EN Official Journal of the European Union L 24/30

Only the original UN/ECE texts have legal effect under international public law. The status and date of entry into force of this Regulation should be checked in the latest version of the UN/ECE status document TRANS/WP.29/343, available at:

http://www.unece.org/trans/main/wp29/wp29wgs/wp29gen/wp29fdocstts.html

Regulation No 78 of the Economic Commission for Europe of the United Nations (UNECE) — Uniform provisions concerning the approval of vehicles of categories L1, L2, L3, L4 and L5 with regard to braking [2015/145]

Incorporating all valid text up to:

Corrigendum 2 to the 03 series of amendments — Date of entry into force: 23 June 2010

CONTENTS

REGULATION

1. Scope

2. Definitions

3. Application for approval

4. Approval

5. Specifications

6. Tests

7. Modifications of vehicle type or braking system and extension of approval

8. Conformity of production

9. Transitional provisions

10. Penalties for non-conformity of production

11. Production definitely discontinued

12. Names and addresses of Technical Services responsible for conducting approval tests and of Administrative Departments

ANNEXES

Annex 1 — Communication concerning the approval or extension or refusal or withdrawal of approval or production definitely discontinued of a type of vehicle of category L with regard to braking pursuant to Regulation No 78

Annex 2 — Arrangements of approval marks

Annex 3 — Test conditions, procedures and performance requirements

1. SCOPE

This Regulation applies to vehicles of categories L1, L2, L3, L4 and L5 (1).

These categories do not include:

(a) Vehicles with a Vmax of < 25 km/h;

(b) Vehicles equipped for disabled riders.

2. DEFINITIONS

For the purposes of this Regulation:

2.1. ‘Antilock brake system (ABS)’ means a system which senses wheel slip and automatically modulates the pressure producing the braking forces at the wheel(s) to limit the degree of wheel slip.

2.2. ‘Approval of a vehicle’ means the approval of a vehicle type with regard to braking.

2.3. ‘Baseline test’ means a stop or a series of stops carried out in order to confirm the performance of the brake prior to subjecting it to a further test such as the heating procedure or wet brake stop.

2.4. ‘Brake’ means those parts of the brake system where the forces opposing the movement of the vehicle are developed.

2.5. ‘Brake system’ means the combination of parts consisting of the control, transmission, and brake, but excluding the engine, whose function it is to progressively reduce the speed of a moving vehicle, bring it to a halt, and keep it stationary when halted.

2.6. ‘Combined brake system (CBS)’ means: For vehicle categories L1 and L3 : a service brake system where at least two brakes on different wheels are operated by the actuation of a single control. For vehicle categories L2 and L5 : a service brake system where the brakes on all wheels are operated by the actuation of a single control. For vehicle category L4 : a service brake system where the brakes on at least the front and rear wheels are operated by the actuation of a single control. (If the rear wheel and sidecar wheel are braked by the same brake system, this is regarded as the rear brake.)

2.7. ‘Components of the braking system’ means one of the individual parts which, when assembled, constitute the braking system.

2.8. ‘Control’ means the part actuated directly by the rider in order to supply or control the energy required for braking the vehicle to the transmission.

2.9. ‘Different types of braking systems’ means devices which differ in such essential respects as: (a) Components having different characteristics; (b) A component made of materials having different characteristics, or a component differing in shape or size; (c) A different assembly of the components.

2.10. ‘Driver mass’ means the nominal mass of a driver that shall be 75 kg (subdivided into 68 kg occupant mass at the seat and 7 kg luggage mass).

2.11. ‘Engine disconnected’ means when the engine is no longer connected to the driving wheel(s).

2.12. ‘Gross vehicle mass’ or ‘maximum mass’ means the technically permissible maximum laden mass as declared by the manufacturer.

2.13. ‘Initial brake temperature’ means the temperature of the hottest brake before any brake application.

2.14. ‘Laden’ means so loaded as to attain the gross vehicle mass as defined in paragraph 2.12.

2.15. ‘Lightly loaded’ means mass in running order plus 15 kg for test equipment, or the laden condition, whichever is less. In the case of ABS tests on a low friction surface (Annex 3, paragraphs 9.4 to 9.7), the mass for test equipment is increased to 30 kg to account for outriggers.

2.16. ‘Mass in running order’ means the sum of the unladen vehicle mass and driver mass.

2.17. ‘Peak braking coefficient (PBC)’ means the measure of tyre to road surface friction based on the maximum deceleration of a rolling tyre.

2.18. ‘Power-assisted braking system’ means a brake system in which the energy necessary to produce the braking force is supplied by the physical effort of the rider assisted by one or more energy supplying devices, for example vacuum assisted (with vacuum booster).

2.19. ‘Secondary brake system’ means the second service brake system on a vehicle equipped with a combined brake system.

2.20. ‘Service brake system’ means a brake system which is used for slowing the vehicle when in motion.

2.21. ‘Single brake system’ means a brake system which acts on only one axle.

2.22. ‘Split service brake system (SSBS)’ means a brake system that operates the brakes on all wheels, consisting of two or more subsystems actuated by a single control designed so that a single failure in any subsystem (such as a leakage type failure of a hydraulic subsystem) does not impair the operation of any other subsystem.

2.23. ‘Stopping distance’ means the distance travelled by the vehicle from the point the rider begins to actuate the brake control to the point at which the vehicle reaches a full stop. For tests where the simultaneous actuation of two controls is specified, the distance travelled is taken from the point the first control is actuated.

2.24. ‘Test speed’ means the vehicle speed measured the moment the driver begins to actuate the brake control(s). For tests where the simultaneous actuation of two controls is specified, the vehicle speed is taken from the point the first control is actuated.

2.25. ‘Transmission’ means the combination of components that provide the functional link between the control and the brake.

2.26. ‘Unladen vehicle mass’ means the nominal mass of the vehicle as indicated by the manufacturer(s) including all factory fitted equipment for normal operation of that vehicle (e.g. fire extinguisher, tools, spare wheel), plus coolant, oils, 90 per cent of fuel and 100 per cent of other gas or liquids, as specified by the manufacturer.

2.27. ‘Vehicle type’ means a sub-category of L-category vehicles which do not differ in such essential respects as: (a) The vehicle category, as defined in the Consolidated Resolution (R.E.3); (b) The gross vehicle mass, as defined in paragraph 2.12; (c) The distribution of the mass between the axles; (d) Vmax; (e) A different type of braking device; (f) The number and arrangement of the axles; (g) The engine type; (h) The number and ratios of gears; (i) The final drive ratios; (j) The tyre dimensions.

2.28. ‘Vmax’ means either the speed attainable by accelerating at a maximum rate from a standing start for a distance of 1,6 km on a level surface, with the vehicle lightly loaded, or the speed measured in accordance with ISO 7117:1995.

2.29. ‘Wheel lock’ means the condition that occurs when there is a slip ratio of 1,00.

3. APPLICATION FOR APPROVAL

3.1. The application for approval of a vehicle type with regard to braking shall be submitted by the vehicle manufacturer or by his duly accredited representative.

3.2. It shall be accompanied by the under mentioned documents in triplicate and by the following particulars:

3.2.1. A description of the vehicle type with regard to the items specified in paragraph 2.27. The numbers and/or symbols identifying the vehicle type and the engine type shall be specified;

3.2.2. A list of components, duly identified, constituting the braking device;

3.2.3. A diagram of the assembled braking system and an indication of the position of its components on the vehicle;

3.2.4. Detailed drawings of each component to enable it to be easily located and identified.

3.3. A vehicle, representative of the vehicle type to be approved, shall be submitted to the technical service responsible for conducting the approval tests.

4. APPROVAL

4.1. If the vehicle type submitted for approval pursuant to this Regulation meets the requirements of paragraphs 5 and 6 below, approval of that vehicle type shall be granted.

4.2. An approval number shall be assigned to each type approved. Its first two digits (at present 03 corresponding to the 03 series of amendments) shall indicate the series of amendments incorporating the most recent major technical amendments made to the Regulation at the time of issue of the approval. The same Contracting Party shall not assign the same number to the same vehicle type equipped with another type of braking device, or to another vehicle type.

4.3. Notice of approval or refusal or extension or withdrawal of approval or production definitely discontinued of a vehicle type pursuant to this Regulation shall be communicated to the Parties to the Agreement which apply this Regulation by means of a form conforming to the model in Annex 1 to this Regulation.

4.4. There shall be affixed, conspicuously and in a readily accessible place specified on the approval form, to every vehicle conforming to a vehicle type approved under this Regulation an international approval mark consisting of:

4.4.1. A circle surrounding the letter ‘E’ followed by the distinguishing number of the country which has granted approval (2);

4.4.2. The number of this Regulation, followed by the letter ‘R’, a dash and the approval number to the right of the circle prescribed in paragraph 4.4.1.

4.5. If the vehicle conforms to a vehicle type approved, under one or more other Regulations annexed to the Agreement, in the country which has granted approval under this Regulation, the symbol prescribed in paragraph 4.4.1 needs not be repeated; in such a case, the Regulation and approval numbers and the additional symbols of all the Regulations under which approval has been granted in the country which has granted approval under this Regulation shall be placed in vertical columns to the right of the symbol prescribed in paragraph 4.4.1.

4.6. The approval mark shall be clearly legible and be indelible.

4.7. The approval mark shall be placed close to or on the vehicle data plate affixed by the manufacturer.

4.8. Annex 2 to this Regulation gives examples of arrangements of approval marks.

5. SPECIFICATIONS

5.1. Brake system requirements

5.1.1. Each vehicle shall meet each of the tests specified for a vehicle of its category and for those brake features on the vehicle.

5.1.2. Service brake system control operation

Vehicles shall have configurations that enable a rider to actuate the service brake system control while seated in the normal driving position and with both hands on the steering control.

5.1.3. Secondary brake system control operation

Vehicles shall have configurations that enable a rider to actuate the secondary brake system control while seated in the normal driving position and with at least one hand on the steering control.

5.1.4. Parking brake system

If a parking brake system is fitted, it shall hold the vehicle stationary on the slope prescribed in paragraph 8.2 of Annex 3.

The parking brake system shall:

(a) Have a control which is separate from the service brake system controls; and

(b) Be held in the locked position by solely mechanical means.

Vehicles shall have configurations that enable a rider to be able to actuate the parking brake system while seated in the normal driving position.

5.1.5. Two-wheeled vehicles of categories L1 and L3 shall be equipped with either two separate service brake systems, or a split service brake system, with at least one brake operating on the front wheel and at least one brake operating on the rear wheel.

5.1.6. Three-wheeled vehicles of vehicles category L4 shall comply with the brake system requirements set out in paragraph 5.1.5. A brake on the sidecar wheel is not required if the vehicle meets the performance requirements prescribed in Annex 3.

5.1.7. Three-wheeled vehicles of category L2 shall be equipped with a parking brake system plus one of the following service brake systems:

(a) Two separate service brake systems, except CBS, which, when applied together, operate the brakes on all wheels; or

(b) A split service brake system; or

(c) A CBS that operates the brakes on all wheels and a secondary brake system which may be the parking brake system.

5.1.8. Category L5 vehicles shall be equipped with:

5.1.8.1. A parking brake system; and

5.1.8.2. A foot-actuated service brake system which operates on the brakes on all wheels, by way of either: (a) A split service brake system; or (b) A CBS that operates the brakes on all wheels and a secondary brake system, which may be the parking brake system.

5.1.9. In cases where two separate service brake systems are installed, the systems may share a common brake, if a failure in one system does not affect the performance of the other.

5.1.10. For vehicles that use hydraulic fluid for brake force transmission, the master cylinder shall:

(a) Have a sealed, covered, separate reservoir for each brake system;

(b) Have a minimum reservoir capacity equivalent to 1,5 times the total fluid displacement required to satisfy the new to fully worn lining condition with the worst case brake adjustment condition; and

(c) Have a reservoir where the fluid level is visible for checking without removal of the cover.

5.1.11. All warning lamps shall be mounted in the rider's view.

5.1.12. Vehicles that are equipped with a split service brake system shall be fitted with a red warning lamp, which shall be activated:

(a) When there is a hydraulic failure on the application of a force of ≤ 90 N on the control; or

(b) Without actuation of the brake control, when the brake fluid level in the master cylinder reservoir falls below the greater of: (i) That which is specified by the manufacturer; and (ii) That which is less than or equal to half of the fluid reservoir capacity.

To permit function checking, the warning lamp shall be illuminated by the activation of the ignition switch and shall be extinguished when the check has been completed. The warning lamp shall remain on while a failure condition exists whenever the ignition switch is in the ‘on’ position.

5.1.13. Vehicles that are equipped with an ABS system shall be fitted with a yellow warning lamp. The lamp shall be activated whenever there is a malfunction that affects the generation or transmission of signals in the vehicle's ABS system.

To permit function checking, the warning lamp shall be illuminated by the activation of the ignition switch and extinguished when the check has been completed.

The warning lamp shall remain on while a failure condition exists whenever the ignition switch is in the ‘on’ position.

5.2. Durability

5.2.1. Wear of the brakes shall be compensated for by means of a system of automatic or manual adjustment.

5.2.2. The friction material thickness shall either be visible without disassembly, or where the friction material is not visible, wear shall be assessed by means of a device designed for that purpose.

5.2.3. During all the tests in this Regulation and on their completion, there shall be no friction material detachment and no leakage of brake fluid.

5.3. Measurement of dynamic performance

The method used to measure performance is as specified in the respective tests in Annex 3. There are three ways in which the service brake system performance may be measured:

5.3.1. MFDD (Mean Fully Developed Deceleration): Calculation of MFDD: in m/s2 where: dm = mean fully developed deceleration V1 = vehicle speed when rider actuates the control Vb = vehicle speed at 0,8 V1 in km/h Ve = vehicle speed at 0,1 V1 in km/h Sb = distance travelled between V1 and Vb in metres Se = distance travelled between V1 and Ve in metres

5.3.2. Stopping distance: Based on the basic equations of motion: S = 0,1 · V + (X) · V2 where: S = stopping distance in metres V = vehicle speed in km/h X = a variable based on the requirement for each test To calculate the corrected stopping distance using the actual vehicle test speed, the following formula is used: Ss = 0,1 · Vs + (Sa – 0,1 · Va) · Vs2/Va2 where: Ss = corrected stopping distance in metres Vs = specified vehicle test speed in km/h Sa = actual stopping distance in metres Va = actual vehicle test speed in km/h Note: This equation is only valid when the actual test speed (Va) is within ± 5 km/h of the specified test speed (Vs).

5.3.3. Continuous deceleration recording: For the burnishing procedure and tests such as the wet brake and heat fade — heating procedure, there is a continuous recording of the vehicle's instantaneous deceleration from the moment a force is applied to the brake control until the end of the stop.

5.4. Brake lining materials:

Brake linings shall not contain asbestos.

6. TESTS

The braking tests (test conditions and procedures) which vehicles submitted for approval are required to undergo, and the braking performance required, are prescribed in Annex 3 to this Regulation.

7. MODIFICATIONS OF VEHICLE TYPE OR BRAKING SYSTEM AND EXTENSION OF APPROVAL

7.1. Every modification of the vehicle type or of its braking system shall be communicated to the Administrative Department which approved the vehicle type. That department may then either:

7.1.1. Consider that the modifications made are unlikely to have an appreciable adverse effect and that in any case the vehicle still complies with the requirements; or

7.1.2. Require a further test report from the Technical Service responsible for conducting the tests.

7.2. Confirmation or refusal of approval, specifying the alterations, shall be communicated, by the procedure specified in paragraph 4.3, to the Parties to the Agreement which apply this Regulation.

7.3. The Competent Authority issuing the extension of approval shall assign a series number to each communication form drawn up for such an extension.

8. CONFORMITY OF PRODUCTION

8.1. Every vehicle (system) approved to this Regulation shall be so manufactured as to conform to the type approved by meeting the requirements set forth in paragraph 5.

8.2. In order to verify that the requirements of paragraph 8.1 are met, suitable controls of the production shall be carried out.

8.3. The holder of the approval shall in particular:

8.3.1. Ensure existence of procedures for the effective control of the quality of products;

8.3.2. Have access to the control equipment necessary for checking the conformity to each approved type;

8.3.3. Ensure that data of test results are recorded and that annexed documents shall remain available for a period to be determined in accordance with the Administrative Service;

8.3.4. Analyse the results of each type of test, in order to verify and ensure the stability of the product characteristics making allowance for variation of industrial production;

8.3.5. Ensure that for each type of product at least the tests prescribed in Annex 3 to this Regulation are carried out;

8.3.6. Ensure that any sampling of samples or test pieces giving evidence of non-conformity with the type of test considered shall give rise to another sampling and another test. All the necessary steps shall be taken to re-establish the conformity of the corresponding production.

8.4. The Competent Authority which has granted type approval may at any time verify the conformity control methods applicable to each production unit.

8.4.1. In every inspection, the test books and production survey records shall be presented to the visiting inspector.

8.4.2. The inspector may take samples at random which will be tested in the manufacturer's laboratory. The minimum number of samples may be determined according to the results of the manufacturer's own verification.

8.4.3. When the quality level appears unsatisfactory or when it seems necessary to verify the validity of the tests carried out in application of paragraph 8.4.2, the inspector shall select samples to be sent to the technical service which has conducted the type-approval tests.

8.4.4. The Competent Authority may carry out any test prescribed in this Regulation.

8.4.5. The normal frequency of inspections authorised by the competent authority shall be once every two years. In the case where negative results are recorded during one of these visits, the Competent Authority shall ensure that all necessary steps are taken to re-establish the conformity of production as rapidly as possible.

9. TRANSITIONAL PROVISIONS

9.1. As from the official date of entry into force of the 03 series of amendments to this Regulation, no Contracting Party applying this Regulation shall refuse an application for approval under this Regulation as amended by the 03 series of amendments. At the request of the manufacturer, Contracting Parties applying this Regulation may agree to the application of these amendments before the official date of their entry into force.

9.2. As from 24 months after the official date of entry into force mentioned in paragraph 9.1, Contracting Parties applying this Regulation shall grant approvals only if the type of vehicle corresponds to the requirements of the Regulation as amended by the 03 series of amendments.

9.3. Approvals granted before the end of the 24-month period following the official date of entry into force shall cease to be valid 48 months after the date of entry into force mentioned in paragraph 9.1, unless the Contracting Party which granted the approval notifies the other Contracting Parties applying this Regulation that the type-approved vehicle meets the requirements of this Regulation as amended by the 03 series of amendments.

9.4. Notwithstanding the transitional provisions above, Contracting Parties whose application of this Regulation comes into force after the date of entry into force of the most recent series of amendments are not obliged to accept approvals which were granted in accordance with any of the preceding series of amendments to this Regulation.

10. PENALTIES FOR NON-CONFORMITY OF PRODUCTION

10.1. The approval granted in respect of a vehicle type pursuant to this Regulation may be withdrawn if the requirements laid down in paragraph 8.1 are not complied with or if a vehicle of this type has failed to pass the checks prescribed in paragraph 8.3.

10.2. If a Party to the Agreement which applies this Regulation withdraws an approval it has previously granted, it shall forthwith so notify the other Contracting Parties applying this Regulation, by means of a copy of the approval form bearing at the end, in large letters, the signed and dated annotation ‘APPROVAL WITHDRAWN’.

11. PRODUCTION DEFINITELY DISCONTINUED

If the holder of the approval completely ceases to manufacture a type of vehicle approved in accordance with this Regulation, he shall so inform the authority which granted the approval. Upon receiving the relevant communication, that authority shall inform thereof the other Parties to the Agreement applying this Regulation by means of a copy of the approval form bearing at the end, in large letters, the signed and dated annotation ‘PRODUCTION DISCONTINUED’.

12. NAMES AND ADDRESSES OF TECHNICAL SERVICES RESPONSIBLE FOR CONDUCTING APPROVAL TESTS AND OF ADMINISTRATIVE DEPARTMENTS

The Parties to the Agreement applying this Regulation shall communicate to the United Nations Secretariat the names and addresses of the Technical Services responsible for conducting approval tests and of Administrative Departments which grant approval and to which forms certifying approval or extension or refusal or withdrawal of approval, issued in other countries, are to be sent.

(1) As defined in the Consolidated resolution on the Construction of vehicles (R.E.3), document ECE/TRANS/WP.29/78/Rev.2, para. 2.

(2) The distinguishing numbers of the Contracting Parties to the 1958 Agreement are reproduced in Annex 3 to the Consolidated Resolution on the Construction of Vehicles (R.E.3), document ECE/TRANS/WP.29/78/Rev.2/Amend.1.

ANNEX 1 (*) APPENDIX LIST OF VEHICLE DATA FOR THE PURPOSE OF REGULATION No 90 APPROVALS 1. Description of the vehicle type: 1.1. Trade name or mark of the vehicle, if available: 1.2. Vehicle category: 1.3. Vehicle type according to Regulation No 78 approval: 1.4. Models or trade names of vehicles constituting the vehicle type, if available: 1.5. Manufacturer's name and address: 2. Make and type of brake linings: 3. Minimum mass of vehicle: 3.1. Distribution of mass of each axle (maximum value): 4. Gross vehicle mass of vehicle: 4.1. Distribution of mass of each axle (maximum value): 5. Vmax km/h 6. Tyre and wheel dimensions: 7. Configuration of the independent braking systems: 8. Specifications of brake valves (if applicable): 8.1. Adjustment specifications of the load sensing valve: 8.2. Setting of pressure valve: 9. Specification of brake: 9.1. Disc brake type (e.g. number of pistons with diameter(s), ventilated or solid disc): 9.2. Drum brake type (e.g. simplex, with piston size and drum dimensions): 10. Master cylinder type and size (if applicable):

ANNEX 2 ARRANGEMENTS OF APPROVAL MARKS MODEL A (see paragraph 4.4 of this Regulation) The above approval mark affixed to a vehicle shows that the vehicle type concerned has, with regard to braking, been approved in the United Kingdom (E11) pursuant to Regulation No 78 under approval number 032439. The first two digits of the approval number indicate that Regulation No 78 already included the 03 series of amendments when the approval was granted. MODEL B (see paragraph 4.5 of this Regulation) The above approval mark affixed to a vehicle shows that the vehicle type concerned has been approved in the United Kingdom (E11) pursuant to Regulations Nos 78 and 40 (1). The first two digits of the approval numbers indicate that, at the dates when the respective approvals were granted, Regulation No 78 included the 03 series of amendments but Regulation No 40 was still in its original form. (1) This latter number is given merely as an example.