TP104-08
June 26, 1996
U.S. DEPARTMENT OF TRANSPORTATION
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
LABORATORY TEST PROCEDURE
FOR
FMVSS 104
Windshield Wiping and Washing Systems
SAFETY ASSURANCE
Office of Vehicle Safety Compliance
Room 6115, NSA-30
400 Seventh Street, SW
Washington, DC 20590
OVSC LABORATORY TEST PROCEDURE NO. 104
TABLE OF CONTENTS
PAGE
1.
PURPOSE AND APPLICATION ........................................................................
1
2.
GENERAL REQUIREMENTS ............................................................................
2
3.
SECURITY.........................................................................................................
3
4.
GOOD HOUSEKEEPING ..................................................................................
3
5.
TEST SCHEDULING AND MONITORING.........................................................
3
6.
TEST DATA DISPOSITION ...............................................................................
3
7.
GOVERNMENT FURNISHED PROPERTY (GFP) ............................................
4
8.
CALIBRATION OF TEST INSTRUMENTS ........................................................
5
9.
SUGGESTED TEST EQUIPMENT ....................................................................
6
10.
PHOTOGRAPHIC DOCUMENTATION .............................................................
7
11.
DEFINITIONS ....................................................................................................
8
12.
PRETEST REQUIREMENTS.............................................................................
10
13.
COMPLIANCE TEST EXECUTION ...................................................................
11
14.
POST TEST REQUIREMENTS .........................................................................
16
15.
REPORTS..........................................................................................................
17
15.1. MONTHLY STATUS REPORTS .............................................................
17
15.2. APPARENT TEST FAILURE...................................................................
17
15.3
FINAL TEST REPORTS..........................................................................
17
15.3.1 COPIES ........................................................................................
15.3.2 REQUIREMENTS.........................................................................
15.3.3 FIRST THREE PAGES.................................................................
15.3.4 TABLE OF CONTENTS ...............................................................
17
18
18
24
16.
DATA SHEETS ..................................................................................................
25
17.
FORMS ..............................................................................................................
29
1
1.
PURPOSE AND APPLICATION
The Office of Vehicle Safety Compliance (OVSC) provides contracted laboratories with
Laboratory Test Procedures (TPs) which serve 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. Any contractor
interpreting any part of an OVSC Laboratory Test Procedure to be in conflict with a
Federal Motor Vehicle Safety Standard or observing any deficiencies in a Laboratory Test
Procedure is required to advise the Contracting Officer's Technical Representative
(COTR) and resolve the discrepancy prior to the start of compliance testing.
Contractors are required to submit a detailed test procedure to the COTR before initiating
the compliance test program. The procedure must include a step-by-step description of
the methodology to be used.
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.
NOTE: The OVSC Laboratory Test Procedures, prepared for use by independent
laboratories under contract to conduct compliance tests for the OVSC, 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. Sometimes, recognizing applicable test tolerances, the Test
Procedures specify test conditions which are less severe than the minimum requirements
of the standards themselves. Therefore, compliance of a vehicle or item of motor vehicle
equipment is not necessarily guaranteed if the manufacturer limits certification tests to
those described in the OVSC Laboratory Test Procedures.
2
2.
GENERAL REQUIREMENTS
FMVSS 104, Windshield Wiping and Washing Systems — Passenger Cars, Multipurpose
Passenger Vehicles, Trucks, and Buses, specifies that each vehicle shall have a powerdriven windshield wiping system with at least two speeds that meets the standard when
tested in accordance with SAE Recommended Practice J903a, and a windshield washing
system that meets the requirements of SAE Recommended Practice J942, Passenger
Car Windshield Washer Systems, except that the reference to "the effective wipe pattern
defined in SAE J903, paragraph 3.1.2" shall be deleted. The areas established in
accordance with S4.1.2.1 of FMVSS 104 shall be used instead. A different exception
applies to multipurpose passenger vehicles (MPVs), trucks and buses.
3
3.
SECURITY
The contractor shall provide appropriate security measures to protect the OVSC test
vehicles from unauthorized personnel during the entire compliance testing program. The
contractor is financially responsible for any acts of theft and/or vandalism which occur
during the storage of test vehicles. Any security problems which arise shall be reported
by telephone to the Industrial Property Manager (IPM), Office of Contracts and
Procurement, within two working days after the incident. A letter containing specific
details of the security problem will be sent to the IPM (with copy to the COTR) within 48
hours.
The contractor shall protect and segregate the data that evolves from compliance testing
before and after each vehicle test. 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 Chief or Division Chief.
NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY
INVOLVED IN THE COMPLIANCE TEST, SHALL BE ALLOWED TO WITNESS ANY
COMPLIANCE TEST UNLESS SPECIFICALLY AUTHORIZED BY THE COTR.
4.
GOOD 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 vehicle test schedule to the COTR prior to conducting the
first compliance test. Tests shall be completed as required in the contract. Scheduling of
vehicle tests shall be adjusted to permit vehicles to be tested to other FMVSSs as may
be required by the OVSC. All vehicle compliance testing shall be coordinated with the
COTR in order to allow monitoring by the COTR and/or other OVSC personnel if desired.
6.
TEST DATA DISPOSITION
The contractor shall make all vehicle preliminary compliance test data available to the
COTR at the test site within four hours after the test. Final test data shall be furnished to
the COTR within five working days. Additionally, the contractor shall analyze the
preliminary test results as directed by the COTR.
All backup data sheets, strip charts, recordings, plots, technician's 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 VEHICLE
The Contractor has the responsibility of accepting the test vehicle from either a new car
dealer or a vehicle transporter. In both instances, the contractor acts in the OVSC's
4
behalf when signing an acceptance of the test vehicle. If the vehicle is delivered by a
dealer, the contractor must check to verify the following:
A.
All options listed on the "window sticker" are present on the test vehicle.
B.
Tires and wheel rims 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.
E.
The glove box contains an owner's manual, warranty document, consumer
information, and extra set of keys.
F.
Proper fuel filler cap is supplied on the test vehicle.
If the test vehicle is delivered by a government contracted transporter, the contractor
should check for damage which may have occurred during transit.
A "Vehicle Condition" form will be supplied to the contractor by the COTR when the test
vehicle is transferred from the new car dealer or between test contracts. The upper half
of the form describes the vehicle in detail, and the lower half provides space for a
detailed description of the post-test condition. Vehicle Condition forms must be returned
to the COTR with the copies of the Final Test Report or the reports will NOT be accepted.
NOTIFICATION OF COTR
The COTR must be notified within 24 hours after a test vehicle has been delivered.
5
8.
CALIBRATION OF TEST INSTRUMENTS
Before the contractor initiates the safety compliance test program, a test instrumentation
calibration system will be implemented and maintained in accordance with established
calibration practices. Guidelines for setting up and maintaining such calibration systems
are described in MIL-C-45662A, "Calibration System Requirements". 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)
(2)
(3)
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)
(2)
(3)
(4)
(5)
E.
9.
Date of calibration
Date of next scheduled calibration
Name of the technician who calibrated the equipment
Type of equipment, manufacturer, model number, etc.
Measurement range
Accuracy
Calibration interval
Type of standard used to calibrate the equipment (calibration traceability of
the standard must be evident)
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 procedure must be approved by the COTR before the test
program commences.
SUGGESTED TEST EQUIPMENT
A
Stop watch or equivalent timing device, 0 to 60 minutes, with accuracy of ± 2
seconds in 60 minutes
B.
Engine tachometer, 0 to 8,000 rpm, with accuracy of ± 15 rpm
C.
Soft water, hardness 12 grains/gallon
6
D.
Water spray system with 2 nozzles, with 50 to 100 cubic inches/minute flow, and
accuracy of ± 2.5 cubic inches/minute. System shall maintain temperature below
100 F.
E.
Nonabrasive windshield washing compound
F.
Wiper cycle counting device, 0 to 1,000 cycles
G.
Oscillograph recorder or equivalent continuous recorder, 10 ipm minimum chart
speed, with an accuracy of ± 1%
H.
Thermocouple or equivalent temperature sensing device, 0 to 250 F, with an
accuracy of ± 1 F
I.
Anemometer, 0 to 20 mph, with accuracy of ± 0.1 mph
J.
Grease pencil
K.
Camera
L.
Nonabrasive windshield washing equipment
M.
Test dust, fine grade, as described in SAE J726 or equivalent
N.
Measuring device for volume of test dust and water, 0 to 32 fluid ounces, with an
accuracy of ± 0.5 fluid ounces
O.
Hand type atomizer or equivalent
P.
Windshield washer fluid, as specified by vehicle manufacturer
7
10.
PHOTOGRAPHIC DOCUMENTATION
Photographs shall be black and white, 8 x 10 inches, and properly focused for clear
images. A tag, label or placard identifying the test vehicle model, NHTSA number and
date or item of equipment part number and date shall appear in each photograph and
must be legible. Each photograph shall be labeled as to the subject matter.
As a minimum the following photographs shall be included in each vehicle final test
report:
A.
Left side view of vehicle
B.
Right side view of vehicle
C.
3/4 frontal view from left side of vehicle
D.
3/4 rear view from right side of vehicle
E.
Vehicle's certification label
F.
Vehicle's tire information label
G.
Wiped Area Test Equipment setup
H.
Wiped Windshield Area Test Pattern on vellum showing AREAS A, B and C
I.
Washer Capability Test - Pretest Coated Windshield
J.
Washer Capability Test - Post Test Cleared Windshield
K.
Washer Capability Test, 1st Run - Cleared Windshield Area Test Pattern on vellum
showing AREAS A, B and C
L.
Washer Capability Test, 2nd Run - Cleared Windshield Area Test Pattern on vellum
showing AREAS A, B and C
M.
Any damage or apparent test failure that cannot be seen in the above photographs
8
11.
D
EFINITIONS
BALLOONING
Unwiped areas within the wiper pattern varying is size and usually round.
CHATTER
Irregular movement of the wiper blade usually accompanied by temporary visible radial
lines and/or noise.
COMMERCIAL ADDITIVES
Materials which are compatible with the system and which may be added to depress the
fluid freezing point, assist in cleansing, and/or increase the wetting capacity of the fluid.
HAZING
An aerated film spread by the blade and resulting in a transient trailing band on the
windshield glazing surface.
LACE CURTAIN
A maze of fine individual water droplets which are formed after the wiper blade passes
over the windshield glazing surface.
SCALLOPING
Uneven wipe at the outer periphery of pattern.
STREAKING
Fine arcuate lines of unwiped moisture within the wipe pattern.
TANDEM PATTERN
The pattern produced by the wiper blades operating in the same direction across the
windshield glazing surface simultaneously.
WASHER SOLUTION
The fluid in the system consisting of water or water with appropriate commercial
additives.
9
11.
EFINITIONS....Continued
D
WINDSHIELD WASHER SYSTEM
An apparatus for storing, filtering and applying fluid to the exterior of the windshield
glazing surface together with the necessary controls to actuate and arrest operations.
WINDSHIELD WASHER SYSTEM CONTROL
A means for actuating and arresting the windshield washer system. The actuation may
be coordinated or semicoordinated with components of the windshield wiper system or
may be fully independent.
WINDSHIELD WIPER SYSTEM
An apparatus for clearing the exterior surface of windshield glazing together with the
necessary devices and controls to actuate and arrest the operations.
WIPER CYCLE
The wiper blade movement during system operation from one extreme of the windshield
wipe pattern to the other extreme and return.
10
12.
PRETEST REQUIREMENTS
Prior to conducting any compliance tests, contractors are required to submit a detailed
in-house compliance test procedure to the COTR which includes a step-by-step
description of the methodology to be used. Written approval must be obtained from the
COTR before initiating the compliance test program so that all parties are in agreement.
The contractor's test procedure shall contain a complete listing of test equipment and a
detailed check-off list. 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 accuracy and calibration dates.
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 (such as impact velocity) in the manner outlined in the applicable OVSC
Laboratory Test Procedure may require a retest at the expense of the contractor. The
retest costs may include the cost of the replacement vehicle (with the same equipment as
the original vehicle) or item of motor vehicle equipment and all costs associated with
conducting the retest. The original test specimen (vehicle or equipment item) used for
the invalid test shall remain the property of OVSC, and the retest specimen shall remain
the property of the contractor.
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.
11
13.
COMPLIANCE TEST EXECUTION
13.1
WINDSHIELD WIPER SYSTEM
PREPARATION
A.
Study the Owner's Manual. Visually and manually inspect the windshield wiping
and washing system controls to determine if they are accessible.
B.
Visually and manually inspect the windshield washer system fluid reservoir to
ascertain that the reservoir filler opening is readily accessible and can be filled
without the use of tools or special filling equipment.
C.
Clean the windshield glazing surface of the test vehicle with a nonabrasive type
cleaner, and position the test vehicle in a test area containing the water spray
system.
D.
Install a wiper cycle counting device on the windshield wiping system as shown
in Figure 1 below. Install a tachometer or equivalent engine r.p.m. monitoring
instrument. The tachometer shall be capable of being monitored during the test
from within the vehicle.
E.
Provide a means to vent the engine exhaust from the test area without affecting
the temperature or other conditions during the test. Verify that the test vehicle
contains sufficient gasoline to operate the vehicle engine for the duration of the
test.
TYPICAL WIPER CYCLE COUNTING DEVICE
����������������������
�������������������������
��������������������������������
����������������
��������������
��������������
�����������
FIGURE 1
������������������������
���������������������������
����������������������������������
�����������������
��������������
��������������
CYCLE COUNTER
OR RECORDING DEVICE
12
13.
COMPLIANCE TEST EXECUTION....Continued
F.
Verify that the hardness of the water does not exceed 12 grains per gallon. The
water hardness certification may be obtained from the local water supplier.
Otherwise, contractor shall obtain an equivalent certification or conduct such test
within 60 days of beginning of compliance test run. A suitable water softener
shall be used if required.
G.
Calibrate the water flow applied to the windshield to ensure a minimum of spray
of not less than 50 and not more than 100 cubic inches of water per minute.
Adjust the spray nozzles to provide an approximately equal distribution of water
spray over the entire windshield glazing surface. The water spray shall be
applied to the windshield throughout the test. Verify that the water temperature
does not exceed 100 F.
H.
A master windshield pattern containing AREAS A, B and C will be provided by
the COTR. Make 3 working copies of the entire glass area pattern from heavy
clear vellum paper. NOTE: 2 are required for the Washer Capability test runs.
FREQUENCY TEST
A.
Maintain ambient temperature of 50 to 100 F and engine speed constant within ±
50 rpm. Transmission shall be placed in neutral.
B.
Start the test vehicle engine. Operate it at manufacturer's recommended idle
speed. Actuate the Windshield wiper control to the high speed position, and
subject the windshield wiper system to a 6 minute Frequency Test with the
external water spray applied directly to the windshield. During the first 3 minutes,
operate the wiper system at high speed with the test vehicle engine at the
manufacturer's recommended idle speed. Upon conclusion of the 3 minute
operational period, increase the engine speed to 2,000 rpm for another 3 minute
period. Calculate the average frequency of the wiper for each 3 minute test
period.
C.
Readjust the engine speed to the manufacturer's recommended idle speed.
Actuate the windshield wiper control to the lowest speed position with at least 20
cycles per minute, and subject the windshield wiper system to a 6 minute
Frequency Test with the water spray applied directly to the windshield. During
the first 3 minutes operate the wiper system at low speed and the engine at the
manufacturer's recommended idle speed. Upon conclusion of the 3 minute
operational period, increase the engine speed to 2,000 rpm for another 3 minute
period. Calculate the average wiper frequency for each 3 minute test period.
13
13.
COMPLIANCE TEST EXECUTION....Continued
WIPED AREA TEST
A.
Clean the exterior and interior surfaces of the vehicle windshield prior to testing
with a commercial nonabrasive glass cleaning agent to provide an oil and grease
free surface for marking the dimensional area as required.
B.
Start the engine and operate it at the manufacturer's recommended idle speed ±
50 rpm with transmission in neutral.
C.
Ambient air flow should not exceed 1 mph to ensure consistent spray patterns.
Verify the velocity of the air flow using an anemometer placed 12 inches in front
of the center of the windshield. Maintain ambient air temperature at 50 to 100 F.
D.
Actuate the water spray system and adjust the windshield wiper control to the
highest speed mode. Maintain water temperature below 100 F.
E.
Using a grease pencil, outline on the internal windshield glazing surface the
areas of the windshield that are cleanly wiped by the wiper blades. The areas
shall include the wiper blade pattern plus the growth due to the high speed
operation and the 1 mph air flow.
F.
After completing the wiped area patterns on the internal windshield surface, turn
off the windshield wiper system, the water spray and air flow. Dry the windshield
and surrounding areas of the test vehicle.
G.
Place the clear vellum containing outlines of AREAS A, B and C, on the exterior
windshield glazing surface. With a grease pencil, trace onto the vellum the wiped
area patterns.
14
13.
COMPLIANCE TEST EXECUTION....Continued
13.2
WINDSHIELD WASHER SYSTEM
PREPARATION
A.
Verify that the windshield washer reservoir contains sufficient windshield washing
fluid to perform the Windshield Washing Capability Test. The washing fluid shall
be a commercial product specified by the manufacturer. Fluid temperature shall
be 75 F ± 5 F immediately prior to the first test run.
B.
With the vehicle in position for testing, actuate the windshield washing system.
Verify that the washer nozzles are properly adjusted so the fluid spray is applied
to the windshield glazing surface target areas recommended by the vehicle
manufacturer. Air velocity at the windshield should not exceed 1 mph to ensure
consistent spray patterns.
C.
Clean the exterior and interior surfaces of the vehicle windshield.
D.
Verify that 2 vellum windshield working patterns containing AREAS A, B and C
(as made in preparation for the wiper test) are available.
E.
Mix one part test dust and two parts water by volume.
(1)
Fine grade test dust as described in SAE J726 is available from AC
Division General Motors Corporation, Flint, Michigan, or from Owns Coring
Fiberglass Co., Santa Clara, California — their 0.5" PF105, or equivalent.
CHEMICAL
SiO2
SIZE
MICRONS
0-5
PERCENT BY
WEIGHT
39 ± 2
Fe2O3
3-5%
5 - 10
18 ± 3
Al2O3
15-17%
10 - 20
16 ± 3
CaO
2-4%
20 - 40
18 ± 3
MgO
.5-1.5%
40 - 80
9±3
Total Alkalis
(2)
PERCENT BY
WEIGHT
69-76%
3-5%
Soft water temperature shall be 75 F ± 5 F and hardness shall be 12
grains/gallon.
15
13.
COMPLIANCE TEST EXECUTION....Continued
WASHER CAPABILITY TEST
A.
Start the test vehicle engine and operate it at idle speed for the remainder of the
test.
B.
Maintain ambient temperature of 75 F ± 5 F, and wind velocity at the windshield
less than 1 mph.
C.
Using a hand-type atomizer or equivalent, wet the entire exterior windshield
glazing surface with a light film of the test dust/water mixture (freshly shaken)
without coating the wiper blades. If the dust/water mixture does not uniformly
adhere to the entire windshield, re-clean it.
D.
Within 15 seconds after the completion of the dust and water application, actuate
the window washer and wiper systems. At the completion of 10 wiper cycles
maximum, turn off the windshield wipers.
E.
Immediately mark on the interior glazing surface of the windshield the outline of
the areas of the windshield that have been cleared of the test dust using a
grease pencil.
F.
Turn off the test vehicle engine and thoroughly dry the exterior windshield
surface.
G.
Using a clear vellum containing AREAS A, B and C, trace onto the vellum pattern
the outline of the areas of the windshield cleared by the windshield washer
system with a grease pencil.
H.
Re-clean the exterior and interior surface of the windshield.
I.
Repeat the windshield washer capability test procedures for a total of 2 capability
tests at 10 wiper cycles each.
16
14.
POST TEST REQUIREMENTS
A.
The contractor shall re-verify all instrumentation and check data sheets and
photographs (as required).
B.
Make photographs of the marked vellum patterns from each test run.
C.
Using the patterns traced onto the vellum windshield patterns, calculate the
percentages of AREAS A, B and C representing the following:
(1)
Wiped area test run
(2)
Washer capability test run 1
(3)
Washer capability test run 2
(4)
Washer capability test averages
D.
Copy applicable pages of Owner's Manual for inclusion in the final test report.
E.
The contractor shall retain all original records in a secure and organized file
unless otherwise directed by the COTR.
17
15.
REPORTS
15.1. MONTHLY STATUS REPORTS
The contractor shall submit a monthly Test Status Report and a Vehicle Status Report
to the COTR. The Vehicle Status report shall be submitted until all vehicles are
transferred to another FMVSS or otherwise disposed of. Samples of the required
reports are found in the report forms section.
15.2. 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.
15.3
FINAL TEST REPORTS
15.3.1 COPIES
In the case of an apparent test failure, SEVEN 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, THREE 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.
18
15.
REPORTS....Continued
15.3.2 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.
15.3.3 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 104-ABC-9X-001, where —
104 is the FMVSS tested
ABC are the initials for the laboratory
9X 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 104
Windshield Wiping and Washing Systems
****************
XYZ Motor Co.
199X Deluxe 4-door sedan
NHTSA No. CX0101
(3)
Contractor's Name and Address such as
COMPLIANCE TESTING LABORATORIES, INC.
4335 West Dearborn Street
Detroit, Michigan 48090
19
15.
REPORTS....Continued
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
Safety Assurance
Office of Vehicle Safety Compliance
400 Seventh Street, SW
Room 6115 (NSA-30)
Washington, DC 20590
20
15.
REPORTS....Continued
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: ___________________
21
15.
REPORTS....Continued
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
104-ABC-9X-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 104 Compliance Testing of 199X XYZ Deluxe 4door sedan, NHTSA No. CX0101
Block 5 — REPORT DATE
March 1, 199X
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-104-001
Block 9 — PERFORMING ORGANIZATION NAME AND ADDRESS
ABC Laboratories
405 Main Street
Detroit, MI 48070
22
15.
EPORTS....Continued
R
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
Safety Assurance
Office of Vehicle Safety Compliance (NSA-30)
400 Seventh Street, SW, Room 6115
Washington, DC 20590
Block 13 — TYPE OF REPORT AND PERIOD COVERED
Final Test Report
Feb. 15 to Mar. 15, 199X
Block 14 — SPONSORING AGENCY CODE
NSA-30
Block 15 — SUPPLEMENTARY NOTES
Leave blank
Block 16 — ABSTRACT
Compliance tests were conducted on the subject 199X XYZ Deluxe 4-door
sedan in accordance with the specifications of the Office of Vehicle Safety
Compliance Test Procedure No. TP-104-XX for the determination of
FMVSS 104 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.
23
15.
EPORTS....Continued
R
Block 17 — KEY WORDS
Compliance Testing
Safety Engineering
FMVSS 104
Block 18 — DISTRIBUTION STATEMENT
Copies of this report are available from —
NHTSA Technical Reference Division
Room 5108 (NAD-52)
400 Seventh St., SW
Washington, DC 20590
Telephone No.: 202-366-4946
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
24
15.
REPORTS....Continued
15.3.4 TABLE OF CONTENTS
Final test report Table of Contents shall include the following:
Section 1 —
Purpose of Compliance Test
Section 2 —
Test Procedure and Discussion of Results
Section 3 —
Test Data
Section 4 —
Test Equipment List and Calibration Information
Section 5 —
Photographs
Section 6 —
Vehicle Owner's Manual (applicable pages only)
Section 7 —
Notice of Test Failure (if applicable)
25
16.
DATA SHEETS
SUMMARY OF DATA
FMVSS 104, WINDSHIELD WIPING AND WASHING SYSTEMS
VEH. MODEL YEAR/MAKE/MODEL/STYLE: _____________________________
VEH. NHTSA No.:
; VIN:
; BUILD DATE: _______
TEST LABORATORY: _______________________________________________
CONTRACT NO.: DTNH22-
; DELIVERY ORDER NO.: ______
DATES OF TEST: __________________________________________________
WIPER TYPE:
; WASHER TYPE: ____________________
WINDSHIELD AREAS: A =
in²; B =
in²; C =
MANUFACTURER'S WINDSHIELD PATTERN USED: Yes -
in²
; No - ___
ACCESSIBILITY:
(1)
Washer Control Accessible:
Yes -
; No - ___
(2)
Wiper Control Accessible:
Yes -
; No - ___
(3)
Washer Reservoir Filler Accessible:
Yes -
; No - ___
DESCRIBE UNUSUAL FEATURES OF WIPING AND WASHING SYSTEMS:
PERFORMANCE:
TEST
PASS
FAIL
WIPER FREQUENCY
WIPED AREA
WASHER CAPABILITY
RECORDED BY:
APPROVED BY: ________________
DATE: _____________
26
16.
DATA SHEETS....Continued
FREQUENCY TEST DATA
FMVSS 104 — WINDSHIELD WIPER SYSTEM
VEH. NHTSA NO.:
: TEST DATE: __________________
VEH. MY/MAKE/MODEL/BODY STYLE: ___________________________
Water Hardness:
Water Spray Flow Rate:
Ambient Air Temp.:
grains/gallon (12 max.); Date Certified: _________
in³/min. (specified range = 50 to 100 in³/min.)
F (50-100 F); Water Temp.:
Manufacturer's Recommended Engine Idle Speed:
F (100 F max.)
rpm
RUN 1, MAXIMUM WIPER FREQUENCY TEST:
TIME
ENGINE
SPEED
TOTAL
CYCLES
AVG. CYCLES/MIN.
(45 MINIMUM)
1st 3 minutes
(idle ± 50 rpm)
2nd 3 minutes
(2000 rpm ± 50 rpm)
Frequency at least 45 cycles/minute regardless of engine speed: Yes-
; No- ___
RUN 2, LOWER WIPER FREQUENCY TEST:
TIME
ENGINE
SPEED
TOTAL
CYCLES
AVG. CYCLES/MIN.
(20 MINIMUM)
1st 3 minutes
(idle ± 50 rpm)
2nd 3 minutes
(2000 rpm ± 50 rpm)
Highest and lower frequency differ by at least 15 cycles/minute, and lower frequency is at least
20 cycles/minute regardless of engine speed: Yes; No- ___
REMARKS:
RECORDED BY:
APPROVED BY: ________________
DATE: _______________
27
16.
DATA SHEETS....Continued
WIPED AREA TEST DATA
FMVSS 104 — WINDSHIELD WIPER SYSTEM
TEST LAB.:
; TEST DATE: ________________
VEH. MODEL YR/MAKE/MODEL/BODY STYLE: _________________________
VEH. NHTSA NO.: _________________
Air temperature in test area =
Air velocity at windshield =
Engine speed =
F (specified range of 50 to 100 F)
mph (specified range of 0 to 1 mph)
rpm (manufacturer's recommended idle ± 50 rpm)
Temperature of water spray =
Water spray flow rate =
Windshield wiper frequency =
F (100 F maximum)
in³/min. (specified range of 50 to 100 in³/min.)
cycles/min. (45 cpm minimum)
TEST RESULTS:
PERCENT WIPED
WINDSHIELD AREA
ACTUAL
A
B
C
REQUIRE
D
PASS
80%
94%
99%
REMARKS:
RECORDED BY:
APPROVED BY: ________________
DATE: _________________
FAIL
28
16.
DATA SHEETS....Continued
CAPABILITY TEST DATA
FMVSS 104 — WINDSHIELD WASHER SYSTEM
TEST LAB.:
; TEST DATE: _____________
VEH. MODEL YR/MAKE/MODEL/BODY STYLE: _______________________
VEH. NHTSA NO.: _____________________
Air temperature in test area =
F (specified range of 70 to 80 F)
Washer reservoir fluid temperature =
Air velocity at windshield =
Engine speed =
F (specified range of 70 to 80 F)
mph (specified range of 0 to 1 mph)
rpm (manufacturer's recommended idle ± 50 rpm)
Number of windshield washer nozzles on the vehicle = ______
Windshield washer system activation coordinated with components of the wiper system: Yes __
; No - _____
TEST RESULTS:
CLEARED AREA PERCENTAGES
WINDSHIELD
AREA
TEST
1
TEST
2
A
B
C
AVG
REQD*
PASS
FAIL
75%
75%
75%
* NOTE FOR REFERENCE ONLY: SAE 942b, revised Jul72, recommends capability to clear
80% of the total wash area and 90% of the wash area included in AREA C.
REMARKS:
RECORDED BY:
APPROVED BY: ________________
DATE: ____________
29
17.
FORMS
LABORATORY NOTICE OF TEST FAILURE TO OVSC
FMVSS NO.: 104
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:
_____________________________________
_________________________________________________________________
_________________________________________________________________
FMVSS REQUIREMENT, PARAGRAPH §
: _________________________
_________________________________________________________________
_________________________________________________________________
NOTIFICATION TO NHTSA (COTR): __________________________________
DATE:
REMARKS:
; BY: ___________________________________
30
17.
FORMS....Continued
MONTHLY TEST STATUS REPORT
FMVSS 104
DATE OF REPORT:
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
VEHICLE NHTSA No.,
MAKE & MODEL
COMPLIANCE
TEST DATE
PASS/
FAIL
DATE
REPORT
SUBMITTED
DATE
INVOICE
SUBMITTED
INVOICE
PAYMENT
DATE
31
17.
REPORT FORMS....Continued
MONTHLY VEHICLE STATUS REPORT
FMVSS 104
DATE OF REPORT:
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
VEHICLE NHTSA No.,
MAKE & MODEL
DATE OF
DELIVERY
TEST
COMPLETE
DATE
VEHICLE
SHIPMENT
DATE
CONDITION OF
VEHICLE
