CIRCULAR 35/02 - 2 - 1
SELECTION OF TEST VEHICLES
INTRODUCTION
1.
This circular should be read in conjunction with circular 0-2-11 "General Procedures for Selection of
Vehicles and Components for ADR Compliance Testing" containing
requirements applicable to all ADRs, as well as Section 7.14 of ADR 35/02
Alternative Procedures. This circular replaces all previously issued fleet selection
circulars for ADR 35/--. NA category vehicles may use Circular 31/01-2-2 in
lieu of this circular.
2.
The intention of the criteria in this circular is to reduce the number
of vehicle specifications required to be tested. This circular details the criteria
to be considered in selecting the variants of a vehicle model to be tested. The
Administrator will usually accept tests conducted in accordance with the
criteria as having demonstrated compliance for all variants in the model range.
Additional tests may be required for combinations of characteristics not
anticipated in this circular.
The
Administrator will consider requests for further reductions in the number of
tests than established by criteria in this circular on receipt of documented
evidence that if tested, the braking test results of the untested vehicles
would not result in a less favourable result compared to the tested vehicle. The
untested vehicle evidence may be simulated or calculated with any such
simulations or calculations being traceable to similar comparisons between
tested vehicles.
3.
It remains the responsibility of the vehicle manufacturer to ensure that
every vehicle to which an identification plate is affixed complies with ADR 35/02
as applicable.
4.
SELECTION REQUIREMENTS
Grouping of Braking Systems
4.1. Each unique braking system must be
tested. To be considered as the same unique braking system, systems must have a
combination of components that have the same physical (material or
metallurgical), functional and dimensional properties. Any variation of the
components of a braking system will constitute a different unique braking
system except for:
4.1.1. length, diameter, material or
routing of hydraulic, vacuum or air exhaust lines, or electrical wiring
included in the system;
4.1.2. location of valves, fittings or
other devices within a hydraulic or vacuum line;
4.1.3. Routing of air pressure lines
included in the system.
Grouping of Vehicle Variants
4.2.
It
is considered that an untested vehicle variant, with the same unique braking
system as a tested vehicle variant, will not require testing if when compared
to the tested vehicle it:
4.2.1. has the same calibration of any ECU
controlling the braking or suspension systems.
4.2.2. has the same configuration of axles;
4.2.3. where applicable, has an equal or
lower unbraked trailer mass;
4.2.4.
has tyres that are smaller, the same or no more than 2% greater
in diameter;
4.2.5. has tyres of the same or greater section
width;
4.2.6. has greater or equal brake cooling
airflow;
4.2.7. has no higher a road speed per 1,000
rpm for the gear ratio required for the Service Brake Fade Test unless the tested
vehicle was fitted with an automatic transmission such that negligible engine
braking is provided (e.g. a system with a fluid coupling torque converter);
4.2.8. for tests conducted at the Lightly Loaded
Test Mass:
4.2.8.1.
has
no lower Lightly Loaded Test Mass;
4.2.8.2.
for
vehicles without ABS or a load sensing variable proportioning system:
4.2.8.2.1. has no less of the proportion of the
unladen mass on the rear wheels;
4.2.8.2.2. has no shorter wheelbase length.
4.2.9. for tests conducted at the Maximum
Loaded Test Mass:
4.2.9.1.
has
no greater Maximum Loaded Test
Note: Where it is not possible to
select from a range of vehicle variants, a single test vehicle that satisfies criteria
4.2.8 and 4.2.9, the manufacturer may choose a test vehicle that does not meet
criteria 4.2.8.1 and 4.2.8.2.2 provided that the wheelbase of the selected vehicle
does not exceed the shortest available wheelbase by more than 15%.
Full Testing of Vehicle Variants
4.3.
Vehicles
should be selected for testing purposes in accordance with the following
criteria:
4.3.1. Where the maximum laden vehicle
speeds of all the vehicles in the range are less than 100 km/h, at least one
test vehicle shall have the power train giving the highest maximum laden
vehicle speed of all vehicles within the range.
4.3.2. Where the maximum laden vehicle
speed of any vehicle in the range is 100km/h or greater, at least one test vehicle
shall have a power train giving a maximum laden vehicle speed of 100 km/h or
greater.
4.3.3. Where the maximum interval between
brake applications specified for the service brake fade test cannot be
maintained by any vehicle within the range, at least one test vehicle shall
have a power train which most nearly permits the specified maximum interval to
be maintained.
4.3.4. Where the maximum interval between applications
specified for the service brake fade test can be maintained by one or more
vehicles within the range, at least one test vehicle shall have a power train which
gives the acceleration which maintains the maximum interval between brake
applications specified in Section 7.9 of ADR 35/02.
4.4.
For
static actuating time and energy reservoir recovery tests, the untested vehicle
(or installation) shall when compared to the tested vehicle:
4.4.1. have no longer length of brake pipe;
4.4.2. have no smaller an internal diameter
of the corresponding brake pipes;
4.4.3. have no lower a rating of the brake energy
generating device (i.e. compressor);
4.4.4. have no lower capacity of the energy
reservoir.
Partial Testing of Vehicle Variants
4.5.
A
previously tested vehicle variant fitted with a variation of a unique braking system
may be tested only to the tests that are relevant to the variation in the
braking system. The conditions where a vehicle may be subject to a partial test
are described in the paragraphs below:
4.5.1. the parking brake system shall be
tested to Section 7.11;
4.5.2. the brake power or assist unit shall
be tested to Sections 7.6, 7.7 & 7.8;
4.5.3. the anti-lock system, variable (load)
proportioning system or the pressure proportioning control system shall be
tested to 7.4, 7.12 & 7.13;
4.5.4. the air pressure actuation system as
described in paragraph 4.4 above shall be tested to Section 7.12 and 7.13 as
applicable.
Note: The varied design should be
assigned its own unique brake system identifier. For the variations requiring
retesting described in clauses 4.5.2. and 4.5.3 above, the relevant SE form
shall contain the results of all in motion tests conducted relevant to the base
braking system, not just those conducted resulting from the design variation.
The test report for the varied braking system referenced on the SE form must
reference the original full test report. Extension sheets attached to the original
test report should reference and collate the additional tests.
ALTERNATIVE STANDARDS
5.
An untested vehicle variant which is listed in an appropriate Economic
Commission for Europe (ECE) approval document (to one of the ECE regulations
listed as an alternative standard in the ADR) may be certified without the
selection criteria in the circular being applied. All variants to be covered in the application
must be included on the Fleet Selection (SF) form. If all variants listed on the SF form are listed
in an ECE approval document the tested/untested status is to be recorded as
“ECE Approved”
6.
An untested vehicle variant that is not listed in an appropriate ECE
approval document (to one of the ECE regulations listed as an alternative
standard in the ADR) may be certified on the basis of comparison to a vehicle variant
tested in accordance with compliance to the technical requirements of an
appropriate ECE regulation if:
·
the
tested vehicle variant is listed in an appropriate ECE approval document and;
·
the
untested vehicle variants(s), when compared to the tested variant, meets the criteria
of this circular.
In
this case the variants tested to the ECE regulation and included on the ECE
approval are to show the tested/untested status as “ECE - Tested”. The variants
not tested to the ECE regulation but included in the ECE approval are to show
the tested/untested status as “ECE - Approved” and the variants not tested to
the ECE regulation and not included on the ECE approval are to show the
tested/untested status as “Untested”.
All variants to be covered in the application must be included on the
Fleet Selection (SF) form. A variant
marked as Untested may only be compared with a relevant variant which is either
“ECE - Tested” or “Tested”.
7.
A vehicle variant fitted with a variation of a unique braking system
(under the conditions set out in paragraph 4.5 above) may be certified on the
basis of comparison to a vehicle variant shown as “ECE – Tested” on the SF form.
In this case, the variant shall be listed on the SF form and shown as “Tested –
Partial”.