Vehicle Standard (Australian Design Rule 80/02 — Emission Control for Heavy Vehicles) 2006 Compilation: 1 (up to and including Amendment 11) Compilation Date: 20/12/2007 Compiled by: Vehicle Safety Standards, Department of Infrastructure, Transport, Regional Development and Local Government CONTENTS 0.1 NAME OF STANDARD 0.2 COMMENCEMENT 1 SCOPE 2 APPLICABILITY AND IMPLEMENTATION 3 DEFINITIONS 4 REQUIREMENTS 5 EXEMPTIONS AND ALTERNATIVE PROCEDURES 6 ALTERNATIVE STANDARDS NOTES--------------------------------------------------------------- 0.1 NAME OF STANDARD 0.1.1 This Standard is the Vehicle Standard (Australian Design Rule 80/02 – Emission Control for Heavy Vehicles) 2006. 0.1.2 This Standard may also be cited as ADR 80/02. 0.2 COMMENCEMENT 0.2.1 This Standard commences on 20 December 2007. 1 SCOPE 1.1 This vehicle standard prescribes the exhaust emissions requirements for engines used in heavy vehicles in order to reduce air pollution. 2 APPLICABILITY AND IMPLEMENTATION 2.1 This vehicle standard applies to vehicles of the M and N categories, with a GVM greater than 3.5 tonnes, as provided in clause 2.2. 2.2 This vehicle standard applies: 2.2.1 from 1 January 2007 in relation to new model vehicles produced on or after 1 January 2007; and 2.2.2 from 29 February 2008 in relation to vehicles produced on or after 29 February 2008, other than new model vehicles referred to in clause 2.2.1. 2.3 For the purposes of clause 2.2.1, a new model vehicle is a vehicle of a model first produced with a date of manufacture on or after 1 January 2007. 2.4 To the extent of any inconsistency, the applicability dates specified in clause 2.2 apply in lieu of any dates specified in Appendix A, Appendix B or Appendix C. 2.5 Vehicles complying with ADR 80/03 need not comply with this vehicle standard. 3 DEFINITIONS 3.1 For the purposes of clause 2.3, "date of manufacture" means the date the vehicle is available in Australia in a condition which will enable an identification plate to be lawfully affixed to the vehicle. 3.2 For the purposes of clauses 6.2.6 and 6.3.4, "reagent" has the meaning defined in section 2 (Definitions) of Annex I to Appendix B. 3.3 For the purposes of clauses 6.2.5, 6.3.3 and 6.4.2, "defeat device" has the meaning defined in section 2 (Definitions and Abbreviations) of Annex I to Appendix A and "defeat strategy" has the meaning defined in section 2 (Definitions) of Annex I to Appendix B, as amended by Appendix C. 4 REQUIREMENTS Requirements for Diesel, Liquefied Petroleum Gas and Natural Gas Engines 4.1 Subject to clauses 4.1.1, 4.1.2 and 4.1.3, engines which operate on diesel, liquefied petroleum gas or natural gas, and which comply with the technical requirements of Appendix A, Appendix B and Appendix C, as varied by Part 5 of this vehicle standard, will be accepted as complying with this vehicle standard. 4.1.1 Engines which operate on diesel shall comply with the relevant limit values in row B1 of Table 1 to section 6.2.1 of Appendix A and with the relevant limit values in row B1 of Table 2 to section 6.2.1 of Appendix A. 4.1.2 Engines which operate on liquefied petroleum gas or natural gas shall comply with the relevant limit values in row B1 of Table 2 to section 6.2.1 of Appendix A. 4.1.3 Engines which operate on diesel shall be equipped with an on board diagnostics (OBD) system which complies with the Stage 1 requirements as described in sections 6.5 of Annex I and 3.2 of Annex IV of Appendix B, as amended by Appendix C, or the Stage 2 requirements as described in sections 6.5 of Annex I and 3.3 of Annex IV of Appendix B, as amended by Appendix C. Requirements for Petrol Engines 4.2 Subject to clause 4.2.1, vehicles which operate on petrol and which comply with technical requirements of United Nations – Economic Commission for Europe Regulation No. 83 Uniform Provisions Concerning the Approval of Vehicles with Regard to the Emissions of Pollutants According to Engine Fuel Requirements, Revision 3, incorporating the 05 series of Amendments, and all amendments up to and including supplement 5, will be accepted as complying with this vehicle standard. 4.2.1 Vehicles shall comply with the limit values in row "A(2000)" of the table to paragraph 5.3.1.4 of the Regulation. 5 EXEMPTIONS AND ALTERNATIVE PROCEDURES 5.1 Any provisions related to the administrative processes for obtaining type approval under a European Commission or Council (EC) Directive, or for obtaining an approval from the United States Environment Protection Authority or from the Japanese Ministry of Land, Infrastructure and Transport, do not apply to this vehicle standard. 5.2 EC, US EPA and Japanese approval certificates alone are not accepted as demonstration of compliance with this vehicle standard. 5.3 The preamble clauses (1) to (20) and Articles 1 to 12 in Appendix A, the preamble clauses (1) to (14) and Articles 1 to 5 in Appendix B, and the preamble clauses (1) to (9) and Articles 1 to 5 in Appendix C, do not apply to this vehicle standard, except for Article 3 and Article 4 of Appendix A. 5.4 The reference to "Council Directive 70/220/EEC of 20 March 1970 on the approximation of the laws of the Member States on measures to be taken against air pollution by emissions from motor vehicles" in Part 1 (Scope) of Annex I to Appendix A, and the reference to "Council Directive 70/220/EEC" in Part 1 (Scope) of Annex I to Appendix B, are both amended to read "ADR 79/01". 6 ALTERNATIVE STANDARDS EC Directive (Diesel, Liquefied Petroleum Gas and Natural Gas Engines) 6.1 Subject to clauses 6.1.1, 6.1.2 and 6.1.3, for engines which operate on diesel, liquefied petroleum gas or natural gas, the technical requirements of Directive 2005/55/EC of the European Parliament and Council of 28 September 2005, together with the technical requirements of Commission Directive 2005/78/EC of 14 November 2005 and Commission Directive 2006/51/EC of 6 June 2006, are deemed to be equivalent to the technical requirements of this vehicle standard. 6.1.1 Engines which operate on diesel shall comply with the relevant limit values in row B1 of Table 1 and in row B1 of Table 2 to section 6.2.1 of Directive 2005/55/EC. 6.1.2 Engines which operate on liquefied petroleum gas or natural gas shall comply with the relevant limit values in row B1 of Table 2 to section 6.2.1 of Directive 2005/55/EC. 6.1.3 Engines which operate on diesel shall be equipped with an OBD system which complies with the Stage 1 requirements as described in sections 6.5 of Annex I and 3.2 of Annex IV of Directive 2005/78/EC, as amended by Directive 2006/51/EC, or the Stage 2 requirements as described in sections 6.5 of Annex I and 3.3 of Annex IV of Directive 2005/78/EC, as amended by Directive 2006/51/EC. US EPA CFR (Diesel, Liquefied Petroleum Gas or Natural Gas Engines) 6.2 Subject to clauses 6.2.1 to 6.2.6 inclusive, for engines which operate on diesel, liquefied petroleum gas or natural gas, the technical requirements of the United States Code of Federal Regulations (CFR), Part 86 – Control of air pollution from new and in-use motor vehicles and new and in-use motor vehicle engines certification and test procedures - Subpart A 40 CFR 86.004-11 Emission standards for 2004 and later model year diesel heavy-duty engines and vehicles, are deemed to be equivalent to the technical requirements of this vehicle standard. 6.2.1 Engines shall meet the emission limits specified in 86.004-11 (a)(1), paragraphs (i)(A) or (i)(C), (ii)(A), and (iii)(B). 6.2.2 Engines shall be tested in accordance with the applicable test procedures as specified in Subpart N 40 CFR 86.1300 series – Emission Regulations for new Otto-cycle and diesel heavy duty engines; gaseous and particulate exhaust test procedures. 6.2.3 Engines which operate on diesel shall also comply with the ESC test specified in Appendix A, except that the emission limits specified under clause 6.2.1 of this vehicle standard apply in lieu of the limits in row B1 of Table 1 to section 6.2.1 of Appendix A. 6.2.4 Engines which operate on diesel, liquefied petroleum gas or natural gas shall satisfy relevant useful life provisions, not to exceed test requirements, and rules regarding use of emission control devices applicable to 2004 and later model year diesel heavy-duty engines and vehicles under CFR Part 86. 6.2.5 Engines shall not be equipped with a defeat device or utilise a defeat strategy. 6.2.6 Engines which operate on diesel are not permitted to use a consumable reagent in order to achieve the emission limits specified under 86.004-11. Japanese MLIT Regulations (Diesel Engines) 6.3 Subject to clauses 6.3.1 to 6.3.4 inclusive, for engines which operate on diesel, the technical requirements of Japanese Ministry of Land, Infrastructure and Transport Announcement No. 619 of 15 July 2002 (as last amended by Announcement No 872 of 16 August 2005), Chapter 2, Section 1, Article 41 (Emission Control Device), paragraph (5) [JE05-Mode Mean Value Regulations at Time of Completion Inspection, etc. for Diesel Motor Vehicles (with GVM exceeding 3.5 tons)], are deemed to be equivalent to the technical requirements of this vehicle standard. 6.3.1 Engines shall also comply with the emission values specified under paragraph (6) [JE05-Mode Upper Limit Value Regulations at Time of Initial Inspection, etc. for Diesel Motor Vehicles (with GVM exceeding 3.5 tons)] when tested in accordance with the Technical Standards Relating to the Safety Regulations for Road Vehicles, Attachment 36, Japanese Technical Standard for 13-Mode Exhaust Emission Measurement for Diesel-Powered Motor Vehicles. 6.3.2 Engines shall satisfy relevant useful life provisions, not to exceed test requirements, and rules regarding use of emission control devices applicable to engines meeting the requirements of clause 6.3. 6.3.3 Engines shall not be equipped with a defeat device or utilise a defeat strategy. 6.3.4 Engines which require the use of a consumable reagent in order to achieve the emission limits specified under the standards adopted in clause 6.3, shall be equipped with an OBD system meeting the requirements specified in clause 6.1.3 or the requirements specified in Appendix D. Japanese MLIT Regulations (Natural Gas Engines) 6.4 Subject to clauses 6.4.1 and 6.4.2, for engines which operate on natural gas, the technical requirements of Japanese Ministry of Land, Infrastructure and Transport Announcement No. 619 of 15 July 2002 (as last amended by Announcement No 872 of 16 August 2005), Chapter 2, Section 1, Article 41 (Emission Control Device), paragraph (9) [JE05-Mode Mean Value Regulations at Time of Completion Inspection, etc. for Motor Vehicles Fueled by Other Fuel (with GVM exceeding 3.5 tons)], are deemed to be equivalent to the technical requirements of this vehicle standard. 6.4.1 Engines shall satisfy relevant useful life provisions, not to exceed test requirements, and rules regarding use of emission control devices applicable to engines meeting the requirements of clause 6.4. 6.4.2 Engines shall not be equipped with a defeat device or utilise a defeat strategy. US EPA CFR (Petrol Engines) 6.5 Subject to clauses 6.5.1 and 6.5.2, for engines which operate on petrol, the technical requirements of the United States Code of Federal Regulations (CFR), Part 86 - Control of air pollution from new and in-use motor vehicles and new and in-use motor vehicle engines certification and test procedures - Subpart A 40 CFR 86.098-10 Emission standards for 1998 and later model year Otto-cycle heavy-duty engines and vehicles are deemed to be equivalent to the technical requirements of this vehicle standard. 6.5.1 Except as specified in clause 6.5.1.1, engines shall meet the exhaust emission limits specified in 86.098-10 (a)(1)(i), paragraphs (A), (B) and (C)(1), and the evaporative emission limits specified in 86.098-10 (b). 6.5.1.1 Engines used in vehicles satisfying the minium weight requirement in (a)(1)(ii) may meet the exhaust emission limits specified in (a)(1)(ii) paragraphs (A), (B)(1) and (C)(1). 6.5.2 Engines shall be tested in accordance with the applicable test procedures as specified in Subpart N 40 CFR 86.1300 series – Emission Regulations for new Otto-cycle and diesel heavy duty engines; gaseous and particulate exhaust test procedures. NOTES This compilation of Vehicle Standard (Australian Design Rule 80/02 - Emission Control for Heavy Vehicles) 2006 includes all the instruments set out in the Table of Instruments. The Table of Amendments provides a history of clauses that have been amended, inserted or deleted. Table of Instruments Name of Instrument Registration Date Commencement Date Vehicle Standard (Australian Design Rule 80/02 - Emission Control for Heavy Vehicles) 2006 13/12/06 14/12/06 Vehicle Standard (Australian Design Rule 80/02 - Emission Control for Heavy Vehicles) 2006 Amendment 1 19/12/07 20/12/07 Table of Amendments Clause affected How affected Amending instrument 2.2.2 am Vehicle Standard (Australian Design Rule 80/02 - Emission Control for Heavy Vehicles) 2006 Amendment 1 am = amended ad = added or inserted VEHICLE STANDARD (AUSTRALIAN DESIGN RULE 80/02 — EMISSION CONTROL FOR HEAVY VEHICLES) 2006 APPENDIX D Japanese Ministry of Land, Infrastructure and Transport Technical Guideline for Urea Selective Catalytic Reduction System No. 105 of 14 September 2004 (Edited translation for the purposes of this vehicle standard) 1 Scope This technical guideline applies to diesel vehicles with gross vehicle weight of 3.5 tonnes or more equipped with urea selective catalyst reduction system (hereinafter called SCR). 2 Urea Solution Standard Urea solution used for the SCR system on the vehicle should conform to DIN V70070 Dieselmotoren–NOx–Reduktionsmittel AUS32–Anforderungen und Pruefverfahren. 3 Construction Requirements 3.1 The SCR system on the vehicle shall be designed to: 3.1.1 keep the temperature of the urea solution liquid at low atmospheric temperature in order to prevent phase separation; 3.1.2 prevent urea from staying at the injection nozzle when the engine stops in order to prevent phase separation; 3.1.3 prevent high urea solution temperatures by adopting shields or other measures in order to maintain the quality of the urea solution in the tank; 3.1.4 provide a pressure regulator in urea solution tank in order to prevent excessively high pressures in the tank; 3.1.5 prevent urea solution from freezing while the engine is running in order to secure proper injection rates for the urea solution; and 3.1.6 use parts which are durable and resist corrosion by the urea solution and other material. 3.2 In order to keep the emission of ammonia as low as possible, a vehicle equipped with an SCR system shall: 3.2.1 be fitted with oxidation catalyst downstream of the SCR system, which has enough oxidation capability to keep emissions of ammonia as low as possible; and 3.2.2 utilise a pressure regulator in the urea tank which incorporates a mechanism to keep emissions of ammonia as low as possible. 3.3 A vehicle equipped with an SCR system should be provided with a meter, which indicates the balance of urea solution in the tank so that the driver is able to refill properly. 3.4 Any catalyst used as part of, or in conjunction with, an SCR system must not emit any of the following metals into the atmosphere: * Vanadium * Chromium * Manganese * Cobalt * Nickel * Copper 4 Cautions and Warnings 4.1 Cautions A vehicle equipped with an SCR system should be provided with caution lamps, which shall engage and inform the driver to take corrective measures when the following conditions are detected: 4.1.1 the urea solution injection rate is incorrect; 4.1.2 the level of urea solution in the tank falls below the level required for 300km of normal operation; or 4.1.3 the urea solution is of abnormal quality (not meeting the requirements of clause 2). 4.2 Warnings An additional warning lamp and an audible warning (buzzer) shall be activated under the following conditions: 4.2.1 where no corrective action is taken within 300km after the first caution lamp is engaged under clause 4.1 in response to the detection of the conditions of clause 4.1.1; 4.2.2 where no corrective action is taken within 300km after the first caution lamp is engaged under clause 4.1 in response to the detection of the conditions of clause 4.1.3; or 4.2.3 where the tank containing the urea solution is empty. 4.3 The onboard diagnostics system of the vehicle shall record a fault code when any of the conditions of clause 4.2 are met. 4.4 All caution and warning lamps shall be clearly visible from the driver's seating position. 4.5 The vehicle shall be able to confirm that the SCR system is operating normally, prior to the start of driving. 4.6 The reason for the triggering of the different caution and warning lamps shall be clear to the driver. 5 Restriction and recovery 5.1 Subject to clause 5.2, where no corrective action is taken following the detection of conditions under clause 4.1.2 or 4.1.3, and the triggering of the warning lamp and buzzer under clause 4.2.2 or 4.2.3 subsequently occurs, the vehicle shall be constructed so that engine is unable to re-start after the engine is stopped by the key being switched to the 'ACC' or 'OFF' position. 5.2 The vehicle shall allow the engine to re-start if the engine stops when the key is in the 'ON' position. 5.3 The vehicle shall be constructed so that caution and warning systems are disengaged once the appropriate corrective action is taken. 5.4 After being stopped under clause 5.1, the engine shall be able to be re-started once the tank has been refilled with a quantity of urea solution meeting the requirements of clause 2 sufficient for vehicle operation of more than 300 km. 6 Notice to driver 6.1 The vehicle manufacturer shall include instructions regarding the following items in the vehicle's operation manual: (a) an explanation of the warning lamps and buzzer, including their meaning; (b) an explanation of the conditions under which the engine is unable to start again after caution is made; (c) a description of the measures operators must take when engine is unable to be re-started; (d) the need to maintain supply of urea solution; (e) the quality standards for urea solution; (f) storage of urea solution; and (g) other relevant operational matters. 6.2 Items (a) and (b) must also be detailed in caution labels which should be affixed in a position that is clearly visible to the driver.