TP-118-06

April 12, 2006

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

FMVSS 118

Power-Operated Window, Partition,

and Roof Panel Systems

ENFORCEMENT
Office of Vehicle Safety Compliance
Room 6115, NVS-220
400 Seventh Street, SW
Washington, DC 20590
 OVSC LABORATORY TEST PROCEDURE NO. 118
TABLE OF CONTENTS

PAGE

1. PURPOSE AND APPLICATION............................................................................. 1

2. GENERAL REQUIREMENTS................................................................................. 2

3. SECURITY ............................................................................................................. 4

4. GOOD HOUSEKEEPING ....................................................................................... 4

5. TEST SCHEDULING AND MONITORING ............................................................. 4

6. TEST DATA DISPOSITION.................................................................................... 5

7. GOVERNMENT FURNISHED PROPERTY (GFP)................................................. 5

8. CALIBRATION OF TEST INSTRUMENTS............................................................. 6

9. PHOTOGRAPHIC DOCUMENTATION.................................................................. 7

10. DEFINITIONS......................................................................................................... 8

11. PRETEST REQUIREMENTS ................................................................................. 8

12. COMPLIANCE TEST EXECUTION........................................................................ 13

13. POST TEST REQUIREMENTS.............................................................................. 24

14. REPORTS .............................................................................................................. 24

14.1. MONTHLY STATUS REPORTS................................................................. 24

14.2. APPARENT TEST FAILURE ...................................................................... 24

14.3. FINAL TEST REPORTS ............................................................................. 25

14.3.1 COPIES .................................................................................. 25

14.3.2 REQUIREMENTS................................................................... 25

14.3.3 FIRST THREE PAGES........................................................... 26

14.3.4 TABLE OF CONTENTS ......................................................... 30

15. DATA SHEETS....................................................................................................... 31

16. FORMS .................................................................................................................. 42

 REVISION CONTROL LOG

FOR OVSC LABORATORY
TEST PROCEDURES

TP118-06
POWER-OPERATED WINDOW, PARTITION, AND ROOF PANEL
SYSTEMS

TEST FMVSS 118

PROCEDURE
DESCRIPTION
REV. EFFECTIVE
No. DATE AMENDMENT DATE

00 Dec. 15, ---- ---- Original Issue

1978
01 Mar. 24, ---- ---- Added Door Option
1983
02 Feb. 8, ---- ---- Added Light Trucks and
1989 “Close”
03 April 58FR16782 4/30/93 Final Rule – Response to
8,1994 3/31/93 Petitions for Reversal
Requirements
04 Sept. 15, 69FR55517 11/15/04 Final Rule – Actuation Device
2004 9/15/04 * Operation and Test
Requirements
05 Mar. 24, 69FR55531 9/1/05 Final Rule – Auto Reversal for
2005 9/15/04 Infrared Reflectance Systems

06 Apr. 12, Final Rule – Response to

71FR18673 6/12/06 Petitions - modification of
2006
4/12/06 * actuation device to steel
sphere and added
requirement for pull up or pull
out switches for power-
operated windows

* Vehicles manufactured before 10/1/2008 need not meet the new requirements of
S6 of the standard.
 1

1. PURPOSE AND APPLICATION

The Office of Vehicle Safety Compliance (OVSC) provides contractor

laboratories with Laboratory Test Procedures as guidelines for obtaining
compliance test data. The data are used to determine if a specific vehicle or item
of motor vehicle equipment meets the minimum performance requirements of the
subject Federal Motor Vehicle Safety Standard (FMVSS). The purpose of the
OVSC Laboratory Test Procedures is to present a uniform testing and data
recording format, and provide suggestions for the use of specific equipment and
procedures. These Laboratory Test Procedures do not constitute an
endorsement or recommendation for use of any product or method. If any
contractor views any part of an OVSC Laboratory Test Procedure to be in conflict
with a FMVSS or observes deficiencies in a Laboratory Test Procedure, the
contractor is required to advise the Contracting Officer's Technical
Representative (COTR) and resolve the discrepancy prior to the start of
compliance testing.

The OVSC Laboratory Test Procedures are not intended to limit or restrain a
contractor from developing or utilizing any testing techniques or equipment which
will assist in procuring the required compliance test data. However, the
application of any such testing technique or equipment is subject to prior
approval of the COTR.

NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose
of use by independent laboratories under contract to conduct compliance tests
for the OVSC, are not rules, regulations or NHTSA interpretations regarding the
meaning of a FMVSS. The Laboratory Test Procedures are not intended to limit
the requirements of the applicable FMVSS(s). In some cases, the OVSC
Laboratory Test Procedures do not include all of the various FMVSS minimum
performance requirements. Recognizing applicable test tolerances, the
Laboratory Test Procedures may specify test conditions that are less severe than
the minimum requirements of the standard. In addition, the Laboratory Test
Procedures may be modified by the OVSC at any time without notice, and the
COTR may direct or authorize contractors to deviate from these procedures, as
long as the tests are performed in a manner consistent with the standard itself
and within the scope of the contract. Laboratory Test Procedures may not be
relied upon to create any right or benefit in any person. Therefore, compliance of
a vehicle or item of motor vehicle equipment is not necessarily guaranteed if the
manufacturer limits its certification tests to those described in the OVSC
Laboratory Test Procedures.
 2

2. GENERAL REQUIREMENTS

FMVSS 118 requires that passenger cars, multipurpose passenger vehicles and
trucks with a gross vehicle weight rating (GVWR) of 4,536 kg (10,000 lb) or less,
equipped with power-operated window (includes vent window), partition and roof
panel (WPRP) systems, meet the requirements as specified below in order to
minimize the likelihood of death or injury from accidental operation.

Unless the vehicle meets the requirements for an automatic reversal system
stated below, WPRP systems may be CLOSED only in the following
circumstances (S4):

A. When the key that controls activation of the vehicle's engine is in the "ON"
"START", or "ACCESSORY" position;

B. By muscular force unassisted by a vehicle supplied power;

C. Upon continuous activation by a locking system on the exterior of the

vehicle;

D. Upon continuous activation of a remote actuation device, provided that the

remote actuation device shall be incapable of closing the WPRP from a
distance of more than 6 meters from the vehicle;

E. During the interval between the time the locking device which controls the
activation of the vehicle's engine is turned off and the opening of either of
a two-door vehicle's doors or, in the case of a vehicle with more than two
doors, the opening of either of its front doors;

F. If the WPRP is in a static position before starting to close and in that

position creates an opening so small that a 4 mm diameter semi-rigid
cylindrical rod cannot be placed through the opening at any location
around its edge; or

G. Upon continuous activation of a remote actuation device, provided that the

remote actuation device shall be incapable of closing the WPRP if the
device and the vehicle are separated by an opaque surface and provided
that the remote actuation device shall be incapable of closing the WPRP
from a distance of more than 11 meters from the vehicle.

Unless the vehicle meets the requirements for an automatic reversal system
stated below, an additional requirement for WPRP systems is that they may NOT
BEGIN TO CLOSE when tested as follows (S6(a) and(b)) (Vehicles
manufactured before 10/1/2008 need not meet this requirement, but
optional early compliance is permitted):
 3

H. Sphere Test - When any part of a stainless steel sphere having a surface
finish between 8 and 4 micro inches and a radius of 20 mm +/- 0.2 mm, is
applied on or over any power-operated window, partition, or roof panel
actuation device mounted in the occupant compartment, and a force not to
exceed 135 Newtons (30 lb) is applied. This requirement does not apply
to actuation devices that are mounted in a vehicle’s roof, headliner, or
overhead console that can close WPRP only by continuous rather than
momentary actuation.

An additional requirement, applicable only to Power-Operated Window

(includes vent windows) actuation devices, is as follows (S6c) (Vehicles
manufactured before 10/1/2008 need not meet this requirement, but
optional early compliance is permitted):

I. Pull Up or Pull Out Test - Any actuation device for closing a power-
operated window (regardless of mounting location or meeting paragraph
S5 (automatic reversal)) must operate by pulling away from the surface in
the vehicle on which the device is mounted. An actuation device must
operate only when pulled vertically up (if horizontally mounted), or out (if
vertically mounted), or in a direction perpendicular to the surrounding
surface if mounted in a sloped orientation, in order to cause the window to
move in the closing direction.

Requirements for WPRP with an automatic reversal system, as certified by the

vehicle manufacturer to those requirements, shall:

J. S5.1 - Be equipped with a reversal system which shall stop and reverse
direction either before contacting a specified test rod, or before exerting a
squeezing force of 100 Newtons on the test rod when such test rod is
placed through the window, partition, or roof panel opening at any location
as illustrated an the end of section 12 of this test procedure.

K. S5.2 - Upon reversal, the power-operated window, partition, or roof panel

system must open to one of the following positions, at the manufacturer's
option:

1. A position that is at least as open as the position at the time closing

was initiated;

2. A position that is not less than 125 millimeters more open than the
position at the time the window reversed direction; or

3. A position that permits a semi-rigid cylindrical rod that is 200 mm in

diameter to be placed through the opening at the same location as the
test rod.
 4

L. S5.3 - If a vehicle uses proximity detection by infrared reflection to stop

and reverse a power-operated window, partition, or roof panel, the infrared
source shall project infrared light at a wavelength of not less than 850 nm
and not more than 1050 nm. The system shall meet the requirements in
J. and K. in all ambient light conditions from total darkness to 64,500 lux
(6,000 foot candles) incandescent light intensity.

3. S
ECURITY

The contractor shall provide appropriate security measures to protect the OVSC
test vehicles and parts during the entire compliance testing program. The
contractor is also financially responsible for any acts of theft and/or vandalism
which occur during the storage of test vehicles. Security problems which arise
shall be reported by telephone to the COTR and the Industrial Property Manager
(IPM), Office of Contracts and Procurement (OCP), within 2 working days after
the incident. A letter containing specific details of the security problem shall be
sent to the IPM (with copy to the COTR) within 4 working days. The contractor
shall protect and segregate all photographs and data that evolve from
compliance testing. No information concerning the vehicle safety compliance
testing program shall be released to anyone except the COTR, unless
specifically authorized by the COTR or the COTR's Branch or Division Chief.

NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY

INVOLVED IN THE COMPLIANCE TESTING PROGRAM, SHALL BE
ALLOWED TO WITNESS ANY VEHICLE COMPLIANCE TEST UNLESS
SPECIFICALLY AUTHORIZED BY THE COTR.

4. G
OOD HOUSEKEEPING

Contractors shall maintain the entire vehicle compliance testing area, test fixtures
and instrumentation in a neat, clean and painted condition with test instruments
arranged in an orderly manner consistent with good test laboratory housekeeping
practices.

5. TEST SCHEDULING AND MONITORING

The contractor shall submit a test schedule to the COTR prior to testing. Tests
shall be completed as required in the contract. Scheduling shall be adjusted to
permit sample motor vehicles to be tested to other FMVSS as may be required
by the OVSC. All testing shall be coordinated to allow monitoring by the FMVSS
No. 118 COTR.
 5

6. TEST DATA DISPOSITION

The contractor shall make all vehicle preliminary compliance test data available
to the COTR on location within 4 hours after the test. Final test data shall be
furnished to the COTR within 5 working days. Additionally, the contractor shall
analyze the preliminary test results as directed by the COTR. All backup data
sheets, technical notes, etc., shall be either sent to the COTR or destroyed at the
conclusion of each delivery order, purchase order, etc.

7. GOVERNMENT FURNISHED PROPERTY (GFP)

ACCEPTANCE OF TEST VEHICLES

The Contractor has the responsibility of accepting each test vehicle whether
delivered by a new vehicle dealership or another vehicle transporter. In both
instances, the contractor acts in the OVSC's behalf when signing an acceptance
of the test vehicle delivery. When a vehicle is delivered, the contractor must
check to verify the following:

A. All options listed on the "window sticker" are present,

B. Tires and wheels are new and the same as listed,

C. There are no dents or other interior or exterior flaws,

D. The vehicle has been properly prepared and is in running condition, and

E. Owner's manual, warranty document, consumer information, and extra set

of keys are present.

A Vehicle Condition form will be supplied to the contractor when the test vehicle
is transferred from a new vehicle dealership or between test contracts. The
contractor must complete a Vehicle Condition form for each vehicle and deliver it
to the COTR with the Final Test Report or the report will not be accepted for
payment.

NOTIFICATION OF COTR

The COTR must be notified within 24 hours after a vehicle has been delivered. In
addition, if any discrepancy or damage is found at the time of delivery, a copy of
the Vehicle Condition form shall be sent to the COTR immediately.
 6

8. CALIBRATION OF TEST INSTRUMENTS

Before the contractor initiates the safety compliance test program, a test
instrumentation calibration system shall be implemented and maintained in
accordance with established calibration practices. The calibration system shall
be set up and maintained as follows:

A. Standards for calibrating the measuring and test equipment will be stored
and used under appropriate environmental conditions to assure their
accuracy and stability.

B. All measuring instruments and standards shall be calibrated by the

contractor, or a commercial facility, against a higher order standard at
periodic intervals NOT TO EXCEED TWELVE (12) MONTHS! Records,
showing the calibration traceability to the National Institute of Standards
and Technology (NIST), shall be maintained for all measuring and test
equipment.

C. All measuring and test equipment and measuring standards will be labeled
with the following information:

(1) Date of calibration

(2) Date of next scheduled calibration
(3) Name of the technician who calibrated the equipment

D. A written calibration procedure shall be provided by the contractor

which includes as a minimum the following information for all
measurement and test equipment:

(1) Type of equipment, manufacturer, model number, etc.

(2) Measurement range
(3) A
ccuracy
(4) C
alibration interval
(5) Type of standard used to calibrate the equipment (calibration
traceability of the standard must be evident)

E. Records of calibration for all test instrumentation shall be kept by the

contractor in a manner which assures the maintenance of established
calibration schedules. All such records shall be readily available for
inspection when requested by the COTR. The calibration system will
need the acceptance of the COTR before the test program commences.

Further guidance is provided in the International Standard ISO 10012-1, “Quality

Assurance Requirements for Measuring Equipment” and American National
Standard ANSI/NCSL Z540-1, “Calibration Laboratories and Measuring and Test
Equipment - General Requirements”.
 7

9. P
HOTOGRAPHIC DOCUMENTATION

Photographs for test reports shall be 8 x 10 inches, and clearly illustrate the
intended features. A tag, label, or placard identifying the test vehicle model and
NHTSA number shall appear in each photograph and be legible. Each
photograph shall be labeled as to subject matter and actuation device
photographs shall properly identify device location. As a minimum, the following
photographs shall be included, as applicable:

A. 3/4 frontal view from right side of vehicle

B. 3/4 rear view from left side of vehicle

C. Close-up view of vehicle's certification label

D. Close-up view of vehicle's tire information placard

E. Close-up views of vehicle's interior locking system and exterior power

window control locks

F. Close-up view of each unique power window, partition, and roof panel
actuation device

G. Close-up view of power window master control panel

H. Close-up view of remote control device

I. Close-up view of remote control receiver(s)

J. Close-up view of automatic reversal system transmitter/receiver(s)

K. Photos of test instrumentation used in conducting this test (may be a

composite photograph with instrumentation removed from vehicle)

L. T
est instrumentation installed on vehicle

M. Close-up view of sphere being applied to actuation switches

N. Close-up of all test failure areas and components

 8

10. DEFINITIONS

Actuation Device – A switch, device, controller or other component that controls

the power window, partition or roof panel.

Express-up capability – One-touch activation in closing direction, i.e. without

continuous activation.

Infrared reflectance - The ratio of the intensity of infrared light reflected and
scattered by a flat sample of the test rod material to the intensity of infrared light
reflected and scattered by a mirror that reflects 99.99 percent of the infrared
radiation incident on its surface.

Interior Locking System – The key-locking system located in the occupant

compartment and controls the activation of the vehicle’s engine.

Power-Operated Roof Panel Systems - Moveable panels in the vehicle roof

which close by vehicle supplied power either by a sliding or hinged motion, and
do not include convertible top systems.

WPRP – Power-Operated Window, Partition, and Roof Panel

11. PRETEST REQUIREMENTS

IN-HOUSE COMPLIANCE TEST PROCEDURE

Prior to conducting any compliance tests, contractors are required to submit a

detailed in-house compliance test procedure and equipment list to the COTR that
includes a step-by-step description of the methodology to be used and a detailed
check-off list. Written approval must be obtained from the COTR before
commencing testing so that all parties are in agreement. There shall be no
contradiction between the OVSC Laboratory Test Procedure and the contractor's
in-house test procedure. The list of test equipment shall include instrument
make, model, range, resolution and accuracy.

TEST DATA LOSS

A compliance test is not to be conducted unless all of the various test conditions
specified in the applicable OVSC Laboratory Test Procedure have been met.
Failure of a contractor to obtain the required test data and to maintain acceptable
limits on test parameters in the manner outlined in the applicable OVSC
Laboratory Test Procedure may require a retest at the expense of the contractor.
The retest costs will include all costs associated with conducting the retest.
 9

The Contracting Officer of NHTSA is the only NHTSA official authorized to notify
the contractor that a retest is required. The retest shall be completed within two
(2) weeks after receipt of notification by the Contracting Officer that a retest is
required. If a retest is conducted, no test report is required for the original test.

REQUIRED TEST EQUIPMENT

A. A stainless steel sphere and force gauge assembly for contacting window,
partition and roof panel actuation devices. The stainless steel sphere
shall have a surface finish between 8 and 4 micro inches and a radius of
20 mm +/- 0.2 mm. The force gauge shall be attached to the sphere in a
manner that will apply force through the geometric center of the sphere.
The force gauge shall have a range of 200 Newtons, a resolution of 1
Newton and an accuracy of +0.5% of full scale.

B. Three (3) test rods for testing systems designed to detect obstructions by
physical contact shall be of cylindrical shape and sufficient length that they
can be hand-held with only the test rod making any contact with any part
of the window, partition, or roof panel or mating surfaces. Test rod
diameters shall be 5 mm, 100 mm and 200 mm diameter (+2/-0 mm).
Each test rod shall have a force-deflection ratio of not less than 65 N/mm
for rods up to 25 mm diameter, and not less than 20 N/mm for larger
diameter rods.

C. Three (3) test rods for testing systems designed to detect obstructions by
light beam interruption shall be the same shape and dimensions as above.
In addition, they shall be opaque to infrared, visible and ultraviolet light.
They are not required to have the same force-deflection ratios as above.

D. One test rod for testing systems designed to detect proximity of

obstructions using infrared reflections shall have the shape and

dimensions as shown below.

minimum of 300mm* 40mm

1% reflectance

10mm
*Excluding end portion used to hold and 20mm
position rod during test
 10

The entire test rod surface shall have an infrared reflectance of not more
than 1.0 percent when measured by the apparatus shown below.

The infrared reflectance of the rod surface material is measured using a

flat sample of the material and an infrared light source and sensor
operating at a wavelength of 950 +/- 100 nm.

The intensity of the incident infrared light is determined using a reference

mirror of nominally 100 percent reflectance mounted in place of the
sample in the Infrared reflectance measuring apparatus (refer to
suggested test equipment section above).

Infrared reflectance measurements of each sample of test rod surface

material and of the reference mirror are connected to remove the
contribution of infrared light reflected and scattered by the sample holder
and other parts of the apparatus before computation of the infrared
reflectance ratio.

E. Force measuring instrumentation to measure window squeezing forces in

range from 10 Newtons to 150 N with accuracy of +/- 1.5 N @ 75N,
maximum nonlinearity of +/- 3 N over the range and resolution of 1.5
Newtons.

F. Incandescent lighting that projects 64,500 lux (6000 foot candles) for
testing infrared reflectance power window reversal systems.

G. Light meter for measuring incandescent light levels from 0 to 70,000 lux
while testing infrared reflectance power window reversal systems.
 11

H. Infrared light wavelength meter to measure the system output(s) in range

from 850 to 1050 nm similar to WaveMate Wavelength meter
manufactured by Coherent.

I. Position transducer or equivalent to measure window, partition, or roof

panel opening distance, 300 mm range with accuracy of +/- 1mm in
100mm and visual output resolution of .01 mm.

J. Continuous recorder to provide permanent, supplemental records of

window, partition, and roof panel force, distance and speed versus time.
When electrical input signals to the recorder are simulated, the accuracy
of that instrument’s recorded data must be verified by at least one physical
check, with the entire instrumentation system connected.

SUPERVISORY REVIEW

The contractor’s responsible laboratory supervisor shall verify the following steps
in preparation for each safety compliance test:

A. COTR approval of contractor’s detailed in-house test procedure including

check-off sheets,

B. Test personnel are trained for and thoroughly familiar with the above test
procedure, use of the test equipment and laboratory safety precautions, and

C. Calibration of all measuring and test equipment has bee performed within the
required intervals.

TEST AREA

A clean, dry, level surface for parking during the test is required. The area must
have sufficient space in every direction from the vehicle to test a remote WPRP
closing control if it is so equipped. Refer to Section 12.3 of this test procedure for
details.

VEHICLE IDENTIFICATION AND PRE-OPERATIONAL CHECK

Each vehicle shall be visually inspected to identify all power windows, partitions
and roof panels (WPRP) and corresponding actuation devices. A pre-operational
check shall be conducted to ensure each WPRP appears to operate in
accordance with manufacturer's specifications outlined in the Vehicle Owner's
Manual. Record data on the WPRP Pre-Operational Check sheet.
 12

A. Thoroughly review contents of vehicle owner’s manual or equivalent

documentation paying particular attention to sections discussing internal
and external locks, manual and remote control, operating instructions and
automatic reversal features.

B. Identify all vehicle installed power WPRPs. (If necessary, modify the list of
vehicle installed power WPRPs on the Pre-Operational Check sheet and
applicable data sheets.)

C. Identify all interior individual and master control actuation devices.

D. Identify WPRPs operable by a remote control actuation device, and/or

exterior locking system.

E. Identify WPRPs equipped with Express-Up and/or Auto-Reverse

capabilities.

F. Describe location(s )of the master control panel and exterior control locks.

G. Identify all interior locking system key positions.

H. Use remote activation device at a distance of approximately 3 meters from

the vehicle in conjunction with an opaque surface to verify whether it is a
Line-of Sight or Non-Line of-Sight control type. Verify the remote
closing function of each WPRP.

I. Turn the interior locking system to the "ON" position. Using the master
control and individual actuation devices, operate each WPRP through 1
complete open-close cycle.

NOTE: One open-close cycle consists of starting with the WPRP in the
fully closed position, moving the WPRP to fully open and back to fully
closed.

j. Turn the interior locking system to the "Accessory" position. Using the
master control and individual actuation devices, operate each WPRP
through 1 complete open-close cycle.

k. If vehicle is equipped with an automatic reversal system, use any suitable

obstruction (not necessarily a prescribed test rod) to verify its function on
each WPRP. Further, if the system uses infrared reflection to stop and
reverse WPRP, conduct this part of the pre-test in an ambient light
condition between total darkness and 10,000 lux (929 foot candles).

The testing laboratory will contact the COTR to resolve any matters of WPRPs
failing to operate properly before proceeding with further testing of the vehicle.
 13

12. COMPLIANCE TEST EXECUTION

NOTE: (Prior to 10/1/2008) A VEHICLE MUST MEET THE REQUIREMENTS OF

SECTIONS 12.1, 12.2, and12.3, OR, IT MUST MEET THE AUTOMATIC REVERSAL
REQUIREMENTS OF SECTION 12.5.

NOTE: (After 10/1/2008) A VEHICLE MUST MEET THE REQUIREMENTS OF

SECTIONS 12.1, 12.2, 12.3, and 12.4.1 (sphere test), OR, IT MUST MEET THE
REVERSAL REQUIREMENTS OF SECTION 12.5.
IT MUST MEET 12.4.2 (Pull-Up or Pull-Out Test)

Any Power-operated WPRP may be closed if the WPRP is in a static position

before starting to close and in that position creates an opening so small that a 4
mm diameter semi-rigid cylindrical rod cannot be placed through the opening at
any location around its edge (excluding power-operated windows which must
have pull up or pull out switches).

12.1 Interior Locking System Test (S4(e)).

Power-operated WPRP systems may be closed during the interval between the
time the locking device which controls the activation of the vehicle’s engine is
turned off and the opening of either of a two-door vehicle’s doors or, in the case
of a vehicle with more than two doors, the opening of either of its front doors.

A. Locking System in “LOCK” and other off positions [Data Sheet 1]

(1) Close all doors and turn locking system to the "ON" position. Open
all WPRPs and then turn the locking system to the "LOCK" position.
Attempt to close each WPRP using the master and individual
actuation devices. Record the results indicating whether the
master and individual actuation devices are operable for Doors
Closed. For any actuation device checked as inoperable in this
section record a pass in the adjacent data sheet column. If any
actuation device is checked as operable, re-open the respective
WPRP and continue testing that particular device to the door open
option test procedure in paragraph (2) of this section.

(2) Open the left front door. Attempt to close each WPRP using the
master and the individual actuation devices. Record the results
indicating whether the master and individual actuation devices are
operable under Left Door Open. Repeat the above test (steps
(1) and (2)) with the right front door open and the left front
door closed. Record a pass if checked inoperable; and a fail if
checked operable.

(3) Repeat steps (1) and (2) above for all other locking system
positions excluding “ON”, “ACCESSORY”, or “START.” For each
 14

additional locking system position tested a separate data sheet

shall be completed.

(4) Repeat steps (1) through (3) starting with the locking system in the
“ACCESSORY” position. Skip this step if the WPRPs are not
operable with the locking system in the “ACCESSORY” position.

B. Locking System With The Key Removed [Data Sheet 2]

(1) Close all doors, turn locking system to the "ON" position, and open
all WPRPs. Remove the key from the locking system and attempt
to close each WPRP using the master and individual actuation
devices. Record the results indicating whether the master and
individual actuation devices are operable. For any device checked
as inoperable, record a pass in the adjacent data sheet column. If
any actuation device is checked as operable, re-open the
respective WPRP and continue testing that particular device to the
door open test procedure in paragraph (2) of this section.

(2) Open the left front door. Attempt to close each WPRP using the
master and the individual actuation devices. Record the results
indicating whether the master and individual actuation devices are
operable under Left Door Open. Repeat the above test (steps
(1) and (2)) with the right front door open. Record a pass if
checked inoperable and a fail if checked operable.

(3) Repeat steps (1) and (2) starting with the locking system in the
“ACCESSORY” position. Skip this step if the WPRPs are not
operable with the locking system in the “ACCESSORY” position.

12.2 Exterior Locking System Test (S4(c))

Power-operated WPRP systems may be closed upon continuous activation by a
locking system on the exterior of the vehicle. Record data in Data Sheet 3.

A. If the vehicle is not equipped with an exterior locking system skip to

section 12.3 of this procedure.

B. Describe the location(s) of the exterior lock(s) and how the system is
activated.
C. Remove key from interior locking system.
D. Activate the exterior locking system through at least 2 complete open-
close cycles, pausing at intermediate points of travel, and identify
locations of operable WPRPs. Determine whether continuous activation
of the exterior locking system is required to close the operable WPRPs.
For each operable WPRP record a pass if the WPRP only closes while the
activation is continuous, or fail if it closes in an express-up mode.
 15

12.3 Remote Actuation Device Test (S4(d) and (g))

Power-operated WPRP systems may be closed upon continuous activation of a remote

actuation device provided that the device shall be incapable of closing any WPRP from
a non line-of-site distance of more than 6 meters, or a line-of-site distance of more than
11meters from the vehicle. Record data in Data Sheet 4.

A. If the vehicle is not equipped with a remote actuation device skip to section 12.4 of
this procedure.

B. Identify type of remote actuation device installed on vehicle. Separate the remote
actuation device and vehicle mounted receivers by an opaque surface and attempt to
activate the system from distances of approximately 3 meters in each direction shown
on Data Sheet 4. Repeat at distances of approximately 9 meters. If the system does
not function, the vehicle is equipped with a “Line-of-Sight” remote actuation device,
proceed to paragraph D below, otherwise, the vehicle is equipped with a “Non Line-of-
Sight” remote actuation device, proceed to paragraph C below.

C. Non Line-of-Sight
With key removed, doors closed and all WPRP open at least half way, determine the
maximum operating distance of the remote actuation device. The range of operation
shall not exceed six meters in any direction from the vehicle and continuous activation
of the remote actuation device is required until all operable WPRPs are completely
closed. If the system operates as required record a pass and the maximum distances
that the control can function, otherwise indicate a fail.

D. Line-of-Sight
With key removed, doors closed and all WPRP open at least half way, determine the
maximum operating distance of the remote actuation device. The range of operation
shall not exceed eleven meters in any direction from the vehicle and continuous
activation of the remote actuation device is required until all operable WPRPs are
completely closed. If the system operates as required record a pass and the maximum
distances that the control can function, otherwise indicate a fail.

E. Repeat test with interior locking system “ON”.

 16

12.4 Occupant Compartment Actuation Device Test (S6)

(Vehicles manufactured before 10/1/2008 are not required to meet the Sphere Test and
the Pull Up or Pull Out Test) Record results on Data Sheet 5 and 6.

12.4.1 Sphere Test (S6a and b) - Any actuation device that is mounted in the
occupant compartment of a vehicle and can be used to close a power-operated
WPRP shall not cause such WPRP to begin closing from any open position when
contacted by the spherical surface of a stainless steel sphere having a surface finish
between 8 and 4 micro inches and a radius of 20mm +/- 0.2 mm and tested as
specified below.
This requirement does not apply to actuation devices that are:
- mounted in a vehicle’s roof, headliner, or overhead console and
that can close a WPRP only by continuous rather than
momentary switch actuation or
- comply with the reversing requirements of FMVSS 118, S5.

A. Close all doors and turn locking system to the "ON" position. Cycle each WPRP,
leaving each WPRP in its fully open position.

B. Identify each actuation device that shall be tested to this requirement.

C. Using the stainless steel sphere and force gauge assembly, attempt to close
each WPRP by contacting each master control panel actuation device and
individual actuation device with the spherical surface. Apply a force of 135
Newtons to the geometric center of the sphere. The force may be applied at
any angle with respect to the actuation device. For actuation devices that
cannot be contacted by the sphere prior to application of the force, apply a force
not to exceed 135 Newtons at any angle in an attempt to make contact with the
actuation device. The sphere shall be directionally applied in such a manner
that, if unimpeded, it would make contact with the actuation device.

D. Repeat the test sequence with each WPRP in at least one intermediate open
position where a 5 mm diameter or larger test rod can be placed through the
opening around its edge.

E. Record the results indicating whether any applicable master or individual

actuation device is capable of closing any WPRP when subjected to the applied
force. For any actuation device that did not cause the WPRP to begin closing
record a pass, otherwise record a fail in the adjacent column on the data sheet.

Record results on Data Sheet 5.

 17

12.4.2 POWER–OPERATED WINDOW switches: Pull UP or Pull OUT Test (S

6(c))
An actuation device may operate to cause a power-operated window (does not
include roof panel or partition) to move in the closing direction only when:
- pulled vertically up (if horizontally mounted), or
- pulled out (if vertically mounted), or
- pulled in a direction perpendicular to and away from the
surrounding surface if mounted in a sloped orientation.

A. Place the vehicle ignition in a position where the power window actuation
devices are enabled. For any actuation device for closing a power-operated
window, apply a force to the device in a direction away from the surface in the
vehicle on which the device is mounted. For a horizontally mounted device pull
vertically up, on a vertically mounted device pull out, and for a device mounted
on a sloped orientation, pull in a direction perpendicular and away from the
surrounding surface on which the device is mounted. Verify that the power-
operated windows can only close with forces applied to the actuation device in
the direction as specified above. The requirement becomes effective on vehicles
manufactured on or after 1 October 2008 but a manufacturer may comply earlier.

NOTE This requirement for power-operated windows must be complied with

regardless of the ability of the device to comply with the sphere test
(S6) above or if automatic reversal equipped (S5).

Record results on Data Sheet 6.

12.5 Automatic Reversal Systems Tests (S5, S7 and S8)

A power-operated WPRP may close under any operational condition if it can stop
and reverse direction either:
- before contacting, or
- before exerting a squeezing force of 100 Newtons or more on a specified
cylindrical test rod, when such test rod is placed through the WPRP opening at
any location as illustrated at the end of this test procedure.

Record results in Data Sheet 7, 8 or 9 (as applicable).

After the automatic reversal tests are conducted, the results shall be compared
with the other test data sheets to ensure that automatic reversal performance
does compensate for the failures of all WPRPs that did not pass any alternative
test.

12.5.1 Physical Contact Reversal Systems (Data Sheet 7)

A. Close all doors and turn locking system to the "ON" position. E
nsure power
to each front door window, leaving each in an approximately half open
position.
 18

B. On one of the front door windows, place temporary reference marks on the
glass and the window frame for measuring reversal distance relative to
original opening dimension. Record window open dimension.

C. On the same window, place a 5mm diameter test rod at the front edge of the
window as shown at the end of this test procedure. Rod must be placed
through the window from inside the vehicle.

D. Utilizing any applicable actuation device provided in the vehicle, close the
window onto the test rod and measure the squeeze force applied before the
system reverses direction. Repeat this step with the test rod in at least 1
additional position.

E. After the window reverses and comes to a stop, measure the distance it has
reversed from the point of contact with the test rod and the open dimension in
relation to the original open dimension measurement.

F. Using the same power window, repeat above test sequence with 100mm and
200mm diameter test rods.

G. With the vehicle doors still closed, turn locking system to the "OFF" or "LOCK"
position. Again, ensure power to each front door window, leaving each
window in its half open position. Repeat steps A. through F. utilizing the
opposite front door window and the test rod placed at the top edge of the
window and at least 1 other location such that the cylindrical surface of the
test rod contacts any part of the structure with which the window mates.
Describe these locations on the data sheet.

H. Repeat steps A. through G. for rear door or rear quarter panel windows.

I. With doors closed and the locking system “ON,” repeat steps A. through F.
with each test rod placed in at least 2 different edge positions around the
power-operated partition(s).

J. Repeat step I. with the locking system in the “OFF” or “LOCK” position.

K. With doors closed and the locking system “ON,” repeat steps A. through F.
with each test rod placed in at least 2 different positions on all edges of the
power-operated roof panel(s). If a roof panel travels in 3 or more modes
(such as up-down hinged and forward-back slide) perform this step in all
modes.

L. Repeat step K. above with the locking system in the “OFF” or “LOCK”
position.
M. For each WPRP tested report a pass or fail in the data sheet in the adjacent
column. The squeezing force exerted cannot exceed 100 newtons.
 19

12.5.2 Light Beam Interruption Reversal Systems (Data Sheet 8)

A. Close all doors and turn locking system to the "ON" position. Ensure
power to each front door window, leaving each approximately half open.

B. On one of the front door windows, place temporary reference marks on

the glass and the window frame for measuring reversal distance relative to
original opening dimension. Record window open dimension.

C. On the same window, place a 5mm diameter opaque cylindrical test rod at
the front edge of the window as shown in the figure below. Rod must be
placed through the window from inside the vehicle.

D. Utilizing any applicable actuation device provided in the vehicle, attempt to

close the window onto the test rod. Repeat with the test rod in at least 1
additional position.

E. After each trial, note if the window does not begin to close. If the window
begins to close and then reverses before contacting the test rod, measure
the distance it has reversed from the point the window came to a stop and
began to open, and the re-opened dimension in relation to the original
open dimension measurement. If the test rod is contacted, measure the
squeezing force.
F.
Using the same window, repeat above test sequence with 100mm and
200mm diameter opaque test rods.

G. With the vehicle doors still closed, turn locking system to the "OFF" or
"LOCK" position. Again, ensure power to each front door window, leaving
each window in its half open position. Repeat steps A. through F. utilizing
the opposite front door window and the test rod placed at the top edge of
the window and at least 1other location such that the cylindrical surface of
the test rod contacts any part of the structure with which the window
mates. Describe these locations on the data sheet. Rod must be placed
through the window from inside the vehicle.

H. Repeat steps A. through G. for rear door or rear quarter panel

windows.

I. Repeat steps A. through F. with each test rod placed in at least 2 different
positions around the power-operated partition(s).

J. Repeat step I. with the locking system in the “OFF” or “LOCK” position.

K. Repeat steps A. through F. with each test rod placed in at least 2 different
positions on all opening edges of the power-operated roof panel(s).
 20

L. Repeat step K. with the locking system in the “OFF” or “LOCK” position.

M. For each WPRP tested report a pass or fail in the data sheet in the
adjacent column. With the test rod placed in the WPRP the applicable
WPRP shall not have begun to close upon activating the applicable
actuation device or if the WPRP did begin to close it shall have reversed to
one of the positions specified below:

(1) A position that is at least as open as the position at the time

closing was initiated;

(2) A position that is not less than 125 millimeters more open
than the position at the time the window reversed direction;
or

(3) A position that permits a semi-rigid cylindrical rod that is 200

mm in diameter to be placed through the opening.

If a WPRP contacts a test rod the squeezing force shall not exceed 100
newtons.
 21

12.5.3 Infrared Reflectance Reversal Systems (Data Sheet 9)

A. Place the test vehicle under incandescent lighting that projects 64,500 lux
(6,000 foot candles) onto the infrared sensor. The light is projected onto
the infrared sensor by aiming the optical axis of a light source outside the
vehicle as perpendicular as possible to the lens of the infrared sensor.
The intensity of light is measured perpendicular to the plane of the lens of
the infrared sensor, as close as possible to the center of the lens of the
infrared sensor.

B. Close all doors and turn locking system to the "ON" position. Ensure
power to each front door window, leaving each approximately half open.

C. On one of the front door windows, place temporary reference marks on

the glass and the window frame for measuring reversal distance relative to
original opening dimension. Record window re-opening dimension.

D. On the same window, place a test rod of the type specified for infrared
reflectance in the window at the front edge of the window as shown in the
figure below. The rod must be placed through the window from inside the
vehicle.

E. Utilizing any applicable actuation device, and while keeping the rod
stationary, attempt to close the window onto the test rod. Repeat the test
with the test rod in at least 1 additional position.

F. After each trial, note if the window does not begin to close. If the window
begins to close and then reverses before contacting the test rod, measure
the distance it has reversed from the point the window came to a stop and
began to re-open, and the re-opened dimension in relation to the original
open dimension measurement. If the test rod is contacted, measure the
squeezing force.

G. Fully open the same window and then begin to close it. While the window
is closing, move the test rod so that it approaches and ultimately extends
through (if necessary) the window in any orientation from the interior of the
vehicle. Repeat while moving the test rod into a different area in the path
of the closing window.

H. If the window begins to close and then reverses before contacting the test
rod, measure the distance it has reversed from the point the window came
to a stop and began to open, and the re-opened dimension in relation to
the original open dimension measurement. If the test rod is contacted,
measure the squeezing force.

I. With the vehicle doors still closed, turn locking system to the "OFF" or
 22

"LOCK" position. Again, ensure power to each front door power window,
leaving each window in its half open position. Repeat steps A. through H.
utilizing the opposite front door power window and the infrared reflectance
test rod placed at the top edge of the window and at least 1 other location.
Describe these locations on the data sheet.
J. Repeat steps A. through I. for rear door or rear quarter panel windows.

K. Repeat steps A. through H. with the test rod placed in at least 2 different
edge positions around the power-operated partition(s).

L. Repeat step K. with the locking system in the “OFF” or “LOCK” position.

M. Repeat steps A. through H. with the test rod placed in at least 2 different
positions on all opening edges of the power-operated roof panel(s).

N. Repeat step M. with the locking system in the “OFF” or “LOCK” position.

O. For each WPRP tested report a pass or fail in the data sheet in the
adjacent column. With the test rod placed in the WPRP, the applicable
WPRP shall not have begun to close upon activating the applicable
actuation device or if the WPRP did begin to close shall have reversed to
one of the positions specified below. When the test rod was moved
towards the WPRP while the WPRP was closing the WPRP shall have
stopped and reversed to one of the positions specified below.

(1) A position that is at least as open as the position at the time

closing was initiated;

(2) A position that is not less than 125 millimeters more open
than the position at the time the window reversed direction;
or

(3) A position that permits a semi-rigid cylindrical rod that is 200

mm in diameter to be placed through the opening.

If a WPRP contacts the test rod the squeezing force shall not exceed 100
newtons.
23

 24

13. POST TEST REQUIREMENTS

After the required tests are completed, the contractor shall:

Verify all instrumentation, test data records and photographs;

Restore the vehicle to its original configuration, if necessary;

Complete the Vehicle Condition Report form including word description of the
vehicle’s post test condition;

Copy applicable pages of the vehicle Owner’s Manual for attachment to the final
test report;

Move the test vehicle to a secure area; and

Place all original records in a secure and organized file awaiting test data
disposition.

14. REPORTS

14.1 MONTHLY STATUS REPORTS

The contractor shall submit a monthly Test Status Report and a Vehicle Status
Report to the FMVSS 118 COTR. The Vehicle Status report shall be submitted
until all FMVSS 118 vehicles are transferred to another FMVSS or otherwise
disposed of. Samples of the required reports are found in the report forms
section.

14.2 APPARENT TEST FAILURE

Any indication of an test failure shall be communicated by telephone or to the

COTR within 24 hours with written notification mailed within 48 hours (Saturday
and Sunday hours excluded). A Notice of Test Failure (see report forms section)
with a copy of the particular compliance test data sheet(s) and preliminary data
plot(s) shall be included.

If possible, repeat that portion of the test where the failure was noted to ensure
that there is a test failure.

In the event of a test failure, a post test calibration check of some critically
sensitive test equipment and instrumentation (if applicable) may be required for
verification of accuracy. The necessity for the calibration shall be at the COTR's
discretion and shall be performed without additional costs to the OVSC.
 25

14.3 FINAL TEST REPORTS

14.3.1 COPIES

In the case of an apparent test failure, 7 copies of the Final Test Report shall be
submitted to the COTR for acceptance within 3 weeks of test completion.

Where there has been no indication of an apparent noncompliance, 3 copies of

each Final Test Report shall be submitted to the COTR for acceptance within 3
weeks of test completion. No payment of contractor's invoices for conducting
compliance tests will be made prior to the Final Test Report acceptance by the
COTR. Contractors are requested to NOT submit invoices before the COTR is
provided with copies of the Final Test Report.

Contractors are required to submit the first Final Test Report in draft form within 1
week after the compliance test is conducted. The contractor and the COTR will
then be able to discuss the details of both test conduct and report content early in
the compliance test program.

Contractors are required to PROOF READ all Final Test Reports before submittal
to the COTR. The OVSC will not act as a report quality control office for
contractors. Reports containing a significant number of errors will be returned to
the contractor for correction, and a "hold" will be placed on invoice payment for
the particular test.

14.3.2 REQUIREMENTS

The Final Test Report, associated documentation (including photographs), are

relied upon as the chronicle of the compliance test. The Final Test Report will be
released to the public domain after review and acceptance by the COTR. For
these reasons, each final report must be a complete document capable of
standing by itself.

The contractor should use detailed descriptions of all compliance test events.
Any events that are not directly associated with the standard but are of technical
interest should also be included. The contractor should include as much detail
as possible in the report.

Instructions for the preparation of the first three pages of the final test report are
provided for standardization.
 26

14.3.3 FIRST THREE PAGES

A. FRONT COVER
A heavy paperback cover (or transparency) shall be provided for the
protection of the final report. The information required on the cover is as
follows:

(1) Final Report Number such as 118-ABC-0X-001 where

118 is the FMVSS tested
ABC are the initials for the laboratory
0X is the Fiscal Year of the test program
001 is the Group Number (001 for the 1st test,
002 for the 2nd test, etc.)

(2) Final Report Title And Subtitle such as

COMPLIANCE TESTING FOR FMVSS 118

Power-Operated Window, Partition and Roof Panel Systems
**********************
XYZ Motor Co.
200X Deluxe 4-door sedan
NHTSA No. CX0101

(3) Contractor's Name and Address such as

ABC LABORATORIES
405 Main Street
Detroit, Michigan 48070

NOTE: DOT SYMBOL WILL BE PLACED BETWEEN ITEMS (3) AND (4)

(4) Date of Final Report completion

(5) The words "FINAL REPORT"

(6) The sponsoring agency's name and address as follows

U. S. DEPARTMENT OF TRANSPORTATION
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance
400 Seventh Street, SW
Room 6111 (NVS-220)
Washington, DC 20590
 27

B. FIRST PAGE AFTER FRONT COVER

A disclaimer statement and an acceptance signature block for the COTR

shall be provided as follows:

This publication is distributed by the U. S. Department of

Transportation, National Highway Traffic Safety
Administration, in the interest of information exchange. The
opinions, findings and conclusions expressed in this
publication are those of the author(s) and not necessarily
those of the Department of Transportation or the National
Highway Traffic Safety Administration. The United States
Government assumes no liability for its contents or use
thereof. If trade or manufacturers' names or products are
mentioned, it is only because they are considered essential
to the object of the publication and should not be construed
as an endorsement. The United States Government does
not endorse products or manufacturers.

Prepared By:

Approved By:

Approval Date:

FINAL REPORT ACCEPTANCE BY OVSC:

Accepted By:

Acceptance Date:
 28

C. SECOND PAGE AFTER FRONT COVER

A completed Technical Report Documentation Page (Form DOT F1700.7)
shall be completed for those items that are applicable with the other
spaces left blank. Sample data for the applicable block numbers of the
title page follows.

Block 1 — REPORT NUMBER

118-ABC-0X-001

Block 2 — GOVERNMENT ACCESSION NUMBER

Leave blank

Block 3 — RECIPIENT'S CATALOG NUMBER

Leave blank

Block 4 — TITLE AND SUBTITLE

Final Report of FMVSS 118 Compliance Testing of 200X XYZ

Deluxe 4-door sedan, NHTSA No. CX0101

Block 5 — REPORT DATE

March 1, 200X

Block 6 — PERFORMING ORGANIZATION CODE

ABC

Block 7 — AUTHOR(S)

John Smith, Project Manager / Bill Doe, Project Engineer

Block 8 — PERFORMING ORGANIZATION REPORT NUMBER

ABC-DOT-XXX-001

Block 9 — PERFORMING ORGANIZATION NAME AND ADDRESS

ABC Laboratories

405 Main Street

Detroit, Michigan 48070

 29

Block 10 — WORK UNIT NUMBER

Leave blank

Block 11 — CONTRACT OR GRANT NUMBER

DTNH22-9X-D-12345

Block 12 — SPONSORING AGENCY NAME AND ADDRESS

US Department of Transportation
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance
400 Seventh Street, SW, Room 6111 (NVS-220)
Washington, DC 20590

Block 13 — TYPE OF REPORT AND PERIOD COVERED

Final Test Report

Feb. 15 to Mar. 15, 200X

Block 14 — SPONSORING AGENCY CODE

NVS-220

Block 15 — SUPPLEMENTARY NOTES

Leave blank

Block 16 — ABSTRACT

Compliance tests were conducted on the subject 200X XYZ Deluxe

4-door sedan in accordance with the specifications of the Office of
Vehicle Safety Compliance Test Procedure No. TP-118-0X for the
determination of FMVSS 118 compliance.

Test failures identified were as follows:

None

NOTE: Above wording must be shown with appropriate changes

made for a particular compliance test. Any questions should be
resolved with the COTR.
 30

Block 17 — KEY WORDS

Compliance Testing

Safety Engineering

FMVSS 118

Block 18 — DISTRIBUTION STATEMENT

Copies of this report are available from —
National Highway Traffic Safety Administration
Technical Information Services (NPO-405)
400 Seventh Street, SW, Room 2336
Washington, DC 20590
e-mail: [email protected]
FAX: 202-493-2833

Block 19 — SECURITY CLASSIFICATION OF REPORT

Unclassified

Block 20 — SECURITY CLASSIFICATION OF PAGE

Unclassified

Block 21 — NUMBER OF PAGES

Add appropriate number

Block 22 — PRICE

Leave blank

14.3.4 TABLE OF CONTENTS

Final test report Table of Contents shall include the following:

A. Section 1 — Purpose of Compliance Test

B. Section 2 — Test Procedure and Discussion of Results

C. Section 3 — Test Data

D. Section 4 — Test Equipment List and Calibration Information

E. Section 5 — Photographs

F. Section 6 — Copy of Test Vehicle Owner's Manual or other document

G. Section 7 — Notice of Test Failure (if applicable)

 31

15. DATA SHEETS

FMVSS 118
COMPLIANCE DATA SUMMARY SHEET

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

VEHICLE TYPE: DATE OF MANUFACTURE:

LABORATORY: TEST DATE:

REQUIREMENT PASS FAIL NOT

APPLICABLE

S4
Interior Locking System in Off Position(s)

S4
Interior Locking System With Key
Removed

S4
Exterior Locking System

S4
Remote Actuation Device

S6
Occupant Compartment Actuation Devices
(Sphere Test/Pull Up or Pull Out Test)
S5
Automatic Reversal System

REMARKS:
 32

WPRP PRE-OPERATIONAL CHECK

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

Identify power-operated WPRP and WPRP actuation devices.

LEFT LEFT RIGHT RIGHT TAIL ROOF
FRONT REAR FRONT REAR GATE PARTITION PANEL

Power WPRP Installed

Individual Interior Actuation Devices

Master Control Panel Actuation

Devices

WPRP Operated by Exterior

Locking System

WPRP Operated by Remote

Control

WPRP with Auto-Reverse

Capability

WPRP with Express-Up Capability

Master Control Panel Location:

Exterior Locking System Location:

Remote Control Type: ( ) Line-of-Sight ( ) Non-line-of-Sight:

WPRP Actuation Device Design [Toggle, Rocker, Push/Pull (Lever), or describe other]:
Master Control Panel
Individual Window
Roof Panel
Partition

Interior Locking System Key Positions (clockwise):

All WPRP open/close cycles are satisfactory with key in “ON” position:
( ) YES ( ) NO If NO, compliance test shall not proceed.

All WPRP open/close cycles are satisfactory with key in “ACCESSORY” position:
( ) YES ( ) Not Applicable - No power to WPRPs
REMARKS:
RECORDED BY: DATE:
APPROVED BY:

 33

DATA SHEET 1
INTERIOR LOCKING SYSTEM TEST

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

Key lock position at start of test execution. ( ) ON ( ) ACCESSORY

Key lock off position during test execution. ( ) LOCK ( ) OFF ( ) OTHER

ACTUATION DOORS CLOSED LEFT DOOR RIGHT DOOR

DEVICES OPEN OPEN PASS
/FAIL
INOP. OPER. INOP. OPER. INOP. OPER.

MASTER CONTROL PANEL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)
Left Rear (LR)
Right Rear (RR)
Vent Window(s)

Tail Gate (TG)

Partition (P)
Roof Panel (RP)

INDIVIDUAL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)
Left Rear (LR)
Right Rear (RR)
Vent Window(s)

Tail Gate (TG)

Partition (P)
Roof Panel (RP)
REMARKS:

RECORDED BY: DATE:

APPROVED BY:

 34

DATA SHEET 2
INTERIOR LOCKING SYSTEM WITH KEY REMOVED TEST

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

Key lock position at start of test execution. ( ) ON ( ) ACCESSORY

ACTUATION DOORS CLOSED LEFT DOOR RIGHT DOOR

DEVICES OPEN OPEN PASS
/FAIL
INOP. OPER. INOP. OPER. INOP. OPER.

MASTER CONTROL PANEL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)
Left Rear (LR)
Right Rear (RR)
Tail Gate (TG)
Vent Window(s)
Partition (P)
Roof Panel (RP)

INDIVIDUAL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)
Left Rear (LR)
Right Rear (RR)
Vent Window(s)
Tail Gate (TG)
Partition (P)
Roof Panel (RP)
REMARKS:

RECORDED BY: DATE:

APPROVED BY:

 35

DATA SHEET 3
EXTERIOR LOCKING SYSTEM TEST

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

Is vehicle equipped with an exterior locking system that can close any of the power windows,

partitions or roof panels? ( ) YES ( ) NO

Location of exterior locking system:

Describe how the exterior locking system is activated:

Identify the windows, partitions or roof panels that can be closed by the exterior locking
system. Also, in each case, identify whether continuous activation of the locking system is
required.

EXTERIOR LOCKING SYSTEM

EXTERIOR
WINDOW, PARTITION OPERABLE CONTINOUS LOCKING
AND ROOF PANEL (YES/NO) ACTIVATION SYSTEM
IDENTIFICATION REQUIRED (PASS/FAIL)*
(YES/NO)

LEFT FRONT (LF)

RIGHT FRONT (RF)
LEFT REAR (LR)
RIGHT REAR (RR)
VENT WINDOW(s)
PARTITION (P)
ROOF PANEL (RP)
TAIL GATE (TG)

* NOTE: Continuous Activation of the locking system is required for each WPRP to pass the
exterior locking system safety standard requirement.

REMARKS:

RECORDED BY: DATE:

APPROVED BY:

 36

DATA SHEET 4
REMOTE ACTUATION DEVICE

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

Type of remote actuation device installed on vehicle (check one):

( )Non Line-of-Site ( ) Line-of-Site

Measured Range of Operation:

Record the maximum operating distance of the remote actuation device in the boxes
below. The range of operation shall not exceed six meters for a Non Line-of-Site
Device or eleven meters for a Line-of-Site Device in any measured direction and
continuous activation of the remote actuation device is required until all operable
windows, partitions or roof panels are completely closed.
PASS/FAIL

Denote places on the vehicle where signals from the remote device are received.
Add directions and distances to other places where remote device does not comply.
REMARKS:

RECORDED BY: DATE:

APPROVED BY:
 37

DATA SHEET 5
OCCUPANT COMPARTMENT ACTUATION DEVICE TEST
SPHERE TEST

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

ACTUATION APPLICABLE SPHERE TEST RESULT COMPLIANCE

DEVICE (YES/NO) ACTIVATED (PASS/FAIL) REQUIRED
* ACTUATION (Y/N)
DEVICE CLOSES
WPRP **
(YES/NO)
MASTER CONTROL PANEL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)

Left Rear (LR)

Right Rear (RR)

Tail Gate (TG)

Vent Window (s)
Partition (P)

Roof Panel (RP)

INDIVIDUAL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)

Left Rear (LR)

Right Rear (RR)

Vent Window (s)
Tail Gate (TG)

Partition (P)

Roof Panel (RP)

* This requirement does not apply to actuation devices that are mounted in a vehicle’s roof,
headliner, or overhead console and that can close a window, partition, or roof panel only
by continuous rather than momentary switch actuation, or actuation devices that comply
with the reversing requirements of FMVSS 118, S5.
** Requirement is effective 1 October 2008. Early compliance is voluntary and test results
are used for information only.
REMARKS:
RECORDED BY: DATE:
APPROVED BY:

 38

DATA SHEET 6
OCCUPANT COMPARTMENT ACTUATION DEVICE TEST
FOR POWER-OPERATED WINDOWS ONLY
PULL UP OR PULL OUT TEST
VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

ACTUATION Switch Orientation Closes power- TEST RESULT COMPLIANCE

DEVICE a. Horizontal operated window (PASS/FAIL) REQUIRED
b. Vertical (Y/N)
c. Angled ONLY IF:
**
Pull Up or
Pull out

MASTER CONTROL PANEL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)

Left Rear (LR)

Right Rear (RR)

Vent Window (s)
INDIVIDUAL ACTUATION DEVICES

Left Front (LF)

Right Front (RF)

Left Rear (LR)

Right Rear (RR)

Vent Window (s)
** Requirement is effective 1 October 2008. Early compliance is voluntary and test results
are used for information only.

REMARKS:

RECORDED BY: DATE:

APPROVED BY:

 39

DATA SHEET 7
WPRP PHYSICAL CONTACT REVERSAL CAPABILITY

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

WPRPs equipped with reversal capability:

WPRPs that must meet reversal requirements:

Locking System Position:

WINDOW, WINDOW,
TEST ROD TEST PARTITION OR MAXIMUM PARTITION, OR
WINDOW, PLACEMENT IN ROD SIZE ROOF PANEL FORCE ROOF PANEL
PARTITION, ROOF OPENING REVERSING PASS/FAIL
WINDOW, (mm) MEASURED
PANEL BEFORE/AFTER ON TEST DISTANCE *
PARTITION OR
CLOSING ROD (mm)
ROOF PANEL
(mm) (NEWTONS)

* WPRP must reverse direction before contacting or exerting a squeezing force of 100 Newtons.
Upon such reversal, the WPRP must open to one of the following positions.
A. A position that is at least as open as the position at the time closing was initiated,
B. A position that is not less than 125 mm more open than the position at the time the
window reversed direction, or
C. A position that permits a semi-rigid cylindrical rod that is 200 mm in diameter to be
placed through the opening at the same contact point(s) used in 12.5.

REMARKS:

RECORDED BY: DATE:

APPROVED BY:
 40

DATA SHEET 8
WPRP NON-CONTACT LIGHT BEAM INTERRUPTION REVERSAL CAPABILITY

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

WPRPs equipped with reversal capability:

WPRPs that must meet reversal requirements:

Locking System Position:

WINDOW, WPRP BEGINS WINDOW,
TEST ROD TEST PARTITION OR TO CLOSE PARTITION, OR
WINDOW, PLACEMENT IN ROD SIZE ROOF PANEL UPON ROOF PANEL
PARTITION, ROOF OPENING ACTIVATION REVERSING PASS/FAIL
WINDOW, (mm)
PANEL BEFORE/AFTER OF DISTANCE *
PARTITION OR
CLOSING ACTUATION (mm)
ROOF PANEL
(mm) DEVICE?
(YES/NO)

* WPRP must not begin to close upon activation of the applicable actuation device or if the WPRP
does begin to close shall reverse to one of the following positions.
A. A position that is at least as open as the position at the time closing was initiated,
B. A position that is not less than 125 mm more open than the position at the time the
window reversed direction, or
C. A position that permits a semi-rigid cylindrical rod that is 200 mm in diameter to be placed
through the opening at the same contact point(s) used in 12.5.

REMARKS:

RECORDED BY: DATE:

APPROVED BY:
 41

DATA SHEET 9
WPRP NON-CONTACT INFRARED REFLECTANCE REVERSAL CAPABILITY

VEHICLE MAKE/MODEL/BODY STYLE:

VEHICLE NHTSA NO.: VIN:

LABORATORY: TEST DATE:

WPRPs equipped with reversal capability:

WPRPs that must meet reversal requirements:

Measured Test Rod Infrared Reflectance: (Not more than 1%)

Intensity of Exterior Incandescent Light Source lux

Intensity of Exterior Light at Vehicle Infrared Sensor lux (64,000 lux max).

Locking System Position:

WINDOW, WPRP BEGINS WINDOW,
TEST ROD PARTITION OR TO CLOSE PARTITION, OR
WINDOW, PARTITION, PLACEMENT IN ROOF PANEL UPON ROOF PANEL
ROOF PANEL OPENING ACTIVATION OF REVERSING PASS/FAIL
WINDOW,
BEFORE/AFTER ACTUATION DISTANCE *
PARTITION OR
CLOSING DEVICE? (mm)
ROOF PANEL
(mm) (YES/NO)

* WPRP must not begin to close upon activation of the applicable actuation device or if the WPRP
does begin to close shall reverse to one of the following positions.
A. A position that is at least as open as the position at the time closing was initiated,
B. A position that is not less than 125 mm more open than the position at the time the
window reversed direction, or
C. A position that permits a semi-rigid cylindrical rod that is 200 mm in diameter to be placed
through the opening at the same contact point(s) used in 12.5.

REMARKS:

RECORDED BY: DATE:

APPROVED BY:
 42

16. FORMS

LABORATORY NOTICE OF TEST FAILURE TO OVSC

FMVSS NO.: 118 TEST DATE:

LABORATORY:

CONTRACT NO.: ; DELV. ORDER NO.:

LABORATORY PROJECT ENGINEER'S NAME:

TEST VEHICLE DESCRIPTION:

VEHICLE NHTSA NO.: ; VIN:

VEHICLE MANUFACTURER:

TEST FAILURE DESCRIPTION:

STD. REQUIREMENT, PARAGRAPH S :

NOTIFICATION TO NHTSA (COTR):

DATE: ; BY:

REMARKS:
 43

MONTHLY TEST STATUS REPORT

FMVSS 118

DATE OF REPORT:

DATE DATE INVOICE

VEHICLE NHTSA NO., COMPLIANCE PASS/ REPORT INVOICE PAYMENT
NO. MAKE & MODEL TEST DATE FAIL SUBMITTED SUBMITTED DATE

10

11

12

13

14
 44

MONTHLY VEHICLE STATUS REPORT

FMVSS 118

DATE OF REPORT:

TEST VEHICLE
VEHICLE NHTSA NO., DATE OF ODOMETER COMPLETE SHIPMENT ODOMETER
NO. MAKE & MODEL DELIVERY READING DATE DATE READING

10

11

12

13

14