Brake assessment manual October 2013
Developed in association with the NSW Vehicle Standards Working Group. AUTHOR: Dan Leavy DATE: October 2013 VERSION: 1.0 REFERENCE: PR12/05984 DIVISION: Policy & Regulation Brake assessment manual Ver 1.
ASSESSING AND CERTIFYING BRAKES FOR MODIFIED VEHICLES AND INDIVIDUALLY CONSTRUCTED VEHICLES Preface This Brake assessment manual (the Manual) is intended to be used to assess the brake systems of modified vehicles and individually constructed vehicles as part of the process for certifying the vehicle for registration in accordance with the Road Transport (Vehicle Registration) Regulation 2007 and the Vehicle Safety Compliance Certification Scheme.
Brake assessment manual Scope This Brake assessment manual (the Manual) applies to all types of light vehicles, except motorcycles. It is intended to be used to assess the brake systems of modified vehicles and individually constructed vehicles. Notes: 1. The term ‘vehicle’ used in this Manual refers to light vehicles, being vehicles with a gross vehicle mass of 4.5 tonnes or less. 2. From hereon, the term ‘modified vehicle’ also applies to ICVs except where stated otherwise. 3.
Limits of assessments The assessments detailed in this Manual apply to vehicles intended to be registered for use on the road, in normal driving operations at posted speed limits. If it is intended to also use a vehicle for specialised activities, such as track racing, more rigorous assessment and tests may be required to ensure the braking system will withstand the additional stresses imposed on it. If a vehicle equipped with electronic stability control (ESC) is modified, the ESC must remain functional.
Table 1 (continued) Mod Description 6. Fitting dual or multi-piston brake callipers to original front disc rotors in place of original single- or multi-piston brake callipers The new dual- or multi-piston brake callipers are fitted with or without adapting brackets. 7 Fitting disc brakes to the front of a vehicle without using brake calliper adapting brackets. Fitting larger-diameter drum brakes to the front of a vehicle.
Table 1 (continued) Mod. Description 22 Wheels and tyres: A change in the diameter of the wheel and tyre combination in excess of +/- 7% and which have not been previously tested. 23 Removal of any form of power assist or full power unit (whether by vacuum, air, or hydraulic means) from an existing brake system that results in the driver supplying all the energy to apply the brakes. 24 Removal or alteration to a motion sensitive brake system pressure differential valve.
o verifies that the components are compatible with the host vehicle as specified by the component’s manufacturer; o the components have been installed in accordance with the manufacturer’s instructions; and o that the vehicle is in suitable condition to accommodate the components (eg there are no signs of rusting where items are secured to the vehicle).
Method 3 – Installation checklist, static brake test and assessment General The following stages apply: 1. The modifier installs the brake components using the checklist provided at Appendix 3. 2. The modifier takes the modified vehicle to a facility approved by the Roads and Maritime Services for a series of basic brake tests using a static brake test machine. Notes: a) Authorised Inspection Stations that do safety checks (i.e.
done correctly, and relate to the vehicle being assessed. If necessary, the licensed certifier should observe the tests. Appendix 4 provides an example of how a plate-type brake test machine can be used to do the basic and additional tests. At the time of writing, data was only available for this type of brake test machine. Additional appendices will be developed when data from other machines types become available.
The modifier should install the brake component using the checklist provided at Appendix 3. Competence of drivers The vehicle should be driven by a person capable of efficiently achieving the specified test conditions. Test equipment It is important that appropriate equipment is used to measure and record test-critical data.
Pre-test check In the interests of road safety and before doing any of the tests described in Appendix 5, the vehicle should be thoroughly examined to ensure it is in a roadworthy condition.
Brake assessment manual Brake assessment manual + K L M N T T T T T T T T T T T T T T T T T T T T T T T T T T T T T T Type-I Recovery performance J I Type-I Recovery procedure H Type-I Hot performance + G Type-I Heating procedure + Type-0 Engine disconnected F Spike stops + Proportion valve failure E Booster failure + Wheel lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16a 16b 17 ICV 18 ICV Donor 19 20 21 # 22a 22b 22c 23 24 25 26 27 28 29 31 D Partial Failure front rear C* Park
Key to Table 3 on page 13: * means this test does not need to be done on a road or road-type test facility. + means this test can be done with a static brake test machine. T means a test is required for a particular modification. Refer to Appendix 5 for details of the tests. # the tests that apply to Modification 21 are under review. T5/10 means the test comprises either 5 runs in the MLTM or 10 runs in the LLTM condition.
Appendix 1: Glossary The terms below are used in this Appendix. Except for those marked with an asterisk (*), they have been taken from “Australian Design Rules – Definitions and Vehicle Categories”; and those marked (†) have been amended specifically for this Manual. To identify where they are used, they are italicised in the text.
MB Forward-Control Passenger Vehicle - a passenger vehicle, not being an off-road passenger vehicle, having up to 9 seating positions, including that of the driver, and in which the centre of the steering wheel is in the forward quarter of the vehicle‘s total length. MC Off-Road Passenger Vehicle - a passenger vehicle having up to 9 seating positions, including that of the driver and being designed with special features for off-road operation.
Appendix 2: Requirements when using a handbrake from a similar vehicle When assessing a handbrake mechanism under similar vehicle criteria the following additional points must be taken into account. 1. For ADR vehicles, the category of the similar vehicles must be the same. For example, a handbrake from a vehicle that complies with ADR 35/-- vehicle may not be used on a vehicle that complies with ADR 31/--.
Appendix 3: Brake system installation checklist This checklist should be used by the vehicle modified and presented to the licensed certifier for the purposes of the initial assessment. Vehicle owner: ………………………………………………. Vehicle modifier: ………………………………………………. Vehicle make and model: ………………………………………………. Date of inspection: ………………………………………………. Vehicle identification: ………………………………………………. Licensed certifier: ………………………………………………. Date of assessment: ……………………………………………….
BRAKING SYSTEM INSTALLATION CHECKLIST 3 4 (b) Is the surface that a service brake control is mounted on, reinforced or of sufficient strength so as to withstand the repetitive brake control application loads? Y N N/A (c) Do test results show that the strength of each fabricated or modified service brake control assembly is suitable for the specified application load? Y N N/A (d) Does the service brake control feature a non-slip surface? Y N N/A (e) Can the service brake control be operated by
BRAKING SYSTEM INSTALLATION CHECKLIST (g) Is the park brake control adjustable? 5 Y N N/A (a) Is each master cylinder securely mounted to a surface that is reinforced or of sufficient strength so as to withstand the repetitive brake control application loads? Y N N/A (b) Is any cross shaft used to actuate a master cylinder securely mounted to a surface that is reinforced or of sufficient strength so as to withstand the repetitive brake control application loads? Y N N/A (c) Is the stroke of each
BRAKING SYSTEM INSTALLATION CHECKLIST 7 8 9 (d) Is a vacuum pump and/or vacuum reserve tank to maintain the vacuum supply for the brake booster provided if an electric motor, diesel engine or petrol engine with a ‘high-lift’ camshaft fitted? Y N N/A (e) Is the vacuum hose used in the system made of suitable material, in good condition, and of sufficient length to allow for free engine movement? Y N N/A (f) Y N N/A (a) Is each master cylinder provided with brake fluid from a reservoir? Y N
BRAKING SYSTEM INSTALLATION CHECKLIST DISCS AND DRUMS 10 11 Unless specifically approved by their manufacturers, brake discs and drums must not be redrilled to suit different stud patterns or machined to fit larger hub centres or wheel bearings.
BRAKING SYSTEM INSTALLATION CHECKLIST (c) Is each flexible brake hose assembly marked with its manufacturer’s name or trademark and to comply with SAE J1401 or its equivalent? Y N N/A (d) Is each flexible brake hose sufficient length to allow full steering and suspension travel? Y N N/A (e) Is each brake line (ie rigid pipe and flexible hose) supported at least every 300mm and secured? Y N N/A (f) Is each brake line passing through a panel, firewall, bulkhead or structural member insulated from
BRAKING SYSTEM INSTALLATION CHECKLIST 14 BRAKE SYSTEM PERFORMANCE (a) When the brakes are applied at any speed, does the vehicle remain within a 3.5m wide lane? Y N N/A (b) Under heavy braking do the front wheels lock up before the rear wheels? Y N N/A (c) Is the vehicle capable of stopping from an initial speed of 35km/h in 12.5m when the service brakes are applied? Y N N/A (d) Is the vehicle capable of stopping from an initial speed of 35km/h in 30.
Appendix 4: Using a Plate-Type Test Machine A plate-type brake test machine may be used to do a basic determination of the performance of the brakes, and some of the tests specified in Table 3. The tests are listed below, with applicable pass criteria; and examples of data and read-outs obtained from a plate-type brake test machine are provided for some of the tests. The tests are: Basic performance test – see data and read-outs for 4.
Figure 4.1.1: Example of data from a plate brake test machine – Basic test Brake assessment manual Ver 1.
Figure 4.1.2: Example of read out using a plate brake test machine – Basic test Note: Front brakes applied before rear brakes, satisfying Test I Brake assessment manual Ver 1.
Figure 4.2.1: Example of data using a plate brake test machine test – Test D Front brakes disconnected Brake assessment manual Ver 1.
Figure 4.2.2: Example of read out using a plate brake test machine test – Test D Front brakes disconnected Brake assessment manual Ver 1.
Figure 4.3.1: Example of data using a plate brake test machine test – Test D Rear brakes disconnected Brake assessment manual Ver 1.
Figure 4.3.2: Example read out from a plate brake test machine test – Test D Rear brakes disconnected Brake assessment manual Ver 1.
Figure 4.4.1: Example of data using a plate brake test machine test – Test E Booster disconnected Brake assessment manual Ver 1.
Figure 4.4.2: Example of read out from a plate brake test machine test – Test E Booster disconnected Brake assessment manual Ver 1.
Appendix 5: Description of tests Order of tests The tests should be done in the order presented, but may be varied at the discretion of the supervising licensed certifier. However, Tests C, E & F and Test D should be done as early as possible as these indicate the likelihood of the vehicle passing the other tests. Test speed The test speed shall be the vehicle speed registered on the test instrumentation, not on the vehicle’s speedometer. Brake assessment manual Ver 1.
Test A: Reservoir volume [Based on: ADR 31/00, Clause 31.2.5.
Test B: Mounting structure This test is required to ensure that the firewall and mounting brackets for the brake pedal, master cylinder and/or booster are structurally adequate. A load shall be applied to the brake pedal with the vehicle stationary and the engine off. An observation of the mounting structure shall be made for local deformation. The mounting structure shall be rigid.
Test C: Park brake The park brake efficiency shall be tested as follows: (a) with the vehicle is stationary, apply the park brake; (b) start the engine and engage low gear; (c) attempt to move the vehicle forward under light throttle; (d) engage reverse gear; (e) attempt to move the vehicle backward. The park brake shall be deemed to have passed the test if the vehicle remains stationary.
Tests D, F & G: Partial failure test front and rear; proportional valve failure; and ABS failure [Based on: ADR 31/00, Clause 31.3.2, Item 8 and Clause 31.5.8.] Test D checks the master cylinder in a Split Service Brake System has enough displacement to operate an individual circuit in the event of one of the circuits failing. Clamping off a brake hose does not simulate a failure in one circuit.
Test E: Booster failure [Based on: ADR 31/00, Clause 31.3.2, Item 9 and Clause 31.5.9.] Test E is required to ensure that the vehicle can be safely brought to rest in the event that the booster fails. For vehicles subject to Modification 19, this test must be done at 55 km/h; for all other vehicles, the test must be done at 80 km/h. In all cases, the vehicle must be in the MLTM condition and the gears in the ‘drive’ position.
Test H: Spike stops [Based on: ADR 31/00, Clause 31.3.2, Item 25 and Clause 31.5.25.] This test is intended to highlight any problems with structural elements of the vehicle modifications by applying a sudden and instantaneous load to the vehicle.
Test I: Wheel lock procedure [Based on: ADR 31/01, Appendix A, Annex 5, Appendix 1.] This test is intended to check that the front wheels lock before the back wheels. The test shall to be done with the vehicle both in the MLTM and LLTM condition, travelling at 65km/h and at a braking rate of less than 0.5 m/s2 This test shall be done with Cold Brakes.
Test J: Type-0 Engine disconnected [Based on: ADR 31/01, Appendix A, Annex 3, Clauses 1.4 to 1.4.2 inclusive.] The following general conditions apply: • vehicles in Modification Category 16b shall be tested at 100km/h • vehicles in Modification Categories 17, 26 & 27 shall be tested at the lesser of 80% of their maximum speed or 100 km/h • vehicles in all other modifications categories shall be tested at 80 km/h • the tests shall be done with the vehicle in the MLTM and LLTM conditions.
Test K: Type-I Heating procedure [Based on: ADR 31/01, Appendix A, Annex 3, Clause 1.5.1.] This test is intended to heat the brakes until the onset of fade to verify the brakes can function when hot. The service Brakes of all vehicles shall be tested by successively applying and releasing the Brakes until the onset of fade but not more than 15 times, with the vehicle in the MLTM condition.
Test L: Type-I Hot performance [Based on: ADR 31/01, Appendix A, Annex 3, Clause 1.5.2.] This test is intended to check the performance of the brakes when hot.
Test M: Type-I Recovery procedure [Based on: ADR 31/01, Appendix A, Annex 3, Clause 1.5.3.] This test is intended to check the performance of the brakes when hot. This test shall take place immediately after Test L (Type-I Hot performance). The vehicle shall be stopped four stops from 50 km/h with the engine connected, at a mean deceleration of 3 m/s2. The interval between the start of successive stops should be 1.5 km.
Test N: Type-I Recovery performance [Based on: ADR 31/01, Appendix A, Annex 3, Clause 1.5.4.] This test is intended to check the performance of the brakes when hot.
Appendix 6: Rationale for the brake tests in Appendix 5 The Regulation specifies that the applicable vehicle standards are those contained in its Schedule 2. For vehicles manufactured after 1972, those standards are the Australian Design Rules (ADRs), and for brake systems, the applicable ADRs are ADR 31 Brake systems for passenger cars, and ADR 35 Commercial Vehicle Brake Systems. This Manual is primarily concerned with ADR 31.
Appendix 7: Variations for N Category vehicles and certain M Category vehicles N Category vehicles subject to ADR 35/-- Commercial Vehicle Brake Systems must comply with the design requirements of that ADR.
