlamps 
before installation and a field specification for headlamps after 
installation. This notice proposes that the laboratory specifications 
be incorporated into Standard No. 108. The field

[[Page 36337]]

specifications represent the Committee's recommendations to all persons 
who perform visual/optical headlamp aiming in the field.#
    1. Laboratory Specification for the Vertical Visual Aim of the 
Lower Beam. The Committee, in establishing and recommending to NHTSA a 
laboratory specification for visual aim of the lower beam, agreed that 
several factors must be considered to ensure accurate and repeatable 
results that would also relate to the requirements for field 
aimability. Accuracy for laboratory aim was specified to be within 
 0.1 degree. This was based on the test equipment 
positioning capability of 0.01 degree along with the 
associated lamp-to-lamp and laboratory-to-laboratory variances. The 
Committee agreed that the specification for the gradient in the 
proposal be based on a required  0.1 degree laboratory aim 
accuracy and a 0.25 degree field aim accuracy with confidence limits of 
 2 sigma (95% of all aims will be in the range).
    A University of Michigan Transportation Research Institute (UMTRI) 
study titled ``Visual Aiming of European and U.S. Low-Beam Headlamps'' 
(Report No. UMTRI-91-34, by Sivak, Flannagan, Chandra, and Gellatly) 
provided information which led to the establishment of the necessary 
gradient level. In the study by UMTRI, a wide range of lamps were 
tested, some of which were not designed for visual aiming. A subsequent 
study of visually aimable headlamps conducted at GE by the Society of 
Automotive Engineers' (SAE) Beam Pattern Task Force (in developing SAE 
J1735 ``Harmonized Vehicle Headlamp Performance Requirements'') found 
the standard deviation of vertical aim to be smaller than the standard 
deviation in the UMTRI study. Based on that study, SAE J1735 specifies 
a design value of 80% contrast based on 0.2 degree spacing of test 
points which corresponds to a value of 0.13 in log units with a 0.1 
degree spacing of test points. The Committee concluded that a gradient 
of 0.13 would satisfy its goal for field aim accuracy.
    Measurement of the specific gradients may be carried out using 
traditional photometric measurement equipment; however, photometric 
distance may vary between companies. It was decided that a procedure 
which has been developed by the Groupe de Travail ``Bruxelles 1952'' 
(GTB) Short-term Scientific Studies Working Group (SSST WG) would 
provide a baseline system for this test. This may be found in ``Draft 
Minutes of the Meeting held at Budapest 1995 October 3'' on file in the 
docket as attachment 3-9 to the Committee's minutes of Meeting No. 3.
    The cutoff can be on either the right or left side of the lower 
beam pattern. When so located, it provides the necessary reference for 
placing the beam in the appropriate vertical location for correct aim. 
In order to achieve a cutoff in a beam, there must be a distinct 
difference in illumination levels above and below the cutoff. This may 
be achieved by numerous methods in the design of a headlamp. For the 
purposes defined by the Committee, a horizontally-oriented cutoff is 
necessary. Based on work done by the SAE Beam Pattern Task Force, 
UMTRI, Commision Internationale de l'Eclairage Working Group on Vehicle 
Lighting (CIE TC4.10) (``Definition of the Vertical Cut-off of Vehicle 
Headlights'' draft 1993-3-15), and the GTB SSST WG, and reviewed by the 
Committee, the method for describing the cutoff is as follows.
    Scientific studies by Blackwell, Olson, Forbes, Sivak, Flannigan, 
et al., have shown that the human eye responds to the logarithm (to 
base 10) of the gradient of screen luminance. This mathematical 
expression simulates in the laboratory where human vision perceives the 
cutoff on a screen during field aiming. A vertical scan of the lower 
beam pattern at a specified number of degrees to the right or left of 
the headlamp beam pattern's vertical axis, where the cutoff is located, 
is taken to gather data on the intensity values. Thes data are then 
analyzed using the mathematical expression to determine where the 
greatest rate of change of illumination occurs; the vertical location 
of the cutoff is thus defined. For example, a person could use a 
goniophotometer to record data in small vertical increments at the 
locations at 2.5 degrees left or 2.0 degrees right in order to 
determine the cutoff location.
    For effective field aiming, the cutoff needs to be finitely long so 
that the person looking at the cutoff has a sufficient cue to find it. 
This range should extend at least one degree on each side of the 
specified measurement point of the cutoff and should be approximately 
straight and horizontal.
    The cutoff on the left side of the beam pattern can be achieved by 
putting more light below the horizontal on the left rather than 
reducing the intensity of light above the cutoff. This added light 
provides more illumination to detect objects on the left side of the 
beam pattern and more uniformity of the total light output from the 
vehicle. The light above the horizontal would not be decreased. The 
right side of the beam needs no such enhancement to achieve an adequate 
gradient for the cutoff. In addition to the above, these changes cause 
small effects in other areas of the beam that will be addressed below.
    The Committee recommends and NHTSA proposes the following changes 
to the existing photometric figures in Standard No. 108 for all 
headlamps designed for visual/optical aiming:
    (a) elimination of the 0.5 deg. D-1.5 deg. L to L test points,
    (b) elimination of the 1.0 deg. D-6.0 deg. L test point,
    (c) addition of an 0.86 deg. D-3.5 deg. L test point with intensity 
requirements of 1800 cd. minimum, and 12000 cd. maximum, and
    (d) addition of an 0.86 deg D-V test point with intensity 
requirements of 4500 cd minimum,
    (e) addition of an 0.6 deg D-1.3 deg R test point replacing the 
current test point at 0.5 deg D-1.5 deg R with intensity requirements 
shown below:

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                                                    Replaced Test Point: 0.5 deg. D-                            
 Proposed test point: 0.6 deg.   Proposed Source               1.5 deg. R                Source of requirement  
   D-1.3 deg. R (cd minimum)      of requirement  ------------------------------------       (Std. No. 108)     
                                  (Std. No. 108)      cd minimum        cd maximum                              
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10000.........................  new Fig. 15va &    10000...........  20000...........  Fig. 15A & 17A.          
                                 17va.                                                                          
10000.........................  new Fig. 27va &    8000............  20000...........  Fig. 27 & 28.            
                                 28va.                                                                          
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    (f) and modification of the 4 degree D-V test point in the Figure 
15va lower beam maximum candela column from 7000 cd to 10000 cd.
    In Figures 27 and 28 of Standard No. 108 the maximum value at 0.5 
degree D-1.5 degrees L is 2500 cd. In Figures

[[Page 36338]]

15A and 17A, the maximum value at 0.5 degree D-1.5 degrees L is 3000 
cd. The value of the 1.0 degree D-6.0 degrees L test point is 750 cd 
minimum, and it becomes superfluous because of the additional 
illumination provided by the new test point specified at 0.86 degree D-
3.5 degrees L.
    The three test points: 0.86 degree D-3.5 degrees L; 0.86 degree D-
V; and 0.6 degree D-1.3 degree R; have all been the subject of lower 
beam headlamp harmonization activities with GTB, GRE, JASIC, and SAE. A 
research study, UMTRI Report 94-27 ``Evaluation of the SAE J1735 Draft 
Proposal for a Harmonized Low-Beam Headlighting Pattern'' reports that 
these three test points contribute to better performance of the lower 
beam headlamp.
    In the past there has been one ``seeing light'' test point at 0.5 
degree D-1.5 degree R. This is being replaced by three new ``seeing 
light'' test points: 0.6 degree D-1.3 degrees R; 0.86 degree D-V; and 
0.86 degree D-3.5 degree L. The new 0.86 degree D-V test point with the 
4500 cd minimum will increase uniformity of the beam pattern below the 
horizontal line between the high intensity zones on the left and right. 
The new 0.6 degree D-1.3 degree R test point represents a relocation of 
a current test point by 0.1 degree D (from 0.5 degree D to 0.6 degree 
D) and 0.2 degree L (from 1.5 degree R to 1.3 degree R). These changes 
represent a significant improvement in providing more light to the left 
side of the beam pattern.
    There is a maximum (20000 cd) requirement at the 0.5 degree D-1.5 
degree R test point. Because of significantly greater control of 
minimum and maximum illumination above the horizontal axis, there is no 
continuing need for a maximum at this location.
    The recommendation to modify the test point value at 4D-V in Fig. 
15va from 7000 cd maximum to 10000 cd maximum is based on the 
substantial increase of light resulting from the test point 
modifications discussed above which extend the high intensity zone on 
the right side of the beam pattern to the left side of the beam. The 
previous test point value at 0.5 degree D-1.5 degrees L to L limited 
not only the light to the left region of the roadway, but also to the 
foreground area. Directing more light to the left will increase 
foreground light levels. Studies performed by UMTRI have shown that 
very high levels of foreground light can depreciate the driver's 
seeing-distance performance. A modest increase in the maximum candela 
level at this test point from 7000 to 10000 will allow the additional 
left-lane light yet not create undue foreground illumination.
    The Committee believes that the compromise between ``seeing light'' 
and glare protection requires an asymmetric beam pattern. The beam 
pattern should be lower on the left to protect oncoming drivers from 
glare. This is consistent with both the current U.S. and European beam 
pattern design. Therefore the Committee recommends and NHTSA proposes 
that the cutoff location be positioned at 0.4 degree below the H-H line 
for headlamps designed to be aimed using the left side of the beam 
pattern and at the H-H line for headlamps designed to be aimed using 
the right side of the beam pattern. The 0.4 degree down aim on the left 
side would cause the top edge of the main part of the beam pattern on 
the left to intersect the road surface at approximately 90 m. (300 
feet) from the vehicle with headlamps mounted at 635 mm. (25 inches) 
above the road surface. This distance is increased from present 
headlamps that are limited by the 0.5 degree D-1.5 degrees L to L test 
point that exists today. The H-H line was selected for the right side 
location of the cutoff so that the high intensity zone of the beam is 
properly placed for adequate seeing distance and because glare is less 
of a concern on the right side.
    The specific mathematical expression for identifying the cutoff is: 
G = log E()-log E(+0.1), where ``G'' is the gradient, 
``E'' is illumination and ``'' is the vertical angular 
position. The maximum value of the gradient ``G'' determines the 
angular location of the cutoff.
    2. Field Specification for Visual Aim of Lower Beam. As noted 
above, the field specification will not be incorporated into Standard 
No. 108 but represents the Committee's recommendation that should be 
used by persons in the field who will be aiming visually/optically 
aimable headlamps. The goal of this specification is to assure that a 
procedure for accurately aiming visually/optically aimable headlamps is 
available for use by people who need to aim headlamps. The intent of 
the Committee for this specification is to make it as similar to 
existing practices as possible. To this end, the practice in SAE J599 
``Lighting Inspection Code'' and the AAMVA ``Vehicle Inspection 
Handbook'', as well as studies done by NHTSA, UMTRI and JASIC, were 
used to develop the specification. The Committee made decisions about 
the field specification that are incorporated below.
    a. Distance.
    (i) Visual aim shall be performed at not less than 7.5 m. (this 
value is a rounded down conversion from the 25-foot distance typical of 
field aim using a screen). The 7.5 m. distance is measured from the 
front of the headlamp lens to the viewing screen.
    (ii) Optical aim shall be performed at the distance specified by 
the manufacturer of the optical aiming device.
    b. Accuracy. The field aiming procedure shall be capable of placing 
the cutoff within 0.25 degree.
    c. Ambient Light. The ambient light level during the aiming process 
affects the accuracy of aiming headlamps installed on motor vehicles. 
The ambient light level should be not more than 110 lux (10 foot-
candle) measured vertically at the screen surface around the H-V point 
for each lamp.
    d. Floor. The surface upon which the vehicle rests is flat and 
approximately level.
    e. Screen. The screen upon which headlamp beams are projected is 
perpendicular to the floor and the vehicle's longitudinal axis, flat, 
uniformly light in color, unobstructed, and wide and high enough to 
accommodate the vehicle beam patterns to be aimed. The screen should be 
wide enough to provide at least 1 m. of space outboard of the vehicle's 
headlamp spacing.
    (i) Placement of the horizontal reference line on the screen for 
lower beam headlamps marked ``VOL'' (the symbol is explained later in 
this notice): 52 mm. with a screen at 7.5 m. (2.1 inches at 24.6 feet) 
below the height of the optical axis of the headlamp (this represents 
approximately 0.4 degree down coincident with the laboratory 
specification).
    (ii) Placement of the horizontal reference line on the screen for 
lower beam headlamps marked ``VOR'': at the height of the optical axis 
of the headlamp (coincident with the laboratory specification).
    (iii) Placement of each of the two vertical reference lines on the 
screen for lower beam headlamps marked either ``VOL'' or ``VOR'': at 
the vertical centerline of each lower beam headlamp.
    f. Aim Procedure. Aim the cutoff vertically so that it is centered 
on the horizontal reference line. This is correct aim. Aim inspection 
limits are  100 mm. (4 in.). Note: only headlamps with a 
VHAD will be horizontally adjustable. (When horizontal aim is non-
adjustable, horizontal aim will not be compromised because most state 
laws require that headlamps be correctly aimed at the time of the first 
sale of the vehicle. Further, proper repair of collision-damaged 
vehicles will assure correct

[[Page 36339]]

placement of headlamps and thus maintain proper horizontal aim.)
    g. Reduction in Vertical Aim Inspection Limits. The Committee 
believes that an improved beam cutoff allows some reduction in the 
vertical inspection limits. For instance, many state aim inspection 
requirements prescribe tolerances for mechanically aimed headlamps 
which allow the beam to vary 4 inches at 25 feet measuring 
distance (0.76 degree) as stated in f. above. The Committee 
believes that a reduction of this tolerance range is feasible for lower 
beam headlamps marked ``VOR'' and ``VOL'' and urges the SAE and the 
states to investigate and implement a uniformly reduced vertical aim 
inspection limit for these types of headlamps.
    B. Horizontal Aim of Lower Beam.
    1. Eliminating Horizontal Aim Adjustability. Horizontal aimability 
is mandatory for mechanically-aimed headlamps under Standard No. 108. 
Because the lower beam of a headlamp designed to conform to Standard 
No. 108 does not have any visual cues for achieving correct horizontal 
aim when aimed visually or optically, and because it is not possible to 
add such visual features without damaging the beam pattern, horizontal 
aim should be either fixed and non-adjustable, or have a horizontal 
VHAD.
    When horizontal aim is non-adjustable, horizontal aim will not be 
compromised because most state laws require that headlamps be correctly 
aimed at the time of the first sale of the vehicle. Generally, the 
vehicle's manufacturer accepts the responsibility for assuring correct 
aim of headlamps on new motor vehicles. Further, proper realignment of 
front-end components of collision-damaged vehicles will assure correct 
placement of headlamps and thus maintain proper horizontal aim. Thus, 
no further specifications are necessary for field use, except to note 
that horizontal aim may not be adjustable on some lamps marked ``VOR'' 
or ``VOL'' on the lens.
    Standard No. 108 specifies for the lower beam, test points at 15 
and 9 degrees left and right, with minimum candela of 850 and 1000 
(test points 15 and 9 degrees, Figures 15A and 17A) and 700 and 750 
(test points 15 and 9 degrees, Figures 27 and 28). NHTSA proposes new 
Figures 15va, 17va, 27va, and 28va in which these values are increased. 
New test points to be added at 20 degrees left and right further widen 
the beam. In addition to the substitution of the above mentioned 0.86D-
3.5L test point for the 0.5D-1.5L to L, to facilitate the cutoff, these 
changes make the new beam pattern less sensitive to horizontal 
positioning. The proposed modifications and additions are:

9 deg L&R-2 deg D.........................  1250 cd. min.               
15 deg L&R-2 deg D........................  1000 cd. min.               
20 deg L&R-4 deg D........................  300 cd. min.                
                                                                        

These locations and values were taken from SAE J1735 which achieves a 
wider beam pattern as a result of these test points.
    2. Horizontal Aim of Lower Beam for Laboratory Photometry tests. 
The headlamp shall be mounted onto a fixture which simulates its actual 
design orientation 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. Shimming or adjustment of the 
headlamp's attachment to the test fixture to comply with the 
photometric requirements is not allowed. If there is a VHAD, the aim of 
the headlamp shall be adjusted, using the headlamp's horizontal aiming 
adjusters so that the VHAD reads zero. When the headlamp has been aimed 
vertically, the lamp is ready to be tested for photometric compliance.
    C. Vertical Aim of Upper Beam. As with vertical aim of the lower 
beam, vertical aim of the upper beam requires both a laboratory 
specification for headlamps before installation and a field 
specification for headlamps after installation; however, the aim of the 
upper beam is not nearly as critical as it is for the lower beam. The 
notice proposes that the laboratory specification be incorporated into 
Standard No. 108 for visually/optically aimable headlamps. For a 
headlamp that incorporates both a lower beam and an upper beam, the 
laboratory procedure and the field procedure for upper beam are not 
applicable, because the headlamp must be aimed using the lower beam, 
and, by design, both beams are photometered in that position.
    For a headlamp that has only an upper beam, the following apply:
    1. Laboratory Specification for Vertical Visual Aim of Upper Beam. 
The vertical aim of the upper beam shall be adjusted so that the 
maximum beam intensity is located on the H-H axis.
    2. Laboratory Specification for Horizontal Visual Aim of Upper 
Beam. The horizontal aim of the upper beam shall be adjusted so that 
the maximum beam intensity is located on the V-V axis unless the 
headlamp has fixed horizontal aim or a VHAD. In these cases, it shall 
be mounted onto a fixture which simulates its actual design orientation 
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. Shimming or adjustment of the headlamp's attachment to 
the test fixture to comply with the photometric requirements is not 
allowed. If there is a VHAD, the aim of the headlamp shall be adjusted, 
using the headlamp's horizontal aiming adjusters so that the VHAD reads 
zero. When the headlamp has been aimed vertically, the lamp is ready to 
be tested for photometric compliance.
    3. Field Specification for Visual Aim of Upper Beam. As noted 
above, the field specification will not be incorporated into Standard 
No. 108 but represents the Committee's recommendation that should be 
used by persons in the field who will be aiming visually/optically 
aimable headlamps. The goal of this specification is to assure that a 
procedure for accurately aiming visually/optically aimable headlamps is 
available for use by people who need to aim headlamps. The intent of 
the Committee for this specification is to make it as similar to 
existing practices as possible. To this end, the practice in SAE J599 
``Lighting Inspection Code'' and the AAMVA ``Vehicle Inspection 
Handbook'', were used to develop the specification. The Committee made 
decisions about the field specification that are incorporated below.
    a. Distance.
    (i) Visual aim shall be performed at not less than 7.5 m. (this 
value is a rounded down conversion from the 25-foot distance typical of 
field aim using a screen). The 7.5 m. distance is measured from the 
front of the headlamp lens to the viewing screen.
    (ii) Optical aim shall be performed at the distance specified by 
the manufacturer of the optical aiming device.
    b. Accuracy. The field aiming procedure shall be capable of placing 
the high intensity zone of the upper beam within 0.3 degree 
vertically and 0.6 degree horizontally.
    c. Ambient Light. The ambient light level during the aiming process 
affects the accuracy of aiming headlamps installed on motor vehicles. 
The ambient light level adequate for visually/optically aiming the 
lower beam is amply low enough for accurate aiming of the upper beam.
    d. Floor. The surface upon which the vehicle rests is flat and 
approximately level.
    e. Screen. The screen upon which headlamp beams are projected is 
perpendicular to the floor and the

[[Page 36340]]

vehicle's longitudinal axis, flat, uniformly light in color, 
unobstructed, and wide and high enough to accommodate the vehicle beam 
patterns to be aimed. The screen should be wide enough to provide at 
least 1 m. of space outboard of the vehicle's headlamp spacing.
    (i) Placement of the horizontal reference lines on the screen for 
upper beam headlamps marked ``VO'': at the height of the optical axis 
of the headlamp.
    (ii) Placement of the vertical reference lines on the screen for 
upper beam headlamps marked ``VO'': each reference line separated 
horizontally from the point of projection of the vehicle's longitudinal 
axis on the screen, by one half the distance separating the optical 
axes of the upper beam headlamps on the vehicle.
    f. Aim Procedure. Adjust the aiming screws so that the high 
intensity zone is centered at the intersection of the horizontal and 
vertical reference lines on the screen and within the allowable 
tolerances of 100mm (4 in.). Note: only headlamps with a 
VHAD will be horizontally adjustable. (When horizontal aim is non-
adjustable, horizontal aim will not be compromised because most state 
laws require that headlamps be correctly aimed at the time of the first 
sale of the vehicle. Further, proper repair of collision damaged 
vehicles will assure correct placement of headlamps and thus maintain 
proper horizontal aim.)
    D. Movable Reflector Headlamps. Movable reflector headlamps have a 
lens and headlamp housing that does not move with respect to the 
surrounding car structure when headlamps are aimed. Therefore the range 
of headlamp aim limits does not need to be as large to cover repairs 
from vehicle collisions. Requirements for the aiming of movable 
reflector headlamps have been clarified and expanded to cover headlamps 
which are visually/optically aimable. The vertical aim range limits 
will now cover only the full range of pitch on the vehicle on which the 
headlamp system is installed. (Full range of pitch on the vehicle is 
defined in S7.8.3 of Standard No. 108.) When horizontal aim is 
incorporated in a headlamp the horizontal aim range limits will remain 
2.5 degrees. Photometry will then be done over the applicable aim 
limits used for the headlamp system.
    E. Marking Requirements
    1. Headlamp Optical Axis Mark. The accuracy and reliability of 
headlamp aim depends upon the correct placement of aiming equipment in 
front of the vehicle and its headlamps. To assure that this placement 
is correct and precise, it is necessary for the headlamps to have an 
indication of the optical axis to act as a geometric reference for 
measuring distances to the floor and between the headlamps and the 
vehicle's longitudinal axis. This may be done by a mark on the interior 
or exterior of the lens, or by a mark or central structure on the 
interior or exterior of the headlamp. Thus, Standard No. 108 should be 
changed to require that a headlamp have this mark.
    While this is necessary for visual/optical aim headlamps, it is 
also desirable for all headlamps because people who aim headlamps use 
visual/optical aim even though today's headlamps are not designed to be 
aimed by this method. In the interest of promoting correct aim, this 
optical axis mark is recommended for all future headlamp designs. This 
proposal may require changes in headlamps for existing production 
vehicles, however it is not intended to be a retroactive requirement. 
Adequate leadtime is required for this proposal. Commenters are invited 
to discuss leadtime concerns.
    2. Visual/Optical Aimability Identification mark. Marking of 
headlamps would indicate that the lamp is visually/optically aimable 
according to the means specified in the final rule. Thus, Standard No. 
108 would require that the visible part of the lens of each original 
and replacement equipment headlamp and headlamp lens, and of each 
original equipment and replacement equipment beam contributor, designed 
to be visually/optically aimable, manufactured on or after the 
effective date of the final rule, be marked with the symbols ``VOL'', 
``VOR'', or ``VO'' either horizontally or vertically. The Committee 
determined that ``VOR'' and ``VO'' respectively should be the only 
marking used for all lower beam and upper beam sealed beam and integral 
beam headlamp types existing before the effective date of the final 
rule resulting from this NPRM if these types are ever redesigned to be 
visually/optically aimable. This will ensure that replacement headlamps 
are identically marked.
    NHTSA proposes that manufacturers which introduce new visually/
optically aimed headlamp types after the effective date be required to 
determine the aim method and apply the required marking. This aim 
method and marking must be followed by all subsequent manufacturers of 
this headlamp type.
    A lower beam headlamp would be marked ``VOL'' if the manufacturer 
designs it to be visually/optically aimed using the left side of the 
lower beam pattern, and ``VOR'' if using the right side. If a sealed 
beam or an integral beam headlamp system is in production before the 
publication of the final rule, the lens of any lamp in such system that 
is manufactured on or after the effective date of the final rule would 
be marked ``VOR'', and would have the gradient on the right side, if 
the system is ever redesigned so that its lamps are visually/optically 
aimable. A headlamp would be marked ``VO'' if it is solely an upper 
beam headlamp and intended to be visually/optically aimed.
    In accordance with other marking requirements of Standard No. 108, 
the letters would be not less than 3 mm high.

Allowing Existing Headlamps to Use the New Photometrics

    The Committee also decided that the improved photometrics 
represented by Figures 15va, 17va, 27va or 28va should be available to 
manufacturers of headlamps that are not visually/optically aimable 
within the meaning of this rulemaking action, but which presently are 
designed to meet the photometrics of Figures 15A, 17A, 27 or 28. This 
raises no safety issues regarding glare or compatibility of replacement 
equipment, and NHTSA is proposing amendments to the text and Figure 26 
appropriate to implement the Committee's decision.

Other Issues

    Independent of the recommendations of the Committee to NHTSA, the 
agency would like to have comment regarding the costs, benefits and 
other impacts associated with the following issues.
    (1) For the express purpose of simplifying the requirements of the 
Standard No. 108 to reduce the burden on regulated persons, please 
comment on the possibility and timing of an eventual mandatory 
requirement for having only visually/optically aimable headlamps. Such 
an action would eliminate at least four Figures (15A, 17A, 27 and 28) 
and significant text associated with mechanical and VHAD aiming.
    (2) For additional significant gains toward simplification and 
burden reduction that could be achieved, please comment on the 
possibility and timing of using only Figures 15va and 17va as the only 
allowed photometric performance at sometime in the future. This can 
eliminate another three Figures (26, 27va and 28va) and many pages of 
text associated with explanations of how to select the correct 
photometric performance.

[[Page 36341]]

Proposed Effective Dates

    The amendments that allow headlamps to be visually/optically 
aimable as an alternative to existing aimability requirements would be 
effective 60 days after publication of the final rule in the Federal 
Register.
    The amendments to S7.8.1 amending the fiducial marking to require 
an optical axis mark for headlamps that are not visually/optically 
aimable would become effective September 1 of the year following one 
year after publication of the final rule. For example, if the final 
rule is published after September 1, 1996 and before September 1, 1997, 
the effective date of the rule would be September 1, 1998. There would 
be no retroactive effect on existing headlamps or their replacements. 
The amendments to S7.8.5.2(c) amending the calibration requirements for 
the VHAD also would become effective September 1 of the year following 
one year after publication of the final rule. There would be no 
retroactive effect on existing headlamps or their replacements.

Rulemaking Analyses and Notices

Executive Order 12866 and DOT Regulatory Policies and Procedures

    This rulemaking action was not reviewed under Executive Order 
12866. Further, it has been determined that the rulemaking action is 
not significant under Department of Transportation regulatory policies 
and procedures. The purpose of the rulemaking action is to provide an 
alternative and more objective means of determining the accuracy of 
headlamp aim. As an alternative, the provisions would not be mandatory 
unless a manufacturer chose to install visually/optically aimable 
headlamps on a motor vehicle that it intends to sell. Because of 
offsetting benefits to vehicle manufacturers when choosing this option, 
it is likely that greater benefits than costs will occur. The costs of 
the final rule would be so minimal as not to warrant preparation of a 
full regulatory evaluation.

National Environmental Policy Act

    NHTSA has analyzed this rulemaking action for the purposes of the 
National Environmental Policy Act. It is not anticipated that a final 
rule based on this proposal would have a significant effect upon the 
environment. The composition of headlamps would not change from those 
presently in production.

Regulatory Flexibility Act

    The agency has also considered the impacts of this rulemaking 
action in relation to the Regulatory Flexibility Act. For the reasons 
stated above and below, I certify that this rulemaking action would not 
have a significant economic impact upon a substantial number of small 
entities. Accordingly, no regulatory flexibility analysis has been 
prepared. Manufacturers of motor vehicles and motor vehicle equipment, 
those affected by the rulemaking action, are generally not small 
businesses within the meaning of the Regulatory Flexibility Act.

Executive Order 12612 (Federalism)

    This rulemaking action has also been analyzed in accordance with 
the principles and criteria contained in Executive Order 12612, and 
NHTSA has determined that this rulemaking action does not have 
sufficient federalism implications to warrant the preparation of a 
Federalism Assessment.

Civil Justice

    A final rule based on this proposal would not have any retroactive 
effect. Under 49 U.S.C. 30103, 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. 49 U.S.C. 30161 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.

Request for Comments

    Interested persons are invited to submit comments on the proposal. 
It is requested 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 for inspection in the docket. The 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.

List of Subjects in 49 CFR Part 571

    Imports, Motor vehicle safety, Motor vehicles, Tires.

PART 571--FEDERAL MOTOR VEHICLE SAFETY STANDARDS

    In consideration of the foregoing, 49 CFR Part 571 would be amended 
as follows:
    1. The authority citation for Part 571 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.

    2. Section 571.108 would be amended by:
    a. amending Section S4 to add new definitions: ``Cutoff'' and 
``Visually/optically aimable headlamp'' in alphabetical order to read 
as set forth below;
    b. revising the definition in S4 of ``Vehicle headlamp aiming 
device'', to read as set forth below;
    c. revising S7.3.2(a)(3); 7.3.3(a); S7.3.4; S7.3.5(a); S7.3.6(a); 
the first sentence of S7.3.7(b); S7.3.7(d); S7.3.7(h)(1); the last 
sentence of S7.3.8(b); S7.4(a)(1)(i); S7.4(a)(1)(ii); S7.4(a)(1)(iii); 
S7.4(a)(2)(i); S7.4(a)(2)(ii); the first sentence of S7.4 (a)(3); 
S7.5(d)(2)(i)(A)(1); S7.5(d)(2)(i)(A)(2), S7.5(d)(2)(ii)(A)(1), 
S7.5(d)(2)(ii)(A)(2), S7.5(d)(3)(i)(A); S7.5(d)(3)(i)(B); 
S7.5(d)(3)(ii)(A); S7.5(d)(3)(ii)(B); S7.5(e)(2)(i)(A); 
S7.5(e)(2)(i)(B); S7.5(e)(2)(ii)(A); S7.5(e)(2)(ii)(B); the

[[Page 36342]]

first sentences of S7.5(e)(3)(i) and S7.5(e)(3)(ii); S7.6.2; S7.6.3; 
and S7.8.1; S7.8.2; S7.8.2.2; and S7.8.5, to read as set forth below;
    d. redesignating paragraph S7.8.5.2(c) as S7.8.5.2(d);
    e. adding new S7.8.5.2(c) and S7.8.5.3 to read as set forth below;
    f. revising the fourth sentence of S10 (a) and the third sentence 
of S10(b) to read as set forth below;
    g. adding new Figures 15B, 17B, 27A, and 28A, to read as set forth 
below; and
    h. revising Figure 26 to read as set forth below:


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

* * * * *
    S4  Definitions.
* * * * *
    Cutoff means a generally horizontal, visual/optical aiming cue in 
the lower beam that marks a separation between areas of higher and 
lower luminance.
* * * * *
    Vehicle headlamp aiming device or VHAD means motor vehicle 
equipment, installed either on a vehicle or headlamp, which is used for 
determining the horizontal or vertical aim, or both the vertical and 
horizontal aim of the headlamp.
    Visually/optically aimable headlamp means a headlamp which is 
designed to be visually/optically aimable in accordance with the 
requirements of S7.8.5.3 of this standard.
    S7.3.2  Type A headlighting system. * * *
    (a) *  *  *
    (3) In S4.5.2 and S5.1.6, the words ``Figure 28 or 28A of Motor 
Vehicle Safety Standard No. 108 are substituted for ``Table 3.''
* * * * *
    S7.3.3  Type B headlighting system. * * *
    (a) The requirements of S7.3.2(a) through (c), except that Figure 
27 or Figure 27A is substituted for Table 3 in S7.3.2(a)(3).
* * * * *
    S7.3.4  Type C headlighting system. A Type C headlighting system 
consists of two Type 1C1 and two Type 2C1 headlamps and associated 
hardware, which are designed to conform to the requirements of 
S7.3.2(a) through (d), except that Figure 28 or 28A is substituted for 
Table 3 in S7.3.2(a)(3).
    S7.3.5  Type D headlighting system. (a) A Type D headlighting 
system consists of two Type 2D1 headlamps and associated hardware, 
which are designed to conform to the requirements of S7.3.2(a) through 
(c), except that Figure 27 or 27A is substituted for Table 3 in 
S7.3.2(a)(3).
* * * * *
    S7.3.6  Type E headlighting system. (a) A Type E headlighting 
system consists of two Type 2E1 headlamps and associated hardware, 
which are designed to conform to the requirements of S7.3.2(a) through 
(c), except that Figure 27 or 27A is substituted for Table 3 in 
S7.3.2(a)(3).
* * * * *
    S7.3.7  Type F headlighting system. * * *
* * * * *
    (b) The photometric requirements of Figure 15A or 15B of this 
standard. *  *  *
* * * * *
    (d) When tested in accordance with paragraph (c) of this section, 
the mounted assembly (either Type UF or Type LF headlamps, respective 
mounting ring, aiming ring, and aim adjustment mechanism) shall be 
designed to conform to the requirements of Figure 15A or 15B for upper 
or lower beams respectively without reaim when any conforming Type UF 
or LF headlamp is tested and replaced by another conforming headlamp of 
the same Type.
* * * * *
    (h) *  *  *
    (1) The assembly (consisting of the Type UF and LF headlamps, 
mounting rings, the aiming/seating rings, and aim adjustment mechanism) 
shall be designed to conform to the test points of Figure 15A or 15B.
* * * * *
    S7.3.8  Type G headlighting system. * * *
* * * * *
    (b) *  *  * In S4.5.2, the words ``either Figure 28 or 28A'' are 
substituted for the words ``Table 3''.
* * * * *
    S7.4  Integral beam headlighting systems. * * *
    (a) *  *  *
    (1) *  *  *
    (i) Figure 15A or 15B; or
    (ii) Figure 15A or 15B, except that the upper beam test value at 
2.5D-V and 2.5D-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
    (iii) Figure 28 or 28A.
    (2) *  *  *
    (i) Figure 17 or 17B; or
    (ii) Figure 27 or 27A.
    (3) In a system in which there is more than one beam contributor 
providing a lower beam, and/or more than one beam contributor providing 
an upper beam, each beam contributor in the system shall be designed to 
meet only the photometric performance requirements of Figure 15A or 15B 
based upon the following mathematical expression: conforming test point 
value = 2 (Figure 15A or 15B test point value)/total number of lower or 
upper beam contributors for the vehicle, as appropriate. *  *  *
* * * * *
    S7.5  Replaceable bulb headlighting systems. *  *  *
* * * * *
    (d) *  *  *
    (2) *  *  *
    (i) *  *  *
    (A) *  *  *
    (1) The lower beam requirements of Figure 27 or 27A or Figure 17A 
or 17B if the light sources in the headlamp system are any combination 
of dual filament replaceable light sources other than Type HB2; or
    (2) The lower beam requirements of Figure 17A or 17B if the light 
sources are Type HB2, or any dual filament replaceable light sources 
that include Type HB2; or
    (B) *  *  *
    (ii) *  *  *
    (A) *  *  *
    (1) The upper beam requirements of Figure 27 or 27A, or Figure 17A 
or 17B if the light sources in the headlamp system are any combination 
of dual filament replaceable light sources that include Type HB2, or
    (2) The upper beam requirements of Figure 17A or 17B if the light 
sources are Type HB2, or any combination of replaceable light sources 
that include Type HB2; or
* * * * *
    (3) *  *  *
    (i) *  *  *
    (A) The lower beam requirements of Figure 27 or 27A, or Figure 15A 
or 15B if the light sources in the headlamp system are any combination 
of dual filament light sources other than Type HB2; or
    (B) The lower beam requirements of Figure 15A or 15B if the light 
sources are Type HB2, or dual filament light sources other than Type 
HB1 and Type HB5. *  *  *
    (ii) *  *  *
    (A) The upper beam requirements of Figure 27 or 27A or Figure 15A 
or 15B if the light sources in the headlamp system are any combination 
of dual filament light sources other than Type HB2; or
    (B) The upper beam requirements of Figure 15A or 15B if the light 
sources are Type HB2, or dual filament light

[[Page 36343]]

sources other than Type HB1 and Type HB5. *  *  *
    (e) *  *  *
* * * * *
    (2) * * *
    (i) * * *
    (A) By the outboard light source (or the uppermost if arranged 
vertically) designed to conform to the lower beam requirements of 
Figure 17A or 17B; or
    (B) By both light sources, designed to conform to the lower beam 
requirements of Figure 17A or 17B.
    (ii) * * *
    (A) By the inboard light source (or the lower one if arranged 
vertically) designed to conform to the upper beam requirements of 
Figure 17A or 17B; or
    (B) By both light sources, designed to conform to the upper beam 
requirements of Figure 17A or 17B.
    (3) * * *
    (i) The lower beam shall be produced by the outboard lamp (or upper 
one if arranged vertically), designed to conform to the lower beam 
requirements of Figure 15A or 15 B. * * *
    (ii) The upper beam shall be produced by the inboard lamp (or lower 
one if arranged vertically), designed to conform to the upper beam 
requirements of Figure 15A or 15B. * * *
* * * * *
    S7.6.2  In a combination headlighting system consisting of two 
headlamps, each headlamp shall be designed to conform to Figure 17A or 
17B and shall be a combination of two different headlamps chosen from 
the following types: a Type F headlamp, an integral beam headlamp, and 
a replaceable bulb headlamp.
* * * * *
    S7.6.3  In a combination headlighting system consisting of four 
headlamps, each headlamp shall be designed to conform to Figure 15A or 
15B, or if an integral beam headlamp in which there is more than one 
beam contributor, designed to conform to Figure 15A or 15B in the 
manner required by S7.4(a)(3) of this standard.
* * * * *
    S7.8.1  (a) Each headlamp or beam contributor that is not visually/
optically aimable in accordance with S7.8.5.3 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 
APR85 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 [of 
the year following one year after publication of the final rule] shall 
be equipped with headlamps or beam contributors which have a mark or 
markings that are visible from the front of the headlamp 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.
    (c) Each headlamp that is visually/optically aimable in accordance 
with S7.8.5.3 of this standard shall be marked in accordance with 
S7.8.5.3(f).
    S7.8.2 Except as provided in this section, 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. A visually/optically aimable headlamp that has a lower beam 
shall not have a horizontal adjustment mechanism unless such mechanism 
meets the requirements of S7.8.5.2 of this standard.
* * * * *
    S7.8.2.2  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 S7.8.4,
    (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 paragraph (a) of this section,
    (c) Be exempted from the aim range limits for testing in a 
laboratory as specified in S7.8.3, and
    (d) Be exempted from S7.8.4 if it is visually/optically aimable and 
has fixed horizontal aim.
* * * * *
    S7.8.5  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. When a headlamp system is 
installed on a motor vehicle, it shall be aimable with at least one of 
the following:
    (a) An externally applied aiming device, as specified in S7.8.5.1;
    (b) An on-vehicle headlamp aiming device installed by the vehicle 
or lamp manufacturer, as specified in S7.8.5.2; or
    (c) By visual/optical means, as specified in S7.8.5.3.
* * * * *
    S7.8.5.2(c) Each headlamp equipped with a VHAD that is manufactured 
for use on motor vehicles manufactured on or after September 1 [of the 
year following one year after publication of the final rule] shall be 
manufactured with its calibration permanently fixed by its 
manufacturer. Calibration in this case means the process of accurately 
aligning the geometry of the VHAD devices with the beam pattern for the 
purposes of compliance with the standard.
* * * * *
    S7.8.5.3  Visual/optical aiming. Each visually/optically aimable 
headlamp shall be designed to conform to the following requirements:
    (a) 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.
    (1) Vertical position of cutoff. The headlamp shall be aimed 
vertically 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.
    (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 paragraph (a)(5) of this section.
    (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.
    (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

[[Page 36344]]

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.)
    (5) Measuring the cutoff parameters. (i) 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.
    (ii) 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.
    (iii) 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.
    (iv) 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&R of the measurement point of the maximum gradient to 
determine the inclination.
    (b) 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 at zero.
    (c) Vertical aim, upper beam. (1) 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 S7.8.5.3 (a) 
and (b) used for the lower beam.
    (2) 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.
    (d) Horizontal aim, upper beam. (1) 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 S7.8.5.3 
(a) and (b) used for the lower beam.
    (2) 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 
12.80.20 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.
    (3) 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.
    (e) Photometric requirements and measurements. (1) Instead of being 
designed to conform to the photometric requirements of Figures 15A, 
17A, 27 or 28, a visually/optically aimable headlamp shall be designed 
to conform to the requirements of Figures 15B, 17B, 27A or 28A when 
tested in accordance with paragraph (e)(2) of this section and SAE J575 
DEC88, with the distance from the photometer to the headlamp no less 
than 18.3 m.
    (2) If the lower beam has a left side cutoff, reaim the headlamp 
vertically to place the maximum gradient found in S7.8.5.3 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 S7.8.5.3 at the H-H line. 
For an upper beam, the headlamp would already be aimed at the end of 
the procedure found in S7.8.5.3. A 0.25 degree reaim is permitted in 
any direction at any test point.
    (f) Marking. (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, 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.
    (2) Visual/optical aimability identification marks. (i) 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.
    (ii) 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.
    (iii) 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 [the effective date of the final rule] and if such headlamp type 
has been redesigned since then to be visually/optically aimable.
    (iv) 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''.
    (v) Each letter used in marking according to this paragraph shall 
be not less than 3 mm. high.
* * * * *
    S10. Simultaneous aim photometry tests.
    (a) Type F headlamp systems. * * * Photometry measurements of the 
UF photometry unit shall be completed using the aiming plane so 
established, and the procedures of section 4.1 and 4.1.4 Standard J1383 
APR85, and Figure 15A or 15Ba. * * *
    (b) Integral beam headlamp systems. * * * Photometric compliance of 
the lower beam shall be determined with all lower beam contributors 
illuminated and in accordance with sections 4.1 and 4.1.6 of SAE 
Standard J1383 APR85, and Figure 15A or 15B. * * *
* * * * *

               Figure 15B.--Photometric Test Point Values               
------------------------------------------------------------------------
                                                  Candela      Candela  
             Test points (degrees)                maximum      minimum  
------------------------------------------------------------------------
                               Upper Beam                               
                                                                        
------------------------------------------------------------------------
2U-V..........................................           --        1,500
1U-3L and 3R..................................           --        5,000
H-V...........................................       70,000       40,000
H-3L and 3R...................................           --       15,000
H-6L and 6R...................................           --        5,000
H-9L and 9R...................................           --        3,000
H-12L and 12R.................................           --        1,500
1.5D-V........................................           --        5,000
1.5D-9L and 9R................................           --        2,000
2.5D-V........................................           --        2,500
2.5D-12L and 12R..............................           --        1,000
4D-V..........................................        5,000           --
                                                                        
------------------------------------------------------------------------
                               Lower Beam                               
                                                                        
------------------------------------------------------------------------
10U-90U.......................................          125           --
4U-8L and 8R..................................           --           64
2U-4L.........................................           --          135
1.5U-1R to 3R.................................           --          200

[[Page 36345]]

                                                                        
1.5U-1R to R..................................        1,400           --
1U-1.5L to L..................................          700           --
0.5U-1.5L to L................................        1,000           --
0.5U-1R to 3R.................................        2,700          500
H-V...........................................        5,000           --
H-4L..........................................           --          135
H-8L..........................................           --           64
0.6D-1.3R.....................................           --       10,000
0.86D-V.......................................           --        4,500
0.86D-3.5L....................................       12,000        1,800
1.5D-2R.......................................           --       15,000
2D-9L and 9R..................................           --        1,250
2D-15L and 15R................................           --        1,000
4D-V..........................................       10,000           --
4D-4R.........................................       12,500           --
4D-20L and 20R................................           --          300
------------------------------------------------------------------------



               Figure 17B.--Photometric Test Point Values               
------------------------------------------------------------------------
                                                  Candela      Candela  
            Test Points  (degrees)                maximum      minimum  
------------------------------------------------------------------------
                               Upper Beam                               
                                                                        
------------------------------------------------------------------------
2U-V..........................................           --        1,500
1U-3L and 3R..................................           --        5,000
H-V...........................................       75,000       40,000
H-3L and 3R...................................           --       15,000
H-6L and 6R...................................           --        5,000
H-9L and 9R...................................           --        3,000
H-12L and 12R.................................           --        1,500
1.5D-V........................................           --        5,000
1.5D-9L and 9R................................           --        2,000
2.5D-V........................................           --        2,500
2.5D-12L and 12R..............................           --        1,000
4D-V..........................................       12,000           --
                                                                        
------------------------------------------------------------------------
                               Lower Beam                               
                                                                        
------------------------------------------------------------------------
10U-90U.......................................          125           --
4U-8L and 8R..................................           --           64
2U-4L.........................................           --          135
1.5U-1R to 3R.................................           --          200
1.5U-1R to R..................................        1,400           --
1U-1.5L to L..................................          700           --
0.5U-1.5L to L................................        1,000           --
0.5U-1R to 3R.................................        2,700          500
H-4L..........................................           --          135
H-8L..........................................           --           64
0.6D-1.3R.....................................           --       10,000
0.86D-V.......................................           --        4,500
0.86D-3.5L....................................       12,000        1,800
1.5D-2R.......................................           --       15,000
2D-9L and 9R..................................           --        1,250
2D-15L and 15R................................           --        1,000
4D-4R.........................................       12,500           --
4D-20L and 20R................................           --          300
------------------------------------------------------------------------


       Figure 26.--Table for Determining the Photometric Requirements of Replaceable Bulb Headlamp Systems      
----------------------------------------------------------------------------------------------------------------
                                         Any dual filament type other than     HB2 or any single filament type  
                                        HB2 used alone or with another dual  used alone or with any other single
                                        filament type other than HB2, filed    or dual filament type, filed in  
                                                in Docket No. 93-11                    Docket No. 93-11         
----------------------------------------------------------------------------------------------------------------
Four-Headlamp Systems.................  Fig. 27 or 27A, Fig. 15 or 15B.....  Fig. 15 or 15B.                    
Two-Headlamp Systems..................  Fig. 27 or 27A, Fig. 17 or 17B.....  Fig. 17 or 17B.                    
----------------------------------------------------------------------------------------------------------------


               Figure 27A.--Photometric Test Point Values               
------------------------------------------------------------------------
                                                  Candela      Candela  
            Test points  (degrees)                maximum      minimum  
------------------------------------------------------------------------
                               Upper Beam                               
                                                                        
------------------------------------------------------------------------
2U-V..........................................           --        1,000
1U-3L and 3R..................................           --        2,000
H-V...........................................       75,000       20,000
H-3L and 3R...................................           --       10,000
H-6L and 6R...................................           --        3,250
H-9L and 9R...................................           --        1,500
H-12L and 12R.................................           --          750
1.5D-V........................................           --        5,000
1.5D-9L and 9R................................           --        1,500
2.5D-V........................................           --        2,500
2.5D-12L and 12R..............................           --          750
4D-V..........................................        5,000           --
                                                                        
------------------------------------------------------------------------
                               Lower Beam                               
                                                                        
------------------------------------------------------------------------
10U-90U.......................................          125           --
4U-8L and 8R..................................           --           64
2U-4L.........................................           --          135
1.5U-1R to 3R.................................           --          200
1.5U-1R to R..................................        1,400           --
1U-1.5L to L..................................          700           --
0.5U-1.5L to L................................        1,000           --
0.5U-1R to 3R.................................        2,700          500
H-4L..........................................           --          135
H-8L..........................................           --           64
0.6D-1.3R.....................................           --       10,000
0.86D-V.......................................           --        4,500
0.86D-3.5L....................................       12,000        1,800
1.5D-2R.......................................           --       15,000
2D-9L and 9R..................................           --        1,250
2D-15L and 15R................................           --        1,000
4D-4R.........................................       12,500           --
4D-20L and 20R................................           --          300
------------------------------------------------------------------------


                                   Figure 28A.--Photometric Test Point Values                                   
----------------------------------------------------------------------------------------------------------------
                        Headlamp type                             1A1, 1C1, and 1G1         2A1, 2C1, and 2G1   
----------------------------------------------------------------------------------------------------------------
                                                                Candela      Candela      Candela      Candela  
                    Test points (degrees)                       maximum      minimum      maximum      minimum  
----------------------------------------------------------------------------------------------------------------
                                                   Upper Beam                                                   
                                                                                                                
----------------------------------------------------------------------------------------------------------------
2U-V........................................................  ...........          750  ...........          750
1U-3L and 3R................................................  ...........        3,000  ...........        2,000
H-V.........................................................       60,000       18,000       15,000        7,000
H-3L and 3R.................................................  ...........       12,000  ...........        3,000
H-6L and 6R.................................................  ...........        3,000  ...........        2,000

[[Page 36346]]

                                                                                                                
H-9L and 9R.................................................  ...........        2,000  ...........        1,000
H-12L and 12R...............................................  ...........          750  ...........          750
1.5D-V......................................................  ...........        3,000  ...........        2,000
1.5D-9L and 9R..............................................  ...........        1,250  ...........          750
2.5D-V......................................................  ...........        1,500  ...........        1,000
2.5D-12L and 12R............................................  ...........          600  ...........          400
4D-V........................................................        5,000  ...........        2,500  ...........
----------------------------------------------------------------------------------------------------------------



------------------------------------------------------------------------
                 Headlamp type                      2A1, 2C1, and 2G1   
------------------------------------------------------------------------
                                                  Candela      Candela  
             Test points (degrees)                maximum      minimum  
------------------------------------------------------------------------
                               Lower Beam                               
                                                                        
------------------------------------------------------------------------
10U-90U.......................................          125  ...........
4U-8L and 8R..................................  ...........           64
2U-4L.........................................  ...........          135
1.5U-1R to 3R.................................  ...........          200
1.5U-1R to R..................................        1,400  ...........
1U-1.5L to L..................................          700  ...........
0.5U-1.5L to L................................        1,000  ...........
0.5U-1R to 3R.................................        2,700          500
H-4L..........................................  ...........          135
H-8L..........................................  ...........           64
0.6D-1.3R.....................................  ...........       10,000
0.86D-V.......................................  ...........        4,500
0.86D-3.5L....................................       12,000        1,800
1.5D-2R.......................................  ...........       15,000
2D-9L and 9R..................................  ...........        1,250
2D-15L and 15R................................  ...........        1,000
4D-4R.........................................       12,500  ...........
4D-20L and 20R................................  ...........          300
------------------------------------------------------------------------

    Issued on July 2, 1996.
Barry Felrice,
Associate Administrator for Safety Performance Standards.
[FR Doc. 96-17299 Filed 7-9-96; 8:45 am]
BILLING CODE 4910-59-P