Auto Certification

&
Homologation
 Contents of Syllabus
CHAP-1
SPECIFICATION & CLASSIFICATION OF VEHICLES
CHAP-2
VEHICLE TESTING
CHAP-3
STEERING IMPACT
CHAP-4
SIZE AND PLY RATING OF TYRES
CHAP-5
PERFORMANCE REQUIREMENT FOR LIGHTING & SIGNALING
DEVICES
 SIAM
Car Segment Length of the car/Model type Car model belonging to
the segment

A1 Up to 3400mm Nano
A2 3401 to 4000mm Alto, i10, Zen, Wagon R
A3 4001 to 4500mm Manza, Logan, Dzire, City

A4 4501 to 4700mm Corolla, Octavia, Optra

A5 4701 to 5000mm Accord, Camry, Sonata
A6 More than 5000 mm Mercedes S class
B1 Vans Versa, Omni
B2 MUV/MPV Sumo, Innova
SUV SUV Vitara, CRV
 CHAP-1
SPECIFICATION & CLASSIFICATION OF VEHICLES
• M, N and O layout,
• Regulations overview (ECE, EEC, FMVSS, AIS,
CMVR, ADR)
• Type approval and Conformity of Production
• Engine and Vehicle specifications
• Two Wheeler certification

Ref : AIS-053: 2005

 Homologation

• Homologation is the process of certifying the

vehicles for roadworthiness as per specified
criteria laid by Government for all vehicles
made or imported in the country.
• The tests ensure that the vehicle matches the
requirements in terms of emission and safety
and road-worthiness standards as notified
under the CMVR - 1988
What needs to be certified ?
 M, N and O layout

• M category
A Motor vehicle with at least four wheels used
for carrying passengers
• N category
Means a Motor vehicle with at least four wheels
used for carrying goods.
• O Category
Trailers (including semi–trailers)
Ref : AIS-053: 2005
 M, N and O layout
Category
M1 category A vehicle used for carriage of passengers, comprising not more than
eight seats in addition to the driver’s seat.
M2 category A vehicle used for carriage of passengers, comprising nine or more
seats in addition to the driver’s seat, and having a maximum Gross
Vehicle Weight (GVW) not exceeding five ton.
M3 category A vehicle used for the carriage of passengers, comprising nine or more
seats in addition to the driver’s seat and having a GVW exceeding 5
ton.
N1 category Means a vehicle used for carriage of goods and having a GVW not
exceeding 3.5 ton.
N2 category A vehicle used for the carriage of goods and having a GVW exceeding
3.5 ton but not exceeding 12 ton.
N3 category Means a vehicle used for the carriage of goods and having a GVW
exceeding 12 ton.
 M, N and O layout

Category O1 Trailers with a maximum mass not exceeding 0.75 tons

Category O2 Trailers with a maximum mass exceeding 0.75 tons, but

not exceeding 3.5 tons.
Category O3 Trailers with a maximum mass exceeding 3.5 tons, but not
exceeding 10 tons.
Category O4 Trailers with a maximum mass exceeding 10 tons.
CMVR - Central Motor Vehicles rules,
(1st July 1989)
In India, the Rules and Regulations related to
driving license, registration of motor vehicles,
control of traffic, construction & maintenance of
motor vehicles etc. are governed by the CMVR
• NCAP- New Car Assessment Program
• AIS- Automotive Industry Standards
• ECE- Economic Commission for Europe
• FMVSS- Federal Motor Vehicle Safety
Standards
 Federal Motor Vehicle Safety Standards
(FMVSS)
• U.S. federal regulations specifying design,
construction, performance, and durability
requirements for motor vehicles and
regulated Automobile safety-related
components, systems, and design features
Type approval and Conformity of Production

• Type approval or certificate of conformity is granted to a

product that meets a minimum set of regulatory,
technical and safety requirements.
• Processes and certifications known as Type approval,
generally called homologation
• Conformity of Production (COP) is a means of
evidencing the ability to produce a series of products
that exactly match the specification, performance and
marking requirements outlined in the type approval
documentation.
• E.g COP of Gas Analyzer
Why you need TYPE APPROVAL
 Type Approval Certification procedure
consists of the following steps:

• Application from the manufacturer

• Review of manufacturers documentation
• Approval of design drawings
• Review of type test program
• Witness of type tests
• Review of the type test reports
• Issuance of Type Approval Certificate
 Two Wheeler certification
Two different Categories
• New Model Approval
Petrol / Diesel / CNG / LPG vehicles of engine
capacity more than 25 cc ( 2W_Certification.pdf )
• BATTERY OPERATED VEHICLES (New Model)
approval
Electric vehicles having power more than 250 W
and having maximum design speed more than 25
kmph. (2W-BoV-certification.pdf)
 CHAP-2
VEHICLE TESTING

Photographs, CMVR physical verification, Vehicle

weighment, Coast down test, Brake test, ABS,
Turning circle diameter test, Steering effort test,
Speedometer calibration, Pass by noise test,
External projection test, Gradability test,
Acceleration control system, Horn installation,
Rear view mirror installation, Installation
requirement for lighting & signaling devices, Wind
screen wiping system.
 Vehicle weighment (IS.11825)
• Scope: Covers the method of measuring the
weight -of two wheelers, three wheelers, car,
jeep, truck and bus.
• The weight measuring device shall be capable of
measuring the weights of the vehicle for any of
the conditions described in IS : 921 l-l 979.

Vehicle Weightment is.11825.1986_0.pdf

 Coast Down Test (IS: 14785)
• It help in determining the road-load resistance of
vehicle, including the aerodynamic and rolling resistance
by coast down technique.
• This equation is expressed as F = a+bv2,
where factors a and b are the constants.
a = coefficient of rolling resistance
b= miscellaneous
• Tyres which have covered only 10 percent or
less of their expected life shall befitted on the vehicle
 Coast Down Test (IS: 14785)

(is.14785.2000 Coast down test.pdf) Coast down test.mp4

 Brake Test (IS:4664:1999)

• It involves determination of stopping time, distance and

deceleration level.

• According to IS 14664:1999, following are the tests

conducted to assess braking performance of a vehicle.
(i) Type P Test (Dynamic Performance)
(ii) Type F Test (Heat Fade)
(iii) Type W Test (Water Fade)
A_Comparative_Study_on_Automotive_Brake_Testing_St.pdf

Volvo Trucks - Emergency braking at its best! (Collision warning).mp4

 Brake Test and ABS (IS 11852:2001)

• This standard include braking test applicable

to various categories of vehicle

• Performance requirement

• Evaluation method

Braking -ABS.pdf videoplayback.mp4

Brake Test and ABS (IS 11852:2001)
 Brake Test and ABS (IS 11852:2001)

• Type P test: ordinary performance test with

brakes cold
• Type F test : Fade test
• Type H test: down fall behavior test.
 Brake Test and ABS (IS 11852:2001)
• Performance can be measured by stopping
distance ( based on initial speed)
• Or by measuring the mean fully developed
deceleration (MFDD) during test
 Brake Test and ABS (IS 11852:2001)
• Surface should be dry ( µ > 0.8)
• Wind velo < 3 m/s
• Tyres must be inflated to prescribed value
• Test should be performed at the 90 percent of the
maximum speed of the vehicle.
• Braking should be obtained without locking the wheels
• Vehicle should go out of the lane of the width equal to
one and half times width of the vehicle. ( incase vehicle is
fitted with ABS, momentary wheel locking is permissible)
Brake Test and ABS (IS 11852:2001)
 Steering Effort Test (IS 11948 : 2010)

• This standard is applies on steering

equipment's of vehicle category M,NO

Steering Effort Test.pdf

 Gradability test.
• This standard specifies the method for measurement µ and
minimum requirements of starting gradeability for all types of
road vehicles, for the purpose of establishing compliance to
statutory requirements
• Additional attachments which consume power like air-
conditioner, etc. shall also be made inoperative.
• Before test, the vehicle including all its parts, components and
systems, shall have reached a stable operating temperature
normal to the vehicle operation.

gradability test.pdf
 Turning circle diameter test.

Anex10-Mercedes-BenzIndia-Comments-IS12222-2011.pdf
 Pass by noise test (IS 3028: 1998)

• This standard specifies the method for measuring the

external noise emitted by road vehicles in moving
condition.

Noise check.pdf
 Pass by noise test (IS 3028: 1998)
pass-by noise procedure require both WOT (wide open throttle)
tests and constant speed tests to be performed.
Pass by noise test (IS 3028: 1998)
 Pass by noise test (IS 3028: 1998)

Wide of throttle test

When the front of the vehicle reaches AA', the throttle shall
be fully engaged and held fully engaged until the rear of the
vehicle reaches BB'. The throttle shall then be returned as
quickly as possible to the idle position. A typical test
requires to hit PP line at 50KPH (+/- 1KPH). Due to this tight
tolerance it is often trial and error testing to get the correct
entry speed. The system offers instant feedback to
driver/rider of the test on the DASH4 display enabling rapid
testing.
Pass by noise test (IS 3028: 1998)
Noise Limit values
 Horn Installation (IS:15796:2008)
Requirement:
• The number and type of horns fitted on the vehicle
• The mountings used to fit the horns to the vehicle
• The position of the horns on the vehicle
• The rigidity of the parts of the structure on which the horns are
mounted
• The shape and materials of the body block at the front of the
vehicle which might effect the level of the sound emitted by
the horn and have a masking effect.
 Types of Approval: Horn Installation
The technical specification of vehicle and horn which
shall include at least the details given below:
Type of vehicle manufacturer Manufacturer of horn
Name of the vehicle Sketch showing mounting of horn
Address of the vehicle Operating voltage of horn
Vehicle model/variants Engine power
Maximum engine speed for continuous Test report of the horn complying
operation requirements of IS 1884

Type of horn fitted on the vehicle Category of vehicle

Horn to be used as dual or single
Horn Installation IS:15796:2008
• Every functional modification in technical specifications
pertaining to installation of horns will be intimated to testing
agency.
• Vehicle with modifications complies with the specified
requirements
• Any testing is necessary to establish the compliance.
Sound Pressure Level Test:
1. Between 83 dB to 112 dB for horns fitted on 2 wheelers or
3 wheelers of a power less than or equal to 7 kW
2. Between 93 dB to 112 dB for the horn fitted on all other
motor vehicles including tractor, cars, 2 wheelers and 3
wheelers of a power greater than 7 kW
 Test Methods: Horn Installation

• The measurement of the sound pressure levels shall be made

using a sound level meter.
• The sound signalling device shall be operated at test voltages of
6.5V, 13V or 26V with tolerance of ± 0.5 V, measured at the
terminals of the source and corresponding respectively to rated
voltage of 6V, 12V, 24V.
• The sound pressure level of the background noise and wind
noise shall be at least 10 dB below the sound level to be
measured.
 Windscreen Wiping System (IS 15802 : 2008)
Requirement:
• The wiper system shall be capable of attaining the minimum operating
frequency of 30 cycles/min regardless of engine load and engine speed.
• If the windscreen wiper is having two or more sweep frequencies then
1. One of them shall not be less than 45 cycles/ min (a cycle being the
forward and return movement of the windscreen wiper)
2. One of them shall not be less than 10 and not more than 55 cycles/min.
3. The difference between the highest and the least one of the lower sweep
frequencies shall be at least 15 cycles/min.
Windscreen Wiper Blade:
• The wiper blade element of the wiper blade assembly shall withstand the ozone
test.
• Chemical Resistance : The wiper blade element shall withstand the chemical
resistance test
Wiped Area
 Test Procedure:
1. Wiped Area Test:
a) Drafting equipment sufficient for full-size windscreen and wiper
system layout.
b) Transparent heavy gauge plastic sheet - prepared in clear acetate
or equivalent.
c) Test Rig - A test rig shall consist of structure capable of
maintaining, throughout the test, the proper relationship of the
glazing surface and the windshield wiping system components
as established by the vehicle manufacturer.
d) Power Source - The power source shall supply to the wiper motor
the maximum power expected by the vehicle manufacturer
under the conditions specified in any of the test procedure's
paragraphs.
e) Spray Equipment - Spray nozzles to apply water to glazing
surface .
2. Wiper System Frequency Test:
Apart from the test rig the additional equipments required will
be counters, water softener, cleanser, temperature measuring
device and voltmeter.
a)Ambient temperature not exceeding 40°C.
b) Water temperature 40°C maximum.
c) Water nozzles - to be located so as to provide an
approximately equally distributed water flow on windscreen
glazing surface at the rate of not less than 820 cdmin.
d) Clean, Oil - free water.
e) Power input level at electrical drive motor (frequency test
only) shall be maintained at 6.75±0.I,13.5±0.1
and27±0.2Vfor6,12 and 24V system respectively.
• Wiper System Stall (Strength):
At an ambient temperature not exceeding 40°C and with the
specified power supply, the wiper arms, in any position in the
wipe circle, are restrained from movement for 15 sec.
• Hot Test:
The test rig and spray equipments are to be soaked in the test
chamber at a temperature of 55 ± 3° C for 4 h. Following this
soak period and in the same temperature environment, the
wiper system and spray equipments are to be turned on and
operated for a period of half an hour at maximum wiper speed
control setting with water applied continuously
• Cold Test:
The test rig is to be soaked in the test chamber at temperature
of 0 ± 3°e for 4 h. Following this soak period and in the same
temperature environment, the IS 15802 : 2008 wiper system is
to be turned 'ON' and the wipers operated for half an hour at
maximum wiper system speed control setting.
• Ozone Test:
Test specimens are to be placed in the ozone test chamber for a
period of 72 h. The test chamber is to be operated at a
temperature of 40 ± 3°C and at a concentration of 50 pphm, by
volume.
• Chemical Resistance Test:
A section of the wiper blade element when placed in a 50
percent solution of either methyl or isopropyl alcohol for a
period of24 h shall not change its weight by more than 2
percent.
 Acceleration Test For 2/3 Wheelers

• Scope-
This standard specifies the method of evaluation
of acceleration performance of two wheelers
such as mopeds, scooters and motorcycles.
 Preparation of Vehicle
• Vehicle and all its parts should conform to specifications provided by
manufacturer.
• Fuel and lubricants used should be verified by manufacturer.
• Vehicle run-in as per practice recommended by manufacturer.
• All parts to be stabilized at normal temperature before use.
• Tyre tread depth should be at least 90% of new depth and operated
for at least 500km or distance recommended for running in,
whichever lower, on the test track.
• Tyre pressure recommended by manufacturer and should not
exceed the Indian Standard maximum value for the same sized tyre.
• Distribution of load recommended by manufacturer.
 Requirement of Driver

• Mass of 68-75 kgs and height of 1.65-1.75

meters.

• Fitting driver suit with a crash helmet.

• Upright position at all times.

 Features of Test Track
• Test carried on dry, smooth, clean, covered
with asphalt in a straight line.
• Longitudinal slope 0.5% at most and lateral
slope 2% at most. Altitude difference between
any 2 points, 1000 meters apart should be 1
meter, at most.
 Atmospheric Conditions
• The ambient condition at the test site shall be
as follows:
i) Atmospheric pressure- 86 to 106 kPa
ii) Temperature- 288 to 308 K ( 15 to 35°C)
iii) Relative humidity- 75 percent, Max
dt = air density at test site expressed in kg/m3,
d0 = air density at reference conditions in kg/m’ (1.168 kg/m3),
Pt = atmospheric pressure at test site in kPa,
P0 = atmospheric pressure at reference condition in kPa
(100kPa),
Tt = ambient temperature at test site K
T,= ambient temperature at reference condition (300 K).

• Wind velocity 3m/s at most and measured at height of 1-1.5

meter above ground.
 Method 1
A reference point on the vehicle such as the
centre line of the front wheel of the vehicle shall
coincide with starting point. The time taken
from the moment the vehicle starts moving till
reference point on the vehicle passes the end
of the measuring strip shall be measured. This
shall be carried out in each direction.
 Method 2
Time taken from start to attain a given speed
shall be noted.
The test may also be conducted for speed
starting from ‘Zero’ and increasing in steps of 10
km/h to the speed indicated below:
Maximum speed specified by Time taken to achieve a speed
vehicle manufacturer (km/h) of
Upto 60 40 km/h or 75 percent of
maximum speed rounded off
to nearest 5 km/h whichever is
lower
60-100 60 km/h or 75 percent of
maximum speed rounded off
to nearest 5 km/h
whichever is lower
More than 100 80km/h
 Method 3
Time taken to attain a required speed from a lower
speed, through gears or any one gear.
This is applicable only for two wheelers whose maximum
speed specified by the vehicle manufacturer exceeds 70
km/h. The vehicle may be driven in any constant speed of
30 km/h and gear recommended by the manufacturer.
When the speed becomes steady, accelerate the vehicle
fully to attain a speed of 60 km/h through gears, the gear
shifting being as recommended by the vehicle
manufacturer. The time taken for this shall be noted. Test
shall be repeated in opposite direction also.
• The time shall be determined with a 0.7 percent
accuracy.
• The average acceleration performance for the run
shall be equal to the arithmetical average of the
time taken to cover the measuring strip or to attain a
given speed from zero speed or to attain a required
speed from a lower speed in each direction.
• This measurement shall be made at least two
consecutive times.
 Result
The acceleration performance shall be
expressed in seconds rounded off to the nearest
two decimals, which corresponds to the
arithmetical average of the values of the time
measured during the consecutive tests, which
do not differ by more than 5 percent.
Acceleration Test For 4 or more Wheelers

• Scope-
Gives the method of evaluation of acceleration
of automotive vehicle such as truck, bus, cars.
 Features of Test Track
• Clean, smooth, dry roadway covered with asphalt or
similar material.
• Longitudinal slope 1% at most, lateral slope 3% at most
in straight line. Altitude difference between 2 points,
1000 meters apart, should be 1 meter at most.
• Track should be allowing to maintain steady speed.
Should either be a straight line or a closed loop, 2000
meters in length with a minimum radius of 200 meters.
• Adequate stretch for purpose of achieving test speed
and stopping the vehicle.
 Preparation of vehicle
• Vehicle and all parts verified according to applicable production
series.
• Run-in as recommended by manufacturer
• Fuel and lubrication adjustment, including ignition system, should
be recommended by manufacturer.
• Vehicle and all parts should reach stable temperature before test.
• Loaded as recommended by manufacturer and load distribution as
recommended by manufacturer.
• Tyres to be used should have at least 90% of their life left and
inflated according to Indian Standards for same size and make of
tyres.
• All windows and latched closed.
 Atmospheric conditions
• Atmospheric Conditions - Shall be as under:
• a) Atmospheric pressure 86 to 106 kPa;
• b) Temperature 288 to 308 K;
• c) Relative humidity 45 to 75 percent;
• d) Maximum wind speed 3 m/s (in any
direction); and
• e) Maximum wind speed for gusts, 8 m/s.
dt = air density at test conditions,
do = air density at reference condition ( 0.9197 ),
HT = atmospheric pressure at test site expressed in kPa,
H o = atmospheric pressure at reference conditions kPa,
T o = temperature at reference condition 298 K, and
TI = atmospheric temperature at the test site expressed in Kelvin.

• The head lights, parking lights and the emergency flasher lights (where
applicable ) shall be kept operative during the trial.
• The test vehicle shall carry a board prominently placed, indicating that the
test is in progress.
• Fitment and operation of all instruments shall be such as not to hamper the
visibility or freedom of the driver to have proper control of the vehicle at
all times.
 Evaluation
• The acceleration performance shall be expressed as the time taken in
seconds
a) to cover a distance of 1 000 m from start or
b) to achieve speed of 90 kmph or to the nearest multiple of 10
kmph to the maximum speed, whichever is less.
• The engine, at the starting point of the measuring strip or track shall
be run at the low idling speed as specified by the manufacturer. The
centreline of the front wheel of the vehicle shall coincide within the
starting point of the measuring strip if distance measurement is based
on fixed marks on the track. If instruments such as fifth wheel or
optical devices are used for the measurement of distance the location
points of such instruments shall be taken as references instead of the
front wheel.
• Starting gear shall be as per manufacturer recommendations and the vehicle
shall be accelerated to achieve speed in shortest duration in different gears
and gears shall be changed for different speeds as recommended by the
manufacturer and shall be recorded in the test report.
• Time taken will be established within range of 0 .7%.
• Test repeated in opposite direction.
• The acceleration performance shall be equal to the arithmetic average of
time taken for 6 readings ( 3 each in either direction ) which do not differ by
more than 5 percent from mean expressed in seconds rounded off to the
nearest second place of decimal.
• For the purposes of detailed analysis, the tests may be conducted for
distances starting from 100 m and increased in steps of 100 m and speeds
similarly from 10 kmph onwards in steps of 10 kmph each.
 Turning Circle Diameter Test
• Scope-
1. This standard specifies the turning circle
requirements for vehicles of category L (fitted with
steering wheel), M and N.
2. This standard also specifies manoeuvrability
requirements for vehicles designed and constructed
for the carriage of persons having a capacity in excess
of 22 passengers, whether seated or standing, in
addition to the driver and having an overall width
exceeding 2.3 m.
 Definition
• Turning Circle Diameter- The diameters of the circles
circumscribing the extensions on the supporting plane of mid
planes of the steered wheels (the steering wheel being
turned to the full lock). (IS 9435:2004-5.31)
• Turning Clearance Circle- The turning clearance circles (the
steering wheel being turned to full lock) are:
a) The diameter of the smallest circle enclosing the projections
onto the supporting plane of all points of the vehicle.
b) The diameter of the largest circle beyond which art located
the projections on the supporting plane of al’ the points of
the vehicle. (IS 9435:2004-5.32)
IS 9435:2004
 Requirements
• Turning diameter (outer) for vehicles covered
under definition 1 must not exceed 24 meters.
• Turning radius (outer) for vehicles covered
under definition 2 must not exceed 12.5
meters. (depending on vehicle- rigid or
articulated)

IS 12222:2011
Rigid Vehicles Articulated Vehicles
• CMVR physical • Speedometer calibration
• Pass by noise test
verification • External projection test
• Vehicle weighment • Gradability test
• Acceleration control system
• Coast down test • Acceleration control system,
• Horn installation,
• Brake test • Rear view mirror installation,
• Installation requirement for
• ABS lighting & signaling devices,
• Wind screen wiping system.
• Turning circle
diameter test
• Steering effort test
 Speedometer calibration
• This standard covers the method of evaluation of calibration of
speedometer fitted on automotive vehicle
Requirements:
• The display of the speedometer shall be located within the direct
field of view of the driver and shall be clearly legible by both day and
night.
• The marked numerical values shall be in Arabic numerals
• The interval between marked numerical values of the speed shall be
as follows:
a) In the case of L1 category of vehicles, not exceeding 10 k/h.
b) In the case of other vehicles:
1) When the range of display does not exceed 200 km/h, not exceeding
20 km/h.
2) When the range of display exceeds 200 km/h, not exceeding 30
km/h
speedometer calibration.pdf
 Speedometer calibration
The vehicle shall be tested at the speeds
 CHAP-3
STEERING IMPACT

Test (GVW<1500 kg), Body block test, Head form

test, Fixtures charges, Crash test with dummies,
OBD I, Bumper testing, Documentation SHL,
Certification charges, Engine power test (petrol
& diesel), Indian driving cycle, Vehicle mass
emission, Evaporative emission (petrol vehicles),
Broad band / Narrow band EMI test.
Safety critical components for two‐wheelers
 Two wheeler and four wheeler Safety Comparison
Four Wheeler Two wheeler
• An automobile has more weight • motorcycle suffers in
and bulk than a motorcycle. comparison when considering
• It has door beams and a roof to vehicle characteristics that
provide some measure of directly contribute to occupant
protection from impact or safety.
rollover. It has cushioning and • What a motorcycle sacrifices
airbags to soften impact and in weight, bulk, and other
safety belts to hold passengers crashworthiness characteristics
in their seats. is somewhat offset by its
• It has windshield washers and agility, maneuverability, ability
wipers to assist visibility in the to stop quickly, and ability to
rain and snow. An automobile swerve quickly when
has more stability because it's necessary.
on four wheels, and because of
its size, it is easier to see.
Rear Protection Device

• All Motorcycles should be equipped

with rear protection device covering
half the wheel.
• It should prevent the intervention
of loose clothes of pillion rider into the
wheel.
Pillion Hand Hold Test
• Strength requirements of pillion straps and
hand holds are checked.
• The straps and its attachment shall withstand
a vertical traction force of 200 kg applied
statically to the center of the surface at a
maximum pressure of 2 MPa, without
snapping.
• The two hand grips should be mounted one
on each side symmetrical manner which shall
withstand a vertical traction force of 100 kg
applied statically to the center of the surface at
a maximum pressure of 1 MPa, without
snapping.
 Rear view mirror
• Rear view mirrors are checked for
• Performance requirements, Mechanical
• Behavior, Environmental Performance test
• Performance requirements
Radius of curvature and dimensions.
Reflectivity
Distortion factor
• Mechanical behavior
• Impact test
• Bending test
• Vibration test
• Environmental performance test
• Temperature resistance
• Moisture resistance test
• Salt spray test AIS 001
• Weather resistance test

Test procedure is aligned with UN R46

Installation requirements of rear view mirror

• Installation requirements cover, General

requirements , Position requirements ,
Adjustment requirements, Field of
visions.
• For 2 wheelers above 70cc shall have 2
mirror on LH and RH side and for 2 wheelers
below 70 cc shall have one
mirror on one side.
• When vehicle is tested at about 80% of
max speed on test track for 10 min , the
mirror shall not show move significantly to
change the field of view.
• Test procedure is aligned with UN R46
Lighting and light‐ signaling devices

STANDARD – AIS : 010

Test procedure is aligned with UN R74

Fuel tank (Metallic and Plastic)
METALLIC FUEL TANK
Test conducted
Leakage Test
• Ordinary position / upside position
• 50gms / min.
Pressure Test
•Should withstand pressure of 130 kPa
absolute
without leakage.
Test procedure is aligned with 70/221/EEC
PLASTIC FUEL TANK
Tests conducted
•Corrosion test
•Over turn test
•Fuel permeability test
•Mechanical Strength Test
•Impact resistance test
•Fire resistance test
•Resistance to High temperature
Test procedure is aligned with UN R34
 Horn installation ( AIS 014 :2001)

• Sound pressure level emitted by the device(s)

fitted on the vehicle shall be measured at a
distance of 7 m in front of the vehicle .
• The maximum sound pressure level shall be
sought within the range of 0.5 and 1.5 m above
the ground.
• Maximum Sound Pressure Level measured on 2
Wheelers of a power less than 7 kW is between
83 dB(A) to 112 dB(A)
 Horn Test (IS 1884:1993)
• These tests are basically required to check,
Functional Performance, Reliability, Quality, etc.
• In an open space of radius 12m in which there
are no obstacles in between, with background
noise at least 10 dB below that produced by
horns under test, and the horn to be mounted
1.2 m above ground and directed horizontally
to microphone of sound level meter at a
distance of 2m from front of the horn
 Hydraulic brake hoses
(IS : 7079 – 1995)
Tests conducted
• Constriction Test
• Expansion test
• Pressure test
• Bursting strength test
• Burst & expansion
• Tensile Test
• Test rig
• Salt Spray test
• Cold bend test
• Ozone resistance test
• Hot Impulse test
• Brake Fluid compatibility Test
 Tyre test (IS 15627)
Tests conducted
•Dynamic growth test
•Endurance Test
•Load/Speed Performance
• Plunger test
•Bead Unseating Resistance
•Dynamic growth test
 Wheel rim test
(AIS 073 PART 1, 2 & 3)
Following tests are conducted on wheel rims
(Light Alloy Wheel Rims, Sheet Metal
• Wheel Rims, Spoke Wheel Rims
• Torsion Moment Test System
• Radial Impact Resistance Test
• Deflection test
• Air leak test
Daytime Running Lamp (DRL)
 Daytime Running Lamp (DRL)
• Daytime running lamp" means a lamp facing in a forward
direction used to make the vehicle more easily visible when
driving during daytime
• DRL reduce daytime accidents by making vehicles more
conspicuous to other road users
• DRLs provide not only improved visibility (detection) but also
improved reaction times and estimation of speed and
distance
• In addition to increasing the distance at which vehicles could
be reliably detected, DRLs make vehicles appear closer. This
makes drivers more likely to reject short gaps for a potentially
hazardous maneuver.
 NCAP - crash-test cars
• New Car Assessment Program to promote vehicle crash-
testing
• in 1978 USA became the first country to come up with a
program to provide car crashworthiness information to
consumers
• Today there is the Australasian NCAP, Euro NCAP, Japan
NCAP, ASEAN NCAP, China NCAP, Korean NCAP and Latin
NCAP.
 NCAP - crash-test cars
• Global NCAP, an independent charity registered in the UK, was
formed in 2011 to enhance cooperation between the various NCAPs
‘Safer Cars For India’ and ‘Safer Cars For Africa’ are its key initiatives at
the moment. 
• Every NCAP has its own protocol to crash-test and score cars
• E.g. Euro NCAP, for instance, conducts full frontal, front offset, side
impact and side pole tests
• Global NCAP ratings, only front offset crash tests alone.
• A front offset crash test is designed to simulate a head-on collision
between two cars.
• In the Global NCAP test, the car is  driven at 64kph and with 40
percent overlap into a deformable barrier which is the equivalent of
a crash between two cars of the same weight, both moving at 50kph.
How does Global NCAP score cars

• rating on a 5-star scale – the higher the star rating,

the safer the car
• The rating itself is based on the Adult Occupant
Protection and Child Occupant Protection scores
resulting from the crash test
• scores are primarily derived from readings of the
crash-test dummies but additional points may be
awarded for driver’s side airbag as the minimum
requirement to qualify for a one star rating.
How does Global NCAP score cars
• The 17-point Adult Occupant Protection
score takes into account driver injury readings
from four body regions – head and neck;
chest; knee, femur and pelvis, and leg and
foot. An additional point is given to cars with a
seatbelt reminder, four-channel ABS and some
form of side-impact protection, tested by a
relevant authority.
How does Global NCAP score cars
• 49- point Child Occupant Protection
• 18- month-old and 3-year-old-sized dummies
Additional points are given for child restraint
system markings, provision of three point seat
belts, Isofix, etc.
NCAP- STAR Rating
full frontal, front offset, side impact and side
pole tests
 whiplash injury
When your car gets bumped from behind,
your head naturally extends backward before being thrown
forward (remember Newton's Laws of Motion). If
your head is unsupported, your neck bends too far
backward, resulting in what is known as whiplash injury
Head restraints (headrests) are an automotive safety
feature, attached or integrated into the top of each seat to
limit the rearward movement of the adult occupant's head,
relative to the torso, in a collision — to prevent or mitigate
whiplash or injury to the cervical vertebrae.
Head restraints are designed to restrict head movement
during a rear-impact collision and reduce the chance of
neck and shoulder injury
Symptoms of whiplash include
• Neck Pain
• Headaches
• Neck or Back Stiffness
• pain between or around the shoulder blades
• Numbness in Arms or Hands
Some vehicles are equipped with an active headrest. These headrests are designed to
move forward during a rear collision to reduce the chance of whiplash injury

Some active headrests may automatically reset, like on the 2010 Toyota Venza. This system
uses a pressure plate in the seat back to move the headrest forward. A spring automatically
returns the headrest to the original position following a rear impact.

Others use pressurized gas for activating the active headrest. A vehicle maker may have
more than one type of system in their vehicle lineup. For example, the 2014 BMW 7 Series
 may be reset by replacing a pressurized gas cartridge (up to five times); while the active
headrest on the 2014 BMW 3 Series require the complete headrest be replaced.
 whiplash injury
When your car gets bumped from behind,
your head naturally extends backward before being thrown
forward (remember Newton's Laws of Motion). If
your head is unsupported, your neck bends too far
backward, resulting in what is known as whiplash injury
Head restraints (headrests) are an automotive safety
feature, attached or integrated into the top of each seat to
limit the rearward movement of the adult occupant's head,
relative to the torso, in a collision — to prevent or mitigate
whiplash or injury to the cervical vertebrae.
Head restraints are designed to restrict head movement
during a rear-impact collision and reduce the chance of
neck and shoulder injury
Symptoms of whiplash include
• Neck Pain
• Headaches
• Neck or Back Stiffness
• pain between or around the shoulder blades
• Numbness in Arms or Hands
Some vehicles are equipped with an active headrest. These headrests are designed to
move forward during a rear collision to reduce the chance of whiplash injury

Some active headrests may automatically reset, like on the 2010 Toyota Venza. This system
uses a pressure plate in the seat back to move the headrest forward. A spring automatically
returns the headrest to the original position following a rear impact.

Others use pressurized gas for activating the active headrest. A vehicle maker may have
more than one type of system in their vehicle lineup. For example, the 2014 BMW 7 Series
 may be reset by replacing a pressurized gas cartridge (up to five times); while the active
headrest on the 2014 BMW 3 Series require the complete headrest be replaced.
 BRAKE TEST

SCOPE
Performance testing of automotive brakes involves determination
of stopping time, distance and deceleration level. Braking
performance of an automobile is required to be ensured for various
surfaces like dry, wet, concrete, bitumen etc. as well as for
prolonged applications. Various brake testing standards are used
worldwide to assure vehicle and pedestrian safety.
 Two Wheelers(IS14664:2010)
GENERAL REQUIREMENTS
1. Brake system requirements
• Two-wheeled vehicles of categories 3-3 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.
2. Mass in running order
• Mass of the vehicle with bodywork and all factory fitted equipment, electrical
and auxiliary equipment for normal operation of vehicle, including liquids,
tools.
• The fuel tank shall be filled in case of liquid fuel to at least 90 per cent of
rated capacity and in case of LPG, CNG and other gaseous fuels to legally
permitted capacity and the other liquid containing systems (except those for
used water) to 100 per cent of the capacity specified by the manufacturer.
• 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 in accordance with IS 9226).
3. For vehicles that use hydraulic fluid for brake
force transmission, the master cylinder shall
• Have a sealed, covered, separate reservoir for each brake system. These may
be in the form of one or more separate reservoirs located within the same
container. Such containers may only have one sealed, covered filling cap;
• 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
• Have a reservoir where the fluid level is visible for checking without removal of
the cover.
4. Durability
• Wear of the brakes shall be compensated for by means of a system of
automatic or manual adjustment.
• The friction material thickness shall either be visible without disassembly of
brakes, or where the friction material is not visible; wear shall be assessed by
means of a device designed for that purpose.
• During all the tests in this standard and on their completion, there shall be no
friction material detachment and no leakage of brake fluid.
TEST CONDITIONS, PROCEDURES AND PERFORMANCE
REQUIREMENTS
1. General
1.1. Test Surfaces
1.1.1. High-friction surface
• Applicable to all dynamic brake tests excluding the ABS tests where a low-
friction surface is specified
• The test area is a clean, dry and level surface, with a gradient ≤ 1 percent
• The surface has a nominal peak braking coefficient (PBC) of 0.9, unless
otherwise specified.
1.1.2. Low-friction surface
• Applicable to ABS tests where a low-friction surface is specified;
• The test area is a clean and level surface, with a gradient ≤ 1 percent; and
• The surface has a PBC ≤ 0.45.
1.1.3. Test lane width
• For two-wheeled vehicles (vehicle categories 3-1 and 3-3) the test lane
width is 2.5 m.
1.2 Ambient Temperature
• The ambient temperature is between 4 °C and 45 °C.
1.3 Wind Speed
• The wind speed is not more than 5 m/s.
1.4 Automatic Transmission
• Vehicles with automatic transmission shall complete all tests — whether
they are for engine connected or engine disconnected.
1.5 Test Speed Tolerance
• Test speed tolerance is ±5 km/h; and b) In the event of the actual test
speed deviating from the specified test speed, the actual stopping
distance is corrected using the formula-
1.5.1. STOPPING DISTANCE FORMULA
1. Based on the basic equations of motion
S = 0.1·V + (X) ·V ²
where S = stopping distance, in m;
V = vehicle speed, in km/h; and
X = variable based on the requirement for each test.
2. To calculate the corrected stopping distance using the actual vehicle test
speed, the following formula is used:
Ss = 0.1Vs + (Sa – 0.1Va ) · Vs² /Va²
where Ss = corrected stopping distance, in m;
Vs = specified vehicle test speed, in km/h;
Sa = actual stopping distance, in m; and
Va = actual vehicle test speed, in km/h.
 PREPARATION

• Engine Idle Speed

The engine idle speed is set to the manufacturer’s specification.
• Tyre Pressures
The tyres are inflated to the manufacturer’s specification for the vehicle
loading condition for the test.
• Control Application Points and Direction
For a hand control lever, the input force (F) is applied on the control
lever’s forward surface perpendicular to the axis of the lever fulcrum and
its outermost point on the plane along which the control lever rotates
The input force is applied to a point located 50 mm from the outermost
point of the control lever, measured along the axis between the central
axis of the fulcrum of the lever and its outermost point.
For a foot control pedal, the input force is applied to the centre of, and at
right angles to, the control pedal.
When the tests are to be conducted with actuation of both controls simultaneously,
there shall be a device to establish time interval elapsed between actuation of two
controls and time elapsed between actuation of these controls shall be less than 0.1s.
 Dry Stop Test — Single Brake Control Actuated
• Vehicle Condition
1. Test is applicable to all vehicle categories
2. Engine disconnected.
• Test Conditions and Procedure
Initial brake temperature: ≥ 55°C and ≤ 100 °C
• Test speed- 60 km/h or 0.9 VMax, whichever is lower.
• Brake application- Each service brake system control actuated
separately
• Brake actuation force-
1. Hand control: ≤ 200 N
2. Foot control: ≤ 350 N
3. Number of stops: Until the vehicle meets the performance
requirements, with a maximum of 6 stops.
• Performance Requirements
MFDD (Mean Fully Developed Deceleration)

d m= mean fully developed deceleration;

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 m; and
Se = distance travelled between V1 and Ve , in m
 Dry Stop Test — All Service Brake Controls Actuated

• Test Conditions and Procedure

Test speed: 100 km/h or 0.9 VMax, whichever is lower
• Brake actuation force
1. Hand control: ≤ 250 N
2. Foot control: ≤ 400 N
• Performance Requirements- the stopping distance (S) shall be
S ≤ 0.006 V² (where V is the specified test speed in km/h and S is the
required stopping distance in metres).
 High Speed Test
• Vehicle Condition
1. Test is not required for vehicles with Vmax ≤ 125 km/h
2. Engine connected with the transmission in the highest gear.
3. Lightly loaded
• Test Conditions and Procedure
Test speed: 0.8 Vmax for vehicles with Vmax > 125 km/h and < 200 km/h
160 km/h for vehicles with Vmax ≥ 200 km/h.
• Brake application- Simultaneous actuation of both service brake
system controls, if so equipped, or of the single service brake system
control in the case of a service brake system that operates on all wheels.
• Brake actuation force
1. Hand control: ≤ 200 N
2. Foot control: ≤ 350 N
• Performance Requirements
1. The stopping distance (S) shall be ≤ 0.1 V + 0.006 7 V² (where V is the
specified test speed in km/h and S is the required stopping distance in
metres).
2. The MFDD shall be ≥ 5.8 m/s²
 Wet Brake Test

• General Information
1. The test is comprised of two parts that are carried out consecutively for
each brake system:
a) a baseline test based on the dry stop test — single brake control actuated.
b) a single wet brake stop using the same test parameters as in (1), but with
the brake(s) being continuously sprayed with water while the test is
conducted in order to measure the brakes’ performance in wet conditions.
2. Drum brakes or fully enclosed disc brakes are excluded from this test unless
ventilation or open inspection ports through which water ingress into the
brakes is possible are present.
3. This test requires the vehicle to be fitted with instrumentation that gives a
continuous recording of brake control force and vehicle deceleration. The
MFDD and the stopping distance measurements are not appropriate in this
case.
• Vehicle Condition
Each brake is fitted with water spray equipment
DISC BRAKE
1. Water is sprayed onto each brake with a flow rate of 15 l/h. The water is
equally distributed on each side of the rotor.
2. If the surface of the rotor has any shielding, the spray is applied 45° prior
to the shield.
3. If it is not possible to locate the spray in the position shown on the
sketch, or if the spray coincides with a brake ventilation hole or similar,
the spray nozzle may be advanced by an additional 90° maximum from
the edge of the pad, using the same radius.
• Drum brakes with ventilation and open inspection ports-
1. Water is sprayed equally onto both sides of the drum brake assembly (on
the stationary back plate and on the rotating drum) with a flow rate of 15
l/ h.
2. The spray nozzles are positioned two thirds of the distance from the
outer circumference of the rotating drum to the wheel hub centre.
3. The nozzle position is > 15 ° from the edge of any opening in the drum
back plate.
Anti-lock braking system(ABS)
Standards and testing
Scope
• This presentation explains the required braking performance for road vehicles
fitted with anti-lock systems.
• The anti-lock systems known at present comprise of sensor or sensors,
controllers and a modulator or modulators as well as any other equivalent for
the anti-lock system
ABS standards

1.) CMVR section 96-B: (High Speed Braking Requirements)

• Should comply with P-type testing defined by the Indian

Standards( IS:11852-2001-Part 3) only for M1 category
vehicles(explained in brake test).
• Carried out in the engine connected mode at a test speed of 120 km/h
or at 80% of the design maximum speed of the vehicle, whichever is
lower.
• Stopping distance (S):
a) S < 0.1 V + (V^2 /130):
b) V is the test speed in km/h, S in meters
c) Control force(F) < 500 Newtons.

2.) IS 15986 : 2015 Annexure E:Test requirements for vehicles fitted with
anti-lock system.
ABS testing pre-requisites
• Any electrical failure(all types) or sensor anomaly, that affecting the system
with respect to the functional and performance shall be signaled to the driver
by a specific optical warning signal. The yellow warning signal specified in
5.2.21.1.2 shall be used for this purpose.
• The manufacturer shall provide the testing agency with documentation
relating to the controller(s) as defined in annexure G.
• The undetected sensor issues when vehicle is stationary must be
signaled(detected) as the vehicle speed exceeds 10km/hr but not later than
15km/hr.
• When the anti-lock braking system is energized with the vehicle stationary,
electrically controlled pneumatic modulator valves shall cycle at least once.
• In case of ABS failure, indicated by yellow warning light the service brakes
performance should not be less than 80% of the performance criteria of O
type brake test with engine disengaged.
Stopping distance = 0.1 v + 0.0075 v^2 (m)
Mean fully developed deceleration(MFDD)= 5.15 m/sec^2.
• ABS must not be affected magnetic and electric fields(AIS 004).
• No manual control or disconnection system must be provided for ABS.
Note: Vehicles using ABS shall maintain
their performance when the service braking
control device is fully applied for long
periods.
Test procedures
• The energy level in the energy storage devices should be sufficient enough to
ensure the prescribed efficiency of service brakes for the loaded vehicle.
• Initial speed should not be less than 50km/hr which is to be maintained on
the surface with coefficient of adhesion of 0.3 or less.
• Vehicle brakes should be fully applied for time t, during this stage the energy
consumption of indirectly controlled wheels is taken into account while the
directly controlled wheels are controlled by the ABS.
• The power transmission should cut-off(engine disengaged) as soon as the
brakes are applied.
• During this stage full actuation of service brake occurs 4 times in succession
with vehicle in stationary.
• During the fifth pulse, it should be possible to brake the vehicle with
performance limit of secondary brakes.
Test criteria
• Vehicle should be tested for idling, engine disengaged and laden.
• The antilock system is claimed to be satisfactory when the adhesion utilized is
greater than or equal to 0.75.
• Braking time must not be less than 15sec and is calculated by the formula
t=vmax /7 (v: max. velocity in km/hr and t in sec).
• The braking time should not exceed more than 4 phases.
• Wheel locking is permitted when the vehicle speed is less than 15 km/h.
• Locking of indirectly controlled wheels is permitted at any speed, but stability
and steer ability shall not be affected and the vehicle shall not exceed a yaw
angle of 15° or deviate from a 3.5 m wide lane.
 Turning Circle Diameter Test
•Turning circle radius gives an indication of the space required to turn a
particular vehicle. Hence, the higher the value of turning circle radius, the
higher is the space you need to turn the vehicle completely and vice
versa.
•This parameter is closely related to the steering geometry and the
suspension system of the vehicle under consideration. The effectiveness
of this specification of a vehicle is clearly evident while maneuvering in a
crunchy parking space.
•The Indian requirements are specified in the Indian standard IS
12222.2011.
Indian standard IS 12222.2011
Scope
• This standard specifies the turning circle requirements for vehicles of
category L (fitted with steering wheel), M and N.
• This standard also specifies maneuverability requirements for single-deck
rigid or articulated vehicles designed and constructed for the carriage of
persons having a capacity in excess of 22 passengers. whether seated or
standing, in addition to the driver and having an overall width exceeding
2.3 m.

PREPARATION OF THE VEHICLE

• The vehicle shall be fitted with tyres. which shall have a tread depth of not
less than 90 percent of the tread depth on new tyre and shall be inflated
to the pressure recommended by the manufacturer. The measurement
may be carried out in laden or unladen condition of the vehicle.
• The steering geometry of the vehicle shall be checked and adjusted in
accordance with the vehicle manufacturer's recommendation.
• The wheel lock angles of the vehicle shall be adjusted to the vehicle
manufacturer's specification.
Indian standard IS 12222.2011(contd.)

MANEUVERABILITY REQUIREMENTS
•The vehicle shall be able to maneuver on either lock inside a circle of 12.5 m radius
without any of its outermost points projecting outside the circumference of the circle.
•When the outermost points of the vehicle are moving on either wheel lock on a circle
of 12.5 m radius the vehicle shall be able to move within the limits of circular track 7.2
m wide as shown in Fig. Nor Fig. 2 as applicable.
•With the vehicle stationary, a vertical plane tangential to the side of the vehicle and
facing outwards from the circle shall be established by marking a line on the ground. In
the case of an articulated vehicle the two rigid portions shall be aligned with the plane.
When the vehicle moves from a straight line without turning the steering wheel in the
opposite direction, approach into the circular area described in 5.1, no part of it shall
move outside of this vertical plane by more than dimension U given in Fig. 1 in the case
of a rigid vehicle, and in Fig. 2. in the case of an articulated vehicle.
•In the case of a vehicle fitted with an axle with an unloading device, these requirements
shall in each case be fulfilled with the axle in the most unfavourable conditions.
Pictorial Representation of Test
Steering Effort Test
 History

• This standard was first published in 1986 and was first revised in 1999. This revision has been taken
up to align
• The standard with ECE Regulation 79 — Revision 2 Amendment 2. This revised standard
additionally considers the following:
a) Provisions for trailers and the trailers with hydraulic steering transmissions.
b) Braking performance for vehicles using the same energy source to supply steering equipment and
braking
device (see Annex A).
c) Additional provisions for vehicles equipped with auxiliary steering equipment.
d) Special requirements to be applied for the safety aspects of complex electronic vehicle control
systems.
 Scope

This standard applies to the steering equipment of vehicles of

Categories M, N and O as defined in IS 14272(Part 1) : 1995 ‘Automotive vehicles — Types —
Terminology: Part 1 Three and four wheelers’.
This standard does not apply to,
a) steering equipment with a purely pneumatic
transmission;
b) autonomous steering systems
c) full power steering systems fitted to trailers
where the energy necessary for operation is
transmitted from the towing vehicle; and
d) the electrical control of full power steering
systems fitted to trailers, other than additional
steering equipment
 M N and O Type Vehicles
Motor vehicle means any mechanically propelled vehicle adopted for use upon roads whether the
propulsion is transmitted there to from an external or internal source and includes a chassis to which
body has not been attached and a trailer; but does not include a vehicle running upon fixed rails or a
vehicle of special type adopted for use in factory or enclosed premises or a vehicle having less than
four wheels fitted with engine capacity of not exceeding 25 cm^3.
M Category — A motor vehicle with at least four wheels used for carrying passengers.
N Category — A motor vehicle with at least four wheels used for carrying goods. These vehicles can
carry persons in addition to the goods subject to the conditions.
Off Road Vehicles (Cross Country Vehicles)
Symbol ‘G’ — A vehicle of category M or N satisfying the requirements
 Parameters
1. Steering Control Effort, means the force applied to the steering control in order to steer the vehicle.
2. Steering Time, means the period of time from the beginning of the movement of the steering control
to the moment at which the steered wheels have reached a specific steering angle.
3. Steering Angle, means the angle between the projection of a longitudinal axis of the vehicle and the
Line of intersection of the wheel plane (being the central plane of the wheel, normal to the axis around
which it rotates) and the road surface.
4. Steering Forces, mean all the forces operating in the steering transmission.
5. Mean Steering Ratio, means the ratio of the angular displacement of the steering control to the mean
of the swept steering angle of the steered wheels for a full lock-to-lock turn.
6. Turning Circle, means the circle within which are located the projections onto the ground plane of all
the points of the vehicle, excluding the external mirrors and the front direction indicators, when the
vehicle is driven in a circle.
7. Nominal Radius of Steering Control, means in the case of a steering wheel the shortest dimension
from its centre of rotation to the outer edge of the rim. In the case of any other form of control it means
the distance between its centre of rotation and the point at which the steering effort is applied. If more
than one such point is provided, the one requiring the greatest effort shall be used.
 Steering Equipment Used

1 Front-wheel steering equipment, in which only the wheels of the front axle(s) are steered. This
includes all wheels which are steered in the same direction.
2 Rear-wheel steering equipment, in which only the wheels of the rear axle(s) are steered. This includes
all wheels which are steered in the same direction.
3 Multi-wheel steering equipment, in which the wheels of one or more of each of the front and the rear
axle(s) are steered.
4 All-wheel steering equipment, in which all the wheels are steered.
5 Buckle steering equipment, in which the movement of chassis parts relative to each other is directly
produced by the steering forces.
 Test Provisions
1. The test shall be conducted on a level surface affording good adhesion.
2. During the test(s) the vehicle shall be loaded to its technically permissible maximum mass
and its technically permissible maximum load on the steered axle(s). In the case of axles fitted
with auxiliary steering equipment (ASE), this test shall be repeated with the vehicle loaded to
its technically permissible maximum mass and the axle equipped with ASE loaded to its
maximum permissible load.
3. Before the test begins, the tyre pressures shall be as prescribed by the manufacturer for the
mass specified when the vehicle is stationary.
4. In the case of any systems that use electrical energy for part or all of the energy supply, all
performance tests shall be carried out under conditions of actual or simulated electrical load of
all essential systems or systems components, which share the same energy supply. Essential
systems shall comprise at least lighting systems, windscreen wipers, engine management and
braking systems.
 Provisions for Motor Vehicles
1. It must be possible to leave a curve with a radius of 50 m at a tangent without unusual vibration
in the steering equipment at the following speed:Category M1 vehicles: 50 km/h Category M2, M3,
N1,N2 and N3 vehicles: 40 km/h or the maximum design speed if this is below the speeds given
above.
2. When the vehicle is driven in a circle with its steered wheels at approximately half lock and at a
constant speed of at least 10 km/h, the turning circle must remain the same or become larger if the
steering control is released.
3. During the measurement of the control effort, forces with duration of less than 0.2 s shall not be
taken into account.
4. Measurement of Steering Efforts on Motor Vehicles with Intact Steering Equipment. The vehicle
shall be driven from straight ahead into a spiral at a speed of 10 km/h. The steering effort shall be
measured at the nominal radius of the steering control until the position of the steering control
corresponds to turning radius given in the table below for the particular category of vehicle with
intact steering. One steering movement shall be made to the right and one to the left.
 Pass By Noise Test
SCOPE
This standard specifies the method for measuring the
external noise emitted by road vehicles in moving condition.
Environmental noise pollution must be minimized to ensure
people’s health and comfort. Traffic noise is, therefore,
regulated and without fulfilling the regional targets for pass-
by noise, a vehicle model can get a type approval or be put
on the market.
 METHOD OF MEASERMENT
1.The maximum sound pressure levels in dB(A) shall be measured between AA’ & BB’
2.Position of the microphone at a distance of 7.5m from the reference line CC’ & ht
of 1.2m
3.The approach speed should be 50kmph or ¾ th of the Engine Max Speed
 4.At least two measurements shall be taken on each side of the vehicle. The measurements are
considered valid if the differenced between two consecutive measurements on the same side of the
vehicle does not exceed 2 dB (A).

TWO TYPES OF TEST:

Wide of throttle test

When the front of the vehicle reaches AA', the throttle shall be fully engaged and held fully engaged
until the rear of the vehicle reaches BB'. The throttle shall then be returned as quickly as possible to
the idle position. A typical test requires to hit PP line at 50KPH (+/- 1KPH).

Constant Speed test

In this test vehicle speed is fixed through out the track.

Operating Conditions
1. For all measurements, the vehicle shall be driven in a straight line over the acceleration section in
such a way that the median longitudinal plane of the vehicle is as close as possible to the line CC’.

2.The vehicle shall approach the line AA’ at a steady approach speed .When the front end of the
vehicle has reached the line AA’, the accelerator control is fully operated as rapidly and smoothly as
possible and held in the fully opened position until the rear of the vehicle reaches the line BB’; the
accelerator control shall be released as quickly as possible.
 For Two Wheelers Gear Ratio

1 Vehicle with Manual Shift Gear Box Vehicle fitted with a

gear box having a maximum of four ratios, shall be tested
only in second gear, whatever may be the cylinder capacities.

2 Vehicles fitted with engines having a cylinder capacity not

exceeding 175 cc and a gearbox with five or more ratios shall
be tested only in third gear.
 2 The vehicle’s tyres shall be of the type normally fitted to such vehicles by
the manufacturer. Tyres that have covered only 10 percent or less of their
expected life shall be fitted on the vehicle.

3 The tyres shall be inflated to the appropriate pressure(s) for the load
condition prescribed for the
test as specified by the vehicle manufacturer.

4 Before the measurements are obtained, the engine shall be brought to its
normal operating condition with regard to temperatures, settings, fuel, spark
plugs, carburetor, etc.

5.If the vehicle is fitted with fan(s) having an automatic actuating mechanism,
this system shall not
be interfered during the measurements.

6. Prior to testing it shall be ensured that the vehicle is in running order as

defined for the kerb weight
condition, and with the test driver/rider. The kerb weight condition shall be
the same as defined in
IS 9211, IS 9726, IS 11422 as appropriate. In the case of two and three
CONDITIONS OF MEASUREMENT
Test Site
• The test acceleration section shall be level; the track
surface shall be dry and such that rolling noise remains
low.
• Meteorological Conditions
• The measurement shall not be made in adverse weather
conditions such as rain, storm and heavy winds that would
affect noise, instruments and test results.
Ambient Noise
• For measurements, the A-weighted sound level of sound
sources other than those of the vehicle to be tested and of
wind effects shall be at least 10 dB (A) below the sound
level produced by the vehicle.
 GRADEABILITY TEST

SCOPE
This standard specifies the method for measurement µ and
minimum
requirements of starting gradeability for all types of road
vehicles, for the
purpose of establishing compliance to statutory requirements.
This may
also be used to verify the capability of vehicle with the
maximum
recommended gradeability declared by the vehicle
manufacturer.
 TEST CONDITIONS

Atmospheric Conditions
1 The atmospheric conditions at test site such as pressure, temperature and
relative humidity shall be recorded.
The air density so calculated shall not differ from the reference air density
(do) by more than 7.5 %.

2 The relative humidity at the test site shall be between 45 to 75 percent.

Features of Test Track

1 The surface of the test track shall be dry, roadway covered with asphalt,
concrete. The lateral gradient of the track shall not exceed 3 percent. The
length of the gradient shall be at least equal to the wheel base of the vehicle
plus 15 meters.
2 The inclination of stretch on which the trials are conducted shall be
measured at least at three places and the average angle of these values shall
be quoted as gradient.
 TEST PROCEDURE
1.The test shall be conducted preferably on the specified gradient. Park the
vehicle on the gradient using parking brake, front of the vehicle facing upwards
with all the wheels standing on the gradient and the rearmost point of the
vehicle lies at least one meter ahead of the bottom of the gradient.
If necessary, wheel chock may also be placed behind the rearmost wheels.

In case of two-wheelers, the vehicle shall be parked as above using the

front/rear brake or by using wheel chock behind rear wheel .

2 The vehicle shall be started from neutral gear position with engagement of
the lowest gear (i.e. the gear with highest numerical reduction ratio). Attempt
shall be made to start the vehicle in this position.

3 In case, the test is done on a gradient which is not the specified gradient,
increase/decrease the load in/on the vehicle till the vehicle is just capable of
starting and negotiating the gradient. Record the weight of vehicle at this
condition. The test shall be repeated three times, successfully
in all three cases. The vehicle shall be brought to the normal operating
temperature of engine/clutch between these tests.
4 The starting gradeability of the vehicle in percentage
shall be expressed as :
G = 100 x tan[sin -1 ((sin q x WT )/ WR )]
where,
G = Starting gradeability of vehicle in percentage
q = Slope angle of the test track used for the test
WT = Weight of the vehicle as recorded
WR = Maximum recommended GVW of the vehicle
 Science behind Coast Down Test

• 1) The key is the engine power

• 2) It affects –
a) Vehicle economy
b) Vehicle Performance
c) Vehicle Efficiency

It is mainly caused by non-elastic effects of material used in

making tyres.
A train with steel wheels running on steel rails will roll farther
than a bus of same mass with rubber tires running on tarmac
road.
DETERMINATION OF ROAD-LOAD CONSTANTS
BY COAST DOWN TEST METHOD

Coast down test is done to obtain valuable information

about the general condition of the vehicle and about its
interaction with environment
It helps in determining the road-load resistance of
vehicle, including the aerodynamic and rolling resistance.
 Vehicle Preparation
• 1) The vehicle shall be clean and complete in all respects, representative of
production series.
• 2) Vehicle shall be run-in as per manufacturer’s recommendation.
• 3) The wheels of vehicle shall be free and without any parasitic drag. For
vehicles with rear chain drive, it shall be-ensured that there is no chain
rubbing.
• 4) Tires which have covered only 10 ~percent or less of their expected life
shall befitted on the vehicle. At the start of the test, tyre shall be cold and
shall be inflated to pressure specified for respective load condition of the
vehicle.
• 5) The grade, quality, quantity of lubricants for various moving parts,
adjustments of brake, clutch, idling speed, etc. shall conform to the
manufacturers recommendation. The vehicle may be serviced before the test
was per the procedure recommended by manufacturer.
 FEATURES OF TEST TRACK
• 1) The test shall be conducted on a dry, level test track
with a coefficient of adhesion not less than 0.8.
• 2) If test surface is of tar, it shall not be traffic smooth
and surface shall not have become soft due to heat.
• 3) Longitudinal slope of the track shall-not exceed 0.5
percent and shall be constant within f 0.1 percent over
the measuring strip
• 4) The track shall have sufcient length and width for
achieving the test speed and carrying out the test
safely.
 INSTRUMENTATION
• 1) All instruments and the additional weights, if any, shall be
mounted in such a way that they do not affect the performance
or stability of the vehicle and do not hamper rider/driver from
normal driving of vehicle and carrying out tests.
• 2) The instrument shall be positioned on the vehicle such that it
does not significantly affect the aerodynamics of the vehicle.
• 3) Automatic speed and distance measuring instruments meeting
following least count and accuracy requirements shall be used.
 Test Requirements
• 1) wind speed – less than 3m/s
• 2) Gust speed – less than 5m/s
• 3) vector component across the test-road shall not be more
than 2 m/s
• 4) wind velocity measurement shall be done at a height of 0.7
m above the road surface
• 5) The ambient temperature shall be preferably between 15”
to 40°C -and relative humidity shall preferably be less than 75
percent
• * 6) Air density shall not differ by more than 7.5% from air
density under reference condition.
Air density calculation
 What is Coast Test
• Coast down test for a specific test speed (v) is basically to establish
the road-load ‘F’ from the deceleration by measuring time elapsed
from speed ‘v + ∂ v’ to speed ‘v - ∂v’, when the transmission is in
neutral. From the values of ‘F at different speeds, values of constants
‘a’ and ‘b ’ in equation F = a + bv*2 are determined by best curve fit
method.
• A) In the case of two wheelers, the recommended height of rider
shall be 1.7 f 0.05 m and the rider shall wear helmet and proper
riding gear.
• B) He shall be seated upright on the seat provided for the rider, his
feet upon the pedals or foot rests
• C) the portion of the test track where the vehicle is decelerated from
‘v + ∂ v’ to ‘v - ∂ v’ shall be kept approximately same in both
directions to reduce the effect of track variation.
 Testing Procedure
• With Load Conditions
• A) Test Speeds –
a) The test shall be conducted at least at 5 speeds. Difference
between each test speed shall not be less than 10 km/h.
b) The lowest speed at which test is done shall not be less than
20 km/h.
c)In case of vehicle with maximum speed attainable under the
test load and track condition is not exceeding 60 km/h,
1) the interval between test speeds (a) above may
be reduced to the extent particularly needed, but not less
than 5 km/h.
2) the lowest speed (b) above may be reduced to 10 km/h.
d) The highest speed shall be more than or equal to speed at
which road load equation is intended to be used. However, the
highest test speed shall not be more than 80 percent of the
maximum speed achievable by the vehicle under the test load
and test track condition.
• e) The vehicle shall be warmed up by running the vehicle for at
least 15 km, at test speed prior to test. Warming up shall be
repeated before tests for each speed.
• f) The vehicle shall be driven along a straight line during the test.
• g) During the test, the windows and other ventilating passages
shall be kept closed.
• h) Attain a speed of about 5 to 10 km/h above (v + ∂v) and shift
the transmission of vehicle in neutral. Measure time (t,) up to 2
decimal places required for the speed to reduce from ‘v + ∂v’ to ‘v
- ∂v’ in one direction.
• i) Repeat the test immediately in the opposite direction and note
the time (t2) as explained and Take arithmetic average of t1, and t2
and find the value of t, calculate the deceleration force ( F mean)
 Repeat the tests sufficient number of times to enable to select the lowest 10
statistically consistent readings of F mean at each speed. The reading shall be
considered as statistically consistent when the statistical error (P) calculated as per
formula given below is within 2 percent:
• Repeat the test for all the desired
test speeds. Depending on
consistent length of test track
available, the tests may be carried
out for more than one speed in the
same run.
 Curve Fitting
• From the values of F, at atleast five
test speeds, the values of
coefficients a and b shall bc
calculated using following
formulae. The curve fitting error
should be within Z-percent.