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National Code of Practice - Building Trailers - June2009
National Code of Practice - Building Trailers - June2009
Department of Infrastructure, Transport, Regional Development and Local Government - Vehicle Safety Standards GPO Box 594 Canberra ACT 2601 Telephone (02) 6274 7111 Fax (02) 6274 7477
VSB 1 Revision 5
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January 2009
4. THE PURPOSE OF THIS BULLETIN. This Vehicle Standards Bulletin establishes a set of design and construction standards for road trailers (with an ATM of 4.5 tonnes or less) that operate as an alternative to the ADRs. The standards are based on the ADRs but are simpler and more practical to use. They offer a low-cost alternative, by eliminating the need for some of the more expensive forms of vehicle testing and evidence that are required under the ADRs. In particular, the standards reflect the common requirements of the States and Territories for trailers to be registered for road use. The standards set out concrete guidance and clearly-defined processed that are more suitable for individuals and small firms. Road trailers that meet the standards of this bulletin do not need to be certified by the Australian Government, and do not need to be issued with an identification plate or a used import plate. That is, manufacturers and importers are exempt from the need to apply to the Australian Government and submit detailed evidence based on the ADRs.
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The certification statement for new trailers is: This trailer was manufactured to comply with the Motor Vehicle Standards Act 1989. The certification statement for used imported trailers is: This trailer is an imported used trailer. It has been modified and assessed as complying with the Motor Vehicle Standards Act 1989. This plate may also include additional information such as the tyre placard information (specified in Section 16). All information must be legible and embossed, indented, etched or engraved in letters and numbers not less than 2.5 mm high.
(Refer to ADR 61/02 Clause 8 for further information). VSB 1 Revision 5 Page 5 of 39 June 2009
9. REGISTRATION Registration of trailers remains the responsibility of the State and Territory registration authorities. Trailer manufacturers or importers should consult the relevant authority for the necessary registration procedures, such as inspection.
(Refer to the local registration authority for further information or click here to go to the VSB1 Contact Page).
9.1 Registration Plate (Number Plate) Provision must be made for mounting of a 372 mm x 136 mm registration plate to the rear of every trailer so that no part of the plate is more than 1300 mm above the ground.
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9.2 Registration Label Holder Trailers are required to display a registration label on the left hand side of the trailer. If there is no window in this location (such as would be found on a caravan), a registration label holder must be fitted on the left hand side of the vehicle.
(Refer to ADR 61/02 clause 9.2 for further information).
10. RESPONSIBILITY FOR SAFETY Manufacturers and importers should note that they have a responsibility for the overall safety of their trailers. Manufacturers and importers should be aware that the Trade Practices Act 1974 allows for mandatory recall and rectification of vehicles with safety related defects that will or may cause injury. The responsibility for recall lies with the manufacturer or importer, whoever is the supplier (distributor) in Australia. The procedures for recall are contained in Procedures for the Rectification of Safety Related Defects in Vehicles and Related Products (the Recall Code). The Recall Code is available at the following website:
http://dynamic.infrastructure.gov.au/recalls/index.asp
Alternatively, it is available via a written request made to:Department of Infrastructure, Transport, Regional Development and Local Government Vehicle Safety Standards GPO Box 594 CANBERRA ACT 2601
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11.2 Dog Trailer A trailer with 2 axle groups of which the front axle group is steered by connection to the drawing Vehicle.
11.3 Semi-Trailer A trailer having one axle group towards the rear end of the length of its goods carrying surface such that significant load is imposed on the drawing vehicle. Or some of the goods carrying surface is over the towing vehicle.
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11.5 Box Trailer A general-purpose trailer with a load space, which is bounded by vertical sides. This category includes a box trailer fitted with a canopy but which is not equipped as a caravan, e.g. is equipped with temporary sleeping accommodation only.
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11.8 Car Trailer A trailer built specifically to carry a motor vehicle such as a passenger car or racing car.
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11.10 Plant Trailer A trailer which, instead of a load space, has fixed to it machinery such as an air compressor, concrete mixer or drilling rig.
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Note Except for semi-trailers, the difference between the ATM and GTM is usually small.
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identifies the country issuing the ECE approval. identifies the side of the vehicle towards which the lamp is to be mounted.
6R00217 identifies the ECE approval number; in this case incorporating the ECE Regulation number 6. Unless specifically mentioned, lamps on a trailer must operate with the corresponding lamps on the towing vehicle, and where pairs of lamps or reflectors are fitted, they must be spaced equally on either side of the centre line of the trailer.
6R00217
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Front position lamp Rear position lamp Rear stop lamp Direction-indicator lamp Rear registration plate lamp Hazard warning signal End-outline marker lamp Side-marker lamp (Option 1) Side-marker lamp (Option 2)
White. May be amber if combined with a side-marker lamp Red Red Amber White Amber White or amber to the front, red to the rear Amber to the front, red to the rear
Front retro-reflector, non triangular Rear retro-reflector Side retro-reflector, non triangular
Amber, except for the rearmost lamp which may emit red if it is grouped or combined or reciprocally incorporated with the rear position lamp, the rear end-outline marker lamp, stop lamp or is grouped or has part of the light emitting surface in common with the rear retro-reflector White or colourless Red Amber, except for the rearmost side retro-reflector can be red if it is grouped or has part of the light emitting surface in common with the rear position lamp, the rear end-outline marker lamp, the stop lamp or the red rearmost sidemarker lamp. White
74/-
Reversing lamps
1/-
ECE R23/-
Note: Grouped lamps have separate bulbs and lenses (or LED elements) but a common lamp body (e.g. rear position/indicator lamp). Combined lamps have separate lenses but a common bulb (or LED element) and lamp body (e.g. rear position/registration plate lamp). Reciprocally incorporated lamps have a separate bulb but a common or partly common lens and lamp body (e.g. rear position/stop lamp).
(Refer to ADR 13/00, for further information).
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13.2 Rear Position (Side) Lamps (Tail Lamps) These lamps indicate the presence and width of a trailer when viewed from the rear. Presence: Must be fitted. Number: 2. Arrangement: At the rear. See Figure 1. Electrical Connections: Must operate with front position (if fitted), end-outline (if fitted), sidemarker (if fitted) and rear registration lamps.
(For further information, refer to ADR 13/00 Appendix A clause 6.10 and ADR 49/00).
13.3 Rear Stop Lamps (Brake Lamps) These lamps indicate to the rear of the trailer that the driver is applying the service brakes. Presence: Must be fitted. Number: 2. Arrangement: At the rear. See Figure 1. Electrical Connections: Must operate with service brake on towing vehicle and (if fitted) service brake on trailer.
(For further information, refer to ADR 13/00 Appendix A clause 6.7 and ADR 49/00).
13.4 Direction Indicator Lamps (Turn Signals) These lamps indicate to the rear and the side of the trailer that the driver is intending to change direction to the left or the right. Presence: Must be fitted. Number: 2. Arrangement: At the rear. See Figure 1. One pair of side-repeating indicators may also be fitted approximately half way along semi-trailers that are over 7500 mm long. Electrical Connections: Must operate by a single control, independently of all other lamps, and must flash in phase all on one side. The flashing must be must be within the range of 60 to 120 flashes per minute.
(For further information, refer to ADR 13/00 Appendix A clause 6.5 and ADR 6/00). VSB 1 Revision 5 Page 17 of 39 June 2009
13.6 Hazard Warning Signal This is the simultaneous operation of all the trailers direction indicator lamps to show that the trailer temporarily presents a special danger to other road users. Presence: See below Number: See below Arrangement: See below Electrical Connections: All direction indicators on the trailer must operate simultaneously with hazard warning lamps of the towing vehicle.
(For further information, refer to ADR 13/00 Appendix A clause 6.6 and ADR 49/00).
13.7 End-Outline Marker (Clearance) Lamps These lamps indicate the presence, width and height of a trailer when viewed from the front or rear. Presence: Must be fitted if a trailer is more than 2100 mm wide. Number: 2 to the front (white or amber) and 2 to the rear (red). Arrangement: At the front and the rear. See Figure 1. If a trailer has no structure at the front and at the rear to which lamps can be attached (such as a boat trailer), then one combination white (or amber) /red end-outline marker lamp midway on each side may be fitted instead. Electrical Connections: Must operate with front position (if fitted), rear position, side-marker (if fitted) and rear registration lamps.
(For further information, refer to ADR 13/00 Appendix A clause 6.13 and ADR 49/00).
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May be increased to 2100 mm if the structure makes it impractical to keep within 1500 mm. May be reduced to 400mm where the overall width of the trailer is less than 1300mm. Compatible with the operational requirements of the trailer and the requirement to keep the dimensions symmetrical on either side. Note Front position lamps and front and rear end outline marker lamps are required for wide trailers only. Refer to text.
13.8 Side-Marking (Marker) Lamps These lamps indicate the presence and length of a trailer when viewed from the side. Either Option 1 or Option 2 must be met. Option 1 is based on an international standards arrangement (an option may be chosen even if it results in no side-marker lamps having to be fitted to a particular trailer). Both options are shown below. OPTION 1 Presence: SM1 type lamps must be fitted if a trailer is more than 6000 mm long. SM1 or SM2 type lamps may optionally be fitted to all other trailers. Note SM1 and SM2 lamps have different visibility limits and are not interchangeable.
Number: Such that the Arrangement below is met. Arrangement: At the side. See Figure 2(a). Trailers that are not more than 6000 mm long may have one lamp fitted each side within the first third and/or one within the last third of the length. Electrical Connections: No requirement.
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May be increased to 2100 mm if the structure makes it impractical to keep within 1500 mm. May be increased to 4000 mm if the structure makes it impractical to keep within 3000 mm. Note Under this option, Side Marker Lamps are only required for long trailers. Refer to text.
OPTION 2 Presence: Must be fitted if a trailer is more than 2100 mm wide or more than 7500 mm long. Must be fitted to all semi-trailers. Number: 2 towards the rear if a trailer is more than 2100 mm wide. 2 towards the front plus 2 towards the rear, if a semi-trailer is equal or less than 7500 mm long. 2 towards the front plus 2 towards the rear, plus 2 midway between the front and the rear lamps, if a trailer over 7500 mm long. Additional pairs of side marker lamps, equally spaced between the front and the rear lamps, may also be fitted, as long as the distances between the centres of adjacent lamps is not more than 5000 mm. Arrangement: At the side. See Figure 2(b). In width, the outermost surface of the lamp must not be more than 150 mm inboard of the extreme outer edge of the trailer. Electrical Connections: No requirement.
(For further information, refer to ADR 13/00 Appendix A clause 6.8 and ADR 74/00).
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May be increased to 2100 mm if the structure makes it impractical to keep within 1500 mm. Also all semi-trailers regardless of size. May be increased to as close as possible to the front and/or rear respectively if the structure makes it impractical to keep within 300 mm (for example a boat trailer). Where this is the case, and the distance between the front and rear lamps would then be less than 2500 mm, only the rearmost lamps need be fitted. Under this option, Side-Marker Lamps are only required for large trailers and any semi-trailer. Refer to text.
Note
13.9 Retro (Reflex) Reflectors Retro-reflectors indicate the presence of a trailer by reflecting light from a separate source.
(For further information, refer to ADR 13/00 and ADR 47/00)
13.10 Front Retro (: Reflex) Reflectors (Non triangular) Presence: Must be fitted. Non-triangular only. Number: 2. Arrangement: At the front. See Figure 3. Electrical Connections: No requirement
(For further information, refer to ADR 13/00 Appendix A clause 6.16 and ADR 47/00)
13.11 Rear Retro (Reflex) Reflectors Presence: Must be fitted. Triangular or non-triangular. Number: 2. Arrangement: At the rear. See Figure 3. Triangular the apex of triangle must point upwards. Non-triangular rear retro reflectors are not required to be grouped together with other rear lightsignalling devices. Electrical Connections: No requirement
(For further information, refer to ADR 13/00 Appendix A clause 6.15 or 6.14 and ADR 47/00) VSB 1 Revision 5 Page 21 of 39 June 2009
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May be increased to 1500 mm if the structure makes it impractical to keep within 900 mm. May be reduced to 400mm where the overall width of the trailer is less than 1300mm. FIGURE 4 Side Retro-Reflectors Dimensional Limits
@ #
May be increased to 1500 mm if the structure makes it impractical to keep within 900 mm. May be increased to 4000 mm if the structure makes it impractical to keep within 3000 mm.
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Note
12.14 Grouping of Rear Lamps Rear position (side) lamps, stop lamps, direction indicator lamps, registration plate lamps and retroreflectors may be grouped into the same units, as long as their individual requirements are met. The following are examples of acceptable arrangements.
(For further information, refer to ADR 13/00)
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Note
Wiring and wiring connections should also be designed to withstand the vibration that they will be subject to during use of the trailer, be of suitable size, and be located in a position where they will not be crushed. Particular care should be taken to ensure that electric brake wiring is adequately shielded from road debris.
Trailers that do not exceed 3.5 tonnes ATM must have electrical connectors between the trailer and towing vehicle that comply with Australian Standard AS 2513-1982 Electrical Connectors for Trailer Vehicles or Australian Standard AS 4177.5-2004 Caravan and light trailer components, Part 5: Electrical connectors. Trailers over 3.5 tonnes ATM may use electrical connectors complying with ISO 1185-2003 or SAE J560-1998 Standards for electrical connectors between towing vehicles and trailers as alternative standards. Three types of seven pin connectors are specified in the Standard and their wiring is shown on page 25. Twelve pin connectors are also specified in the Standard. Note Seven and twelve pin connectors should be of a robust design to reduce the risk of short circuits developing. Lamps and wiring may be detachable from trailers such as boat trailers, where they are exposed to conditions such as immersion in water, which might cause short-circuiting or other malfunctions. Electrical installations on a trailer that are intended for connection to a power system other than that of the drawing vehicle must comply with Australian Standard 3001-1981 Electrical Installations in Caravans and Caravan Parks or Australian Standard AS 3001-2001 Electrical Installations Relocatable premises (including caravans and tents) and their site installations.
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Note
Because of interchangeability problems that may arise, it is recommended that pin 5 in the 7 pin connectors be used only for service brakes. If auxiliary circuits are required, then the 12-pin type 3 connector would be preferable.
Front view of trailer plugs (Type 1 and Type 2 plugs also have a locating notch at the bottom):
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Note Two axles with centres spaced less than 1 metre apart are regarded as a single axle.
15.2 All other trailers that do not exceed 4.5 tonnes ATM These trailers must be fitted with an efficient brake system that complies with ADR 38/-. Except for over-run brakes, all brakes must be operable from the driver's seat of the towing vehicle. For trailers up 2 tonnes GTM, an efficient braking system is considered to have brakes operating on the wheels of at least one axle. Over-run brakes may only be used on trailers that do not exceed 2 tonnes GTM. Every trailer over 2 tonnes GTM must have brakes operating on all wheels. The brake system must cause immediate application of the trailer brakes in the event of the trailer becoming detached from the towing vehicle. Under these circumstances, the brakes must remain applied for at least 15 minutes. All flexible hydraulic brake hoses, air or vacuum brake tubing and air and vacuum flexible hoses must conform to SAA, SAE, BS, JIS, DIN, ISO or ECE Standards and be fitted to the vehicle in a way that will prevent chafing, kinking or other mechanical damage under normal motion of the parts to which they are attached.
(For further information, refer to ADR 38/02 clause 5)
Note Manufacturers should consider the merits of including a parking brake function when designing the braking system. ADR 38/03 clause 8 and 14 provides guidance for parking brake systems. 16. DRAWBARS, SAFETY CHAINS, SAFETY CHAIN ATTACHMENTS AND COUPLINGS 16.1 Drawbars Drawbars must be securely attached to a substantial portion of the trailer. Drawbars must withstand the following forces applied at the centre of the intended coupling without detachment or any distortion or failure, which will affect the safe drawing of the towed trailer: Longitudinal tension and compression (N) 1.5 x 9.81 x ATM (kg) Transverse thrust (N) 0.5 x 9.81 x ATM (kg) 0.5 x 9.81 x ATM (kg)
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16.3 Drawbar Safety Chain Attachment Points Safety chain attachment points are the means by which the safety chains are attached to the drawbar. These points must be located as near as practicable to the tow coupling. Where two points of attachment are required, they must be mounted one on either side of the centreline of the drawbar. Each safety chain attachment point must be capable of withstanding the following minimum forces without incurring either any residual deformation that would interfere or degrade the function of the assembly, or any breaks, cracks or separation of components: Longitudinal tension and compression (N) 1.5 x 9.81 x ATM (in kg) Vertical tension and compression (N) 0.5 x 9.81 x ATM (in kg).
Caution
Load levelling bars should only be used with towbars designed for load levelling. Very high forces can be generated when the vehicle and trailer combination travels through dips in the roadway. These high forces may exceed the design limits of the towbar and or its mountings. Drawbar safety chain attachment points should not come into contact with the road surface when the trailer is disconnected.
Caution
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Alternatively, ball couplings may comply with ECE R55/- as Class B coupling heads. A coupling body complying with AS 4177.3 must be marked with: the manufacturer's name or trademark; the mark 50; the maximum rating for the coupling body in one of the following, as applicable, 750 kg; or 2000 kg; or 3500 kg; a code to indicate the serial number, batch, production date, or similar; the words DO NOT WELD if the coupling body is manufactured from non -weldable materials; the words WELD ONLY if the coupling body is specifically designed to be attached by welding only.
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Caution
The Australian Standard and ECE standard contain 50mm ball coupling articulation limits. These angular limits are not intended to cover off road operation. Trailers for this type of operation should be designed accordingly.
16.4.2 Fifth Wheel Assemblies and Kingpins Fifth Wheel Assemblies and Kingpins with a D-Value rating of 40 kN or less must comply with Australian Standard AS 4968.1-2003 Heavy road vehicles Mechanical coupling between articulated vehicle combinations, Part 1 Design criteria and selection requirements for fifth wheel, kingpin and associated equipment, or to other requirements as listed in ADR 62/02. Alternatively, they may instead comply with ECE R55/- as Class G fifth wheel couplings and Class H fifth wheel coupling pins.\ A coupling complying with AS 4968.1 must be marked with: the manufacturer's name or trademark; the size, D-value and the plate thickness (for weld in kingpins) e.g. 50/D40/10; Note M rated kingpins may be used instead of D-value rated kingpins. Refer to AS 4968.1 for details.
A coupling complying with ECE R55/- must be marked with: the manufacturer's name or trademark; the mark G50 or G50-X or H50 or H50-X; the mark D, followed by the D-Value rating for the coupling; and the mark U, followed by the permissible static vertical load in kg. The ADR also allows fifth wheel assemblies and kingpins to instead be rated and marked with the allowable ATM, as long as this does not exceed 3.5 tonnes.
(For further information, refer to ADR 62/01)
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The wheel guards on the rearmost wheels must provide continuous protection between a point in area A and a point in area B in the figure above, and must cover the overall width of all tyres. In the case of steerable wheels, the requirements only apply when the wheels are in the straightahead position. Where two or more axles form an axle group, separate wheel guards may be fitted to each wheel or a single wheel guard which provides continuous protection from area A of the foremost wheel to area B of the rearmost wheel may be used. Wheel guards may consist of either permanent body structure or part structure and other components, including mudflaps. The end of a wheel guard including a mudflap (if fitted) need not be less than 230 mm from the ground. Note Wheel guards should be of sufficient structural strength to retain their function while the trailer is moving.
17.1. Visibility of Wheel Guards (Mudguards) On every trailer which is 2.2 metres or more in width and which has a body of the tray type, that portion of the external surface of any rear wheel guard, which is visible to the rear, must be white or silver in colour and clearly visible. 18: VISIBILITY OF TRAY On every trailer, which is 2.2 metres or more in width and which has a body of the tray type, and is not fitted with a rear marking plate. There must be displayed by painting or otherwise across the full width of the rearmost portion of the tray, a clearly visible white or silver coloured horizontal band having a uniform depth of at least 75mm.
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Within a group of axles: two axles must not be more than 2 metres apart; three axles must not be more than 3.2 metres apart overall. All axles in a group must be interconnected by a load sharing suspension except in a close-coupled axle group (where the two axles in a group have their centres not more than one metre apart, three axles not more than 2 metres apart or four or more axles not more than 3.2 metres apart) provided that the load carrying capacity of each axle in the group and the wheels and tyres fitted to it is: at least 120% of the load on that axle with the trailer at its ATM; and at least equal to the load on that axle with the trailer at its ATM and any retractable axle retracted.
OR
Load sharing suspensions must be designed so that each axle in a group carries the same load irrespective of the relative movement of the wheels.
Caution
Leaf springs that are galvanised should only be used in corrosive environments and only when there are no better alternatives available. It is important not to overload trailers fitted with such leaf springs. Only purchase them from a supplier with adequate control over the galvanising process. Extreme care needs to be taken with the cleaning phase during galvanising, to reduce the risk of brittle failure while in service
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The length of a drawbar must not exceed 5 metres for a dog trailer or 8.5 metres for a pig trailer. 21.2 Rear Overhang Dog Trailers Rear overhang must not exceed the lesser of 3.7 metres or 60% of the wheelbase.
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22 GENERAL CARAVANS REQUIRMENTS 22.1 Doors A caravan or trailer equipped with cooking facilities or living or sleeping accommodation must have only outward opening or sliding doors. At least one such door must be located on the left-hand side or at the rear. 22.2 LPG Installation The local state or territory registering authority should be consulted for acceptability of LPG installations requirements. In cases where the local state and territory does not mandate a minimum requirement. Then Manufacturers are required to comply with Australian Standard AS 5601-2004 Gas installations. 22.3 Fire Extinguisher Caravans must be provided with a fire extinguisher(s) selected and located in accordance with Australian Standards AS1850-1994 Portable Fire Extinguishers Classification, Rating and Performance Testing or AS 1850 -1997 Portable Fire Extinguishers Classification, Rating and Performance Testing and AS2444-1995 Portable Fire Extinguishers and Fire Blankets Selection and Location or Australian Standard AS 24442001 Portable fire extinguishers and fire blankets Selection and location. Note Fire authorities strongly recommend that caravans or trailers equipped with cooking facilities, or living or sleeping accommodation, be fitted with approved fire blankets and smoke detectors. 22.4 Toilets, Basins and Sinks Refer to ADR 42 for more information on the fitment of lavatory closets, urinals, basins and sinks. 23. GENERAL REQUIREMENTS FOR TRAILERS 23.1 Carriage of Passengers Trailers of any kind must not be designed or used for the carriage of passengers. 23.2 Internal or External Projections No part of a trailer shall be hazardous to other road users; there must be no unduly sharp edges or projections. Note The use of toughened or laminated safety glass on trailers that have windows is strongly recommended.
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Mailing Details (Please print): Contact Name: ____________________________________________________________ Company Name: ____________________________________________________________ Postal Address: _____________________________________________________________ Suburb: ______________________State: _______________Post Code: _______________ Country: ______________________________ Telephone No.: ____________________ Fax No.: ____________________
For Australian Subscribers: With Subscription per year Without Subscription/One-Off For Overseas Subscribers: With Subscription per year Without Subscription/One-Off $AUD64.18 (tax-free). $AUD21.41 (tax-free). $70.60 ($6.42 GST included). $23.55 ($2.14 GST included).
Please make your payment by one of the following methods: 1. EFT your payment to: Reserve Bank of Australia, Canberra [swift: RSKAU2S] Bank Details: BSB: 092009 Account No. 110951 (Please quote ADRs in the reference) 2. Cheques to be made out to: The Receiver of Public Monies Please mail your cheque and this form complete with all your details to: ADR Subscriptions Vehicle Safety Standards Branch AL2E Department of Infrastructure, Transport, Regional Development and Local Government GPO Box 594 CANBERRA ACT 2601 AUSTRALIA 3. Credit Card Debit my card: MasterCard VISA
Card Number:
_______________
June 2009
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Definitions (1) In this Instrument: aggregate trailer mass means the total mass of a road trailer when carrying the maximum load recommended by the manufacturer. This includes the mass imposed onto the towing vehicle when the combination vehicle is resting on a horizontal supporting plane. the Act means the Motor Vehicle Standards Act 1989. (2) Unless the contrary intention appears, a word or expression that is used in this Instrument and in the Act has the same meaning in this Instrument as it has in the Act. Note: The following terms are defined in the Act: new vehicle. road trailer. used imported vehicle.
Supply of nonstandard new trailers (1) (2) This approval is made under subsection 14A(1) of the Act. Road trailers: (a) (b) (c) that are new vehicles; and with an aggregate trailer mass of 4.5 tonnes or less; and that comply with the design and construction standards specified under Vehicle Standards Bulletin 1 issued on 1 December 2008; are approved for supply to the market.
(3)
This approval is made subject to the condition that the road trailers comply with all necessary requirements for registration by a State or Territory Government for use on a public road.
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