Heavy Commercial vehicle - Testers manual - Road Safety Authority

Road Safety Authority
Heavy Commercial Vehicle Testers’ Manual
Applies to vehicle types;
M2, M3, N2, N3, O3, O4 and
Special Purpose M (Ambulance and Motor Caravan)
These guidelines (also referred to as the “Manual”) are issued by the Road Safety Authority under section 38
of the Road Safety Authority (Commercial Vehicle Roadworthiness) Act 2012 (No. 16 of 2012). The intention
behind this Manual is to set out requirements and guidance in relation to the carrying out of CVR tests at
CVR testing centres.
This Manual is to be complied with from the effective date advised by the RSA. CVR test operators and CVR
testers shall ensure that CVR testing is carried out in accordance with this Manual from that date.
This Manual sets out the testing methods to be employed by those involved in CVR testing. It also provides
guidance to CVR test operators and CVR testers in relation to the reasons why a vehicle may fail a CVR test
and the categorisation of defects identified in relation to a CVR vehicle.
From the effective date, this Manual replaces the previous edition of the Roadworthiness Testers Manual
which, as of that date, is no longer in force.
Owners of CVR vehicles to which this Manual applies may also find the Manual useful in that it provides
details of the inspections to which a CVR vehicle may be subjected and the reasons why it may not be
issued with a pass statement following a CVR test.

REVISIONS
This manual may be revised and updated from time to time. A current version is always available on the Road Safety
Authority website, www.cvrt.ie. If printing all or part of the manual, the website or CoVIS should always be checked to
ensure any printed copy remains current.
Version
Date
Section Number
updated
Description
Page(s) Inserted by
(responsible
person);
1.0 Sept 2013 All

CONTENTS
The Testing Sequence
Inspection Methodology
and defect type by item
Section
Page
Section
Page
Introduction 5
Testing Sequence 9
Inspection Methodology 14
Registration/Trailer Plate and VIN 1 15
Vehicle Weights and Dimensions Plate 2 18
Pollution/Smoke 3 22
Air/Vacuum Warning 4 25
Air/Vacuum Build Up 5 26
Horn 6 27
Windscreen Wipers and Washers 7 28
Mirrors 8 29
Driver’s Seat 9 34
Safety Belts 10 35
Glass 11 38
Mechanical Brake Hand Lever 12 43
Service Brake Pedal 13 44
Service Brake Operation 14 45
Air/Vacuum Hand Control/Valves 15 47
N/A 16 48
Steering Wheel & Steering Play 17 49
Warning Triangle 18 50
Doors/Locks/Anti Theft Devices 19 52
Electrical System 20 53
Running Boards and Steps 21 54
Cab and Bodywork 22 55
N/A 23 —
Tyre Condition 24 62
Tyre Specification 25 63
Tyre Tread 26 66
Wheels 27 67
Reflectors and Rear and Side Markings 28 68
Malfunction Indicators 29 75
Brake Fluid 30 76
Side Guards and Rear Underrun Protection 31 77
Spare Wheel and Carrier 32 84
Reservoirs/Valves/Master Cylinders/Connections 33 85
Fuel System 34 87
Towing Coupling/Fifth Wheel 35 89
Steering Alignment 36 93
Service Brake Performance 37 94
Service Brake Imbalance 38 96
Emergency/secondary brake Performance 39 97
Emergency/secondary brake Imbalance 40 99
Parking Brake Performance 41 100
Parking Brake Imbalance 42 101
Steering Linkage 43 102
Wheel Bearings 44 105
Chassis Underbody 45 106
Exhaust System/Noise 46 108
Brake Wheel Units 47 109
Mechanical Brake Components 48 110
Brake Lines and Hoses 49 112
Front Springs 50 114
Front Suspension 51 117
Shock Absorber Condition 52 119
Transmission, Engine & Final Drive 53 120
Rear Springs 54 122
Rear Suspension 55 124
Rear Lamps and Registration Plate Lamps 56 125
Stop Lamps 57 126
Indicators 58 127
Side Lamps/Marker Lamp 59 128
Headlamp Condition 60 129
Headlamp Aim 61 130
Fire Extinguishers (All Buses) 62 135
Emergency Exits (All Buses) 63 136
Passenger Seats (All Buses) 64 137
Internal Lighting (All Buses) 65 138
First Aid Kit (All Buses) 66 139
Fuel Cut Off (All Buses) 67 140
Spray Suppression 68 141
Tachograph/Speedometer 69 146
Speed Limiter 70 148
Modifications Report 71 150

INTRODUCTION
1. Definitions.
“CVR” means Commercial Vehicle Roadworthiness.
“CVR Tester” means a person authorised by the Road
Safety Authority to be a CVR tester in respect of a
particular category of vehicles.
“CVR Test Operator” means a person authorised by the
Road Safety Authority to conduct CVR tests.
“CVR Testing Centre” means a premises specified in a
CVR test operator authorisation and complying with
current Premises and Equipment Guidelines at which CVR
tests may be carried out.
“CRW” means a Certificate of Roadworthiness.
The term CVR Test means;
an initial CVR test;
a periodic CVR test;
a partial CVR test;
a re-test;
An initial CVR test is the first roadworthiness test of a
HCV and this test is due on the first anniversary of its
registration. In the case of motor caravans, the initial CVR
test is due on the fourth anniversary of its first registration.
A periodic CVR test is a subsequent annual
roadworthiness test of a HCV following its initial CVR test.
An Enforcement Test (legally called a partial CVR test)
is conducted when a vehicle is presented to a CVR
Testing Centre on foot of a direction given by a RSA
Authorised Officer or CVR Inspector. This test may include
one or more test items and may include all test items
applicable to that vehicle. Details of the test items to be
tested will be available on CoVIS or listed on the copy of
the Roadside Check Inspection report as supplied to the
driver of the vehicle and all items should be tested as per
this manual. An Enforcement test may be conducted on
any CVR Vehicle including vehicles that are registered
outside of the State.
A re-test is a test carried out where a vehicle has failed an
initial or periodic test, where:
(a)
(b)
the re-test is carried out on a day which is not more
than 21 calendar days after the day on which the
vehicle has failed it’s initial or periodic test, and
the reading on the vehicle's odometer at presentation
for the re-test is no more than 4,000 kilometres
greater than the reading at the time the vehicle failed
it’s initial or periodic test.
A re-test can only be conducted at the CVR testing centre
where the original test was failed.
In carrying out a re-test on a vehicle only those items
which gave rise to the refusal of the pass statement are
to be tested.
If during a retest the CVR tester notices any other
obvious defects, then the owner shall be notified and
these additional items must be tested. Where a
reason for failure is issued with respect to these
additional test items, then this will be recorded on the
test report.
Where a vehicle is refused a pass statement in
relation to the brake performance/brake imbalance
test or where it is failed on any brake components,
then it must have a full brake test carried out on
retest.
A “voluntary safety CVR test” is a roadworthiness test,
other than a CVR test, carried out in respect of one or
more test items specified in this manual, which is
recorded on CoVIS. As well as CVR vehicles, a voluntary
safety CVR test can also be carried out on vehicles
owned by the Gardaí or the Defence Forces.
The term “owner” in the context of applying for a CVR
test is taken to include the owner’s agent.
“CoVIS” is the CVR computerised information system
established by the Road Safety Authority. A CVR tester
shall use CoVIS in order to process a CVR test on the
lane equipment. CoVIS allows the tester to record defects
and other standard inspection data such as mileage. The
tester will also be able to record differences to Vehicle
Details identified as part of the Test to the Vehicle Details
on CoVIS that have come from the Driver and Vehicle
Licensing Computer Services Division (DVCSD).
“Method of Testing” details the ways in which the test
of items on a vehicle are to be carried out and the
equipment to be used. When carrying out each test,
particular attention should be paid to the information
given in the “Notes” since this gives guidance on the
conduct and scope of the test.
“Reasons for Failure” gives direction on the type of
defects which will result in the vehicle failing. A vehicle
should only be assessed against the items and reasons
for failure listed in this manual.
An “Advisory Notice” is used to inform the customer of
an item that should be rectified but does not prevent the
vehicle from achieving a minimum standard of
roadworthiness. This will be included on the Test Report
or Pass Statement.
"Semi-trailer" means the drawn component of an
articulated vehicle, or a vehicle constructed or adapted for
use as such drawn component.
“Design Gross Vehicle Weight (DGVW)”, also known
as the technically permissible maximum laden mass is the
gross weight of a vehicle laden with the heaviest load
which it can reasonably carry. This must take into
consideration; the engine, brakes, tyres and general
construction of such vehicle and shall, until the contrary is
shown, be taken to be its design gross weight as
specified by its manufacturer or an automotive engineer.
HCV TESTERS MANUAL V 1.0 Page | 5

“Gross Combination Weight”, (GCW) (also known as
the technically permissible maximum mass of the
combination) is the maximum mass allocated to the
combination of a motor vehicle and one or more trailers on
the basis of its construction features and its design
performances or the maximum mass allocated to the
combination of a vehicle and trailer.
“Individual design axle weight” means the mass
corresponding to the maximum permissible static vertical
load transmitted to the ground by the wheels of the axle,
on the basis of the construction features of the axle and of
the vehicle and their design performances.
“Manufacturer's plate” means a plate or label, affixed by
the manufacturer on a vehicle that provide the main
technical characteristics which are necessary for the
identification of the vehicle and provides the competent
authorities with the relevant information concerning the
technically permissible maximum laden masses;
“First registered”’ means the date when the vehicle was
first registered with the Revenue Commissioners or the
date when first registered in accordance with the laws of
another country.
“First licensed” means the date a semi-trailer or trailer is
first licensed with the Local Authority in whose functional
area it is normally kept, irrespective of the original date of
manufacture and irrespective of whether or not the semitrailer
was previously registered/licensed in another
country.
"Appropriate motor vehicle" means a mechanically
propelled vehicle having at least three axles, twin tyres, air
suspension or an equivalent suspension on each driving
axle and ABS brakes. The vehicle must also be fitted with
a plate complying with the requirements of the Regulations
of 2000.
"Appropriate semi-trailer" means a semi-trailer which
has an air suspension or an equivalent suspension and
ABS brakes. It must also be fitted with a plate complying
with the requirements of the Regulations of 2000.
The ‘appropriate semi-trailer’ concept came into force
on 1 st April 2013 and applies to all semi-trailers
(irrespective of when they were first licensed) operating
as part of a combination of vehicles with a gross weight
in excess of 40 tonnes.
“Insecure”
The term “insecure” is used throughout this Manual to
describe a defective condition. The term should be
taken by testers to mean the following:
(a) that a component on the vehicle has relative
movement either at its fixing or in relation to an
associated component where there should be none
or
(b) that a component is not safely or completely
attached either at its fixing or to an associated
component.
“Worn”
A component will be considered worn where the wear is
to such an extent that it is either;
HCV TESTERS MANUAL V 1.0 Page | 6
(a) likely to fail, or
(b) clearly not functioning effectively as designed, or
(c) visibly worn beyond manufacturers known permitted
limits, or
(d) likely to affect the operation or condition of another
safety related component.
2. Scope.
This Manual applies to the following categories of
vehicles;
Category M2: Vehicles designed and constructed for
the carriage of passengers, comprising more than
eight seats in addition to the driver’s seat, and having a
DGVW not exceeding 5 tonnes.
Category M3: Vehicles designed and constructed for
the carriage of passengers, comprising more than
eight seats in addition to the driver’s seat, and having a
DGVW exceeding 5 tonnes.
Category N2: Vehicles designed and constructed
primarily for the carriage of goods and having a DGVW
exceeding 3.5 tonnes but not exceeding 12 tonnes.
Category N3: Vehicles designed and constructed
primarily for the carriage of goods and having a DGVW
exceeding 12 tonnes.
Category O3: Trailers with a DGVW exceeding 3.5
tonnes but not exceeding 10 tonnes.
Category O4: Trailers with a DGVW exceeding 10
tonnes.
Ambulances (special purpose vehicles in category M).
Motor caravans with a DGVW exceeding 3.5 tonnes
(special purpose vehicles in category M).
3. Making a request for a CVR Test Booking.
A request for a CVR test booking must be made to a CVR
test operator in person, or by using CoVIS. An application
for a booking to a CVR test operator may be made at the
test centre before the test commences. Full details of how
to make a request for a test booking can be found at
www.cvrt.ie.
4. Presentation of ID.
A person who presents a vehicle or a trailer to be tested is
required to produce a valid identification e.g. a driving
licence or passport. Where a valid identification is not
presented at the time of the test, the CVR test may be
carried out but a pass statement will not be issued. The
CVR test operator may issue a pass statement in respect
of the vehicle where the person who presented the vehicle
provides the required identification subsequently and this
should be presented within 21 calendar days from the date
of the CVR test.
5. CoVIS, Test Reports and Pass Statements.
The CVR tester must complete a checklist printed from
CoVIS for each test conducted confirming that all required
test items have been tested and these must be recorded
on CoVIS. Once a CVR test has been completed, the CVR
tester must complete a declaration that he or she has
completed the test correctly. A test report is issued by the
CVR tester to the owner giving details of the captured
equipment results and any failed visual items. Where the
CVR tester is satisfied that the vehicle has passed all the
required test items specified in this manual, then a pass

statement is issued (apart from point 4 above). Where a
pass statement is not issued, the reasons for refusal will be
provided to the owner in the test report. In the case of a
voluntary safety test, a test report will be provided but no
pass statement will be issued. If a CVR test is not
completed, then the test report issued will contain the
words “Not complete”.
Where the test lane equipment is not automatically linked
to CoVIS, the CVR Tester will have to manually input the
test results on CoVIS. The paperwork associated with
these tests shall be retained by the CVR Test Operator.
Any supplementary documentation required as part of the
test (such as modification reports, safety belt
documentation, tachograph declaration) shall be scanned
and uploaded onto the CoVIS system.
If either the scanner or CoVIS are not operational, the
documents shall be retained by the test operator.
Figure 1.“Fail Dangerous” Notice: Windscreen Front
If the CVR Tester needs to stop in the middle of the test
they will be able to save results up to that point and
resume testing later that day. Only the tester who
commenced the test may resume the test. Where a tester
has started a test and is not available to complete it for
whatever reason, the test must be abandoned and it must
be started again on the vehicle by another tester, from the
beginning.
6. Assessment of Defects.
In line with Commission Recommendation 2010/378/EU,
this test manual categorises the seriousness of failure for
each defect into the following;
Minor Defects (MiD)
Technical defects that have no significant effect
on the safety of the vehicle and other minor noncompliances.
Major Defects (MaD)
Defects that may prejudice the safety of the
vehicle or put other road users at risk and other
more significant non- compliances.
Dangerous Defects (DD)
Defects that constitute a direct and immediate
risk to road safety such that the vehicle should
not be used on the road under any
circumstances.
For defects which can be classified in more than one
category, the tester shall use his experience and technical
expertise to categorise the particular defect in the
appropriate defect category.
On completion of a CVR test, voluntary safety test or a
enforcement test, and where a vehicle is failed because
of a Dangerous Defect, the CVR tester shall affix a “Fail
Dangerous” notice to the vehicle. For vehicles with a
windscreen, a double-sided “Fail Dangerous” notice shall
be affixed on the passenger side of the windscreen so as
not to impair the vision of the driver. The template that
this double sided notice shall take is set out in Figures 1
and 2 that follow. In the case of trailers, a “Fail
Dangerous” notice as set out in Figure 3 shall be affixed
to an area of the vehicle which is clearly visible and
readily accessible for inspection.
Figure 2.“Fail Dangerous” Notice: Windscreen Back
Figure 3.“Fail Dangerous” Notice: Trailer
7. Restriction on CVR Testers carrying out
certain tests.
During a CVR test, a CVR tester shall not carry out any
repairs on the vehicle other than an adjustment of
headlight focus to the required standard. Where this
adjustment is made, it must be noted on CoVIS. Where
the vehicle fails on other items, the test must be
completed and a test report issued. It shall be possible for
a vehicle to be tested and retested on the same day.
A CVR tester shall not carry out a test on a vehicle which
he/she has carried out any repairs or maintenance work
on in the 2 days previous.
A CVR tester shall not carry out a CVR test on a vehicle
where that CVR tester has a legal or beneficial interest in
the vehicle, unless details of the proposed test have been
given to the Road Safety Authority at least 2 working days
in advance.
HCV TESTERS MANUAL V 1.0 Page | 7

A CVR tester can only carry out tests on the categories of
vehicles to which he or she is authorised.
8. Reasons to Refuse to Carry Out a CVR Test.
A CVR tester may refuse to carry out a CVR test if
(a) in his or her opinion
(i) any part of the vehicle or any of its equipment is in
such a condition that it would not be safe or
practicable to carry out the CVR test or
(ii) a load on the vehicle is in such condition or is not
adequately secured that it would be safe or
practicable to carry out the CVR test.
or
(b) fee payable in respect of the CVR test has not been
paid.
The equipment to be used for the purposes of carrying
out CVR tests are those specified in The Premises and
Equipment Guidelines 2013 issued by the Road Safety
Authority. Where specific equipment is designated for a
particular test, only this equipment shall be used for the
test. Where the brakes cannot be tested on a roller brake
tester due to the design of the vehicle, a road test must
be carried out using a decelerometer to evaluate the
brake performance.
The specialised equipment used for the test should only
be used by trained and experienced personnel. CVR
testers should be thoroughly familiar with the
manufacturer’s detailed operating instructions and the
procedures which must be followed to ensure the safe
operation of this specialised equipment.
9. Postponing the issue of a CRW.
Where a pass statement is issued by a CVR test
operator, the CVR tester shall verify with the presenter
that the details of the registered owner on the pass
statement are correct. Where the details differ, the
presenter may request that the issuing of the CRW be
postponed for a period of up to 14 days. The CVR tester
shall advise the presenter to contact the DVCSD in order
to have the ownership details updated as soon as
possible. The presenter/owner should be advised that the
CRW will issue after 14 days to the registered owner on
the National Vehicle Driver File.
prediction of future vehicle roadworthiness.
Because it is not practicable to lay down limits of wear and
tolerance for all types of components of different models of
vehicle, CVR testers are expected to use their experience
and judgment in making an assessment of the condition of
components, i.e. is replacement, repair, adjustment or
certification necessary Where the vehicle or trailer
manufacturer has provided wear tolerances these should
be adhered to.
The Methods of Testing detailed in this Manual are
designed to comply with normal workshop practice. The
Road Safety Authority cannot accept responsibility for any
injury to any person or any damage to any property arising
from the conduct of any test described in this Manual.
Nothing in this Manual may be construed as diminishing in
any way the obligations on employers from health and
safety regulatory acts in relation to the occupational health
and safety at work of their employees.
It is the responsibility of the person presenting the vehicle
for test to prove exemption from any requirement listed in
this manual.
The testing sequence.
Pages 9, 10, 11 and 12 illustrate in general terms the
sequence of tests to be carried out. Page 10 is mainly
involved with tests which may be carried out on hard
standing and Page 11 is mainly involved with tests carried
out from underneath the vehicle. It is essential that
headlamp checks be carried out with the vehicle in the
certified area only. Class V and Class VI mirrors must be
checked in the dedicated area. Checks on such items as
steering play, linkage wear, leaks or play in braking
systems, suspension wear, smoke emission and brake
lights will normally require a two person team working
together. The test sequence will of course vary with
different vehicle types.
10. Odometer.
The CVR tester must record the odometer reading at
the time of the test where an odometer is fitted. When
the test report or pass statement is being presented to
the owner or the presenter of the vehicle, the CVR
tester shall point out the odometer reading. The owner
or the presenter of the vehicle shall be asked to
confirm that the entry of the odometer reading is
correct, and if not shall immediately advise the CVR
Tester.
11. General.
The test is essentially a maintenance and condition
check. A detailed assessment of a vehicle’s design and
constructionisnotpartofthetest.Itshouldalsobenoted
that the test can only confirm the roadworthiness
condition of the vehicle at the time of the test. It is not a
HCV TESTERS MANUAL V 1.0 Page | 8

TEST PROCEDURE TO BE FOLLOWED
Brake Test and lights may be changed around depending on equipment layout
IN CAB AROUND VEHICLE BRAKE TEST UNDERBODY LIGHTS
Chassis/No.Plate (1)
Weights & Dimensions Plate (2)
Dash/Malfunction Indicators/
main beam light (20, 14, 60)
Indicator Tell Tales (58)
Battery Light (20)
Oil Warning Light (3)
Smoke test (3)
Brake Gauges/Buzzer (4)
Air/Vac Build up time (5)
Horn (6)
Wipers/Washers (7)
Mirrors (8)
Driver’s Seat (9)
Seat Belts (10)
Glass/Window Winder (11)
Brake Controls (12, 13, 14, 15)
Tachograph/Speedometer (69)
Speedlimiter (70)
Steering Play (17)
Warning Triangle (18)
Door/Locks/Anti Theft
Devices (19)
Electrical System (20)
Transmission (53)
Cab Condition (22)
Running Board Steps (21)
R/H Door (19)
Demister [Bus] (22)
First Aid Kit [Bus] (66)
Fire extinguisher [Bus] (62)
Seat Belts (10)
R/H Step (22)
R/H Front Mudguard (22)
R/H Front Tyre (24, 25, 26)
R/H Front Wheel (27)
Side Marking (28)
Front No. Plate (1)
Windscreen Markings (11)
Wipers (7)
Brake Fluid (30) Clutch Fluid
(53)
Power Steering Fluid (43)
Steering Column (17)
Bumper Bar (22)
L/H Door/Locks (19)
L/H Step (21)
Cab Mounting (22)
L/H Front Mudguard (22)
L/H Front Tyre (24, 25, 26)
L/H Front Wheel (27)
Body Condition (22)
Brake Reservoirs (33)
Side Marking (28)
Side Guards (31)
L/H Rear Mudguard (22)
L/H Rear Tyre (24, 25, 26)
L/H Rear Wheel (27)
Electrical System (20)
Body Condition (22)
Rear Underrun Guard (31)
Towing Coupling (35)
Electrical System (20)
Body Condition (22)
Spare Wheel Carrier (32)
Rear No. Plate (1)
Brake Connections (49)
Suzie pressure (49)
Rear Markings (28)
R/H Rear Tyre (24, 25, 26)
R/H Rear Wheel (27)
R/H Rear Mudguard (22)
Body Condition (22)
Side Markings (28)
Side Guards (31)
Air/Vac Tanks (33)
Electrical System (20)
Fuel Tank (34)
Brake Fluid (30)
Brake Reservoirs (33)
Tipping Gear (22)
Fuel Cut Off [Bus] (67)
Emergency Exit [Bus] (63)
Steering Alignment (36)
Service Brake
Performance (37)
Service Brake
Imbalance (38)
Secondary Brake
Performance (39)
Secondary Brake
Imbalance (40)
Parking Brake
Performance (41)
Parking Brake
Imbalance (42)
Steering Linkage (43)
Wheel Bearings (44)
Chassis/Cross Members (45)
Electrical System (20)
Exhaust System (46)
Front Axle Brake
Wheel Units (47)
Front Axle Brake
Components (48)
Brake Pipes (49)
Front Axle Springs (50)
Front Axle Shock
Absorbers (52)
Front Axle Beam (51)
Front Axle Suspension (51)
Front Axle Tyres (24, 25, 26)
Oil Leaks (53)
Engine Mountings (53)
Gearbox Mountings (53)
Drivetrain (53)
Tachograph Seals (69)
Chassis /Cross members (45)
Fuel System (34)
Exhaust System (46)
Drive Shaft[s] (53)
Silencer Box (46)
Body Clamps (22)
Brake Valves (33)
Brake Pipes (49)
Electrical Wiring (20)
Brake Air/Vac Tanks ( 33)
Mechanical Brake
Components (48)
Chassis/Cross Members (45)
Drive Shaft[s] (53)
Rear Axle (55)
Rear Axle Brake
Wheel Units (47)
Rear Axle Brake
Components (48)
Brake Pipes (49)
Rear Axle Springs (54)
Rear Axle Shock
Absorbers (52)
Rear Suspension (55)
Rear Axle Tyres (24, 25, 26)
Electrical Wiring (20)
Chassis/Cross
members (45, 22)
Towing Coupling (35)
Headlamp
Condition (60)
Headlamp Aim
(61)
Headlamp Main
Beam (60)
Side Lights (59)
Front
Indicators/
Repeaters (58)
Rear Lights
(56)
No. Plate Lamp
(56)
Stop Lamps
(57)
Indicators Rear
(58)
Rear Reflectors
(28)
Side Reflectors
(28)
Long Vehicle
Sign (28)
HCV TESTERS MANUAL V 1.0 Page | 9

TEST PROCEDURE TO BE FOLLOWED
HCV TESTERS MANUAL V 1.0 Page | 10

PROCEDURE FOR UNDERBODY INSPECTION
Electrical
Air/Vac Tanks
HCV TESTERS MANUAL V 1.0 Page | 11

VEHICLE ON CERTIFIED AREA FOR TESTING HEADLAMP AIM
NOTE: Floor Area to be within ± 1mm of a chosen Reference Point for a distance of 10 metres before
the beamsetter. Rails to be within ± 0.5mm of a chosen Reference Point.
HCV TESTERS MANUAL V 1.0 Page | 12

ADDITIONAL ITEMS TO BE CHECKED ON A BUS
ADDITIONAL ITEMS TO BE CHECKED ON A SEMI-TRAILER
HCV TESTERS MANUAL V 1.0 Page | 13

TESTING METHODOLOGY AND
DEFECT TYPE BY ITEM
NOTE: Testers should not start a test in any of the following circumstances:
(i)
(ii)
where in their opinion any part of the vehicle or any of its equipment is in such a dirty or dangerous
condition as to make it unreasonably difficult to carry out the test.
where the load or other items are not adequately secured.
(iii) If any relevant test equipment is missing, not working, or out of calibration.
The vehicle should be logged in the system as a Fail due to conditions (i) or (ii) above.
HCV TESTERS MANUAL V 1.0 Page | 14

1
1
REGISTRATION/TRAILER PLATE AND VIN
Method of Testing
1. Check the registration number plates or trailer mark plate for security, location, format, legibility and that the numbers
are the same as that on CoVIS. No other marks may appear on the plate. Any additional tabs, etc. outside the
dimensions shown for the registration plate are not considered part of the plate.
2. Check that the VIN is indelibly marked on the chassis and corresponds to the number on CoVIS for this vehicle
3. Check in the case of a trailer that the trailer mark is indelibly marked on the offside chassis rail and are of the
correct dimensions.
4. Check that the vehicle meets with the description assigned to it on CoVIS.
5. Check that the vehicle meets with the EU Category assigned to it on CoVIS.
NOTES
Owners of vehicles registered prior to 31 st December, 1990, have the option of converting their registration
plates to the new format
(1) Vehicles Registered on or after 1 st January 1991
For vehicles registered on or after 1 st January, 1991, registration plate letters and numbers must be black,
set against a white background of reflex reflective material. The flag of the European Union, the Nationality
Symbol IRL and the Irish language name of the City/County of registration to be shown.
(2) Vehicles Registered on or after 1 st January 1987
For vehicles registered on or after 1 st January, 1987, registration plate letters and numbers must be black,
set against a white background of reflex reflective material and minimum dimensions should be as shown
in the sketches on page 16.
(3) Vehicles registered prior to 1 st January 1987
Reflex Reflecting Registration Plates
(a) Reflex Reflecting
Front registration plates should have black numbers and letters on a white background. Rear
registration plates should have black numbers and letters on a red or white background.
(b) Non-Reflex Reflecting
Front and rear registration plates should have white, silver or light grey numbers and letters on a
black background.
(c) Back Lit Registration Numbers and Letters
Where registration numbers and letters are back lit they should appear white in front and either white
or red to the rear during lighting up hours. At all other times they should appear white on a black
background.
(4) Dimensions should be as shown in the illustration on page 16.
(5) Where the indented space provided for the number plate is not sufficient to accommodate a
standard size number plate, the registration plate and registration letters and numbers may be
reduced in size relative to the space provided for the number plate.
(6) Trailer Registration Number Plate
The trailer registration number plate should consist of black numbers and letters 76mm (3”) high on
a white background and should be fitted to the nearside chassis rail.
The trailer registration letters and numbers must also be clearly and indelibly marked with characters
at least 30mm high on the offside chassis rail.
(7) Where a new VIN plate has been fitted, then the original VIN plate shall be retained alongside the new
VIN plate.
HCV TESTERS MANUAL V 1.0 Page | 15

1
REGISTRATION PLATE AND VIN (CHASSIS NUMBER) Cont..
DIMENSIONS FOR NUMBER PLATES
All dimensions in millimetres
HCV TESTERS MANUAL V 1.0 Page | 16

1
REGISTRATION/TRAILER PLATE AND VIN
ITEM REASONS FOR FAILURE MiD MaD DD
01 Registration Number Plate
(see page 16) or trailer
registration number plate.
(1) One or both plates missing or insecure. X
(2) Numbers or letters missing or illegible or wrong size (see page
16).
X
X
(3) Numbers, letters or background of incorrect colour (see notes on
page 15).
X
(4) Registration number does not correspond with that stated on
CoVIS.
(5) In the case of trailers and semi-trailers the trailer registration
number plate is not fitted to the near side chassis rail.
X
X
(6) The trailer registration number is not indelibly marked on the
offside chassis rail with characters of minimum 30mm height in an
accessible position.
X
(7) Other letters, numbers, or marks are on the registration number
plate.
X
02 VIN (1) VIN not available or does not correspond with the number stated
on CoVIS.
X
(2) VIN is missing or not legible on chassis. X
03 EU category (where stated
on CoVIS)
(1) EU category for the vehcile presented does not correspond with
the EU category stated on CoVIS.
X
ADVISORY NOTICE
Where the vehicle does not match description on CoVIS.
Where the EU category for the vehicle does not correspond with the EU category stated on CoVIS.
HCV TESTERS MANUAL V 1.0 Page | 17

2
VEHICLE WEIGHTS AND DIMENSIONS PLATE
Method of Testing
1. Check in the case of a vehicle, trailer or semi-trailer with a design G.V.W. exceeding 3,500kg that a metal plate
similar to that shown on pages 19 and 20 is securely fitted to the vehicle.
2. Check in the case of a passenger vehicle with a design G.V.W. exceeding 5,000kg that a metal plate similar to that
shown on page 19 is securely fitted to the vehicle.
3. Check that in the case of a plate fitted by an Authorised Plate Fitter that the plate seal is intact.
4. Check that the plate shows all the required details (see plate on pages 19 and 20).
5. A 3-axle tractor unit plated for 44 tonnes GCW is required to have an anti-lock braking system and an air
suspension system (or equivalent) as per the definition of “appropriate motor vehicle” (please see Note 1of
Introduction for definition).
6. A 3-axle tractor unit plated for 46 tonnes GCW first registered prior to 1 st April 2013 (in addition to satisfying the
definition of an “appropriate motor vehicle” as outlined in Note 1 of the Introduction) is required to have an Electronic
Braking System (EBS) 1 .
7. A 3-axle tractor unit plated for 46 tonnes GCW first registered on or after 1 st April 2013 (in addition to satisfying the
definition of an “appropriate motor vehicle” as outlined in Note 1 of the Introduction) is required to have an Electronic
Braking System (EBS) & be fitted with a Vehicle Stability Function (VSF) 2 , which is more commonly known as
Electronic Stability Control (ESC).
Motor-caravans and passenger vehicles with a DGVW up to 5,000kg
8. Examine alterations made to the manufacturers plate. In cases where the details contained on the original
manufacturers plate have been altered, then this alteration must be justified, approved and documented by the
manufacturer or his authorised distributor. In the absence of a manufacturers report, then a modifications report in
the format prescribed in Section 71 of this test manual must be provided.
NOTES
(1) The only plates acceptable are those fitted by the vehicle/trailer manufacturer or an Authorised Person
appointed by NSAI.
(2) A single plate affixed by the vehicle manufacturer which contains all of the required information as
detailed on pages and 19 and 20 respectively is sufficient.
(3) Where a vehicle or trailer has been plated by the manufacturer a combination of two plates is acceptable.
(4) Plates fitted by an Authorised Person will bear a number issued to that person by NSAI. Vehicle
Identification Number (VIN) is the manufacturer’s unique vehicle identification number, also known as the
chassis number.
1 “electronic braking system” means a braking system that employs an electronic control system to control the
braking function.
2 ‘vehicle stability function’ (more commonly known as Electronic Stability Control) means an electronic control
function for a vehicle which improves the dynamic stability of the vehicle. A vehicle stability function includes
one or both of the following: (a) Directional control & (b) Roll-over control.
HCV TESTERS MANUAL V 1.0 Page | 18

2
WEIGHTS AND DIMENSIONS PLATE
(MECHANICALLY PROPELLED VEHICLE)
(All inscriptions 4mm in height)
Name of Manufacturer:
Type Approval Number:
Vehicle Identification Number:
Maximum permitted laden weight
Maximum permitted laden weight
of combination (if permitted to
tow a trailer)
Weights Not to be
Exceeded in
Ireland
Maximum Weights
Permitted under
EU Directives
Design Weights
(if higher than
permitted in Ireland)
Axle 1
Axle 2
Axle weights
Axle 3
Axle 4
Vehicle Length L =
Vehicle Width W =
Data relating to Length of
Combinations
Centre of coupling to front of
vehicle (a)
amax =
amin =
HCV TESTERS MANUAL V 1.0 Page | 19

2
WEIGHTS AND DIMENSIONS PLATE
(TRAILER AND SEMI -TRAILER)
(All inscriptions 4mm in height)
Name of Manufacturer:
Type Approval Number:
Vehicle Identification Number:
Maximum permitted laden weight
Axle 1
Weights Not to be
Exceeded in Ireland
Maximum Weights
Permitted under EU
Directives
Design Weights
(if higher than
permitted in Ireland)
Axle weights
Axle 2
Axle 3
Axle 4
Maximum kingpin load
(semi-trailer)
Vehicle Length L =
Vehicle Width W =
Data relating to Length of
Combinations
Centre of coupling to rear of
trailer (b)
bmax =
bmin =
HCV TESTERS MANUAL V 1.0 Page | 20

2
VEHICLE WEIGHTS AND DIMENSIONS PLATE
ITEM REASONS FOR FAILURE MiD MaD DD
01 Plate (where
required see
method of
inspection)
(1) Not fitted. X
(2) Seal missing. This only applies to a plate fitted by an Authorised Person
appointed by NSAI.
(3) Insufficient information on plate. X
(4) Missing or incomplete VIN. X
X
(5) Information on plate is not compatible with vehicle. X
(6) Information on plate not clear or easily read. X
(7) Plate insecure. X
(8) Plate has not been fitted by either the vehicle/trailer manufacturer or an
Authorised Person appointed by NSAI.
X
(9) The weights displayed (axle weights, GVW or GCW) on the NSAI
Authorised weights and dimensions plate exceeds those on the
manufacturers design weights plate.
X
Note:
In relation to tractor units plated for operation at gross combination weights
of 44 or 46 tonnes, if qualifying conditions 5, 6 or 7 under ‘method of testing’
on page 18 of this manual are not met (as required); this would be a reason
for failure under reason 5 above entitled “Information on plate not
compatible with vehicle.”
02 Manufacturers
plate (Motorcaravans
and
passenger vehicles
with a DGVW up to
5,000kg)
(1) The details on the manufacturers plate have been altered and also there
is no corresponding documentation from the manufacturer (or his
authorised distributor) or a modifications report.
X
X
NOTES
(1) All letters and all numbers should be shown on the Irish Weights and Dimensions plate and
where axle 3 and 4 are not fitted the Weights and Dimensions plate should be marked X.
HCV TESTERS MANUAL V 1.0 Page | 21

POLLUTION/SMOKE (DIESEL)
3
Preliminary Check before carrying Out Diesel Engine Smoke Test
Vehicles registered before
1 st January 1980
(Visual check)
Vehicles registered on or after
1 st January 1980
(Measured test)
Pre-test Checks (Engine Off)
Engine Oil Level Ok
Water Coolant Level Ok
YES
On all items
Purge exhaust system
and carry out
Smoke Test.
Ok
Camshaft Belt Ok*
Start Engine and Check
Engine Warning Light
NO
On any item
Decline to do
Smoke Test
until fault rectified.
Engine Oil Pressure /Light Ok
Engine Temperature Ok
Engine Free of Obvious Defects
Engine Max RPM within 90%
of Manufacturer’s Spec
NOTES
(1) * Check with the vehicle owner/presenter that the camshaft belt has been changed at the manufacturer’s specified
interval. Removing the camshaft belt cover is not part of the roadworthiness test.
HCV TESTERS MANUAL V 1.0 Page | 22

3
POLLUTION/SMOKE
NOTES
(1) No smoke test should be carried out on a diesel engine without first carrying out a pre test check,
see page 22.
(2) It is absolutely essential that an engine is at normal operating temperature before carrying out an
emission test. This shall be established by the use of a temperature probe in the dipstick tube or by
an infrared temperature monitor. Engines must not be warmed up by leaving the engine at idle or
half throttle. They must be warmed up by normal driving.
(3) A diesel engine left idling for any length of time will give a high smoke opacity reading.
(4) There is no requirement to tilt the cab of a H.C.V. when carrying out this test.
(5) There is no requirement to reach maximum engine rpm on a vehicle that will not allow maximum rpm
when the vehicle is stationary.
(6) For each initial/periodic CVR test carried out, a diesel smoke test is required.
Method of Testing
Diesel Engine Vehicles
1. With the engine at normal operating temperature, raise the engine speed slowly to approximately half the engine
governed speed and hold for 20 seconds in order to purge the exhaust system. If the engine emits any unusual
noises discontinue the test. Slowly raise the engine speed to its maximum rpm and note if the governor operates
within the vehicle manufacturer’s recommended governed speed. If not discontinue the test. Do not hold the
engine at maximum speed for any length of time.
2. In the case of diesel engine vehicles first registered on or after 1 st January, 1980, connect the diesel smoke meter
to the vehicle following the manufacturer’s instructions. Where the vehicle engine camshaft is driven by a belt
select the Light Commercial Vehicle smoke test programme. In all other cases select the Heavy Commercial
Vehicle smoke test programme. Depress the accelerator pedal from the idling position to the maximum fuel
delivery position and follow the prompts of the smoke meter. Note the average smoke meter reading recorded.
3. In the case of diesel engine vehicles first registered before 1 st January, 1980, depress the accelerator pedal firmly
from the idling position to the maximum fuel delivery position. Immediately maximum engine speed is reached
and the governor operates, release the pedal until the engine slows to a steady idling speed. Ignore smoke
emission from this first acceleration. Repeat the operation a maximum of four times and note if the emission is
coloured black haze or darker for two successive accelerations not including the first. Smoke haze should be
assessed against a white background.
The above test (3) does not apply to a turbo charged diesel engine. In such cases the vehicle should be driven under
load, past the tester so that he/she may make an assessment of the smoke.
Petrol/Gas Engine Vehicles
1. In the case of petrol/gas engine vehicles check the carbon monoxide content of the exhaust gases at the
manufacturers recommended idling speed in accordance with the instructions supplied by the manufacturer of
the carbon monoxide tester. The engine must be at normal operating temperature but must not be left idling for
an excessive period of time due to possible damage to the catalytic converter.
Electric/Hybrid Electric Vehicles
1. Purely electric vehicles are exempt from emissions testing.
2. Hybrid Electric Vehicles are to have emissions tests carried out as per the type of internal combustion engine
fitted unless there is no switch to run the engine when the vehicle is stationary.
HCV TESTERS MANUAL V 1.0 Page | 23

3
POLLUTION/SMOKE
ITEM REASONS FOR FAILURE MiD MaD DD
01 Preliminary Check (1) Engine oil level too high or too low, coolant level too low.
X
(2) Obvious engine defects.
X
02 Exhaust Smoke (for
diesel engine vehicles first
registered from the 1 st
January, 1980 up to and
including 30 th June 2008).
(1) The average smoke meter reading is higher than 2.5m -1 in the case of
naturally aspirated diesel engines and 3.0m -1 in the case of turbo
charged diesel engines.
X
03 Exhaust Smoke (for
diesel engine first registered
after the 1 st July, 2008)
(1) The average smoke reading is higher than 1.5m –1 . X
04 Exhaust Smoke (for
diesel engine vehicles first
registered before 1 st
January, 1980).
05 Carbon Monoxide (CO)
Emission (petrol/gas engine
vehicles)
(1) The exhaust emission is coloured black haze or darker for two
successive accelerations after the first.
(1) For vehicles registered before 1 st day of October, 1986, the carbon
monoxide content is more than 4.5% at idling speed.
(2) For vehicles registered on or after 1 st day of October, 1986, the
carbon monoxide content is more than 3.5% at idling speed.
X
X
X
06 On Board Diagnostics
(where diagnostic tools
have been connected to the
vehicle by the tester)
(1) OBD readout indicating significant malfunction. X X
HCV TESTERS MANUAL V 1.0 Page | 24

4
AIR/VACUUM WARNING
Method of Testing
1 Check that either a gauge or other visual or audible warning system is fitted. (This check is not necessary where
effective braking is possible without the use of stored energy such as vacuum servo or compressed air assistance).
2 By repeated application of the foot-brake (service brake) pedal gradually exhaust the braking system of air or vacuum
(with engine stopped).
3 If a gauge is fitted, note that the reading on the gauge falls steadily with each application of the brake and that when the
gauge needle has reached the “warning mark” there is still enough vacuum (or air pressure) in the system to allow the
brake to be applied at least twice more with vacuum (or air pressure) assistance.
4 If a warning lamp or audible or mechanical warning system is fitted, note that after this has operated there is still
enough vacuum (or air pressure) in the system to allow the brake to be applied at least twice more with vacuum (or air
pressure) assistance.
NOTES
(1) If vacuum gauge has no “warning mark” take the 25 to 30cm (10” to 12”) mark as the “warning mark”. If air
gauge has no “warning mark” take the 3.1kg/cm 2 (45 p.s.i.) (3 bar) reading as the “warning mark”. If no
gauges are fitted an audible or visual warning should operate.
(2) Where a vehicle is fitted with more than one warning system they must all be working.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Air/Vacuum Warning where
necessary
(1) A warning device not fitted, or defective.
(2) Optical warning device not visible to driver, or not illuminated.
X
X
X
X
(3) Insufficient air pressure or vacuum to give assistance to brakes
for two or more applications after warning device has operated.
(4) Spring brakes activate before warning signal.
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 25

5
5
AIR/VACUUM BUILD UP
Method of Testing
1. In vehicles where a warning device is required empty the reservoir, start the engine, and run it at just below
governed speed. Note the time it takes for the warning device to cease to operate.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Build-up of
Air/Vacuum (Brake
Reservoir)
(1) Appreciably longer than maximum time allowed by the Manufacturer (in the
absence of information on the above, use 3 minutes for compressed air
systems, 1 minute for vacuum systems).
X
HCV TESTERS MANUAL V 1.0 Page | 26

6
HORN
Method of Testing
1. Check that the horn control is accessible to the driver when seated.
2. Check the security of the horn and control.
3. Depress the horn control and note that the horn sounds correctly.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Horn (1) Not working or not fitted.
(2) Not working satisfactorily.
(3) Insecurely mounted.
(4) Control inconveniently placed.
(5) Control insecure.
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 27

7
WINDSCREEN WIPERS AND WASHERS
Method of Testing
1. Switch on the windscreen wipers and washers (if fitted) and check that the wipers move over an arc of the
windscreen glass which is sufficient to give the driver an adequate view.
2. Examine the condition of any visible wires or pipes provided for the operation of the wipers and washers. Check
the wiper controls.
3. Examine the condition of the wiper arms and blades. Check that the springs are not weak or broken.
4. Check that the windscreen washer(s) function satisfactorily.
NOTES
(1) Washers will be considered as being fitted if there is any part of a washer system fitted.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wiper Arms and
Blades
(1) Missing.
(2) Worn out or defective.
(3) Wiped area less than sufficient to give the driver an adequate view.
X
X
X
X
X
02 Speed of Wipers Speed obviously:
(1) Too fast.
(2) Too slow.
03 Wiper Control (1) Insecurely mounted.
(2) Not working, defective or missing.
X
X
X
X
X
X
X
04 Washers (if fitted) (1) Not working or incorrectly aimed.
X X
(2) Leaks.
X
05 Wiper Linkage (1) Worn or insecure. X X
HCV TESTERS MANUAL V 1.0 Page | 28

8
MIRRORS
Method of Testing
1. Check the number and position of the mirrors.
2. Check the condition of each mirror to see that the reflecting surface is not deteriorated or broken so as to impair the
driver’s view.
3. Examine the security and condition of each mirror mounting bracket.
A class VI mirror must be fitted to all N2 & N3 vehicles over 7.5 tonnes DGVW, regardless of year of registration:
4. Check that at least 95% of the field of vision in front of the vehicle as shown in Figure 2 on the following page can be
seen either by means of a Class VI mirror or mirrors, other means of indirect vision or by a combination of the two.
For N2 & N3 category vehicles with a DGVW exceeding 7,500kg and registered after 1 st January 2000 the following
additional tests will apply.
5. Check that wide angle (Class IV) and close proximity (Class V) mirrors are fitted to the passenger’s side of goods
vehicle of categories N2 and N3 per points 5 & 6 below.
6. Vehicles of Class N2 with a DGVW exceeding 3,500kg and not exceeding 7,500kg will not be tested for the presence
of either a wide angle (Class IV) or a close proximity (Class V) mirror at this time.
7. For vehicles that must be tested for a close proximity (Class V) mirror, (i.e. N2 vehicles with a DGVW exceeding
7500kg and all N3 category vehicles), check the required field of view of this mirror is as shown in Figure 1 below by
ensuring that the hatched area is visible from the driver’s seat. The line A-B must be in line with the driver’s “eye-line”
to ensure a compliant field of view. The field of vision of the close proximity (Class V) mirror must be physically
checked using the painted area on the test centre floor and NOT using the RSA approved mirror checking tool.
8. For vehicles that must be tested for a wide angle (Class IV) mirror (i.e. N2 vehicles exceeding 7,500kg DGVW and all
N3 category vehicles), check that the radius of curvature of the wide angle (Class IV) mirror is not less than 300mm
but is less than 400mm using the RSA approved mirror checking tool.
NOTES
(1) Class VI mirrors are not required where the vehicle owner can provide evidence that a supplementary
device has been fitted which meets with the indirect vision requirements of Directive 2003/97/EC
(2) If no Close Proximity mirror is fitted but the hatched area below can be seen through a combination
of Mirrors and/or other devices for indirect vision, a Class V mirror is not required.
(3) For vehicles first registered since 1 st January 2000 if there is no close proximity (Class V) mirror fitted
but the hatched area in Figure 1 above can be seen through a combination of the Front and Wide
Angle mirrors or other supplementary devices for indirect vision then there is no need for a close
proximity (Class V) mirror to be fitted.
(4) Class IV and V mirrors are not required where the vehicle owner can provide evidence that a
supplementary device has been fitted which meets with the indirect vision requirements of Directive
2007/38/EC.
HCV TESTERS MANUAL V 1.0 Page | 29

8
MIRRORS
Figure 1: Field of vision of Class V close-proximity mirror. (All dimensions in millimetres).
Figure 2: Field of vision of Class VI front mirror (All dimensions in millimetres)
HCV TESTERS MANUAL V 1.0 Page | 30

8
MIRRORS
Tool for checking radius of curvature of the wide angle (Class IV) mirror for
vehicles registered after 1 st January 2000
To ensure compliance for vehicles registered after 1 st January 2000, these vehicles are required to be equipped with a wide
angle mirror glass having a radius of curvature of approximately 300mm. Mirror glasses of 400mm and above will not be
able to generate the required field of vision necessary to comply with the new requirements. The RSA approved mirror
checking tool is shown in Figure 2 below and must be used to perform the check and ensure compliance with the
regulations.
Figure 2: Tool for checking the radius of curvature of the wide angle (Class IV) mirror. (Dimensions shown are in millimetres)
Examples of Wide Angle (Class IV) Mirrors that are Outside Spec
Figure 3 below shows an example of where the wide angle mirror FAILS to meet the specification as the radius of
curvature is less than 300mm. For example, a mirror with a radius of curvature of 250mm would NOT meet the new
requirements as indicated by the presence of gaps either side of the measuring tool.
Figure 3: Image showing an incorrect radius of curvature i.e. less than 300mm.
HCV TESTERS MANUAL V 1.0 Page | 31

8
MIRRORS Cont…
Figure 4 below shows another example of where the wide angle mirror FAILS to meet the specification as the radius of
curvature is greater than 400mm. For example, a mirror with a radius of curvature of 450mm would NOT meet the new
requirements as indicated by the presence a gap in the middle of the measuring tool.
Figure 4: Image showing an incorrect radius of curvature i.e. greater than 400mm.
Example of Acceptable Wide Angle (Class IV) Mirror
Figure 5: Image showing in the correct range of curvature i.e. more than 300mm and less than 400mm
Mirrors should be tested using both curves on the measuring tool to ensure that they fall within the limits of between
300mm and 400mm, i.e. the radius of curvature can be greater than 300mm BUT it must be less than 400mm.
HCV TESTERS MANUAL V 1.0 Page | 32

8
MIRRORS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Mirrors,
internal and
external
(1) Missing.
(2) Reflecting surface deteriorated or broken so as to impair the driver’s view.
(3) Unsuitably placed or not designed to give an adequate view to the rear.
(4) So designed that it may cause undue injury in accidents.
X
X
X
X
X
X
X
X
(5) Head or mounting loose.
(6) Mirror not adjustable.
(7) Ambulance, goods vehicle, passenger vehicle for more than 8 passengers
(excluding the driver’s seat) not equipped with two rear view mirrors.
(8) For goods vehicles, and passenger vehicles for more than 8 passengers one of
the required rear view mirrors is not fitted externally on the right hand side.
X
X
X
X
X
X
X
X
All N2 and N3 vehicles with a DGVW exceeding 7,500kg:
(9) Class VI mirror not fitted.
(10) At least 95% of the field of vision in front of the vehicle as shown in Figure 2
cannot be seen by means of a Class VI mirror (or mirrors).
X
X
X
X
N2 and N3 vehicles with a DGVW exceeding 7,500kg registered after 1 st Jan 2000:
(11) Class IV (wide angle) mirror not fitted.
(12) An incorrect radius of curvature of the wide angle (Class IV) mirror, i.e. the radius
must be greater than or equal to 300mm and must be less than 400mm. The
RSA Mirror Checking Tool must be used to perform the check.
(13) Class V (close proximity) mirror not fitted.
(14) At least 85% of the Class V mirror diagram (Figure 1) cannot be seen when
seated in normal driving position.
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 33

9
DRIVER’S SEAT
Method of Testing
1. Examine the driver’s seat and its mountings.
2. Note any movement of the seat relative to the vehicle body and the condition of the seat back and seat cushion.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Driver Seat (1) Loose on runners or insecurely mounted.
(2) Collapsed or framework damaged.
(3) Adjustment mechanism not working correctly.
(4) Seat upholstery so torn or otherwise damaged that driver’s comfort
is affected or interior foam is protruding beyond the seat trim.
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 34

10
SAFETY BELTS
NOTES
(1) Methods 1 and 2 apply only to passenger vehicles with more than eight passenger seats and a
DGVW of 3,500kg or less first registered before 20 th October 2007
(2) If safety belts are fitted to any seat of any vehicle, they must be tested per Methods of Testing 3-8.
(3) From first registration date 20 th October 2007 the seats of all vehicles must be fitted with safety
belts with the exception of buses designed for standee passengers. Standee passenger buses will
have letters or pictograms in the vicinity of the front door giving details of the maximum number
of standing and seating places the vehicle is designed to carry.
(4) In the case of motorcaravans, seatbelts are only required in the front seats. Where seatbelts are
fitted in the rear of a motor caravan, they should be tested as normal.
(5) Restraint systems for all vehicles registered after 20 th October 2007 must be type approved to
Directive 76/115/EEC (as amended) and be e /E marked.
(6) Where a lap belt (only) is fitted to a forward facing front seat or exposed forward facing seat other
than the driver’s seat, padding to a depth of at least 50mm must be provided on any bar or the top
edge of any screen or partition likely to be struck by the head of a passenger wearing a lap belt in
the event of a sudden deceleration. Such padding must meet the requirements of UNECE
Regulation 21, Annex 4.
Method of Testing
1. For vehicles registered on or after the 1 st day of June, 1971, check that a lap and diagonal type safety belt is provided for
the driver and front outer passenger seat.
2. For vehicles registered on or after the 1 st day of January, 1992, check that all outer forward facing front seats are provided
with a lap and diagonal type safety belt and all other forward facing front seats are provided with a lap and diagonal or lap
type safety belt.
3. Pull each safety belt webbing against its anchorage and see that it is properly secured to the vehicle structure.
4. Examine the condition of all safety belt webbing for cuts or obvious signs of deterioration. In the case of the retractable type
safety belt ensure that the belt is fully extended during this examination.
5. With the seat unoccupied fasten the safety belt buckle and check that the adjustment mechanism functions properly. In the
case of retractable belts ensure that all the slack is removed and by pulling the belt quickly check that the locking
mechanism operates. Attempt to separate the fastened belt at the buckle and check that the belt can be released when
required.
6. Examine the condition of the attachment and adjustment fittings on each belt for distortion or fracture.
7. As far as is practicable without dismantling, check the condition of the vehicle structure in the vicinity of the safety belt
anchorage points. The condition of floor mounted anchorage points may best be inspected from underneath the vehicle.
8. If fitted, check that the safety belt warning system is working correctly.
1. The first level warning shall be tested according to the following conditions:
(a) Safety-belt is not fastened;
(b)
(c)
(d)
Engine is stopped or idling and the vehicle is not in forward or reverse motion;
Transmission is in neutral position;
Ignition switch is engaged.
HCV TESTERS MANUAL V 1.0 Page | 35

10
SAFETY BELTS
9. Check safety belt installation documentation.
(a)
(b)
(c)
(d)
(e)
(f)
Check if bus is fitted with safety belts – if not continue roadworthiness test as usual.
If this is the first time a safety belt installation documentation check is being carried out on the vehicle and the
bus is fitted with safety belts check that there is a completed owner declaration form and supporting safety
belt certification for that vehicle.
Check seat belt certification is for that bus and is valid (i.e. number of seats/safety belts, and vehicle’s
VIN/Registration number correspond). If not the bus will fail its test.
If certification is acceptable, complete & stamp owner declaration form and copy completed declaration form and
seat belt certification.
Return original documentation to owner and retain the documentation copies on file with bus test results. Advise
owner to retain and bring stamped declaration form to any future roadworthiness test.
If safety belt installation documentation check has been previously carried out on the vehicle the vehicle owner
only needs to present stamped owner declaration form.
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10
SAFETY BELTS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Safety Belts (1) For vehicles registered on or after the 1 st day of June, 1971, a lap and
diagonal type safety belt is not provided for the driver and outer front
seat.
(2) For vehicles registered on or after the 1 st day of January, 1992 a lap
and diagonal type belt is not provided for all outer forward facing front
seats.
X
X
(3) For vehicles registered on or after the 1 st day of January, 1992 a lap
and diagonal or lap type safety belt is not provided for all other forward
facing front seats.
(4) Belt badly frayed or cut.
(5) Belts not operating properly (e.g. damaged buckles, loose or detached
fixing bolts, retracting or locking mechanism not functioning properly as
designed and manufactured).
(6) Any vehicle first registered on or after 20 th October 2007 not fitted with
safety belts.
Note: Safety belts which only operate when the vehicle is in motion should
be checked when driving to or from the test lane.
(7) Any vehicle first registered on or after 20 th October 2007 not fitted with
type approved restraints (e-marked).
(8) Padding missing or damaged on any hard structure in front of two-point
safety belt (lap belt).
X
X
X
X
X
X
X
X
02 Safety Belt
Anchorage System
(1) Any load bearing member of the vehicle structure or panelling within
30cm of an anchorage point cracked, corroded or in an otherwise
weakened condition. This applies to the seat mounting if the belt is
anchored to the seat.
X
X
(2) A belt mounting unsatisfactory (e.g. incorrect bolts fitted or no owner
declaration form presented).
X
X
03 Warning System (1) The safety belt warning system, where fitted, is not operating
correctly.
X
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11
GLASS
Method of Testing
1. Check the condition and security of the windscreen and all side and rear windows.
2. Check that where the windscreen is made of glass it is marked as automotive safety glass, e/E-marked or to an
automotive standard per Fig 1 below.
3. Check that there is an adequate view from the driving seat and that it is not interfered with by objects or stickers.
4. Check that in the case of vehicles first registered on or after 1 st January, 1986 the windscreen is made of
laminated safety glass and marked as shown on page 40.
5. If the glazing presented is not marked or is marked to a standard not listed below, it is the responsibility of
the owner/presenter to provide documentary evidence that the glazing material is not likely, if fractured, to
produce fragments capable of causing severe cuts.
6. Check that the driver’s and front passenger’s window operating mechanisms are functioning properly.
7. Check the opacity of the glazing in the windscreen and front side windows. If it appears to be excessively
tinted it should be tested using a light meter capable of measuring the amount of light transmitted through the
glazing to an accuracy of ± 3% and suitable for reliable use in an inspection centre environment.
Australia:
Canada:
India:
Japan:
COUNTRY
SAFETY GLASS STANDARD
AS/NZS 2080 AS/NZS 2080T
CMVSS 205 (C2)
IS2553 (Part 2) 1992 (Note 11)
11-4-21 (window glass) JISR 3211
South Africa:
UK:
USA:
SABS 1191 / SABS 1193
BS AU I78 / BS 85 7-2 / BS 5282
FMVSS 205 (U)
ANSI/SAE Z26.1-1996 (Section 7)
Germany:
A three-period sine wave followed by the letter D. This is an older
German type approval for automotive glazing. (See image below).
Glazing marked Birkholz, Seitz, Roxite, Para Press or Bonoplex.
Glazing marked PMMA (polymethylmethylacrylate) or PC
(polycarbonate).
Figure 1: Acceptable safety glass standards.
HCV TESTERS MANUAL V 1.0 Page | 38

11
GLASS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Glass Windscreen (1) Windscreen not marked as automotive safety glass.
X
(2) In vehicle registered on or after 1/1/86 windscreen is not
marked as shown on page 40 or marked to an equivalent
certified standard (see Note 3 below).
X
(3) Objects or stickers in driver’s direct line of vision.
X
(4) Damaged beyond acceptable limits. See pages 41 and 42.
X
X
(5) Glass has a visible light transmissibility level of less than 65%.
X
X
02 Glass Side and
Rear Windows/
Partitions
(1) Not marked as automotive safety glass (if first registered
after 1 st July 1964).
(2) In vehicle registered on or after 1/1/86 glass side and rear/
partition is not marked as shown on page 40 or marked to an
equivalent certified standard (see Note 3 below).
X
X
(3) Broken or missing.
X
X
(4) Glazing in front side windows has a visible light transmissibility
level of less than 65%.
X
X
03 Windscreens,
Windows
(1) Missing or insecure.
(2) Opening mechanism of driver’s window not operating.
X
X
(3) Opening mechanism of front passenger’s window not operating X
04 Non Glass
Windscreens and Side
or Rear Windows
(1) Made of material not certified that it is likely, if fractured, to
produce fragments capable of causing severe lacerations.
(2) Side or rear windows damaged such that drivers view is restricted.
X
X
X
(3) Broken or missing.
X
X
NOTES
(1) Windscreen repairs are acceptable provided they meet BS Codes of Practice BS AU242 and BS AU25
(2) Side and rear windows must be BS marked to PSV standard.
(3) It is the responsibility of the owner/presenter to provide proof of standards equivalency if a vehicle is
presented with glass marked to another standard other than one shown in Fig. 1 above.
(4) Where the vehicle has been fitted with double glazed windows, both inner and outer
panels must be intact.
HCV TESTERS MANUAL V 1.0 Page | 39

11
GLASS Cont…
COUNTRY IN WHICH MARK ISSUES
Any country which has subscribed to the
Agreement of the United Nations
Economic Commission for Europe
concerning the adopting of uniform
conditions of approval and reciprocal
recognition of approval for motor vehicle
equipment and parts. Done at Geneva on
20 th March, 1958.
United Kingdom
APPROVED STANDARD MARKS
II
E4*
43R- **
* This number varies and relates to the country which
issued the approval.
** In association with the standard mark a serial number
assigned by the issuing country is shown in this position.
NOTE
The absence of II or III above or beside the approved
standard mark indicates that the glass is not laminated.
B.S. 857-2 or
B.S. 5282 or
B.S.AU 178
See also note below
NOTE
The B.S. must be accompanied by the word
laminated or the letter L.WL or WLT. The absence of
these will indicate that the glass is not laminated.
HCV TESTERS MANUAL V 1.0 Page | 40

11
GLASS Cont…
(Goods Vehicles, Buses and Ambulances up to 7,500kg D.G.V.W.)
ACCEPTABLE LIMITS
ZONE A Damage that can be contained within a 10mm diameter circle (maximum of two defects provided they are
more than 100mm apart).
ZONE B Damage that can be contained within a 20mm diameter circle or hairline cracks up to 30mm long
(maximum of two defects provided they are more than 100mm apart).
ZONE C Damage that can be contained within a 40mm diameter circle (maximum of three defects provided they are
more than 100mm apart).
NOTE (1) The vehicle should be failed where damage is beyond the above limits.
(2) Damaged windscreens may be repaired provided the repairs meet the requirements of Codes of
Practice BS AU242 and BS AU 251.
(3) Light scratching which does not obscure the driver’s view should be ignored.
HCV TESTERS MANUAL V 1.0 Page | 41

11
11
GLASS Cont…
(Goods Vehicles, Buses and Ambulances up to 7,500kg D.G.V.W.)
ACCEPTABLE LIMITS
ZONE A Damage that can be contained within a 10mm diameter circle (maximum of two defects provided they are
more than 100mm apart).
ZONE B Damage that can be contained within a 20mm diameter circle or hairline cracks up to 30mm long
(maximum of two defects provided they are more than 100mm apart).
ZONE C Damage that can be contained within a 40mm diameter circle (maximum of three defects provided they are
more than 100mm apart).
NOTE (1) The vehicle should be failed where damage is beyond the above limits.
(2) Damaged windscreens may be repaired provided the repairs meet the requirements of Codes of
Practice BS AU242 and BS AU 251.
(3) Light scratching which does not obscure the driver’s view should be ignored.
HCV TESTERS MANUAL V 1.0 Page | 42

12
121212
MECHANICAL BRAKE HAND LEVER
Method of Testing
For Hand Brake Levers:
1. Examine the condition of the brake lever and its position.
2. With the brake lever in the “off” position.
a. note the amount of side play in the lever pivot by moving the lever from side to side.
b. check the condition of the pawl mechanism pivots.
c. check safety guard.
3. Without operating the pawl mechanism, apply the brake slowly and check the effective operation of the pawl
mechanism by listening for definite and regular clicks as the pawl moves over the ratchet teeth.
4. When the brake is fully applied:
a. knock the top and each side of the lever and check that the lever is held in the “on” position.
b. check that the lever is not at the end of its permitted travel and that there is no fouling of adjacent parts.
NOTES
(1) Before carrying out this inspection chock the road wheels.
(2) This inspection applies to all vehicles and trailers fitted with hand levers controlling mechanical
braking systems.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Lever/Lever
Mounting
(1) Missing, fractured, badly corroded, insecure or mounting unsatisfactory or
movement is obstructed.
X
(2) Travel is excessive or movement is obstructed.
X
(3) Seized or inoperative.
X
(4) Parking brake ratchet not holding correctly. Excessive wear at lever pivot or ratchet
mechanism.
X
(5) Excessive movement of lever indicating incorrect adjustment.
X
02 Pawl
Mechanism/
safety guard
(1) Missing, worn, insecure, damaged or sticking.
(2) Missing, fractured, badly corroded, insecure or mounting unsatisfactory.
X
X
X
( 3 ) When the brake is applied, knocking the top or sides of the lever releases the
brake.
X
(4) Cracked or damaged control, excessive wear.
X
HCV TESTERS MANUAL V 1.0 Page | 43

13
13
SERVICE BRAKE PEDAL
Method of Testing
1. Check the anti-slip provisions on the pedal pad.
2. Move the pedal from side to side and examine the condition of the pedal pivot bearing/bush.
3. Depress the pedal to check for fouling on parts of the vehicle.
4. Release the handbrake, depress the pedal fully and check the position of the back of the pedal relative to the floor
(hydraulic systems only).
5. Check the fixing of the pedal pad to the pedal and the fixing of the pedal to the operating lever.
6. Examine the condition of the pedal.
NOTES
(1) Before carrying out this inspection chock the road wheels.
(2) Brake pedals should not be rejected for not having a pedal rubber if they were never designed to have
one.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Service Brake Pedal
Anti-slip provision
(1) Anti-slip provision on brake pedal missing, loose or worn smooth X
02 Service Brake Pedal
Mounting
(1) Worn, insecure or badly corroded. X
03 Service Brake Pedal
Travel
(1) Insufficient clearance between the back of the pedal and the floor
of the cab (Hydraulic Systems only).
(2) Pedal travel is obstructed, excessive or insufficient reserve travel.
X
X
HCV TESTERS MANUAL V 1.0 Page | 44

14
SERVICE BRAKE OPERATION
Method of Testing
1. For brake systems using air or vacuum, note the reading on the gauge and then fully depress the brake pedal and
keep it depressed. Note the gauge reading whilst this is being done with the engine stopped. See Note 1.
2. For hydraulic systems, fully depress the pedal and keep it depressed under a steady pressure. Note whether the
pedal tends to creep down.
3. For hydraulic systems, depress the pedal and note whether there is sponginess.
4. On some vehicles the action of the brakes is assisted by vacuum from the engine. Note whether this is operating
satisfactorily by partially depressing the pedal, starting the engine and noting whether the pedal can be felt to dip.
5. In the case of a trailer fitted with ABS/EBS, attach the ISO 7638 connector and ensure that the light follows the correct
sequence for the trailer concerned.
NOTES
(1) If the vehicle is fitted with vacuum or air brakes and does not have a gauge this inspection
cannot be carried out.
In such cases the system is to be examined for leaks during the under-vehicle examination.
(2) Vehicles and trailers on which ABS/EBS are mandatory:
TYPE OF VEHICLE
APPLICABLE DATES
An “appropriate motor vehicle” All ABS/EBS
TYPE OF BRAKING
SYSTEM
A vehicle plated for 44 tonne
GCW
A tractor unit plated for 46
tonne GCW
All motor vehicles with a
DGVW greater than 3.5 tonnes
All
All
First registered on or after 1 st
June 2011.
ABS/EBS
EBS
ABS/EBS
All trailers with a DGVW
greater than 3.5 tonnes
First licensed in the State on or
after 1 st June 2011.
ABS/EBS
HCV TESTERS MANUAL V 1.0 Page | 45

14
14
SERVICE BRAKE OPERATION Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Service brake
operation
(1) When pedal is held depressed, air or vacuum gauge reading decreases.
(2) If in hydraulic systems, pedal tends to creep down, or is felt to be spongy
when held depressed.
(3) If, in systems assisted by vacuum from engine, with the pedal depressed
and the engine started, no dip is felt in brake pedal.
(4) On two or three axle mechanically propelled vehicles, brakes are not
acting on all wheels.
(5) On four or more axle mechanically propelled vehicles, brakes are not
acting on at least three quarters of axles.
(6) The brake anti-lock (ABS) warning lamp does not follow its correct
sequence of operation.
(7) EBS warning light does not follow the correct sequence.
(8) Servo unit is defective or ineffective.
(9) Master cylinder insecure, defective or leaking.
(10) ABS/EBS not fitted where mandatory.
Note:
X
X
X
X
X
X
X
X
X
X
ABS/EBS is mandatory on an appropriate motor vehicle or an appropriate semi–
trailer as defined in Note 1 of the Introduction of this manual.
Tractor Units
If the Weights and Dimensions plate of a Three Axle Tractor Unit shows a
Maximum Permitted Laden Weight of Combination of 44 or 46 tonnes, qualifying
conditions 5, 6 or 7 under ‘method of testing’ on page 18 of this manual must be
met (as required).
HCV TESTERS MANUAL V 1.0 Page | 46

15
AIR/VACUUM HAND CONTROL/VALVES
Method of Testing
1. Examine the control for:
(a) fractures, damage or excessive corrosion.
(b) security to operating valve spindle.
(c) amount of travel.
(d) loose connections or leaks.
(e) correct fitment.
2. Check each valve unit for security of its mounting and its connections.
For electronic parking brake:
3. Visually inspect the electronic parking brake controls while the braking system is operated.
NOTES
(1) This inspection applies to all valves fitted in the cab to control emergency/secondary
brakes, parking brakes, spring brakes or lock actuators.
(2) On trailers, this inspection applies to the trailer parking brake valve.
(3) In some cases it is not possible to check these items completely from the cab position, but only
to obtain an indication of their condition. If a defect is suspected which cannot be verified from
the cab position, the inspection must be continued from a position underneath the vehicle.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Air/Vacuum Hand Control (1) Missing, worn, insecure, damaged, sticking, defective or leaking.
(2) Cannot be moved over its full travel.
X
X
02 Hand-operated brake control
valve
(1) Connections loose or leak in system.
(2) Control insecure on valve spindle or valve unit insecure.
(3) Unsatisfactory operation.
(4) Malfunction of control valve.
X
X
X
X
03 Electronic Park Brake (where
fitted)
(1) Activator missing, damaged or inoperative X
HCV TESTERS MANUAL V 1.0 Page | 47

Section 16
Not Applicable
HCV TESTERS MANUAL V 1.0 Page | 48

17
STEERING WHEEL & STEERING PLAY
Method of Testing
1. With the road wheels in the straight-ahead position, lightly turn the steering wheel to the left and right as far as
possible without moving the road wheels, and note the amount of free play.
2. Attempt to lift the steering wheel in line with the steering column and note any movement at the centre of the steering
wheel or of the steering column.
3. Push steering wheel away and pull it towards the body and note the movement of the steering column radially and its
security of mounting.
4. Examine the universal joints/flexible couplings for wear, security or deterioration.
5. Examine steering lock where fitted.
6. Examine if there has been an unsafe repair or modification carried out to the steering wheel/column/shaft or to the
universal joint/clamp.
NOTES
(1) Where a steering mechanism is fitted with flexible couplings care must be taken to distinguish
between play due to wear and apparent play due to the construction of the mechanism.
(2) Some vehicles have flexible top bearings for the steering column in which case more than average
movement is permissible.
(3) An unsafe repair or modification carried out to the steering wheel/column/shaft or to the universal
joint/clamp may require a modifications report to be presented as per Section 71 of this manual.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Steering Box– Worm &
Roller or Recirculating Ball
(1) Excessive rotational play (c. 20°). X X
02 Rack and Pinion (1) Excessive rotational play (c. 5°). X
03 Steering Wheel/
Column/Shaft
(1) Excessive end float.
(2) Bushes/Bearings/Mounting brackets missing, worn, damaged
or insecure.
X
X
(3) Loose or badly mounted.
(4) Cracked or bent. Broken, missing or loose steering wheel,
spokes, hub, rim or retaining device. Shear pin in telescopic
column broken.
(5) Unsafe Repair or Modification
X
X
X
X
X
04 Universal Joint/Clamp (1) Damaged, worn, insecure or badly deteriorated.
(2) Unsafe Repair or Modification
X
X
X
X
Notes:
Excessive rotational play (measured at wheel ramp)
Steering Box
20° on 15” (381mm) Diameter wheel = 67mm on rim
20° on 18” (457mm) Diameter wheel = 80mm on rim
20° on 21” (533mm) Diameter wheel = 93mm on rim
20° on 24” (610mm) Diameter wheel = 107mm on rim
Rack and Pinion 5° on 15” (381mm) Diameter wheel = 17mm on rim
5° on 18” (457mm) Diameter wheel = 20mm on rim
5° on 21” (533mm) Diameter wheel = 23mm on rim
5° on 24” (610mm) Diameter wheel = 27mm on rim
HCV TESTERS MANUAL V 1.0 Page | 49

18
WARNING TRIANGLE (Mechanically Propelled Vehicles)
Method of Testing
Check that a warning triangle as shown in either of the diagrams that follow is being carried in the case of;
1. All N2, N3 category vehicles.
2. Category M3 vehicles first registered on or after 1 st January 2010.
NOTES
(1) These requirements do not apply to motor caravans.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Warning Triangle (1) Not carried.
X
X
(2) Not in good condition
X
X
UNECE Regulation 27
HCV TESTERS MANUAL V 1.0 Page | 50

18
WARNING TRIANGLE (MECHANICALLY PROPELLED VEHICLES)
HCV TESTERS MANUAL V 1.0 Page | 51

19
DOORS/LOCKS/ANTI-THEFT DEVICES
Method of Testing
Examine the general condition of the driver and passenger doors.
1. Open each door and by lifting the bottom of the door check the play in the door hinges.
Check the security of door locks and receivers.
2. Close the door and, without operating the door release mechanism, note whether the door primary and secondary
catches hold the door closed.
3. By opening and closing each door note whether the door pillars are sound.
4. If the vehicle is fitted with sliding doors and/or power operated doors examine the condition of the runners and
tracks and actuating mechanism.
5. Check anti-theft devices (except in the case of diesel powered large public service vehicles fitted with power doors).
6. Operate any power door or doors and check that the safety devices are working.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Doors (1) Door missing.
(2) Faulty hinges or check straps.
(3) Worn locks.
(4) Unsafe, not working, door cannot be shut or opened properly or
is liable to open on its own.
(5) Catches missing, loose or not working.
(6) Insecure receivers or locks.
X
X
X
X
X
X
X
X
X
02 Sliding Doors or power
doors
(1) Runners, tracks, or actuating mechanism so badly worn or
defective that the door does not open or close properly.
(2) Door missing.
(3) Safety devices not working or defective.
X
X
X
03 Anti-Theft Device (1) Doors not capable of being locked by a key or other means
operated by a key or combination lock to prevent vehicle
movement are not provided (e.g. ignition key). Electronic locks
are acceptable.
X
04 Steering Lock (where
originally fitted)
(1) Excessive wear or jamming of lock/barrel/key mechanism of a
steering lock.
(2) Steering lock not working.
(3) Steering lock missing. X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 52

20
ELECTRICAL SYSTEM
Method of Testing
Electrical System
1. If accessible, examine the battery for security and leaks.
2. Examine all visible electrical wiring connections and components for condition, security and position.
3. Examine fan belt/alternator/dynamo drive.
4. With engine running, check instrument panel for any red warning lights illuminated.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Battery (1) Mounting unsatisfactory.
(2) Risk of short-circuiting.
(3) Leakages.
X
X
X
X
X
02 Radio Suppression (1) High tension leads are not suppressed. X
03 Wiring, cables and connections (1) Mounting unsatisfactory.
X
X
X
(2) Insecure or insulation damaged.
X
X
X
04 Generator or alternator (1) Loose or mounting unsatisfactory.
X
X
(2) Not charging.
X
X
05 Warning light and/or
Ammeter or Voltmeter
(1) Not working. X
06 Fuse/s (1) Substituted by anything other than the specified rated
fuse.
X
X
07 Ignition Switch (1) Faulty. X
08 Fan Belt (1) Loose, badly worn, or liable to failure. X X
09 General (1) Any red warning light on instrument panel. X X
HCV TESTERS MANUAL V 1.0 Page | 53

21
RUNNING BOARDS AND STEPS
Method of Testing
1. Examine the condition and security of the running boards (where fitted).
2. Examine the condition and security of the steps (or step rings) to the cab.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Running Boards, Arches, or
Steps
(1) Missing/unsafe or liable to cause injury to users. X X
HCV TESTERS MANUAL V 1.0 Page | 54

22
22
CAB AND BODYWORK
Method of Testing
1. Examine the body structure for rust or damage or any inessential projections which might cause injury. Examine
the cab for rust or damage and check the cab mountings by rocking and pushing the cab where necessary. On
tilt cabs check the retention and/ or locking devices for security.
2. Check that fumes are unlikely to enter the cab e.g. gear lever rubber boot should not be torn.
3. Check from both sides of the vehicle that the body is sitting squarely on the chassis.
4. Examine the following items for security, freedom from fracture or distortion, serious structural corrosion,
excessive wear or damage and check that none is missing:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
fixings (e.g. brackets) securing the body to the cross members or chassis;
fixings (e.g. brackets) securing cross or longitudinal members to the chassis;
securing bolts or rivets for the above fixings;
twist locks and swap body retaining devices;
parts of the body designed to carry or contain the load including the floor and main support pillars;
cross and longitudinal members;
hinges, locking and retaining devices of drop sides, tail boards and loading doors;
body hinges.
5. Examine all wings and other similar devices to see that they are in position and that they are:
(a)
(b)
(c)
(d)
(e)
securely fixed;
not badly affected by corrosion;
free from tears and jagged edges;
not rubbing on a tyre, (except special spray suppression devices e.g. “cats whiskers”.)
spray suppression equipment is European type approval marked.
6. Examine tipping/lifting gear for security, serious leaks or obvious defects in valves. Examine bonnet lock and
safety catch.
7. Examine bumper bars for security, jagged edges or damage that could cause injury. Examine condition of any
internal wheel arches.
8. Examine if there has been an unsafe repair or modification carried out to the cab or body structure.
9. Where fitted, examine that ventilation system is fully operational and that where a heating system is fitted that
this heating system is such that it can blow warm air into the vehicle and demist the windscreen.
10. In the case of passenger vehicles check:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
All body panels including engine and luggage compartment covers/doors, access flaps, for presence, rust,
security, jagged edges or inessential projections.
The body structure for rust, cracks, damage or insecurity.
Entrance/exit steps, staircases, gangways and anti-slip provisions for deterioration and security.
That gangways are free from protrusions or obstructions that are likely to cause injury.
That handrails, handholds, luggage racks are secure and free of jagged edges.
That (other than on an open deck passenger vehicle) water or fumes are unlikely to enter the vehicle.
That in the case of an articulated bus, the body bellows is not torn, deteriorated or damaged.
That engine sound proofing material is secure and free from contamination by oil (risk of fire).
If fitted, ensure that the heating and ventilation system is fully operational, such that it can blow warm air
into the passenger area of the vehicle.
That spray suppression equipment is European type approval marked.
HCV TESTERS MANUAL V 1.0 Page | 55

22
CAB AND BODYWORK Cont…
NOTES
1. Corrosion
The effect of corrosion on the safety of the vehicle depends on its extent and the location where it has
occurred.
A small amount of corrosion on an important part of the vehicle structure can make a vehicle unsafe where it
destroys the continuity of the load bearing structure. On the other hand, heavy corrosion of unimportant
sections may have no effect on the vehicle safety.
2. Detecting Rust in Vehicles
Since advanced rust is almost always associated with an eruption of oxidised metal and pitting or bubbling of
paint, a visual inspection is usually adequate to determine its presence. However, this method may not be
adequate in all cases. In underbody areas prone to rust, such as steering and suspension mounting points and
major structural components which include chassis, floor, structural sills and sub frames, the presence of rust
should be checked using thumb pressure or by tapping with a hammer or other appropriate tools. Corrosion
affected heavy gauge metal may be tapped harder than light gauge, but unwarranted force and damage must
be avoided. In using this technique, care should be taken to avoid damage to panels or paint work not rust
affected in any way. When checking for advanced rust, particular attention should be paid to seam welds and
spot welds. These frequently corrode through from the interior and can result in the eventual detachment of
panels. Any panel which is made insecure by such corrosion must be repaired even if it is an area of the
component where rust holes are not an immediate danger.
3. Classification of Rust
The extent of corrosion can range from light surface rust to the total breakdown of parent metal.
In general, the formation of rust and resultant loss of metal occurs in areas which retain moisture, because of
a build-up of road dirt and mud etc. The extent of corrosion is classified in three stages.
Stage 1 – Surface Rust
Light, powdery corrosion on the surface of a section of metal is termed surface rust.
Surface rust can occur on or behind any body panel, particularly if the protective coating is scratched or
damaged.
Stage 2 – Advanced Rust
Surface rust, if left unattended, will develop into an advanced form of corrosion which can usually be seen
as an eruption of oxidised metal, either on bare metal or under paint. This eruption occurs because the rust
reaction involves an increase in volume which causes pitting or bubbling of paint.
An example of a section affected by advanced rust is illustrated below.
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22
CAB AND BODYWORK Cont…
Stage 3 – Extensive Rust
The final stage of the corrosion process is the formation of a heavy encrustation of oxidised metal which
completely replaces the parent metal. This results in a hole or series of holes in the body panel or structural
member of the vehicle when the rust is removed. This category of rust can usually only be rectified by
replacement of the affected body panels and parts. The illustration below shows a section affected by
extensive rust.
4. Vehicle Structures
Vehicle structural components can be categorised according to their importance to safety.
Primary Structure
The primary structure includes any structure or component which, if it collapsed, would render the vehicle
uncontrollable or would considerably reduce occupant safety in a crash/collision situation. Only surface rust
is acceptable in primary structure components. Any part of a load bearing member or load bearing panelling
should be considered a reason for failure if it is weakened by corrosion to the extent that:
By finger and thumb pressure it does not feel rigid, or
It crumbles to leave a hole, or
When tapped there is penetration, or it causes the metal to crumble or disintegrate.
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22
CAB AND BODYWORK Cont…
Examples of components in this category are illustrated below.
Typical Primary Structure Components
The weakening of any of these components can lead either to a crash or make the outcome of a crash
very much worse.
(1) Main Structural Members such as subframes and chassis rails.
(2) Suspension mounting areas.
(3) Steering box mounting point.
(4) Door sills and pillars.
(5) Door hinge mounting areas.
(6) Seat and seat belt anchorage points.
(7) All floor panels.
(8) Bulk head.
(9) Body Structural Members.
Secondary Structure
The second category includes any structure or component which, if it collapsed, would not immediately affect
a vehicle’s controllability. Normally, surface rust or advanced rust in these structures or components would
not make the vehicle unsafe. Extensive rust in these components is usually either hazardous to people in or
near the vehicle because of its sharp edges or because exhaust fumes may escape into the vehicle. In such
cases, this type of rust would make the vehicle unsafe.
Typical Secondary Components
Extensive rust in these components can be hazardous to vehicle occupants and other road users.
1 Mudguards or bumpers.
2 Roof.
3 Bootlid, bonnet and doors (areas within 100 mm of mounting and locking points are primary structures
and must be free of advanced or extensive rust).
4 Exhaust system (vehicle may fail to meet noise emission standards if exhaust system is deteriorated
due to rust).
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22
CAB AND BODYWORK Cont…
5. How to determine if a vehicle is safe
TYPE OF CORROSION
CATEGORY OF STRUCTURE
Primary
Secondary
Surface Rust Acceptable Acceptable
Advanced Rust Not Acceptable Acceptable*
Extensive Rust Not Acceptable Not Acceptable**
* Areas within 100 mm of hinges and locks (e.g. bootlid, bonnet and doors), are considered primary structures and must be free of
advanced and extensive rust.
** Extensive rust is not acceptable in secondary components, if it renders the component hazardous to persons in or near the vehicle eg.
sharp edges, loose panels, or in the case of exhaust fumes, leakage of exhaust gases into the passenger compartment.
6. Repairs
Repairs made to primary structure components solely by using body filling compounds are not acceptable. Repairs should
be made by completely welding in new metal of the same gauge as that of the manufactured component. However, plastic
filler or fibreglass can be used to cosmetically smooth a non-structural component.
Extensive rust in structural members can only be repaired by replacing the affected member or by completely removing all
rusted material and reinforcing it so that the original strength of the affected structural member is re-established.
7. An unsafe repair or modification
An unsafe repair or modification carried out to the cab or body structure may require a modifications report to be presented
as per Section 71 of this manual.
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22
CAB AND BODYWORK Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Body Structure (1) Advanced rust, cracked, damage or insecure.
X X
(2) Advanced rust or damage in bracing and support spars.
(3) Advanced rust or damage in the body panels or floor.
(4) Unsafe repair or modification.
02 Cab (1) Advanced rust or damage in door(s), pillars, floor or mounting area.
(2) Cab mountings, worn, insecure or interfering with control functions.
(3) A retention and/or locking device on a tilt cab defective or missing.
(4) Fumes entering cab.
(5) Unsafe repair or modification.
03 Body Security (1) Body not located squarely on the chassis.
(2) Body fixings (e.g. brackets) missing, or so loose, worn or damaged as to
be likely to cause danger.
(3) Cross or longitudinal members so deteriorated or damaged to such an
extent that it would be dangerous to carry a load.
04 Body Condition (1) Body panels, pillars or floor deteriorated or damaged to such an extent
that it would be dangerous to carry a load.
(2) Cross or longitudinal members in such condition that the
integrity of the body is seriously affected.
(3) Defective hinges, twist locks, doors or retaining devices. X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
05 Wings/Mudflaps or
other Items
(1) Insecurely mounted.
(2) Liable to foul other vehicle components or endanger road users.
X
X
X
X
(3) Wings fitted in two halves on rear of tractor units not fitted with covering
for use when the trailer is disconnected.
X
(4) Split, missing, torn or damaged.
X
X
(5) Rusted through.
X
X
06 Tipping or Lifting
Gear
(1) Tipping gear on/off valve defective.
(2) Tipping gear insecurely mounted.
X
X
X
X
(3) Serious leak.
X
(4) Tipping gear pivots excessively worn.
X
07 Bumper Bar (1) Bumper bar missing, insecure, has jagged edges or damaged in a
manner likely to cause injury.
X X X
08 Bonnet locking
mechanism (front
opening)
(1) Main lock not working.
(2) Safety catch not working.
X
X
X
X
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22
2
CAB AND BODYWORK Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
09 Boot (1) Cannot be shut or opened. X X
10 Inessential
projections
(1) Any projecting item liable to injure a pedestrian or other road user. X
11 Tanker body (1) Leaking or evidence of leakage.* X X
12 Heating System/
Ventilation System
(where fitted) –
including for the
passenger area of the
vehicle
(1) Defective operation.
(2) Heater Fan inoperative (not heating/working).
X
X
Passenger vehicles
(additional to above)
13 Body Condition
(1) Body panels, luggage compartment doors, flaps, covers, missing,
insecure, badly deteriorated or with jagged edges or inessential
projections.
X
X
(2) Defective hinges or devices for retaining any of the above devices in the
closed position.
X
X
(3) Defective hinges or devices for retaining the luggage compartment in the
open position.
X
X
14 Body Integrity (1) Leaks permitting the entry of water or fumes into the driver or
passenger compartment (other than open deck vehicles).
(2) Bellows on articulated bus torn, deteriorated or damaged.
X
X
X
X
15 Handrails and
Handholds
(1) Unsafe or obviously missing. X X
16 Luggage Racks (1) Insecure. X X
17 Gangways (1) Floor deteriorated or floor covering loose or so worn or damaged as
to be dangerous. Beading loose or trap doors insecure or so fitted
as to be likely to cause injury or an accident.
X
X
18 Entrance/Exit/Steps
Staircase
(1) Missing, insecure, deteriorated or step linkage inoperative. X X
19 Anti-Slip Provisions (1) Unsafe – Liable to cause injury to users. X X
20 Engine Sound Proof
Material
(1) Contaminated with oil (e.g. dripping on to ground). X X
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24
TYRE CONDITION
Method of Testing
1. Check whether the tyre appears to have been recut.
2. Check visually that the tyre is not seriously under-inflated. This is a major factor in load capability. If checked
visually, this check is done with the axle loaded to its Gross Design Weight.
3. Check tyres on twin wheels for wall contact [see note (2)].
4. Examine the tyre for:
(a) any cut or break in the fabric,
(b) any lump or bulge,
(c) any exposure of the ply or cord structure.
5. Examine the valve stem for distortion or chafing.
NOTES
(1) It will not always be possible to see the complete tyre on a vehicle from ground level, especially
on twin wheels and on some vehicles where the body shrouds part of the tyres. In such cases the
vehicle should be moved to expose the hidden parts of tyres, or the examination should be
completed from a position under the vehicle.
(2) Side wall contact on twin wheels is unacceptable if caused by:
(i) under-inflation;
(ii) incorrect wheel or tyre fitment.
(3) Examination of tyres will be confined to those fitted to the road wheels. Spare wheel tyres will not
be examined. If, however, any defect on a tyre carried on a spare wheel of the vehicle is seen, the
driver should be advised.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Tyre Structure (1) Evidence of any recutting of tread pattern where tyre design does not
permit this.
(2) Seriously under-inflated or cannot be inflated.
(3) Wall contact on twin wheel fitment [see note (2) above].
X
X
X
X
X
(4) Rupture in or exposure of ply or cord structure, tread lifting, lump or bulge,
weakness in cord structure, or tread distortion.
(5) Any tyre having a “flat spot” where the tread is worn through to the fabric.
X
X
X
X
02 Valve (1) Obvious damage or distortion of the valve stem.
(2) Valve stem chafing against valve hole.
X
X
X
X
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25
25
TYRE SPECIFICATION
Method of Testing
1. Check that the sizes and ply ratings of the tyres are such that they will carry the loads specified in the Weights in
Ireland column on the Vehicle Weights Plate at the maximum legal speed permitted for the vehicle. The additional
load-speed index may also be used when making this determination. (Refer to tyre load data tables made
available by the RSA).
In the case of category N2 & N3 vehicles only, where it is apparent that a vehicle has its speed restricted, either
by design (as certified by the manufacturer or his authorised Irish Distributor), or via the speed limiter setting, such
that it is incapable of exceeding the 90km/h national speed limit in force for these vehicle categories; tyre bonus
loads may apply. Note that bonus loads only apply on the basis of the nominal load-speed index stamped on the
tyre sidewall. (Refer to tyre bonus load data tables made available by the RSA).
2. Examine all the tyres fitted and note the type of structure (radial or cross-ply or bias-belted) and the nominal size
of tyres.
3. All tyres on the same axle must be of the same structure and nominal size.
4. Tyres on an axle may be of different structures and nominal sizes to those on another axle with the following
exceptions:
All tyres on all steered axles must have the same structure.
On a two axle motor vehicle where each axle is fitted with single wheels, then all the tyres must be of the same
structure, otherwise then the only tyre combination that is allowed is cross-ply in the front and radial at the
rear. This does not apply to an axle on which wide single tyres with a road contact width of more than 300mm
are fitted.
5. Check the tyre speed rating (table on the page that follows).
6. Check that each tyre is E- or e-marked similar to the examples on page 65.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Tyre
Fitment
(1) Tyres fitted to individual axles including twin wheels are not of the same type (i.e.
cross ply or radial ply) or size.
(2) A tyre on a steerable axle which is not of the same structure as any other tyre on
any steerable axle.
(3) Are incorrectly matched with the wheels.
(4) On a two axle motor vehicle fitted with single tyres on both axles where radial ply
tyres are fitted to the front wheels but not to the rear wheels. [This is, however,
permissible in the case of vehicles with rear twin wheels or with wide tyres with a
contact area exceeding 300mm (12” in width)].
(5) Insufficient speed index or load capacity for axle weight specified in Weight in
Ireland column on the vehicle weights plate.
(6) A tyre is not E- or e-marked.
(7) "TRAILER USE ONLY" marked on any tyre of a vehicle other than a trailer.
X
X
X
X
X
X
X
X
X
X
NOTES
(1) It will not always be possible to see the complete tyre on a vehicle from ground level, especially on
twin wheels and some vehicles where the body shrouds part of the tyres. In such cases the vehicle
should be moved to expose the hidden parts of tyres, or the examination should be completed from a
position under the vehicle.
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25
TYRE SPECIFICATION Cont…
Tyre-Sidewall Markings showing additional load-speed index
Tyre Speed rating table
Code km/h Code km/h
A1 5 L 120
A2 10 M 130
A3 15 N 140
A4 20 P 150
A5 25 Q 160
A6 30 R 170
A7 35 S 180
A8 40 T 190
B 50 U 200
C 60 H 210
D 65 V 240
E 70 Z over 240
F 80 W 270
G 90 (W) over 270
J 100 Y 300
K 110 (Y) over 300
The speed rating of a tyre indicated by speed symbol which is made up of a single letter or an A with one number.
It indicates the maximum speed at which the tyre can carry a load corresponding to its Load Index.
E-mark
All tyres sold for road use in the EU after July 1997 must carry an e/E-mark. The mark itself is either an upper case “E” or
lower case “e” - followed by a number in a circle or rectangle, followed by a further number. An (upper case)”E” indicates that
the tyre is certified to comply with the dimensional, performance and marking requirements of ECE Regulation 30 (primarily
M1, O1, O2), Regulation 54 (primarily M2, M3, N, O3, O4) or Regulation 109 (retreaded tyres for commercial vehicles and
their trailers). A (lower case) “e” indicates that the tyre is certified to comply with the dimensional, performance and marking
requirements of Directive 92/23/EEC. The number in the circle or rectangle denotes the country code of the government that
granted the type approval. The last number outside the circle or rectangle is the number of the type approval certificate
issued for that particular tyre size and type.
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25
TYRE SPECIFICATION Cont…
ARRANGEMENT OF APPROVAL MARK
OR
UNECE 30 APPROVAL MARK
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26
26
TYRE TREAD
Method of Testing
1. Check with a tyre tread depth gauge, that the central three-quarters of the tread pattern has a depth of at least the
minimum legal requirement (currently 1.6 millimetres) around the full circumference of the tyre. It will be necessary
to move the vehicle to ensure the full circumference of each tyre is checked.
NOTES
(1) Where the pattern is interrupted by tread wear indicators but has at least 1.6mm overall tread depth
the tyre concerned should not be failed for inadequate tread-depth.
(2) Driver to be advised if tyre tread is less than 3mm deep. Although legal to a tread depth of 1.6mm,
anything less than 3mm presents a risk of greatly reduced wet traction.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Depth of tread (1) Depth of less than the minimum legal requirement (currently 1.6mm)
in the central three-quarters of the tread pattern.
X
X
ADVISORY NOTICE
Advisory Notice for tread depth less than 3mm.
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27
27
WHEELS
Method of Testing
1. Make an inspection of each part of the road wheel, paying particular attention to whether there is:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
any fracture of flanges,
any fracture on tyre retaining rings,
any welding breaking away,
any stud hole badly worn,
any wheel stud missing,
any wheel nut missing,
any wheel nut loose,
any tyre retaining ring, the ends of which are butting,
any wheel badly distorted.
2. Check that the correct type of wheel and wheel nut is fitted.
NOTES
(1) It is not always possible to see the complete road wheel on a vehicle from ground level, especially
on twin wheels and on some vehicles where the body shrouds part of the wheels. In such cases the
vehicle should be moved to expose the hidden parts of wheels or the examination should be
completed from a position under the vehicle.
(2) Where wheel embellishers or hub caps are fitted they should be removed by the vehicle operator
prior to the test. Where an owner has not removed or refuses to allow the wheel embellishers or hub
caps of the vehicle to be removed, then a CVR test may be carried out but a pass statement will not
be issued.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wheel or wheel with split rim (1) Any crack or defective weld.
(2) More than 13mm (½”) askew or buckled.
(3) Turned the wrong way or incorrectly fitted.
(4) Out of balance.
(5) Damaged.
(6) Incorrect size or incorrect wheel type fitted.
(7) Any spoke or wheel component in such a condition that there is
a danger of failure.
X
X
X
X
X
X
X
X
X
X
X
02 Wheel embellishers or hub
caps
(8) Any tyre retaining ring damaged or fitted in a manner likely to
cause danger.
(1) Not removed (See Note 2 above) X
03 Studs/nuts and stud holes (1) Elongated, damaged or threads stripped or crossed.
X
X
X
(2) Any stud or nut missing or loose.
(3) Any stud hole, stud, or nut in such a condition that there is a
danger the wheel will come loose.
(4) Wheel nut incorrectly fitted.
(5) Incorrect wheel nut fitted.
(6) Stud holes worn, elongated, or damaged.
X
X
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 67

28
28
REFLECTORS AND REAR AND SIDE MARKINGS
Method of Testing:
Rear Reflectors (required on all vehicles)
1. Check that two red reflectors are fitted to the rear of the vehicle with one on each side of the centre line of
the vehicle and that on combinations over 12.19m (40’) they are triangular in shape.
2. Check that each reflector is so positioned that:
(a) It is vertical and facing squarely to the rear;
(b) No part of the vehicle extends laterally more than 16” beyond reflector;
(c) No part of the reflecting area of one reflector is less than 533mm (21”) from any part of the reflecting
area of the other reflector;
(d) It is not more than 762mm (2’ 6”) from the extreme rear of the vehicle;
(e) It has no part of the reflecting area higher than that allowed, for the vehicle being tested (see page 70);
(f) It has no part of the reflecting area lower than that allowed, for the vehicle being tested (see page 70);
(g) It is at the same height as the red reflector on the other side of the vehicle.
Side Reflectors (if fitted)
3. Side reflectors if fitted must be amber in colour.
Rear and Side Markings
4. Required on goods vehicles and trailers having a design gross vehicle weight exceeding 3,500kg. Required on any
trailer in combination of vehicles where such combination or such combination and its load exceeds 11 metres in
overall length.
Not required on motor caravans, ambulances or buses.
Notes:
Either Irish markings UN ECE Regulation 104 markings are acceptable.
Tape used for retro-reflective marking to UN ECE 104 must be type approved and carry E markings at least
every 50cm.
5. Check that sufficient prescribed rear and side markings are securely attached to the vehicle (see diagram) and:
(a) Are fitted so that every part is clearly visible when viewed from the rear or side respectively;
(b) Every part is facing substantially square to the rear or side as the case may be and forms a V at the
centre (unless fitted in two halves) see leaflet RT- 16.
(c) No part of a rear marking extends beyond the outermost part of the vehicle on either side and the
marking is symmetrical about the longitudinal axis of the vehicle.
(d) The spacing, area and positioning of the markings are correct.
Long Vehicle Signs
6. Check that a “Long Vehicle” sign of the type shown in diagram 1 or alternatively two signs of the type shown in
diagram 2 are fitted to the rear of combinations over 13 metres in length and are clearly visible. Rear trailer or semi
trailer markings to UNECE 70 with the words “LONG VEHICLE” are also acceptable.
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28
REFLECTORS AND REAR AND SIDE MARKINGS Cont…
Size, colour and wording of rear marking signs
Rear Marking Plates for Trailers & Semi-trailers
To UNECE Regulation 70
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28
28
REFLECTORS AND REAR AND SIDE MARKINGS Cont…
Extent of Display of Side Markings (Irish)
See diagrams below
The side marking must be displayed over not less than 75% of the length of a vehicle exclusive of:
(i) the sum of the diameters of wheels on the same side and,
(ii)
in the case of a trailer, the sum of the diameter of wheels on the same side and the length of the draw bar.
The side marking must also be displayed over not less than 75% of any distances between wheels on the same side of a
vehicle the centres of which are 2.2 metres or more apart.
Position of rear lamps on HCV’s, trailers, semi-trailers, and buses
HCV TESTERS MANUAL V 1.0 Page | 70

28
REFLECTORS AND REAR AND SIDE MARKINGS
Examples of UN ECE 104 Markings:
1. Side marking with strips
1.1. Retro-reflective marking materials installed on vehicles may be made up of an element or several elements
preferably continuously, parallel or as close as possible parallel to the ground. The same rule applies for
tractor units, semi-trailers and other vehicle combinations. A combination of vehicles and trailers marked and
unmarked in the sense of this Regulation is discouraged.
1.2. The mounting of the markings should identify as close as possible the entire length and width of the vehicle.
“Entire” means at least 80 per cent of the length and/or width.
1.3. In case of non-continuous strips the distance between single elements should be as small as possible and
should not exceed 50 per cent of the shortest element length.
1.4. Retro-reflective marking materials shall have a minimum height above the ground of at least 250mm and a
maximum height of 1,500mm. However, 2,100mm may be accepted in cases where technical conditions forbid the
compliance with the maximum value of 1,500mm.
2. Contour marking for the sides and rear (full contour marking mandatory on the rear of vehicles over 2.1
Metres wide)
2.1. The mounting of the contour markings should identify as close as possible the overall shape
of the vehicle to the side and rear.
2.2. In case of non-continuous strips, the distance between single elements should be as small as possible and
should not exceed 50 per cent of the shortest element length.
2.3. The lower part of the retro-reflective marking materials should have a minimum height above the ground of at
least 250mm and a maximum height of 1,500mm.
Specification of marking dimensions
1. Side and rear marking with strips
1.1. General.
The markings shall be made of strips of retro-reflective material.
1.2. Dimensions.
1.2.1. The width of a side and/or rear marking material shall be 50mm +10/-0mm (i.e. 50 - 60mm).
1.2.2. The minimum length of an element of a retro-reflective marking material shall be such that at least one
approval mark is visible.
NOTES
(1) Tape used for retro-reflective marking to UNECE 104 must be type approved and
carry E markings at least every 50cm.
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2
28
REFLECTORS AND REAR AND SIDE MARKINGS Cont…
Reflectors and rear and side markings UNECE markings
max 150cm 2
min. 25cm
*special cases 210
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28
REFLECTORS AND REAR AND SIDE MARKINGS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Rear
Reflectors
(1) One or both missing or ineffective, or dirty.
(2) Not red in colour.
(3) Seriously cracked or damaged.
(4) Incorrectly mounted (see diagram).
(5) Not matching in size and appearance.
(6) Insecurely mounted.
(7) More than 762mm (2’6”) from the extreme rear of vehicle.
(8) Not triangular on a trailer or semi-trailer where the combination is over
12.19 m (40’ long).
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
(9) Triangular reflectors fitted other than to a trailer.
Note (One piece retro-reflective type triangular reflectors are acceptable.)
X
X
02 Side
reflectors (if
fitted)
03 Rear and
side markings –
Irish
04 Rear Marking
–Irish
(1) Not amber in colour. X X
(1) Not fitted.
(2) Incorrect colour or design.
(3) Lower edge of marking is less than 600mm (24” approx.) above the ground.
(4) Lower edge of marking is more than 2m (78” approx.) above the ground.
(5) Marking is less than 150mm (6” approx.) in height.
(6) Retro-reflective or fluorescent material obviously not used.
(7) Damaged or in such condition that effectiveness is seriously reduced.
(8) Insecurely fitted.
(9) Irish side and UNECE rear markings fitted or UNECE side and Irish rear
markings fitted.
(1) Is fitted more than 600mm (24” approx.) from the extreme rear of the
vehicle (except in the case of the drawing component of an articulated
vehicle).
(2) Does not lie mainly in a horizontal plane.
(3) Fitted more than 300mm (12” approx.) in from the outer edge of the
vehicle.
(4) If fitted in two parts the two parts are not at the same height or the space
between them is more than 650mm (26” approx.)
(5) Area less than 3000 cm 2 (465 in 2 . Approx.)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 73

28
REFLECTORS AND REAR AND SIDE MARKINGS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
05 Side Marking
–Irish
(1) Marking is fitted more than 450mm (18” approx.) from the front or rear of
the vehicle (except in the case of the rear of the drawing component of an
articulated vehicle).
(2) If fitted in sections any section is less than 450mm (18” approx.) in length.
(3) Displayed over less than three quarters of the overall length of the vehicle
less the sum of the diameters the wheels (disregarding also the length of
the drawbar in the case of a trailer).
(4) Displayed over less than three quarters of distance between two adjacent
wheels (unless wheels are less than 2.2m (approx. 87” apart).
(5) Located more than 450mm (18” approx.) in from the side of the vehicle.
(6) Does not lie in a mainly horizontal plane.
X
X
X
X
X
X
06 Vehicle
Combination
over 13 metres
long
07 Rear and side
markings –
UNECE
08 Rear Marking
– UNECE
09 Side Marking
– UNECE
(1) For Irish spec signs, the “Long Vehicle” sign or signs of one of the types
shown in the diagram are not fitted.
(2) The “Long Vehicle” sign is not fitted horizontally and/ or between 350mm
and 2 metres above the ground.
(3) In a case where there are two “Long Vehicle” signs they are not at the
same height and as near as practicable to the outermost edges of the
vehicle.
(4) A “Long Vehicle” sign is damaged or in such condition that its effectiveness
is seriously reduced.
(5) Retro-reflective or fluorescent material is obviously not used.
Note: For UNECE markings, either yellow or white is acceptable for side
markings. Rear markings must be red.
(1) Not fitted.
(2) Incorrect colour or design.
(3) Damaged or in such condition that effectiveness is seriously reduced.
(4) For UNECE markings, material is not type approved to Regulation 104
(not E-marked).
(5) For UNECE markings, marking material is less than 50mm or more than
60mm wide.
(1) For UNECE 104 markings, the cumulative length is less than 80% of the
vehicle width and as close to the edges of the vehicle as is practical.
(2) UNECE rear markings not full contour marking for vehicle more than 2.1
metres wide.
(3) For UNECE markings, lower element is less than 250mm or greater than
1500mm above the ground.
(4) For UNECE markings, the upper element is more than 400mm lower than the
top of the vehicle.
(1) For UNECE side markings, is not contour marked (partial or full) on vehicles
over 6m in total length. Trailer length includes drawbar.
(2) For UNECE markings, lower element is less than 250mm or greater than
1500mm above the ground.
(3) For UNECE Contour markings upper element is more than 400mm lower
than the top of the vehicle.
(4) For UNECE 104 markings, the cumulative length is less than 80% of the
vehicle overall length.
(5) For UNECE markings is not within 600mm of each end of the vehicle.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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29
MALFUNCTION INDICATORS
Method of Testing
1. Where fitted, check the malfunction indicators for the engine, Airbags, Vehicle Stability Function (also known
as Electronic Stability Control), Anti-Lock Braking Systems (ABS/EBS), steering. Manufacturer’s check
sequence must be verified.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Airbags ( 1 ) Malfunction indicator not working or indicates a defect in
the system.
02 ‘Vehicle Stability Function’
(VSF) also known as Electronic
Stability Control
03 Anti-Lock Brake System
(ABS/EBS)
(1) Malfunction indicator (where fitted) not working or indicates
a defect in the system.
( 1 ) Malfunction indicator not working or indicates a defect in
the system.
X
X
X
04 Steering ( 1 ) Malfunction indicator not working or indicates a defect in
the system.
05 Engine (1) Malfunction indicator not working or indicates a defect in the
system.
X
X
ADVISORY NOTICE
Other warning light(s) illuminated.
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30
BRAKE FLUID
Method of Testing
1. Examine brake fluid reservoir for fluid level, leaks and condition of fluid.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Reservoir (1) Lower than 1/2 full or below manufacturers “minimum” level.
(2) Leaking or cap missing.
(3) Fluid obviously dirty or contaminated.
(4) Mounting unsatisfactory.
X
X
X
X
X
X
X
X
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31
SIDE GUARDS AND REAR UNDERRUN PROTECTION
Method of Inspection
Side Guards
1. For the purpose of the vehicle roadworthiness testing scheme side guards are required on goods vehicles, trailers or
semi-trailers exceeding a D.G.V.W. of 3,500kg first licensed in the Republic of Ireland on or after the 1 st day of January,
1986. They are required to give protection on any side of the vehicle where the distance between any two adjacent
axles exceeds 3 metres.
2. The following vehicles and trailers do not require side guards:
(a) a vehicle which by its construction is incapable of exceeding 25kph (15 mph);
(b) a side or rear tipper;
(c)
(d)
(e)
(f)
(g)
a vehicle, trailer or semi-trailer designed for refuse collection, street cleaning or for the collection or disposal of the
contents of gullies or cesspools;
the tractor unit of an articulated vehicle;
a vehicle or trailer designed to carry other vehicles loaded on it from the front or rear;
a vehicle with a load platform the upper surface of which is not more than 750mm from the ground along the
length for which protection is required;
a vehicle, trailer or semi-trailer specially designed and constructed to carry exceptionally long timber poles,
tree trunks, beams or girders.
For vehicles, trailers and semi-trailers that are required to have side guards check that the side guards are securely fitted,
free from cracks, corrosion, jagged edges or damage that would render the side guard ineffective or would endanger other
road users.
3. Check visually that the dimensions are correct – see pages 79 and 80.
4. Check that the side guards are fitted not more than 30mm inboard of the outermost tyre of the widest rear axle
(except near the foremost edge of the sideguard) and do not increase the overall width of the vehicle.
NOTES
(1) The provision of 3 metres is from centre to centre of axles.
(2) In the case of a vehicle, trailer or semi-trailer, designed solely for the carriage of a fluid
substance in a closed tank, which is permanently fitted to the vehicle or trailer and provided
with valves and hose or pipe connections for loading or unloading, the dimensions in the
attached sketch shall only apply in as far as is practicable.
(3) In the case of a vehicle, trailer or semi-trailer, which is fitted on one or both sides with an
extendable device to provide stability in operation, the dimensions in the attached sketch shall
only apply in so far as is practicable.
(4) In the case of a trailer with an extendable chassis the area to be protected by side guards
shall be determined when the chassis is at its minimum length.
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31
SIDE GUARDS AND REAR UNDERRUN PROTECTION
HCV TESTERS MANUAL V 1.0 Page | 78

31
SIDE GUARDS AND REAR UNDERRUN PROTECTION Cont…
Examples of Maximum and Minimum Dimensions for Sideguards for Vehicles
with Superstructure Wider than Tyres
HCV TESTERS MANUAL V 1.0 Page | 79

31
SIDE GUARDS AND REAR UNDERRUN PROTECTION Cont…
Examples of Maximum and Minimum Dimensions for Sideguards for Vehicles
with Superstructure Wider than Tyres
Dimensions in Millimetres
Single rail guards are required to be fitted with the same size front upright as shown for the twin rail guards on page 83. A single rail
guard open ended at the front is not acceptable under any circumstances. However, single rail guards could be accepted where the
front upright is substituted by a fixed item which would afford the same protection as a front upright.
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31
SIDE GUARDS AND REAR UNDERRUN PROTECTION Cont…
Method of Inspection
Rear Underrun Protection
1. For the purpose of the vehicle roadworthiness testing scheme a rear underrun protective device is required on
goods vehicles, trailers and semi-trailers exceeding a D.G.V.W. of 3,500kg and first licensed in the Republic of
Ireland on or after the 1 st day of January, 1986. The following vehicles do not require rear underrun protection
devices:
(a) A mechanically propelled vehicle which by its construction is incapable of exceeding 25kph (15 mph).
(b) The tractor unit of an articulated vehicle;
(c)
(d)
(e)
(f)
(g)
(h)
A vehicle or trailer fitted with apparatus specially designed for spreading material on road;
A vehicle or trailer which tips to the rear;
A vehicle or trailer specially designed and constructed to carry other vehicles loaded on it from the rear
(e.g. car transporter);
A concrete mixer;
Vehicle, trailer or semi-trailer specially designed and constructed to carry exceptionally long timber
poles, tree trunks, beams or girders;
Vehicle fitted with a tail lift which forms at least 1 metre of the floor at the rear.
2. For vehicles, trailers and semi-trailers that are required to be equipped with a rear underrun protective device check
that the device is securely fitted, free from cracks, corrosion, jagged or sharp edges or damage that would render the
rear guard ineffective or endanger other road users and that it has a ground clearance of not more than 550mm.
Check that the underrun device extends to within 100mm of the outer edge of the outermost tyres but not beyond this
edge. The outer edges of the device must be radiused to a curvature of 2.5mm or more and must not be bent to the
rear. The depth of the underrun device should be not less than 100mm (see page 83).
3. Where a vehicle required to be fitted with a rear underrun device cannot be practically fitted with a one piece device
it shall be fitted with two or more devices which comply with the clearance requirements in the diagram. Check that
the space between one device and the device adjacent to it in such a case is not more than 500mm.
HCV TESTERS MANUAL V 1.0 Page | 81

SIDE GUARDS AND REAR UNDERRUN PROTECTION Cont…
31
31
ITEM REASONS FOR FAILURE MiD MaD DD
01 Side Guards (Where
required– see method
of inspection)
(1) Not fitted to vehicle, trailer or semi-trailer where required by law.
(2) Dimensions incorrect (see pages 78-80).
(3) Insecure, cracked, corroded or has sharp or jagged edges.
(4) Damaged in such a manner that would endanger other road
users or render it ineffective.
X
X
X
X
X
X
X
X
(5) Outer surface not flat or corrugated horizontally.
X
X
(6) Fitted more than 30mm inboard of the outer edge of the
outermost tyre of the widest rear axle.
X
X
(7) Increases overall width of the vehicle.
X
X
02 Rear Underrun
Protection (Where
required – see method
of inspection)
(1) Not fitted to vehicle, trailer or semi-trailer where required by law.
(2) Dimensions incorrect (see page 83).
(3) Insecure, cracked, corroded or has sharp or jagged edges.
(4) Damaged in such a manner that would render it ineffective
or endanger other road users.
X
X
X
X
X
X
X
(5) Increases overall width of vehicle.
X
X
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31
SIDE GUARDS AND REAR UNDERRUN PROTECTION Cont…
2
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32
SPARE WHEEL AND CARRIER
Method of Inspection
1. Examine the spare wheel carrier, if fitted, for security and attachment to vehicle.
2. Examine the mounting points and the structure of the carrier to see that they are free from fractures.
3. If there is a spare wheel in the carrier, check that this is securely held.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Spare wheel carrier (if fitted) (1) Cracked or insecurely mounted. X
02 Spare Wheel (1) Insecurely mounted. X X
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33
RESERVOIRS/VALVES/MASTER CYLINDERS/CONNECTIONS
Method of Testing
Reservoirs (Air or Vacuum)
1. Examine reservoirs for security of mounting.
2. Check that the securing straps are free from cracks, fractures and excessive corrosion, and do not chafe reservoirs or
other fittings.
3. Check that reservoir capacity is not unduly reduced by dents.
4. With air pressure or vacuum built-up, check for leaks in the system.
5. Check reservoirs for oil or water contamination.
6. Where automatic drain valves are fitted check that they are working.
Servos (Air or Vacuum)
1. Examine servos for security of mounting.
2. Where an adjustment indicating rod is provided check that this indicates proper adjustment.
Valves (Air or Vacuum)
1. Examine all valves for security of mounting.
2. With brakes off and applied, check for leaks.
3. Check whether excessive discharges of oil are evident or occur from pedal exhaust valve, unloader valve and/or
governor valve.
4. Check that load sensing/brake proportioning valves are not damaged or inoperative. Check that the operating arm is
free to move and appears to be operating normally.
Master Cylinders and Reservoirs (Hydraulic)
1. Examine for security.
2. Check for leaks.
ABS/EBS
1. Check any sensors, valves or wiring for insecurity or damage.
In the case of vehicles showing a Maximum Permitted Laden Weight of Combination of 44 or 46 tonnes; these vehicles
are also required to satisfy qualifying conditions 5, 6 or 7 (as required) under ‘method of testing’ on page 18 of this
manual respectively.
2. In the case of mechanically propelled vehicles registered on or after 1 st June 2011 and trailers first licensed in Ireland on
or after 1 st June 2011, check that an anti-lock braking system (ABS or EBS) is fitted.
Note: The new braking requirements introduced since 1 st June 2011 do not apply to trailers designed and constructed
specifically to be towed by land tractors. These are known as Category R Trailers. If, however, anti-lock brakes have been
fitted to a trailer that is presented for a test, it is a legal requirement under existing Road Traffic legislation that they be
maintained in good and efficient working order and shall be properly adjusted.
NOTES
(1) It is not acceptable to remove an ABS/EBS system fitted to a vehicle or trailer/semitrailer.
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33
RESERVOIRS/VALVES/MASTER CYLINDERS/CONNECTIONS
Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Master cylinder/
servo
(1) Insecurely mounted/mounting panel cracked.
(2) Leaking or defective.
X
X
X
X
02 Valves (1) Insecurely mounted, leaking or defective.
(2) Excessive discharge of oil.
(3) Valve seized or inoperative.
03 Servos (1) Adjusting rod indicates adjustment is required.
(2) Not working, insecure or defective.
(3) Damaged, badly corroded or leaking.
X
X
X
X
X
X
X
X
X
X
X
04 Air/Vacuum
Reservoirs
(1) Obvious evidence of excessive oil or water in air brake system.
(2) Insecurely mounted, damaged or leaking.
X
X
X
X
(3) Securing straps damaged or corroded.
X
X
(4) Securing straps chafing reservoir or other fittings.
X
X
05 Load sensing and
brake proportioning
valves/brackets
(1) Damaged, inoperative, missing, or not functioning correctly.
Defective linkage, incorrect adjustment, seized, not working.
(2) Data plate missing (where originally fitted) or data illegible or not in
accordance with requirements.
X
X
X
06 ABS/EBS
Components or Wiring
(1) Any component or wiring missing, insecure, damaged or not
operating.
X
(2) ABS/EBS removed or disabled.
X
(3) Wheel speed sensors missing or damaged.
X
07 Vehicle classed as
an “appropriate motor
vehicle” or an
appropriate semitrailer’
(1) No ABS/EBS fitted.
(2) No EBS fitted to tractor unit plated for 46 tonne operation.
X
X
08 Vehicles registered
on or after 1 st June
2011 and trailers first
licensed on or after 1 st
June 2011
(1) No anti-lock brake system fitted (ABS/EBS). X
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34
FUEL SYSTEM
Method of Testing
1. Examine the fuel tanks to see that they are firmly held and secure on their mountings and in the case of Liquid
Petroleum Gas/Compressed Natural Gas that the fuel tank is not damaged.
2. Examine fuel tank straps or supports and mounting brackets to see that they are secure and free from fracture and
that none is missing.
3. Examine the mounting bracket bolts to chassis to see that they are secure.
4. On vehicles fitted with LPG or CNG, ensure that the retest date of the fuel tank (if present) has not passed.
5. Where the LPG/CNG fuel tank is fitted inside the vehicle check that the tank valves are either piped separately to the
outside of the vehicle or contained in a gas tight sub-compartment which is vented to the outside of the vehicle.
6. Check that any ducting used for venting sub-compartments or tank valves is not damaged or blocked.
7. Check that no fuel tank is fitted to the roof of the vehicle or, in the case of LPG/CNG tanks, the vehicle has type
approval to UNECE 110. If type approval is not listed on manufacturer’s plate, documentation will be required if an
exemption from this requirement is claimed.
8. Where LPG/CNG is fitted check that the manual hand valve on the tank can be closed off or where a solenoid is
fitted in place of or as an extra protection for the manual valve that it can be heard to open and close when the
ignition key is switched on and off with the LPG/CNG switch on the dash in the ‘on’ position.
9. In CNG systems a second manual valve will normally be found near the filler valve which is usually in the
engine compartment, this should also be checked.
10. Check that a fuel tank cap is present and of the correct type.
11. Check that there are no leaks from the system in the case of petrol or in the case of diesel there are no leaks such
that fuel is dripping or in the case of LPG/CNG if a hissing noise (pressure leak) can be heard.
12. Examine fuel pipes to see they are securely clipped to prevent damage by vibration, chafing or cracking.
13. Check that pipelines/hoses are not damaged or deteriorated (e.g. kinked or flattened) and are not in a position to be
fouled by moving parts or the road.
14. Check that all components of the fuel system are securely mounted.
15. While seated in the driving position, check that the throttle control is:
(a) functionally complete;
(b)
(c)
not cracked, fractured or excessively worn or corroded;
not obstructed or impeded in its travel.
16. Check that the excess fuel device on diesel engined vehicles cannot be readily operated from within the cab if it is
of a type which, with the engine running, will cause an increase in smoke.
17. Check that engine stop control is working satisfactorily on diesel engined vehicles. Where LPG/CNG is fitted, check
that the engine fuel supply solenoids (usually in engine compartment for each fuel used) can be heard to open and
close when each fuel system is selected on the dash LPG/CNG switch.
18. Check that the air filter is present and secure.
NOTES
(1) The extent of this inspection is limited to those parts which can readily be seen and which are
readily accessible without dismantling.
(2) All fuel tanks on the vehicle trailer or semi-trailer are included in the inspection.
HCV TESTERS MANUAL V 1.0 Page | 87

34
FUEL SYSTEM Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Fuel system
including fuel tank,
fuel pump, fuel filters
and fuel lines.
(1) Incorrectly or loosely mounted.
(2) Very rusty.
(3) Leaks.
(4) No fuel cap.
(5) Unsuitable fuel tank or in the case of LPG/CNG test date has expired.
X
X
X
X
X
X
X
X
X
(6) LPG/CNG tank fitted inside vehicle without being sub-compartmented or
having valves piped to the outside.
(7) Fuel tank fitted to roof unless type-approved to UNECE Regulation 110.
(8) Manual or solenoid valves not operating.
(9) LPG/CNG venting or ducting pipes damaged or blocked or subcompartment
obviously not gas tight.
(10) Possibility of fuel lines being crushed, chafed, ruptured or subject to
excessive vibration.
02 Air Filter Assembly (1) Air filter insecure or missing. X
X
X
X
X
X
X
03 Throttle Control (1) Sticking or binding, excessively worn or loose.
(2) Link pins, retaining devices or safety devices missing.
(3) Cracked or fractured mounting bracket or panel.
04 Excess Fuel Device ( 1 ) Gives off excessive smoke if operated from within the cab after the
engine has been started.
X
X
X
X
X
05 Engine stop control (1) Not working or missing. X X
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35
35
TOWING/COUPLING/FIFTH WHEEL
Method of Testing
All Vehicles
1. Examine if there has been an unsafe repair or modification carried out to the coupling device.
DRAWING VEHICLE
Drawing Coupling
2. Examine the drawing vehicle coupling/bar/jaw/pin/eye/ball/hook. Note the condition of these components and ensure
that they are free from distortion and/or fracture.
(1) Check the hook/ball or pin/bushes for wear using a gauge where appropriate.
(2) Check the body of the coupling for wear, distortion or cracks.
(3) Examine the cross member to which the coupling is mounted paying particular attention to the inner face of the
cross member for security and cracks.
(4) Note that the coupling assembly is securely attached to the vehicle.
(5) Check that locking and safety devices are in position and working correctly.
(6) Check any rubber components for deterioration (e.g. wear/cracks or swelling).
(7) Correctly positioned.
Fifth Wheel Coupling
1. Examine the security of the fifth wheel assembly to the chassis.
2. Examine the jaw of the fifth wheel coupling for wear.
3. Examine the fifth wheel coupling plate for cracks or wear.
4. Examine the safety locking device of the fifth wheel coupling.
5. Examine the articulating brackets of the fifth wheel assembly for cracks or damage.
6. Unlock jaw by pulling release handle to fully out position. Using an unworn dummy kingpin check that the coupling
mechanism operates satisfactorily. With the dummy kingpin locked in position measure the amount of wear in the
mechanism by moving the kingpin backwards and forwards.
7. Check any adjustable mechanism (e.g. sliding mechanism) for wear and security.
8. Correctly positioned.
Automatic Coupling
1. Examine the coupling hooks and operating members for wear and security.
Articulated Bus
1. Open both inspection covers (in the floor).
2. Check the coupling framework for cracks or damage.
3. Inspect the coupling framework bushes/pins for deterioration, wear and security.
4. Check ram pins for wear and security.
5. Check hydraulic rams and pipes for leaks and deterioration.
6. Have a colleague drive the vehicle backward and forward and note any movement in the coupling.
7. Check air pipes for leaks, deterioration and/or security.
8. Check sensors or sensor brackets for security.
HCV TESTERS MANUAL V 1.0 Page | 89

35
TOWING BRACKET/COUPLING/FIFTH WHEEL Cont…
NOTES
(1) If a trailer or semi-trailer is coupled to the drawing vehicle at the time of the inspection disconnect the
red suzie (i.e. the breakaway protection line) and request the driver to move the drawing vehicle
backwards and forwards. Check for excessive movement between drawing vehicle and trailer or
semi-trailer. Have the driver uncouple the trailer or semi-trailer in order that the towing mechanism on
the drawing vehicle and trailer or semi-trailer may be examined more effectively. Having carried out
the required examination request the driver to reconnect the trailer and drawing vehicle.
(2) Where a trailer or semi-trailer is presented for test in combination, a defect in the drawing vehicle will
not be a reason for failing the trailer. However, the owner of the vehicle should be made aware of any
such defect.
(3) This inspection applies only where a vehicle is fitted with equipment for towing trailers or semitrailers.
(4) Care should be taken to ensure that an automatic tow hitch on a drawing vehicle is suitably matched
to the towing eye on the accompanying trailer (where a combination of vehicles is presented) and
that adequate provision is made for oscillation of the hitch/eye assembly.
TRAILER OR SEMI-TRAILER
Drawbar Trailer
1. Examine the drawbar and note its condition and that it is free from distortion and/or fracture.
2. Examine the drawbar assembly for wear and security.
3. Examine the drawbar eye and bushes for wear and provision for vertical articulation.
4. Note that safety devices are in position and working correctly.
Fifth Wheel Coupling
1. Clean off the rubbing plate area around the kingpin for a distance of 400mm (c. 16”) from the centre of the kingpin.
Examine the rubbing plate for cracks. Examine the kingpin for security, damage, cracks or excessive wear using a
kingpin gauge.
2. Place a straight edge (e.g. spirit level) across the rubbing plate and check for wear/distortion.
3. Examine the rubbing plate attachment to the semi-trailer.
4. If it is possible to examine the attachment of the kingpin to the chassis/rubbing plate (e.g. via a hatch in the floor)
check that the kingpin “mushroom” is securely attached to the trailer framework/rubbing plate.
NOTES
(1) Where more than one kingpin is fitted or used all are required to be checked.
Automatic Coupling
1. Check the condition of operating members for wear and security.
2. Note that safety devices are in the correct position.
NOTES
(1) Normal safety precautions should be taken when examining semi-trailer kingpins e.g. the use of
supports to supplement the landing legs before commencing inspection.
HCV TESTERS MANUAL V 1.0 Page | 90

35
3
TOWING BRACKET/COUPLING/FIFTH WHEEL Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Tractor or drawing
vehicle (Drawing bar, jaw,
eye, hook, pin, ball, fifth
wheel coupling, automatic
coupling)
(1) Loose or missing fastening bolts or securing devices.
(2) Excessive wear.
(3) Unsafe lock and blocking devices.
(4) Cracks in the main parts of the coupling or bar.
X
X
X
X
X
X
X
X
(5) A deformed or damaged eye, hook, jaw, pin or ball.
X
X
(6) More than 3mm of wear in eye, hook, or ball (see note 2).
X
X
(7) A safety device (e.g. warning light) not operating.
X
X
(8) Fifth wheel assembly insecurely mounted, bolts loose.
X
X
( 9 ) Cracks or severe gouging on the coupler plate.
X
X
(10) Excessively worn jaw in fifth wheel coupling.
X
X
(11) Any defective welding associated with coupling.
X
X
(12) An insecure or excessively worn articulating bracket/bush on a
fifth wheel coupling.
X
X
(13) More than 3mm of play with dummy kingpin in locked position.
X
X
(14) Weak or broken springs in coupling.
X
X
(15) Rubber blocks badly deteriorated.
X
X
(16) Fifth wheel assembly mounting position obviously outside
vehicle manufacturer’s parameters (e.g. behind the rear axle
centreline).
X
X
(17) Unsafe repair or modification.
X
X
02 Trailer/semi-trailers
(Drawbar, kingpin,
coupling assembly,
rubbing plate)
(1) Seriously deformed, fractured or insecure drawbar.
(2) Loose fastening bolts or securing devices.
(3) Worn drawbar bushes.
X
X
X
X
X
X
(4) Missing or inadequate safety or locking devices.
X
X
(5) More than 3mm wear in drawbar eye (see note 2).
X
X
(6) More than 3mm wear in kingpin (see note 2).
X
X
(7) Bent, cracked or damaged kingpin.
X
X
(8) Any defective welding associated with kingpin or rubbing plate.
X
X
(9) Excessively worn/distorted rubbing plate.
X
X
(10) Cracks in rubbing plate.
X
X
(11) Welding of fatigue cracks on rubbing plate surface.
X
X
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35
TOWING BRACKET/COUPLING/FIFTH WHEEL Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
03 Trailer/semi-trailers
(Drawbar, kingpin,
coupling assembly,
rubbing plate) cont.
(1) Insecure rubbing plate or kingpin.
(2) Rubbing plate in such a condition that the kingpin/rubbing plate
assembly is unduly distorting or flexing under load.
(3) Inadequate provision for vertical articulation.
(4) Worn or defective automatic coupling components.
(5) A safety device (e.g. warning device) not operating.
(6) Unsafe repair or modification.
X
X
X
X
X
X
X
X
X
X
X
X
04 Vehicle Combination/
Articulated Bus Coupling
(1) More than 6mm total free play movement in coupling between
the vehicle and trailer.
X
X
(2) Cracks or damage in coupling framework.
X
X
(3) Framework bushes/pins, insecure, deteriorated and worn
(see note 2).
X
X
(4) Ram pins insecure/worn (see note 2).
X
X
(5) Hydraulic rams leaking.
X
X
(6) Hydraulic pipe leaking or deteriorated (e.g. cracks in flexible
hydraulic pipes).
X
X
(7) Wear in coupling beyond manufacturer’s tolerance.
X
X
(8) Air pipe leaking or insecure.
X
X
(9) Sensor or sensor bracket insecure.
X
X
(10) Unsafe repair or modification.
X
X
NOTES
(1) Normal safety precautions should be taken when examining semi-trailer kingpins e.g. the use of
supports to supplement the landing legs before inspection of trailer kingpin and rubbing plate.
(2) The 3mm wear limit applies to a typical 50mm eye, hook, ball or pin. For other dimensions of eye,
hook, ball or pin, wear beyond 1/20 of the original thickness of the metal would be a reason for
failure.
(3) An unsafe repair or modification carried out to the coupling may require a modifications report to
be presented as per Section 71 of this manual.
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36
STEERING ALIGNMENT
Method of Testing
1. Examine steered wheels for any evidence of misalignment e.g. tyre feathering or uneven wear.
2. Check steering alignment, if misalignment is suspected. With steered wheels straight ahead, steering wheel
should be centred rotationally within 90º.
3. Check steered wheel side slip.by driving the R/H steered wheel slowly and straight over the side slip plate
without moving the steering wheel or applying the brakes and note the reading. This check is for steered
axles only.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Side slip (1) More than ±14m/km. X X
NOTES
(1) Steering alignment to be checked on re-test if steering or suspension joints fail.
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37
SERVICE BRAKE PERFORMANCE
Method of Testing
Roller Brake Test
1. If the vehicle is of a type which can be tested on the roller brake test machine proceed as follows:
(a) Position the vehicle so that the wheels of each axle can in turn be properly placed on the brake test machine rollers.
(b) With the roller brake test machine driving each roadwheel in turn, apply the service brake slowly until the
roadwheel is just at the point of slip relative to the rollers, or until the service brake is fully applied or until sufficient
braking effort is obtained whichever occurs first. Note the braking effort indicated from the brake on each
roadwheel and calculate the total braking force available. Calculate the braking efficiency as a percentage of the
manufacturers design gross vehicle weight. In the case of semi-trailers with up to 3 axles, calculate the braking
efficiency as a percentage of the total axle weights not to be exceeded in Ireland. In the case of semi-trailers with
more than 3 axles, calculate the braking efficiency as a percentage of the sum of the individual design axle
weights at 90km/hr (or the maximum speed rating by design), whichever is less.
(c) Ensure that no person or persons are near to the brake tester rollers or vehicle propeller shaft while they are in motion.
No one should attempt to adjust brakes or dry tyres during a brake test.
2. Decelerometer Test
If the vehicle is of a type that cannot be tested on the roller brake test machine it should be subject to a decelerometer test
as follows:
(a) With the vehicle laden set the decelerometer on the vehicle in line with the instrument manufacturer’s instructions.
(b) Have the vehicle driven at a speed of approximately thirty-two kilometres per hour (twenty miles per hour), have the
service brake applied and note the reading on the decelerometer.
NOTES
(1) It is compulsory to record and retain brake test readings and relevant axle weight specifications (if brake
test results have been automatically captured by CoVIS, there is no requirement to keep a hard copy of
the brake test readings).
(2) Where it is necessary to obtain a higher reading of the braking effort than is possible with the vehicle as
presented, use the axle load simulator. Under no circumstances should an axle be subjected to a total
load (i.e. simulated load plus axle loading as presented for test) beyond its design axle weight. Generally
speaking the total axle load required will be considerably less than the design axle weight.
(3) In the case of a system with a mechanical load sensing valve the mechanical arm may be tied up in the
fully open position. Testers must ensure that the load sensing valve arm is released before moving the
vehicle or trailer. In the case of air suspension systems see Note 6. In some EBS’s the front axle may also
be controlled by the load sensing valve on the rear axle. In such systems the load sensing valve may be
by-passed by switching off the engine. Before switching off the engine ensure that the brake system has
full air pressure. The brake test may now be carried out with the engine switched off.
(4) Where the wheels of an axle lock up or slip out of the rollers during the brake test resulting in the
required overall vehicle or trailer braking efficiency not being reached, neither a pass or fail decision can
be made. The brake test must continue until either the required efficiency has been reached or, with full
air pressure and the brake fully applied, the efficiency cannot be reached. Only then can a pass or fail
decision be made.
(5) Tyres must be correctly inflated and the gear selector should be in the neutral position.
(6) In the case of vehicle combinations each unit of the combination is considered separately.
(7) Some difficulty has been experienced in reaching the required brake performance on certain 3 axle
tractive units fitted with air suspension when being tested on a roller brake tester. The difficulty arises
where the load sensing valve is operated via the air suspension bellows.
(8) It is recommended therefore that these vehicle types be presented for test at or near the maximum gross
vehicle/train weight.
(9) It should be noted that where such vehicles are tested in the laden condition it will not be necessary to
interfere with the load sensing valve.
(10) Where it is not practical to have the vehicle presented for test laden the load sensing valve may be bypassed
following the vehicle manufacturer’s instructions. This by-pass operation could be carried out by
the Authorised Tester when the vehicle arrives at the test station and must be reversed before the vehicle
leaves the test area. When carrying out this operation the pressure to the load sensing valve must never
be more than that stated on the load sensing valve plate for a vehicle in the fully laden condition. Under
no circumstances should the vehicle be driven on the road with the load sensing valve by-passed.
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37
(11) Vehicles having an automatic transmission must never be roller brake tested with the gear selector
in the ‘P’ park position.
(12) Occasions will arise when the required brake efficiency is just obtained or just exceeded without
lock occurring but the tester knows that a higher performance figure is normally obtainable for the
type of vehicle being tested. In such cases although the vehicle has passed the brake performance
test, the tester should advise the owner that the braking system appears to be in need of adjustment
or repair.
(13) For vehicles with servo assisted or power braking systems, the engine must be running (idling)
when the service brake is tested.
(14) In some cases it may be necessary to chock the roadwheels of the vehicle during a roller brake test.
(15) Some roller brake testers are fitted with a means of checking ovality. For the purpose of the RSA
test this should be ignored.
(16) A vehicle should only be failed on the basis of excessive ovality where it affects the brake
performance on the road.
(17) In view of the tyre to road grip normally available in service it is not considered necessary to aim for
maximum service brake performance figures exceeding 60% of the design gross weight of the
vehicle being tested.
(18) Care should be taken to ensure that tyres are free from mud, stones, oil or water and that brake
tester rollers are in good condition to ensure that premature wheel slip does not occur.
(19) Where defective brakes are rectified and the vehicle test report marked “pass with defects rectified”
a note should be made on the test report form of the brake performance figures obtained both
before and after the repair work was carried out.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Mechanically propelled
Vehicles with seating
accommodation for up to 14
passengers
(1) Where the braking force of the vehicle is less than 55% of the
design gross weight of the vehicle when not more than 45kgf (100
lbf) pressure is applied to the brake pedal.
X
X
02 Mechanically propelled
vehicles with seating
accommodation for more
than 14 passengers
(1) *Where the braking force of the vehicle is less than 50% of the
design gross weight of the vehicle when not more than 68kgf (150
lbf) pressure is applied to the brake pedal.
X
X
03 Other mechanically
propelled vehicles and
trailers
(1) Where the braking force of the vehicle is less than 45% of the
design gross weight of the vehicle when not more than 68kgf (150
lbf) pressure is applied to the brake pedal.
(1) Where the braking force is less than 45% of the total of the axle
weights not to be exceeded in Ireland when not more than 68kgf
(150 lbf) pressure is applied to the brake pedal.
X
X
04 Semi-trailers up to 3
axles
X
X
05 Semi-trailers with more
than 3 axles
( 1 ) Where the braking force is less than 45% of the total of the sum of
the design axle weights at 90km/hr (or the maximum speed rating
by design), whichever is less when not more than 68kgf (150 lbf)
pressure is applied to the brake pedal.
06 All vehicles (1) Excessive fluctuation of brake force due to distorted disc or drum.
(2) Abnormal lag in brake operation of any wheel.
07 N2 and N3 Goods Vehicle
registered on or after 1 st
June 2011
(1) Where the braking force is less than 50% of the design gross weight
of the vehicle when not more than 68kgf (150lbs) force is applied to
the brake pedal.
X
X
X
X
X
X
08 Drawbar trailers(with the
exception of trailers
designed and constructed
specifically to be towed by
land tractors) first licensed
on or after 1 st June 2011
(1) Where the braking force is less than 50% of the design gross weight
of the vehicle when not more than 68kgf (150 lbs) force is applied to
the brake pedal.
X
X
09 Motor Caravans (1) Where the braking force of the vehicle is less than 55% of the test
weight of the vehicle when not more than 68kgf (150 lbs) is applied
to the brake pedal i.e. the Motor Caravan service brake
performance must be calculated using the vehicle weight presented
and the axle load simulator need not be used.
X
X
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38
SERVICE BRAKE IMBALANCE
Method of Testing
1. Normally this test and the service brake performance test will be carried out concurrently and the same general
precautions apply. (See “method of testing” and “notes” for service brake performance). Where possible the roller
brake test should be carried out for all vehicles. If this is not possible, road test can be carried out.
2. Roller Brake Test. With the roller brake test machine driving the wheels of each axle in turn apply the service brake
slowly and note the braking effort indicated from the brake on each roadwheel. Record and store the readings.
3. Road Test. If a road test is carried out this should be done in traffic free circumstances at a speed of approximately
thirty-two kilometres per hour (twenty miles per hour).
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wheels on same axle (1) More than 30% difference in braking effort (i.e. the braking
effort on one side should not be less than 70% of the braking
effort on the other side).
02 Road Test (2) Obvious pull to one side when brakes are applied. X X
X
X
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39
39
EMERGENCY/SECONDARY BRAKE PERFORMANCE
Method of Testing
Roller Brake Test
1. Normally this test and the service brake test will be carried out concurrently and the same general precautions apply
(see “Method of Testing” and “Notes” for Service Brake Performance). It should be ensured that the
emergency/secondary braking system to be tested is the emergency/secondary braking system as defined by the
vehicle manufacturer.
2. With the roller brake test machine driving each roadwheel in turn, apply the emergency/secondary brake slowly
until the road wheel is just at the point of slip relative to the rollers, or until sufficient braking is achieved whichever
occurs first. Record and retain the braking effort indicated from the brake of each roadwheel and calculate the total
braking force available. Calculate the braking efficiency as a percentage of the manufacturers design gross vehicle
weight. In the case of semi-trailers with up to 3 axles, calculate the braking efficiency as a percentage of the total
axle weights not to be exceeded in Ireland. In the case of semi-trailers with more than 3 axles, calculate the braking
efficiency as a percentage of the sum of the individual design axle weights at 90km/hr (or the maximum speed
rating by design), whichever is less.
NOTES
(1) If the vehicle is fitted with a transmission brake, all wheels on an axle braked by it must be driven by
the roller test machine at the same time.
(2) This inspection applies to vehicles where the emergency/secondary brake can readily be tested
separately from the service brake.
(3) On trailers and semi-trailers fitted with ECE or EEC two line braking systems an
emergency/secondary brake performance test is not required. However, the trailer protection valve
should be checked by venting the yellow service line to atmosphere and applying the footbrake.
Under these conditions the trailer brake should come on automatically.
(4) In the case of a 3 line trailer being drawn by a two line tractor the emergency/secondary brake
performance on the trailer will have to be established by either using the service brake air on the
tractor or some other source of air supply. Where the service brake air is used a special coupling
will have to be made up for this purpose. In the case of a 3 line trailer being drawn by a 3 line tractor
which is not fitted with a separate emergency/secondary brake control the performance of the
emergency/secondary brake on the trailer will have to be established by depleting the air in the
trailer reservoir or where this is not practical by venting the service brake line to atmosphere in
order to initiate the operation of the emergency/secondary brake.
1. Decelerometer Test.
If the vehicle is of a type which cannot be tested on the roller brake test machine it should be subject to a
decelerometer test as follows:
(a)
(b)
Set the declerometer on the vehicle in accordance with the instrument manufacturer’s instructions;
Have the laden vehicle driven at a speed of approximately thirty-two kilometres per hour (twenty miles per
hour). Have the emergency/secondary brake applied and note the reading on the decelerometer.
2. Automatic Breakaway Brake on Trailers and Semi-Trailers.
With the vehicle on hard standing disconnect the suzie brake hose and then attempt to drive the vehicle/trailer
combination forward. In some EBS it may be necessary to disconnect the electrical coupling.
NOTES
(1) No specific performance requirement is laid down for the automatic breakaway brake.
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39
39
EMERGENCY/SECONDARY BRAKE PERFORMANCE Cont…
ITEM REASONS FOR FAILURE MiD MiD DD
01 Mechanically propelled vehicles
registered before 1 st July, 1964
(1) Where the braking force of the vehicle is less than 20% of
the design gross weight of the vehicle.
X
X
02 Mechanically propelled vehicles
registered on or after 1 st July 1964
being vehicles with passenger
accommodation for up to 14
passengers
(1) Where the braking force is less than 27.5% of the design
gross weight of the vehicle.
X
X
03 Mechanically propelled vehicles
with seating accommodation for
more than 14 passengers
(1) Where the braking force is less than 25% of the design
gross weight of the vehicle.
X
X
04 Other vehicles, including drawbar
trailers
(1) Where the braking force is less than 22.5% of the design
gross vehicle weight of the vehicle.
X
X
(2) For vehicles and drawbar trailers registered or first
licensed in the State on or after 1 st June 2011 (with the
exception of trailers designed and constructed specifically
to be towed by land tractors), where the braking force is
less than 25% of the design gross vehicle weight.
X
X
05 Semi-trailers up to 3 axles (1) Where the braking force is less than 22.5% of the total of
the axle weights not to be exceeded in Ireland.
X
X
06 Semi-trailers with more than 3
axles
(1) Where the braking force is less than 22.5% of the total of
the sum of the design axle weights at 90km/hr.
X
X
07 Motor Caravans (1) Where the braking force of the vehicle is less than 27.5%
of the test weight of the vehicle. i.e. the Motor Caravan
emergency/ secondary brake performance is calculated
using the vehicle weight presented.
X
X
08 Automatic Emergency breakaway
brake
09 Trailer/Semi-Trailer Protection
Valve
(1) Not working. X
(1) Not working. X
NOTES
(1) The maximum pressure to be applied to the foot control of the braking device should not exceed 45kgf
(100 lbf) for vehicles with passenger accommodation for up to 14 passengers. For other vehicles the
pressure should not exceed 68kgf (150 lbf).
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40
40
EMERGENCY/SECONDARY BRAKE IMBALANCE
Method of Testing
1. Roller Brake Test
With the roller brake test machine driving the wheels of each axle in turn, apply the emergency/secondary brake
slowly and record and retain the braking effort indicated from the brake of each roadwheel.
NOTES
(1) Normally this test and the emergency/secondary brake performance test will be carried out
concurrently and the same general precautions apply. See “Method of Testing” and “Notes” for
Emergency/secondary brake Performance. This test is not relevant to transmission type
emergency/secondary brakes.
(2) This inspection applies to vehicles where the emergency/secondary brake can readily be tested
separately from the service brake.
(3) In the case of vehicle combinations each unit of the combination is considered separately.
2. Road Test (Decelerometer)
If a road test is carried out this should be done in traffic free circumstances at a steady speed of approximately thirty-two
kilometres per hour (twenty miles per hour).
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wheels on same axle (1) More than 30% difference in braking effort (i.e. the braking effort on one
side should not be less than 70% of the braking effort on the other side).
X
X
02 Road Test
(Decelerometer)
NOTE
The 30% difference in braking effort applies throughout the brake range.
(1) Obvious pull to one side when brakes. X X
41
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41
PARKING BRAKE PERFORMANCE
Method of Testing
1. Roller Brake Test
(a)
(b)
Normally this test and the service brake test will be carried out concurrently and the same general precautions
apply (see “method of testing” and “notes” for service brake performance). It should be ensured that the
parking brake system to be tested is the parking brake system as defined by the vehicle manufacturer.
With the roller brake test machine driving each roadwheel in turn apply the parking brake slowly until each
roadwheel is just at the point of slip relative to the rollers, or until sufficient braking is achieved, whichever occurs
first. Record and retain the braking effort indicated from the brake of each roadwheel, and calculate the total
braking force available. Calculate the braking efficiency as a percentage of the manufacturers design gross vehicle
weight. In the case of semi-trailers with up to 3 axles, calculate the braking efficiency as a percentage of the total
axle weights not to be exceeded in Ireland. In the case of semi-trailers with more than 3 axles, calculate the
braking efficiency as a percentage of the sum of the individual design axle weights at 90km/hr (or the maximum
speed rating by design), whichever is less.
NOTES
(1) If the parking brake is a transmission brake all wheels on the axle braked by it must be driven by the roller
test machine at the same time. It should be remembered that if a transmission brake is fully applied and
the wheels of the axle being tested are still turning then the readings obtained are the maximum that can
be attributed to that transmission brake. Where more than one axle is braked by a transmission brake e.g.
the two bogie axles on a 6 x 4 tipper, then the performance of the transmission brake should be
considered to be the braking force available from only one axle and not two.
(2) On certain vehicles the parking brake cannot be tested dynamically. These vehicles must have a static
brake test.
(3) Spring braking systems on trailers or semi-trailers are acceptable as parking brakes in lieu of hand lever
applied systems provided the required efficiencies are met.
Decelerometer Test
2. If the vehicle is of a type which cannot be tested on the roller brake test machine it should be subject to a
decelerometer test on the road as follows:
(a)
(b)
with the vehicle laden set the decelerometer on the vehicle in accordance with the instrument manufacturer’s
instructions;
have the vehicle driven at a speed of approximately thirty-two kilometres per hour (twenty miles per hour).
Have the parkingbrake applied and note the reading on the decelerometer.
NOTES
(1) The declerometer test for parking brake performance does not apply to trailers or semi-trailers.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Brake Performance - Semi
trailer with up to 3 axles
(1) Where the braking force is less than 16% of the total of the
axle weights not to be exceeded in Ireland.
X
X
02 Brake Performance - Semi
trailer with more than 3 axles
(1) Where the braking force is less than 16% of the total of the
sum of the design axle weights at 90km/hr (or the maximum
speed rating by design), whichever is less.
X
X
03 Brake Performance – All
other vehicles
(1) Where the braking force is less than 16% of the design
gross weight of the vehicle or trailer.
X
X
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42
4
PARKING BRAKE IMBALANCE
Method of Testing
1. Roller Brake Test
With the roller brake machine driving the wheels of each axle in turn apply the parking brake and record and retain
the braking effort indicated from the brake of each roadwheel.
2. Road Test
If a road test is carried out this should be done in traffic free circumstances at a speed of 32kph (20 mph).
NOTES
(1) Normally this test and the parking brake performance test will be carried out concurrently and
the same general precautions apply. (This test is not relevant to transmission type parking
brakes.) Where possible the roller brake test should be carried out for all vehicles. If this is not
possible, road test can be carried out.
(2) On certain vehicles the parking brake cannot be tested dynamically. These vehicles must be
tested per the manufacturer’s recommendation.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wheels on same axle (1) More than 50% difference in braking effort. X X
02 Road Test (Decelerometer) (1) Obvious pull to one side when parking brake is applied. X X
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43
STEERING LINKAGE
Method of Testing
1. With the road wheels on the ground and the steering wheel rotated clockwise and anti-clockwise against the
road resistance, examine the steering mechanism from the point it is secured to the chassis, to the point where
the steering arms are secured to their fixings. For vehicles fitted with power steering it may be necessary to have
the engine running.
During this inspection check for:
(a) excessive wear at joints;
(b) fracture of or damage to components;
(c) insecure components.
2. With steering wheels off the ground:
(a)
(b)
(c)
(d)
(e)
(f)
Check for fouling of wheels, tyres and components of the steering linkage with any part of the vehicle by
rotating the steering wheel through its full working range and also by examining likely fouling points for
abrasion.
While the steering wheel is being rotated check the steering column shaft and steering box for stiffness or worn
or damaged bearings.
Note the amount of movement between the axle beam and the stub axle whilst each wheel in turn is rocked
with a bar, (approximately one meter long) one end inserted in the wheel disc and the other end lifted.
Alternatively a wheel play detector device should be used.
Note the amount of upward movement of the stub axle, whilst each wheel in turn is lifted with a bar placed
underneath it.
Examine visible parts of the stub axle for condition and security.
Where possible examine the kingpin retaining device.
3. For steered wheels on trailers check the joints and components for wear and condition. The turntable
on a drawbar trailer should be examined for wear or fouling between the upper and lower flanges.
4. For external (Ram Type) Power Steering
With the road wheels on the ground, the engine running and the steering being rocked:
(a) Examine the ram anchorage and note that it is securely fixed to the frame or other fixed member of the
vehicle.
(b) Examine the body of the ram and the fluid feed pipes while power is on, for fluid leakage and/or fracture of
the ram body.
(c) Check the chassis anchorage end of the piston rod where it enters the anchorage housing for sign of
weakness, damage, wear or insecurity.
(d) Check that the unit is reasonably in alignment and that fluid pipes are free from damage and are not chafing
on other parts of the vehicle.
(e) Check that the play in the ram ball joints does not exceed the manufacturer’s recommended tolerances.
(f) Check threaded joints for wear, damage and security.
5. For Integral Power Steering
Check by the feel on the steering wheel that the power steering is operating, by rocking the steering
wheel with the engine running and the road wheels on the ground.
6. Check all steering types for oil leaks.
7. Examine if there has been an unsafe repair or modification carried out to any steering components.
NOTES
(1) All steered wheels are to be examined including trailers where applicable.
(2) If power steering is optional on the type of vehicle being tested and is fitted but has been
disconnected in such a way that it can have no adverse effect on the manual steering, this should
not be the subject of a defect.
(3) Welding of steering parts other than by a manufacturer is not acceptable.
(4) Where play is detected under 4(c) it should be established whether it is due to wear in the ball joint
or due to wear in the threads securing the ball joint to the piston shaft.
(5) An unsafe repair or modification carried out to steering components may require a modifications
report to be presented as per Section 71 of this manual.
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43
43
STEERING LINKAGE Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Rack and pinion
type steering
(1) Damaged or insecure. X X
02 Rack/pinion/
bushes/bearings
(1) Splines worn or damaged.
(2) Bushes/bearings excessively worn.
X
X
X
X
(3) Excessive end float in pinion.
X
X
(4) Obvious stiffness.
X
X
(5) Rubber gaiter split, damaged, missing or displaced. X
X
03 Worm type steering
box
(1) Obvious stiffness or bearings obviously damaged or worn.
(2) Damaged or insecure.
X
X
X
X
(3) Obvious axial or radial play, worn splines or shaft twisted.
X
X
(4) Excessive end float.
X
X
(5) Dust cover missing, damaged or severely deteriorated. X
X
04 Drop Arm (1) Mounting obviously damaged or loose. X X
05 Drag Link (1) Mounting obviously loose.
(2) Obviously bent.
X
X
X
X
06 Drag link ends and
track rod end (inner
and outer)
(1) Obviously worn (beyond manufacturers limit).
(2) Mounting obviously loose.
(3) Rubber gaiter split, damaged, missing or displaced.
(4) Dust cover missing, damaged or severely deteriorated.
07 Idler Assembly (1) Obvious axial or radial play.
(2) Mounting loose.
08 Track rod (1) Obviously deformed or mounting insecure. X X
09 Steering arm (1) Obviously loose, bent or cracked. X X
10 Kingpin/Bushes/
Bearings
(1) Excessively worn – 5mm play (3/16”) at wheel rim on 20” wheel, others pro-rata.
(2) Excessive lift between stub axle and axle beam (beyond manufacturer’s limit).
11 Stub Axle (1) Damaged or bent. X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
12 Retaining or
locking devices e.g
split pin, nut, rivet or
weld
(1) Absent, insecure, worn or broken. X X
43
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43
STEERING LINKAGE Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
13 Steering box or
rack housing
(1) Housing fractured, damaged or worn.
(2) Mounting Bolts missing or loose.
(3) Any steering component repaired by welding (other than by manufacturer).
(4) Rubber gaiter split, damaged, missing or displaced.
X
X
X
X
X
X
X
X
14 Attachment
points on steering
box, rack or
steering idler
(1) Cracks or corrosion around attachment points. X X
15 Power steering
function/pump
(1) Power assistance not available smoothly and consistently over full lock to lock
range on one or both locks.
(2) Missing or disconnected where power steering is a standard fitment by the
manufacturer.
(3) Electrical power steering not working.
X
X
X
X
X
X
(4) Power steering pump worn, noisy, leaking or drive defective.
X
X
16 Steering fluid
reservoir, hoses
and Lines
(1) Fluid pipes fouling other components.
(2) Leaks on reservoir side or pressure side.
(3) Insufficient fluid.
(4) Cables/hoses damaged excessively corroded.
(5) Unsafe repair or modification.
17 Ram (1) Excessive oil leakage.
(2) Anchorage damaged insecure or worn.
(3) Mounting bushes excessively worn.
(4) Ram or body distorted or damaged.
(5) Misalignment of assembly.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
18 All steering
components
19 Oil leaks (other
than power
steering)
20 Steering
(including road
wheels and tyres)
(1) Unsafe repair or modification. X X
(1) Serious oil leaks from steering box or rack. X X
(1) Overlocking or underlocking or fouling any other component on the vehicle. X X
21 Turntable on
trailer/semi-trailer
(1) Any cracks, excessive wear, damage or fouling.
(2) Attachment defective.
NOTE
X
X
X
X
(a)
Certain vehicles have a built-in play in the steering rack mounting bushes
and this should be taken into consideration.
(b)
Wear would be considered excessive on a turntable of a trailer/semi-trailer
when the upper flange is resting on the lower flange or when the lateral
movement is more than 3mm.
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44
44
WHEEL BEARINGS
Method of Testing
1. This check is to be carried out on steered wheels of all vehicles and all the wheels of trailers. Raise the axle(s) of
the wheels being examined so that they are clear of the ground.
2. Note the movement of the wheel relative to the axle or stub axle in order to assess the play in the wheel
bearings, whilst each wheel in turn is rocked with a bar.
3. Spin each wheel rapidly and listen for any roughness or harshness in the bearings.
4. The vehicle should be failed if a distinctive rumble or growl is heard that indicates the bearing is damaged.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Wheel bearings (1) Obviously too much play.
X X
(2) Bearings damaged.
X
X
NOTES
(1) Where a vehicle is fitted with ABS/EBS the wheel bearings should not be checked while the
ignition switch is turned in the on position as this can affect the ABS/EBS warning light
circuit.
HCV TESTERS MANUAL V 1.0 Page | 105

45
45
CHASSIS/UNDERBODY
Method of Testing
1. Examine main members for deformation and/or fractures and/or advanced corrosion.
2. Examine cross members for deformation and/or fractures and/or advanced corrosion.
3. Examine the welding and/or securing bolts/rivets for soundness and security.
4. Examine frame/cross member junctions for indications of movement.
5. Examine landing legs to see that they are securely fixed.
6. Examine if there has been an unsafe repair or modification carried out to the chassis or underbody.
NOTES
(1) The extent of this inspection is limited to that part of the chassis which can readily be seen without
dismantling any part of the vehicle.
(2) Pay particular attention to a chassis or underbody which is encrusted with dirt. There may be cracks
or fractures in high stress areas obscured by this dirt.
(3) Pay particular attention to areas around spring and running gear mountings.
(4) Where misalignment is suspected it may be necessary to confirm that the frame/chassis is within the
manufacturers tolerances.
(5) An unsafe repair or modification carried out to the chassis or underbody may require a
modifications report to be presented as per Section 71 of this manual.
(6) For Corrosion assessment and failure criteria, see Notes of Section 22 of this manual.
HCV TESTERS MANUAL V 1.0 Page | 106

45
CHASSIS/UNDERBODY Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Chassis/frame/subframe/flitch
plates,
underbody
(1) Welds breaking away.
02 Trailer Landing Legs (1) Insecure.
(2) Cracked, insecure or pronounced misalignment.
(3) Loose rivets/bolts/bent members.
(4) Considerably weakened by holes.
(5) Advanced rust or other damage.
(6) Unsafe repair or modification.
(2) Cracks in landing leg or around chassis/underbody attachment.
(3) Landing pad/wheel missing or liable to failure.
(4) Defective operating mechanism.
(5) Landing, leg inoperative or missing.
(6) Landing leg support missing, insecure or damaged.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 107

46
46
EXHAUST SYSTEM/NOISE
Method of Testing
1. Examine the condition of the exhaust pipe and silencer for security and leaks.
2. Assess the effectiveness of the silencer in reducing, as far as is reasonable, the noise caused by the exhaust from
the engine.
3. Check that there is no obvious contamination of toxic or exhaust gases into driver’s or passenger compartment.
4. Examine if there has been an unsafe repair or modification carried out to the exhaust system.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Exhaust Pipe (1) Badly mounted or liable to fall off.
X X
(2) Serious leaks.
02 Silencer (1) Missing or not functioning giving excessive noise.
(2) Badly mounted or liable to fall off.
(3) Serious leaks.
03 Exhaust System (1) Possibility of fire being caused by leaks or broken components.
(2) Unsafe repair or modification.
X
X
X
X
X
X
X
X
X
X
X
NOTES
(1) An unsafe repair or modification carried out to the exhaust system may require a modifications
report to be presented as per Section 71 of this manual.
HCV TESTERS MANUAL V 1.0 Page | 108

47
BRAKE WHEEL UNITS
Method of Testing
1. Examine each brake operating wheel unit for security, leaks, corrosion or damage. By applying the brakes check
each brake operating unit for leaks and, where possible, operation. Check that all appropriate items e.g. fixing
nuts, bolts and split pins are secure and locked. In the case of spring brakes ensure that the brake control
operating lever is in the off position i.e. that there is air in the spring brake unit during this test.
NOTES
(1) The vehicle wheels should be chocked during this test and the parking brake should be released.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Brake Actuators
(Including spring brakes or
hydraulic brake cylinder)
(1) Damaged, excessively corroded, insecure or leaking.
(2) Excessive travel of operating cylinder or diaphragm indicating a
need for adjustment.
X
X
X
X
(3) Different sized actuators fitted to the same axle.
X
X
02 Hydraulic brake cylinders (1) Insecurely mounted.
(2) Leaking.
(3) Sluggish in operation or seized.
(4) Dust protection cover missing or excessively damaged. X
X
X
X
X
X
X
X
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48
MECHANICAL BRAKE COMPONENTS
Method of Testing
1. Examine the mechanical components of the brakes which can be seen without dismantling.
Look particularly for:
(a) Badly chafed rods or levers.
(b) Frayed cables.
(c) Corroded rods, levers or linkages.
(d) Wear in rod or cable ends or similar connections. Wear in eyes of relay levers.
(e) Wear in clevis pins, bolts, stationary pins, pivots. Absence of locking devices on clevis pins.
(f) Excessively worn brake linings or pads.
(g) Fractures in brake drums or discs or any disc or drum worn beyond manufacturer’s limit.
(h) Any obstruction to free movement in the system.
(i) Any abnormal movement of levers rods, or cables indicating maladjustment.
(j) Security of brake back plates or discs (including transmission brakes).
(k) Brakes incorrectly adjusted (gap between brake drum and shoes excessive).
(l) Wear in slack adjuster.
(m) Locking sleeve on slack adjusters out of position.
(n) Excessive wear in S cam bushes.
(o) Brakes binding.
(p) Missing/loose or badly deteriorated compressor belt. Missing/loose or cracked compressor pulley.
(q) Test connections (where fitted or required).
2. Examine if there has been an unsafe repair or modification carried out to the braking system.
NOTES
(1) Drum/disc ovality should only be considered a reason for failure when it affects the brake
performance on a road test i.e. the presence of brake judder or pulling to one side, or the ovality
can be felt through movement in the brake pedal.
(2) In the absence of wear indicators or manufacturers recommendations regarding brake lining or
disc pad wear a figure of 2.5mm should be taken as a minimum thickness.
(3) Where no facility is provided for inspection of brake shoes/pads item (h) above will not apply.
(4) Dust covers should not be confused as being the same as back plates on brake assemblies.
Where a dust cover is missing this should not be considered a reason for failure.
(5) The wheels shall be chocked and the parking brake released while this test is being carried out.
(6) Brakes binding may be noted when carrying out the brake performance test or when the axle is
raised to check the wheel bearings.
(7) Slack adjusters may be tested by applying a small torque wrench to the adjusting nut and the
value obtained compared to the manufacturer’s specification.
(8) Automatic slack adjusters are mandatory on vehicles originally fitted with them. It is not
permitted to replace automatic slack adjusters with manual slack adjusters.
(9) Automatic slack adjusters are mandatory on vehicles registered or first licensed in the State on
or after 1 st June 2011 (with the exception of trailers specifically designed and constructed to be
only towed by an agricultural tractor).
(10) An unsafe repair or modification carried out to the braking system may require a modifications
report to be presented as per Section 71 of this manual.
HCV TESTERS MANUAL V 1.0 Page | 110

48
MECHANICAL BRAKE COMPONENTS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Brake Rods/Levers/
Cable/Cable Guides/
Linkages/Pivots
02 Brackets, mounting
bolts, split pins or other
retaining devices
(1) Missing, damaged, cracked, knotted (cables), insecure or
obstructed.
(2) Obviously worn, defective, corroded, seized or incorrectly fitted.
(1) Missing, insecure or worn. X X
03 Brake linings (1) Brake linings contaminated (oil, grease, etc.).
(2) Incorrectly adjusted or binding [see note (6 )].
(3) Brake shoes or pads missing or in need of replacement [see note (2)].
X
X
X
X
X
X
X
X
X
X
04 Brake Drums/Discs/
Backplates
(1) Missing or obviously damaged, askew or insecure.
(2) Any disc or drum worn beyond manufacturer’s limit.
(3) Disc or drum contaminated.
05 Actuating Levers (1) Damaged, insecure or in need of adjustment.
(2) Abnormal movement of the levers/linkage indicating maladjustment
or excessive wear.
(3) Danger of brakes locking. (vehicles with air brakes: S-cams locking
over).
06 Free Movement (1) Restricted, seized or abnormal movement, excessive wear
or wrong adjustment
07 Slack Adjuster (1) Missing, excessively worn, inoperative, defective, seized or having
abnormal movement or adjusting nut torque obviously not within the
manufacturer’s specification.
(2) Manual slack adjusters fitted in place of original automatic adjusters.
(3) Automatic slack adjusters not fitted to a vehicle registered on or after
1 st June 2011.
(4) Automatic slack adjusters not fitted to trailers first licensed in the State
on or after 1 st June 2011.
08 Air Compressor (1) Drive belt missing, loose or badly deteriorated.
(2) Drive pulley missing/loose or cracked.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
09 Retarder system
(where fitted)
(1) Insecure connectors or mountings.
(2) Obviously defective.
X
X
X
10 Test Connections (1) Missing (where required).
(2) Damaged, unusable or leaking. X
X
X
11 Complete Braking
System
(1) Unsafe repair or modification. X X
HCV TESTERS MANUAL V 1.0 Page | 111

49
49
BRAKE LINES AND HOSES
Method of Testing
Brake Pipes
1. Examine all accessible brake pipes, to ensure that they are in serviceable condition, free from chafing and
external corrosion and damage.
2. Check that rigid pipes are securely held by clips or other means and that rigid pipes and flexible hoses are not
positioned in such a manner as to be fouled by moving parts.
3. Examine all flexible hoses, to ensure that they are not constrained in tight bends, that they have adequate room
to move as necessary without fouling any other parts of the vehicle and that they are not damaged or
deteriorated.
4. Check whether there are any leaks in the system by having the brakes applied while examining the system.
5. Examine flexible pipes for signs of weakness under pressure with the footbrake fully applied.
6. Examine brake pipes for repair or unsuitable fittings.
Suzie Connections
7. With the brakes fully applied check all connections for leaks.
8. If fitted, check ISO7638 connector for correct outputs.
9. ISO 7638 connectors (with correct outputs) are mandatory on all trailers first licensed in the State on or after 1 st
June 2011 and motor vehicles authorised to tow trailers or semi-trailers registered on or after 1 st June 2011.
10. Check brake hose couplings for:
(a) Leakage,
(b) Security of mounting,
(c) Outlet pressure in line with manufacturers recommendations (use calibrated pressure gauges),
(d) The possibility of incorrect coupling e.g. due to the absence of colour,
(e) On trailers and semi-trailers, attach the checking tool and verify the correct functioning of the self sealer lifter.
11. A tractor unit plated for operation at 46 tonnes must be fitted with a 7 pin ISO 7638 connector.
HCV TESTERS MANUAL V 1.0 Page | 112

49
BRAKE LINES/HOSES Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Brake pipes,
flexible hoses, taps
(1) Perished, kinked, damaged or rusted.
(2) Unsatisfactorily mounted/possibility of failing.
(3) Flexible brakelines deteriorated or of unsatisfactory material and
specification.
(4) Leaks.
(5) Risk of failure or fracture.
(6) Damaged, chafing, brake hoses too short, twisted.
(7) Hose bulging under pressure.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
02 Connections
(including hose
couplings for trailer)
(1) Damaged, leaking or insecurely mounted.
(2) Inadequate repairs or unsuitable fittings.
(3) Pressure at suzie brakeline connections not within manufacturer’s
specifications.
X
X
X
X
X
X
(4) Possibility of incorrect coupling of brake lines.
X
X
X
(5) Trailers or semi-trailers: incorrect functioning of the self sealer lifter
X
X
(6) Incorrect or no outputs on ISO7638 connector.
( 7 ) No ISO 7638 connector fitted to trailer or semi-trailer first licensed
in the State on or after 1 st June 2011 or to vehicle registered on or
after 1 st June 2011 that is authorised to tow trailers.
X
X
X
X
(8) No 7 pin ISO 7638 connector fitted on a tractor unit plated for 46
tonne operation.
X
NOTE
The pressure at the service suzie brakeline connection should be not
less than 5.5 bar (c 80 psi) and not greater than 8.5 bar in the absence
of manufacturers specifications.
HCV TESTERS MANUAL V 1.0 Page | 113

50
FRONT SPRINGS
Method of Testing
Leaf Springs
1. Examine each spring for its general condition and in particular for fractures in the leaves, especially in the vicinity of
the anchor eye of the main leaf.
2. Note whether any one spring is so weak that it is not holding the body sufficiently far away from the road wheels.
3. Examine condition of spring eyes/bushes.
4. Examine spring clamps to see that none is missing or insecure, thus allowing leaves to splay.
5. Check that the springs on each axle are symmetrically located.
6. Check that there is no movement of spring leaves denoting a fractured centre bolt.
7. Check that the attachments of the shackle/anchor brackets to the chassis are secure, looking for signs of movement
of rivets or bolts or elongated holes.
8. Examine the bolts and/or nuts securing the spring to the axle for tightness and examine the spring and axle for
evidence that these have been moving relative to each other.
9. Check that the spring consists of standard leaves.
Coil Springs
10. Examine each spring for its general condition and in particular for fractures.
11. Note whether any one spring is so weak that it is not holding the body sufficiently far away from the road wheels.
12. Examine the attachment of the coil springs for security.
Air Suspension
13. By listening for air leaks, check the condition of the air supply lines and suspension bellows.
14. Check the condition of levelling valve linkages.
15. Examine the attachment of the suspension bellows for security.
Bonded Suspension Unit
16. Examine the bonding of the flexible element to its associated metal fixings.
17. Examine the condition of the flexible element by applying pressure.
18. Examine the attachments for security to frame and axle.
Torsion Bars
19. Check torsion bars for fracture or damage.
20. Examine the attachment of the torsion bars.
Spring Pins and Bushes
21. (a) Examine the amount of play due to wear at,
(b) the spring anchor brackets,
(c) the pins or bushes of the spring shackles.
22. Examine the condition and security of any slipper brackets.
23. Check that the anchor/shackle pins are fully in place, that they are secure and that the locking devices are in
position and secure.
24. Examine the spring mountings for excessive side play.
Spring (coil/leaf/torsion bar)
25. Examine if there has been an unsafe repair or modification carried out to any Spring (coil/leaf/torsion bar).
HCV TESTERS MANUAL V 1.0 Page | 114

50
50
FRONT SPRINGS Cont…
NOTES
(1) Wear in spring pins and bushes.
A bush and/or pin would be considered excessively worn if wear exceeded 2mm (3/32”) for 12mm
(1/2”) diameter pins, 3mm (1/8”) for 25mm (1”) diameter pins and 1/8 of diameter for pins over
25mm (1”) diameter.
For side play in spring mountings 6mm (1/4”) is to be considered excessive for normal
suspensions although this does not apply to single spring bogie suspensions. Caution should be
exercised in the case of springs and suspensions with rubber/compliant mountings where the
amount of free movement in new components might well exceed the above limit. In such cases
the manufacturer’s tolerances should be sought. Observation of the vehicle attitude when
stationary can often reveal the effect of exhausted or broken springs, e.g. vehicle “sitting down”
at front.
(2) An unsafe repair or modification carried out to the front Spring (coil/leaf/torsion bar) may require
a modifications report to be presented as per Section 71 of this manual.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Spring (coil/leaf/torsion
bar)
(1) Worn or exhausted.
(2) Any spring leaf broken, fractured, repaired by welding or missing.
X
X
X
X
(3) Spring fitted incorrectly.
X
X
(4) Spring clamps loose or missing.
X
X
(5) U-bolts loose or missing.
X
X
(6) A coil spring or torsion bar broken.
X
X
(7) Spring contains leaves that are non standard.
X
X
(8) Unsafe repair or modification.
X
X
02 Spring eye bolt/shackle
pins
(1) Locking device missing or insecurely fitted.
(2) Worn, incorrectly positioned, incorrect type or missing.
X
X
X
X
(3) Obviously loose in the bush.
X
X
03 Spring or shackle
bushes or slipper pads
(1) Missing, worn or perished. X X
04 Spring mounting or
torsion bar mounting
(1) Broken/insecure.
(2) Bolts/rivets missing or loose.
X
X
X
X
(3) Cracked or damaged.
X
X
05 Slipper bracket/pin (1) Missing, worn, damaged or insecure. X X
06 Spring centre bolt (1) Missing, damaged or broken. X X
07 Bump stop (1) Missing, damaged or ineffective. X X
HCV TESTERS MANUAL V 1.0 Page | 115

50
50
FRONT SPRINGS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
08 Air Suspension,
Hydrolastic, Hydrogas,
hydro-pneumatic
suspension
(1) Leaks.
(2) Levelling valve/linkage defective/insecure.
(3) Suspension bellows giving inadequate movement (risk of wheel
fouling).
(4) Air or hydraulic pipe damaged or deteriorated to such an extent
that it is likely to fail.
X
X
X
X
X
X
X
X
09 Bonded Suspension
Units
(1) Failure of rubber/metal attachment.
(2) Deterioration of suspension medium (soft and sticky).
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 116

51
FRONT SUSPENSION
Method of Testing
1. When checking suspensions use the vehicle manufacturer’s recommended jacking points and procedure for
checking the suspension. In the absence of manufacturer’s recommendations see 2, 3 and 4 below and
diagrams on page 118.
2. For suspension of the type shown in figure 1 jack up the front suspension so that the roadwheels are clear of the
ground and the suspension is as near as possible to normal running height and whilst each wheel is held at the
top and bottom and rocked, examine for movement in the top and bottom swivel joints and movement in the
wishbone bushes.
3. For suspensions of the type shown in figure 2 and 3 jack up the front suspension so that the road wheels are clear
of the ground and shake each roadwheel vigorously to determine the condition of the outer suspension ball joint
assembly for play between the ball and the housing.
4. For suspension of the type shown in figure 4 jack up the front suspension so that the road wheels are clear of
the ground, shake each wheel vigorously and examine each suspension strut for wear at the strut sliding bush
and gland as well as for movement at the strut upper support bearing and:
(a)
check for damage or excessive corrosion of the strut casing, wear in the rod and the condition of the
bonding between the metal and flexible material in the strut upper support bearing.
(b) whilst each front wheel is shaken vigorously (grasping at the 3 o’clock and 9 o’clock positions) check the
condition of the outer ball joints and track control arm inner bushes, for movement indicating the degree of
wear.
5. For all suspension types examine:
(a)
(b)
the condition of wishbones and their inner bearings, ball joints, swivel joints, track control arms, anti-roll
bars, radius rods and their mountings bushes or washers.
examine axle beams, leading arms and swinging arms for damage or distortion.
(c) examine the condition of the chassis frame and body shell structure in the vicinity of suspension mounting
points and suspension subframe mounting points for fractures, excessive corrosion or distortion.
(d) manufacturer’s permissible gross axle weight compared to presented weight.
6. Examine if there has been an unsafe repair or modification carried out to an axle beam, leading arm, wish- bones or
swinging arm.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Axle beam, leading
arm, wish - bones,
swinging arm
(1) Obviously out of line.
(2) Presented axle weight exceeds manufacturer’s permissible gross axle
weight.
(3) Unsafe repair or modification.
X
X
X
X
X
X
02 Track control arm (1) Mounting obviously loose or worn.
03 Anti-roll bar, torque
arm/rod, radius rod/link
04 Bushes, ball joints;
sliding bushes or swivel
joints
(2) Cracked, damaged or deformed.
(1) Missing or broken.
(2) Mounting loose.
(3) Cracked, damaged or deformed.
(1) Play exceeds manufacturer’s specified tolerance.
(2) Dust cover missing or badly deteriorated. X
05 Mounting Area (1) Damaged or corroded to such an extent that the security or
alignment of the suspension component is affected.
X
X
X
X
X
X
X
X
X
X
X
X
NOTES
(1) The above defects may be present in both rigid axle and independent suspension systems.
(2) An unsafe repair or modification carried out to an axle beam, leading arm, wish- bones or swinging
arm may require a modifications report to be presented as per Section 71 of this manual.
HCV TESTERS MANUAL V 1.0 Page | 117

51
51
FRONT SUSPENSION Cont…
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
HCV TESTERS MANUAL V 1.0 Page | 118

52
2
SHOCK ABSORBER CONDITION
Method of Testing
1. Check each shock absorber for leak(s).
2. Examine the anchorage of each shock absorber to see that it is connected and in good condition.
3. Examine the condition of any pivots.
NOTES
(1) Some vehicles have shock absorbers as optional fittings. If fitted these must meet the
requirements.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Shock Absorbers (1) Mounting bracket or bushes, missing, worn, loose or damaged.
(2) Not working or missing.
(3) Obvious leak.
(4) Damaged.
X
X
X
X
X
HCV TESTERS MANUAL V 1.0 Page | 119

53
53
TRANSMISSION, ENGINE, & FINAL DRIVE
Method of Testing
1. Examine the transmission, paying particular attention to the condition of:
(a) transmission shafts (both propeller shafts and half shafts),
(b) transmission shaft flanges,
(c) flange bolts/nuts and safeguards,
(d) transmission shaft bearings where fitted and the security and condition of the bearing housing,
(e) universal joints,
(f) engine/gearbox mountings,
(g) clutch linkage and pedal rubber and clutch operation,
(h) oil leaks.
2. Examine if there has been an unsafe repair or modification carried out to the engine or power train.
NOTES
(1) When carrying out this inspection it is important that the vehicle is in neutral gear and that, if a
transmission brake is fitted, it is released. Wheels should be chocked.
(2) When leaking oil is found to be continually dropping to the ground during an inspection, from
whatever source, it is a reason for failure.
(3) Defects found in gearbox, differential or hub reduction gears can only be those noted when driving
the vehicle at low speed in the test area. A full road test including the use of all gears under load,
braking and hot and cold running conditions is not part of the test.
(4) Drive train includes engine, gearbox, drive shafts, and final drive.
(5) An unsafe repair or modification carried out to the engine/powertrain may require a modifications
report to be presented as per Section 71 of this manual.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Clutch (1) Slips or drags so that driving is made considerably difficult. X X
02 Clutch Pedal anti-slip
provision
(1) Anti-slip provision on clutch pedal missing, loose or worn
smooth.
X
03 Clutch operating linkage (1) Not working, defective or leaking.
04 Gear Box/differential/
hub reduction gears
05 Propeller shaft or half
shaft/bearing/bearing
housing/housing
mounting/safeguard
(2) Risk of failure.
(1) Damaged gear(s) or bearing housings.
(2) Gear jumps out of engagement.
(3) Bearings badly worn or damaged.
(4) Obvious oil leak. X
(1) Any drive line component liable to lock up or breakaway.
(2) Askew, damaged, bent or worn.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
53
HCV TESTERS MANUAL V 1.0 Page | 120

53
TRANSMISSION, ENGINE, & FINAL DRIVE Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
06 Propeller shaft couplings/
halfshafts (e.g. universal
joints or flexible couplings)
(1) Worn.
(2) Bolts, nuts or studs loose/missing.
(3) Fastening bolts, locking tabs or split pins missing.
X
X
X
X
X
X
07 Final drive (1) Pinion or gear or sprocket seriously damaged or worn.
(2) Serious damage to bearings or shafts.
X
X
X
X
08 Driving axle (including
constant velocity joints)
(1) Obviously askew or badly mounted.
(2) Obviously worn.
X
X
X
X
(3) Obvious oil leak.
(4) Grease boot missing or torn.
X
X
X
X
09 Gear shift linkage
(including gear lever)
(1) Obviously worn or loose or damaged. X X
10 Lubrication (other) (1) Obvious oil leaks. X X
11 Engine Mounting or
Gearbox Mountings
(1) Insecure, deteriorated or broken. X X
12 Engine/Power Train (1) Unsafe repair or modification. X X
HCV TESTERS MANUAL V 1.0 Page | 121

54
REAR SPRINGS
Method of Testing
Leaf Springs
1. Examine each spring for its general condition and in particular for fractures in the leaves, especially in the vicinity of
the anchor eye of the main leaf.
2. Note whether any one spring is so weak that it is not holding the body sufficiently far away from the road wheels.
3. Examine condition of spring eyes and bushes and slipper pads.
4. Examine spring clamps to see that none is missing or insecure (thus allowing leaves to splay).
5. Check that the springs on each axle are symmetrically located.
6. Check that there is no movement of spring leaves denoting a fractured centre bolt.
7. Check that the attachments of the shackle/anchor brackets to the chassis are secure, looking for signs of movement
of rivets or bolts or elongated holes.
8. Examine the bolts and/or nuts securing the spring to the axle for tightness and examine the spring and axle for
evidence that these have been moving relative to each other.
9. Check that the spring consists of standard leaves.
Coil Springs
10. Examine each spring for its general condition and in particular for fractures.
11. Note whether any one spring is so weak that it is not holding the body sufficiently far away from the road wheels.
12. Examine the attachment of the coil springs for security.
Air Suspension
13. By listening for air leaks, check the condition of the air supply lines and suspension bellows.
14. Check the condition of levelling valve linkages.
15. Examine the attachments of the suspension bellows for security.
Bonded Suspension Units
16. Examine the bonding of the flexible element to its associated metal fixings.
17. Examine the condition of the flexible element by applying pressure.
18. Examine the attachments for security to frame and axle.
Torsion Bar
19. Check torsion bars/bushes for fracture or damage.
20. Examine the attachment of torsion bars.
Spring Pins and Bushes
21. Examine the amount of play due to wear at:
(a) the spring anchor brackets.
(b) all pins and bushes of the spring shackles.
22. Examine the condition and security of any slipper brackets.
23. Check that anchor/shackle pins are fully in place, that they are secure and that the locking devices are in position and
secure.
24. Examine the spring mountings for excessive side play.
Spring (coil/leaf/torsion bar)
25. Examine if there has been an unsafe repair or modification carried out to any Spring (coil/leaf/torsion bar).
NOTES
(1) Wear in Spring Pins and Bushes
A bush and/or pin would be considered excessively worn if play exceeded 2mm (3/32”) for 12mm (1/2”)
diameter pins, 3mm (1/8”) for 25mm (1”) diameter pins and 1/8 of diameter for pins over 25mm (1”) in
diameter.
For side play in spring mountings 6mm (1/4”) is to be considered excessive for normal suspension
although this does not apply to single spring bogie suspensions. Caution should be exercised however
in the case of springs and suspension with rubber/complaint mountings where the amount of free
movement in new components might well exceed the above limits. In such cases the manufacturer’s
tolerance should be sought.
Observation of the vehicle attitude when stationary can often reveal the effect of exhausted or broken
springs e.g. vehicle “sitting down at the rear”.
(2) An unsafe repair or modification carried out to any Spring (coil/leaf/torsion bar) may require a
modifications report to be presented as per Section 71 of this manual.
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54
REAR SPRINGS Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Spring (coil/leaf/
torsion bar)
(1) Worn or exhausted.
(2) Any spring leaf broken, fractured, repaired by welding or missing.
(3) Spring fitted incorrectly.
X
X
X
X
X
X
(4) Spring clamps loose or missing.
(5) U-bolts loose or missing.
(6) A coil spring or torsion bar broken.
(7) Spring contains leaves that are non standard.
(8) Unsafe repair or modification.
X
X
X
X
X
X
X
X
X
X
02 Spring eye
bolt/shackle pins
(1) Locking device missing or insecurely fitted.
(2) Worn, incorrectly positioned, incorrect type or missing.
X
X
X
X
(3) Obviously loose in the bush.
X
X
03 Spring or shackle
bushes or slipper pads
(1) Missing, worn or perished. X X
04 Spring mounting
or torsion bar
mounting
(1) Broken/insecure.
(2) Bolts/rivets missing or loose.
X
X
X
X
(3) Cracked or damaged.
X
X
05 Slipper bracket/pin (1) Missing, worn, damaged or insecure. X X
06 Spring centre bolt (1) Missing, damaged or broken. X X
07 Bump stop (1) Missing, damaged or ineffective. X X
08 Air Suspension,
Hydrolastic,
Hydrogas, hydropneumatic
suspension
(1) Leaks.
(2) Levelling valve/linkage defective/insecure.
(3) Suspension bellows giving inadequate movement (risk of wheel fouling).
(4) Air or hydraulic pipe damaged or deteriorated to such an extent that it is
likely to fail.
X
X
X
X
X
X
X
X
(5) Air bellows damaged or deteriorated to such an extent that it is likely
to fail.
X
X
09 Bonded Suspension
Units
(1) Failure of rubber/metal attachment.
(2) Deterioration of suspension medium (soft and sticky).
X
X
X
X
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55
REAR SUSPENSION
Method of Testing
1. Examine axle beams, trailing arms, swinging arms and their mounting bushes/bearing/shaft/ball joints for wear
damage or distortion.
2. Examine the condition of the chassis frame and body shell structure in the vicinity of suspension mounting points and
suspension subframe mounting points for fractures, excessive corrosion or distortion.
3. Check for damage or excessive corrosion of any suspension strut mounting, wear in the shaft and the condition of the
bonding between the metal and flexible material in the strut support bearing.
4. For all suspension types examine the condition of wishbones, ball joints track control arms, anti-roll bars, transverse
rods, radius rods and their mounting bushes, bearings, shafts, washers and retaining devices.
5. Manufacturer’s permissible gross axle weight compared to presented weight.
6. Particular attention should be paid to vehicles where additional axles have been fitted. In the case of trailers the
licence card must have been amended to include the extra axle weight. There must be an effective load
compensating system between all the axles of a bogie or tri-axle.
7. Examine if there has been an unsafe repair or modification carried out to the axle beam, trailing arm, wishbones,
swinging arm, track control arm, suspension strut or balance beam.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Axle beam, trailing
arm, wishbones,
swinging arm, track
control arm, suspension
strut, balance beam
(1) Obviously askew.
(2) Mounting bushes, bearing or bearing carrier, shafts, ball
joints, obviously loose, worn or insecure.
(3) Cracked or damaged.
X
X
X
X
X
X
(4) Presented axle weight exceeds manufacturer’s
permissible gross axle weight.
X
X
(5) Unsafe repair or modification.
X
X
02 Wishbones, anti-roll
bar, transverse rod,
radius rod/link
(1) Mounting loose.
(2) Cracked or deformed.
(3) Missing or broken.
X
X
X
X
X
X
(4) Play exceeds manufacturer’s specified tolerance.
X
X
(5) Non-standard suspension or unacceptable repairs liable
to cause instability or loss of control.
X
X
(6) Insecure.
X
X
(7) Rubber gaiter split, damaged, missing or displaced. X
X
03 Mounting Area (1) Damaged or corroded to such an extent that the security
or alignment of the suspension component is affected.
X
X
04 Compensating
mechanism on multiple
axle sets (e.g. on bogie
or triple axles)
(1) Load compensating linkage missing or not operating
correctly.
X
X
NOTES
(1) An unsafe repair or modification carried out to the axle beam, trailing arm, wishbones, swinging arm,
track control arm, suspension strut or balance beam may require a modifications report to be
presented as per Section 71 of this manual.
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56
56
REAR LAMPS AND REGISTRATION PLATE LAMPS
Method of Testing
1. Check that two or four rear lamps are correctly fitted to the rear of the vehicle, that they are on each side of
the centre line of the vehicle, and that no part of the vehicle extends laterally more than 16 inches beyond
either rear lamp (see diagram, page 70).
2. Check that each rear lamp when in use provides a red light which is clearly visible from a reasonable distance
from the rear.
3. Check that the registration number plate lamp(s) shows a white light and is operating effectively.
NOTES
(1) In this section “rear lamps” refers to the rear running lamps and not brake or directional indicator
lamps.
(2) Any rear marker lamps fitted should be in working order.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Rear Lamps (1) Not working correctly or not fitted.
(2) Any lamp not working or defective.
(3) Not of the same dimensions and power.
(4) Incorrectly positioned, not symmetrically located, (see page 70) or
insecurely mounted.
(5) Lens missing, broken or badly cracked.
(6) Lamp contains water/moisture.
(7) Not red in colour.
(8) Fitted more than 2 foot 6 inches (762mm) from the extreme rear of the
vehicle.
(9) Less than 50% of LEDs operating on any lamp unit.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
02 Registration Plate
Lamp
(1) Not working correctly or not fitted.
(2) Not white in colour.
X
X
X
X
(3) Lamp throws direct light to the rear.
X
X
(4) Lamp not securely attached.
X
X
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57
STOP LAMPS
Method of Testing
1. With the ignition switched on and rear lights switched on and the service brake (footbrake) applied, observe the
functioning of the stop lamp(s).
ITEM REASONS FOR FAILURE MiD MaD DD
01 Stop Lamps (1) Missing or not clearly visible.
X
X
X
(2) Not working or defective.
X
X
X
(3) Not of the same dimensions and power.
X
X
(4) Incorrectly positioned, not symmetrically located, (see page 70) or
insecurely mounted.
X
X
(5) Lens missing, broken or badly cracked.
X
X
(6) Lamp contains water/moisture.
X
X
(7) Not red in colour.
X
X
(8) Not brighter than rear lamps.
(9) Less than 50% of LEDs operating on any lamp.
X
X
X
X
(10) Switch does not operate correctly.
X
X
(11) Function of switch control device impaired.
X
X
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58
58
INDICATORS/TELL TALES
Method of Testing
1. Switch on the direction indicators and check that:
(a)
(b)
(c)
(d)
Each is working correctly and is clearly visible.
Each is of the correct colour and correctly located.
Means are available for the driver to be readily aware from his seat that each direction indicator is functioning.
If fitted, four-way flasher or hazard warning lights must all be working.
NOTES
(1) Where “repeater” indicators are fitted these must be working.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Indicators/hazard
warning flashers (including
repeater lamps)
(1) Missing or not clearly visible.
(2) Not working or defective, e.g. not flashing constantly between 60 and
120 flashes per minute (flashing type).
X
X
X
X
(3) Not of the same dimensions and power.
X
(4) Incorrectly positioned, not symmetrically located, (see page 70) or
insecurely mounted.
X
(Note that there is no specified lateral clearance for indicators.)
(5) Lens missing, broken or badly cracked.
(6) Lamp contains water/moisture.
X
X
Post-July 1964
(7) Not amber in colour.
X
Pre-July 1964
(8) Fronts – both not amber or white in colour.
X
(9) Rears – both not amber or red in colour.
X
(10) Where only one indicator (on each side) used for front and rear;
(a) Not amber in colour.
(b) Does not extend six inches beyond the outline of the vehicle
(semaphore type only).
X
X
All
(11) Rate of flashing not constant and between 60 and 120 flashes per
minute.
02 Switch (1) Missing.
X
X
X
(2) Not working or faulty.
X
X
03 Tell Tale (lights or
audible indicator)
(1) Missing.
(2) Not working or faulty.
X
X
X
X
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59
59
SIDE LAMP/MARKER LAMP
Method of Testing
1. Side Lamps
Check that the two lamps showing a white light are fitted to the front of the vehicle; one on each side of the centre line of the
vehicle and;
(a) when illuminated are clearly visible from a reasonable distance;
(b) are securely fixed and do not flicker;
(c) that no part of the vehicle or trailer extends laterally more than 406mm (16”) beyond the lamp;
(d) that they are fitted at the same height and not more than 2100mm (6’ 11”) from the ground.
2. Marker Lamps
Applies only to trailers or semi-trailers in combinations exceeding 12.2m (40’) in length.
Check that a marker lamp on a trailer/semi-trailer is fitted midway on the right hand side and the illuminated surface of the
lamp shows a white light and is facing outwards and to the front at an angle of 45° to the longitudinal axis of the trailer/semitrailer.
The illuminated surface should not be higher than 1.52m (5’) from the ground. Any marker lamps fitted should be in
working order.
Note: EC specification Side Marker Lamps will be accepted as an alternative to the Irish side marker lamps as above.
The Method of Testing for EC specification Side Marker Lamps is as follows:
(a) On each side of the trailer/semi-trailer, check that at least one side-marker lamp is fitted to the middle third of the
vehicle, the foremost side-marker lamp being not further than 3m from the front and distance between two adjacent
side-marker lamps not exceeding 3m (if the structure of the vehicle makes it impossible to comply with such a
requirement, this distance may be increased to 4m).
(b) The distance between the rearmost side-marker lamp and the rear of the vehicle shall not exceed 1m.
(c) The lamps should be positioned not less than 350mm and not more than 1,500mm from the ground (if the structure of
the vehicle does not allow for compliance with the maximum height, this limit may be raised to 2,100mm).
(d) The side-marker lamps should be amber in colour (the rearmost side-marker lamp may be red if grouped or combined
or reciprocally incorporated with the rear position lamp) and should be visible from a 45 degree angle from the front and
rear of the vehicle.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Side Lamps (1) Missing or not clearly visible.
X X
(2) Not working or defective.
X X
(3) Not symmetrically located and of the same dimensions and power. X
(4) Incorrectly positioned (see page 70) or insecurely mounted.
X
(5) Lens missing, broken or badly cracked.
X
(6) Lamp contains water/moisture.
X
(7) Not white in colour.
X X
(8) Power exceeds 7 watts in any lamp.
X
02 Marker Lamp(on semitrailer
or trailer) where
combination is more than 1
2.2m (40’ long)
(1) Missing.
(2) Not working or faulty.
(3) Badly cracked or missing lens.
X
X
X
X
X
(4) Incorrect colour.
X
(5) Incorrectly positioned or incorrectly mounted (see page 13).
X
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60
60
HEADLAMP CONDITION
Method of Testing
1. With the headlamps switched on main and dipped beam in turn, see that they each show as
selected a light both of the same colour (white or yellow) to illuminate sufficiently the road in front of
the vehicle.
2. Check if a High Intensity Discharge (HID) light source is fitted. A HID light source may be recognised by:
- the light having a bluish tinge,
- the light taking a few seconds to reach full intensity,
- the headlamp having an igniter module/inverter (ballast) behind the headlamp,
- the headlamp having "DCR" marked on the lens.
NOTES
(1) Headlamps should consist of either two or four lamps, or one lamp in the case of an electric
vehicle.
(2) Extra lamps fitted are not to be considered as part of the test.
(3) Any headlamp range adjuster must be in the basic position.
(4) Headlamp beam converters fitted to right hand dipping headlamps of vehicles which are mainly
used on the continent, which effectively mask/deflect the beam are acceptable provided that the
pass/fail criteria is met.
(5) HID light sources may not be fitted to a conventional lamp reflector unit (light source and lamp not
compatible) and may only be fitted as part of a type approved headlamp system. In order to
determine that the HID system fitted has been type approved, automatic cleaning and headlamp
levelling devices (manual or automatic) shall be present. Where automatic cleaning devices or
levelling devices are not fitted to a HID system, then confirmation from the
manufacturer/authorised distributor should be sought in order to confirm that the vehicle
presented was originally manufactured with a type approved HID system.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Main or dipped beams (1) Dipped beams not working simultaneously.
(2) Full beams not working simultaneously.
(3) Contains water/moisture.
(4) HID bulb fitted in a non-HID headlamp.
HID Light Sources
(5) Automatic headlamp levelling device not operating or manual
headlamp levelling device cannot be operated from driver’s seat.
02 Glass and reflecting
material
(6) Headlamp cleaning device not present.
(7) Headlamp cleaning device not operating.
(1) Insufficient intensity to illuminate the road in front of the vehicle.
(2) Glass badly cracked.
(3) Reflecting material damaged/discoloured.
(4) Missing.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
03 Mounting of lamps (1) Incorrectly mounted.
04 Dip or headlamp
switch
(2) Insecurely mounted.
(1) Insecurely mounted or missing.
(2) Not working properly.
05 Dipped beam (1) Right hand dipping headlamps not masked/deflected to meet
test pass criteria.
06 Colour (1) All lamps (Not white or yellow). X
07 Main beam warning
light
(1) Not working. X X
X
X
X
X
X
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1
61
HEADLAMP AIM
Method of Testing
1. Place a properly calibrated headlamp beamsetter in front of each headlamp in turn, and with the headlamp
emitting the dipped beam or the main beam as appropriate (see Note below) determine the gradient % of the
highest intensity of the beam relative to the plane on which the vehicle is standing.
NOTES
(1) Headlamps fall into three main categories as follows:
(i)
(ii)
European Type Headlamp – checked on dip beam (see Fig. 1 for method of test),
British-American Type Headlamp – checked on dip beam
(see Fig. 2 for method of test),
(iii) British-American Type Headlamp – checked on main beam
(see Fig. 3 for method of test).
(2) Tyre pressures should be checked and corrected if necessary before headlamp aim is checked.
The vehicle and beamsetter should be located on the special headlamp aim checking area
within the test premises.
(i) Any headlamp range adjuster must be in the basic position.
(ii)
If a vehicle is presented with left hand drive headlamps and beam masks, the masks must be
installed to ensure they effectively block any light projection above the 0% horizontal
reference line. This would then show a pattern similar to a mirror image of Fig. 2 and can be
checked as on that guide.
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61
HEADLAMP AIM Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 European Type
Headlamp (checked on dip
beam) (All 2 or 3 axle rigid
vehicles with a wheelbase
of 5m or less and all 2 or 3
axled tractor units in either
case not fitted with air
suspension on the rear
axle, self levelling
headlamps or a driver’s
headlamp aim adjustment
control)
02 Vehicles other than
those specified above
(1) For headlamps whose centre is not more than 850mm above the
ground the horizontal cut off line does not lie between the 0.5% and
3.25% boundary lines.
(2) For headlamps whose centre is more than 850mm above the ground
the horizontal cut off line does not lie between the 1.25% and 4.0%
boundary lines.
(3) The junction of the 15 degree cut-off and horizontal cut off line does not
lie between the 0% and 2% vertical lines.
(1) For headlamps whose centre is not more than 850mm above the
ground the horizontal cut off line does not lie between the 0.5% and 2%
horizontal lines.
X
X
X
X
03 British American Type
Headlamp (checked on dip
beam) (All 2 or 3 axle rigid
vehicles with a wheelbase
of 5m or less and all 2 or 3
axled tractor units in either
case not fitted with air
suspension, self levelling
headlamps or a driver’s
headlamp aim adjustment
control)
04 Vehicles other than
those specified above
05 British-American Type
Headlamp (checked on
main beam)
(2) For headlamps whose centre is more than 850mm above the ground
the horizontal cut off line does not lie between the 1.25% and 2.75%
horizontal lines.
(3) The junction of the 15 degree cut off and horizontal cut off line does not
lie between the 0% and 2% vertical lines.
(1) The upper edge of the hot spot does not lie between the 0% and 4%
boundary lines.
(2) The right edge of the hot spot is to the right of the vertical 0% line or
more than 2% to the left of it.
(1) The upper edge of the hot spot does not lie between the 0% and 2.75%
boundary lines.
(2) The right edge of hot spot is to the right of the vertical 0% line or more
than 2% to the left of it.
(1) For headlamps whose centre is not more than 850mm above the
ground the hot spot centre does not lie between the 0% and 2%
horizontal lines.
(2) For headlamps whose centre is more than 850mm above the ground
the hot spot centre does not lie between the 0% and 2.75% horizontal
lines.
(3) The centre of the hot spot does not lie between the 0% and 2% vertical
lines.
X
X
X
X
X
X
X
X
X
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61
HEADLAMP AIM Cont…
Fig. 1 European Type Headlamp – checked on Dipped Beam
For all two or three axle rigid vehicles with a wheelbase of 5m or less and all two or three axled tractor units in
either case not fitted with air suspension on the rear axle, self levelling headlamps or a driver’s headlamp aim
adjustment control the horizontal cut off line must be between:
(a)
0.5% and 3.25% boundary lines for headlamps whose centre is not more than 850mm above the ground.
(i)
1.25% and 4.00% boundary lines for headlamps whose centre is more than 850mm above the
ground.
For vehicles other than those specified above the horizontal cut off line must be between:
(b) 0.5% and 2% for headlamps whose centre is not more than 850mm above the ground.
(i)
1.25% and 2.75% for headlamps whose centre is more than 850mm above the ground.
The junction of the 1 5 degree cut off and the horizontal cut off line must be between the 0% and 2% vertical lines.
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61
HEADLAMP AIM Cont…
Fig. 2 British - American Type Headlamp – checked on Dipped Beam
For all two or three axle rigid vehicles with a wheelbase of 5m or less and all two or three axled tractor units in
wither case not fitted with air suspension, self levelling headlamps aim adjustment control the upper edge of
the hot spot must be between 0% and 4%. For vehicles other than those above the upper edge of the hot spot
must be between 0% and 2.75%.
The right edge of the hot spot must be between the 0% and 2% vertical lines.
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61
HEADLAMP AIM Cont…
Fig. 3 British - American Type Headlamp – checked on Main Beam
The lens of this type of headlamp is circular and likely to be of the sealed beam construction. It may be marked
with ‘1’ and an arrow. It will not have ‘C’ above either an ‘E’ or ‘e’. The dipped beam pattern will not match either of
the figures shown on the previous pages but the main beam will be similar to figure above.
Check on main beam and determine that:
(a) The centre of the hot spot lies between the 0% and 2% vertical lines.
(b) For headlamps whose centres is not more than 850mm above the ground the hot spot centre lies between
the 0% and 2% horizontal lines.
(c) For headlamps whose centre is more than 850mm above the ground the hot spot centre lies between the
0% and 2.75% horizontal lines.
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62
FIRE EXTINGUISHER
(Passenger vehicles with more than eight seats excluding the driver’s seat)
Method of Testing
1. (a) Check that a fire extinguisher is fitted.
(b)
(c)
Check that extinguisher is of the correct size and type.
Check that the most recent inspection date is within limits.
NOTES
(1) Fire extinguisher must be at least 2kg or 2 litre capacity and rated for class A and B
fires.
(2) Where a fire extinguisher is behind a glass panel, then the information required in this
test item shall be verified visually, alternatively a letter shall be presented by a
competent person verifying these details.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Fire Extinguisher (1) Not fitted.
(2) Not fully charged.
(3) Insecure.
(4) Incorrect type or size.
(5) Out of date inspection. In the absence of a date of renewal, one year
since last inspection.
(6) Absence of date of inspection.
X
X
X
X
X
X
X
X
X
X
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63
EMERGENCY EXITS
(Passenger vehicles with more than eight seats excluding the driver’s seat)
Method of Testing
1. Check that any emergency exit(s) in the vehicle operate satisfactorily, and that the means of operation is
clearly marked.
2. Check that notices indicating the presence of any emergency exit(s) are present both on the inside and
the outside of the vehicle.
NOTES
(1) An 'Emergency door' is a door intended for use by passengers as an exit only exceptionally and
in particular in an emergency.
(2) A bolt on the emergency door that would enable the door to be locked is not acceptable.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Emergency Exit(s)
and Signs
(1) Emergency exit(s) not operating satisfactorily, not opening
outwards, locked or inoperative.
(2) Signs indicating presence of emergency exits or their means of
operation not present.
(3) Warning buzzer or lights (where fitted) not working.
(4) Break glass hammer missing (where originally fitted) Emergency
exit obstructed.
X
X
X
X
X
X
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64
SEATS (Passenger Vehicles)
(Passenger vehicles with more than eight seats excluding the driver’s seat)
Method of Testing
1. Examine passenger seats and their mountings and upholstery.
2. Note any movement of the seats relative to the vehicle body.
3. Check that the seat spacing and layout is such that adequate gangway width and access to exits are assured.
NOTES
(1) Note that detailed measurements are not required for this check.
(2) This test item does not apply to motorcaravans.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Passenger Seats (1) Incorrectly mounted.
(2) Collapsed.
(3) Damaged.
(4) Upholstery torn.
(5) Seat insecure.
(6) Seat spacing or layout obviously incorrect.
(7) Any seat obstructed.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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65
INTERNAL LIGHTING
(Passenger vehicle with more than eight seats excluding the driver’s seat)
Method of Testing
1. Check that in the case of passenger vehicles with more than eight seats (excluding the driver’s seat) that there is
sufficient internal lighting is available to illuminate every deck, every stairway and any step or platform forming
part of any passenger entrance or exit other than an emergency exit.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Internal lighting (1) Any deck, inadequately illuminated.
(2) Stairways, steps or platforms inadequately illuminated.
X
X
X
X
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66
FIRST AID KIT
(Passenger vehicles with more than eight seats excluding the driver’s seat)
Method of Testing
1. Check that a first aid kit is carried and appears to be complete.
NOTES
(1) A first aid kit is not required on an omnibus with a scheduled route not exceeding 15 miles.
An omnibus is a large public service vehicle used on definite routes and charging separate
fares. Persons claiming an exemption from the requirement to have a first aid kit because
they are in receipt of a special permit from the RSA must produce a copy of the actual permit
granted on the day of the test.
ITEM REASONS FOR FAILURE MiD MaD DD
01 First Aid Kit (1) Not carried or obviously not complete. X
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67
FUEL CUT OFF
(Passenger vehicles with more than 14 seats excluding the driver’s seat)
Method of Testing
1. Check that in the case passenger vehicles with accommodation for more than 14 passengers a fuel cut off device
is accessible without tools (in all fuel systems), functioning correctly and its position is clearly marked on the
outside of the vehicle.
NOTES
(1) For vehicles first registered after 28 th May 2004 that are type approved to 2001/85/EC, this test
does not apply.
(2) Persons claiming an exemption from the requirement to have a fuel cut off because they are in
receipt of a special permit from the RSA must produce a copy of the actual permit granted on
the day of the test.
(3) The use of the ignition key from outside the vehicle may not be used as the fuel cut off.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Fuel Cut Off Device
(where required)
(1) Missing, not operating or not accessible from outside the vehicle.
(2) Position not clearly marked outside the vehicle.
X
X
X
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68
SPRAY SUPPRESSION
Method of Testing
1. Examine Spray Suppression system for type approval (e-mark).
2. Examine mounting for security, damage, etc.
3. Check mounting dimensions and clearances.
The following outlines the dates from which the relevant vehicle must be fitted with the appropriate Spray Suppression
Device/System.
Unless exempted by Regulation 3 (2) of S.I. No. 272 of 2011.
– Goods vehicles with a DGVW exceeding 7.5t registered on or after 1 st September 2011.
– Goods trailers or semi-trailers exceeding 3.5t maximum permissible mass and first licenced on or after 1 st September
2011.
NOTES
As per regulation 3 (2) of S.I. No. 272 of 2011, the following are exempted from the requirement to be fitted
with spray suppression devices;
(1) a mechanically propelled vehicle which is designed and constructed so as to be incapable of
exceeding a speed of 50 kilometres per hour,
(2) a mechanically propelled vehicle which is limited to a speed of 50 kilometres per hour or less,
(3) a trailer in a combination of vehicles which, by reason of the design and construction of the
mechanically propelled component, is incapable of exceeding a speed of 50 kilometres per
hour,
(4) a semi-trailer as a component of an articulated vehicle which, by reason of the design and
construction of the mechanically propelled component, is incapable of exceeding a speed of 50
kilometres per hour,
(5) a mechanically propelled vehicle having a design gross vehicle weight not exceeding 7.5
tonnes, nor to a trailer or semi-trailer having a design gross vehicle weight not exceeding 3.5
tonnes,
(6) vehicles or their trailers, used by, or which are intended for use by the Defence Forces, the
Garda Síochána, the Irish Coast Guard, local authority fire and rescue services, the Civil
Defence or Customs and Excise,
(7) a road maintenance vehicle, or,
(8) an excluded vehicle. Where an “excluded vehicle” means either an off-road vehicle or a vehicle
which in the normal course of its work is required to operate off the road and includes the
following —
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
a vehicle designed, and not merely adapted, for the carriage and mixing of liquid concrete,
a vehicle designed or adapted for the carriage of concrete building blocks or bricks,
a works truck,
a works trailer,
an agricultural tractor,
an agricultural trailer,
a vehicle so constructed that it can be unloaded by part of the vehicle being tipped sideways or
rearwards,
a refuse vehicle,
a trailer specially designed and constructed, and not merely adapted, to carry round timber,
a vehicle used in the provision or maintenance of telephone services or of gas or electricity
supply,
a vehicle used for the collection of un-processed milk from farms for transport to a processing
facility, and
a vehicle designed, and not merely adapted, for the transportation of livestock.
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68
SPRAY SUPPRESSION
Examples of Appropriate Dimensions for a Spray Suppression Device/System
Note: The figures refer to the corresponding items in Annex III of
Appendix III of Council Directive 91/226/EEC and its amendments.
Figure 1: Width (q) of Mudguard (a) and Position of Valance (j)
Figure 2: Dimensions of Mudguard and Outer Valance (j)
Note: T: extent of mudguard
Figure 3: Position of Mudguard and Rain Flap
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68
SPRAY SUPPRESSION Cont…
Note: The figures refer to the corresponding items in Annex 111 of
Appendix 111 of Council Directive 91/226/EEC and its amendments
(a)
Dimensions of mudguards and outer valances for multiple axles
Note: T: extent of mudguard
(b)
Position of spray suppression devices for multiple axles
Figure 4: Mudguards and outer valance for steered or self-steering or non-steered wheels
(a) Multiple axles where the distance between the tyres in less (b) Single axles or multiple axles where the distance between the
tyres in not less than 250mm
less than 250mm
(Annex 111 – items 6.2 and 8)
Figure 5: Diagram showing assembly of a spray-suppression system incorporating spray-suppression devices
fitted with energy absorbers for axles fitted with non-steered or self-steering wheels.
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68
SPRAY SUPPRESSION Cont…
Note: The figures refer to the corresponding items in Annex 111 of
Appendix 111 of Council Directive 91/226/EEC and its amendments
Note: T: extent of mudguard
Figure 6: Diagram showing assembly of a spray-suppression system incorporating spray-suppression devices
fitted with air/water separators for axles fitted with steered, self-steering or non steered wheels.
Note: T: extent of mudguard
Figure 7: Diagram showing assembly of a spray-suppression system incorporating spray-suppression devices
(mudguard, rain flap, outer valance) for multiple axles where the distance between the tyres does not exceed
300mm.
Appendix 3: Model for the EEC Component Type-Approval Mark
The spray-suppression device bearing the example EEC typeapproval
mark is a device of the energy-absorption type (A), which
has been approved in Spain (e 9) under number 148.
The figures used are only indicative.
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68
SPRAY SUPPRESSION Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Spray Suppression (1) Not e-marked.
(2) Insecurely mounted.
(3) Liable to foul other vehicle components or endanger road users.
(4) Split, missing, torn, or damaged.
(5) Rusted through.
(6) Not fitted to vehicle, trailer, or semi-trailer where required by law.
(7) Dimensions/clearances incorrect.
(8) More than 25% of the minimum required wheel flap or spray
suppression material area clogged with mud or debris.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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69
69
TACHOGRAPH/SPEEDOMETER
NOTES
(1) Any vehicle that requires a tachograph to be fitted and is first registered on or after 1 st May 2006, must
be equipped with a digital tachograph (unless a tachograph declaration form is completed).
(2) A speedometer is only required on a vehicle capable of exceeding 48kph (30 mph) or 32kph (20 mph)
in the case of a large tractor. The speedometer functions check is limited to the movement of the
vehicle within the test area.
(3) If a speed limitation device works through the tachograph, the tachograph must meet the
requirements of this section of the testers manual.
(4) Modular tachographs using encrypted sender units (there are two types and these are easily identified
as they are shaped like a car radio: VDO Keinzel 1324 and Stoneridge) do not require the cable end
connections to be sealed. However, in these cases the sender unit itself is still required to be sealed to
the gearbox.
Method of Testing
Tachograph
1. Give the vehicle driver/owner/operator the option of completing the tachograph declaration form. If this form
is satisfactorily completed and signed, carry out the test only on the speedometer, otherwise proceed as in 2,
3, 4, 5, 6, 7, 8 below. This also applies to motor caravans.
2. Check that the tachograph is of an EC-approved type by identifying the approval mark on the descriptive
plaque. This mark consists of a rectangle within which is the letter “e” followed by a number.
3. Check that the tachograph is positioned so that the driver when seated has a clear view of the speedometer,
distance recorder and clock.
4. Check that the tachograph is positioned so that all parts are protected against accidental damage.
5. Check that the tachograph is in working order i.e. that time, speed and distance travelled are being recorded on the
chart in the tachograph head, that it can be illuminated, and that speed is being indicated to the driver.
6. On a digital tachograph, check that the vehicle registration number is recorded in the vehicle unit.
7. Check that there is a current installation plaque affixed to the vehicle near the tachograph or on the instrument itself.
Check that the installation plaque shows the registration number or VIN (VIN required for digital tachograph), name
and address or trade name of an approved tachograph fitter or workshop, the characteristic coefficient (“w”) of the
vehicle, the effective circumference (“l”) of the wheel in millimetres, and the date on which these measurements were
made. On the evidence of this date, the installation plaque should be no more than six years old.
8. Check that a current two-year inspection plaque (required every two years after installation or calibration) is affixed
to the vehicle near the tachograph or on the instrument itself, showing the date the inspection was carried out and
the seal number of the tachograph centre which carried out the inspection. The two-year plaque shall be fitted as
well as and not in place of the installation plaque.
9. Check where possible the integrity of the seals at all connecting points in the overall installation which
comprises the tachograph head, the adaptor at or near the vehicle’s gearbox and the connecting cable(s).
10. The following points should be sealed:
a) Each end of all connecting cables.
b) The adaptor and its connection to the gearbox.
c) The inner casing of the tachograph head which protects the internal parts of the instrument.
d) The installation plaque and the two year plaque unless it is attached in such a way
that it cannot be removed without the markings thereon being defaced.
11. For vehicles not required to be fitted with a tachograph, where a tachograph is fitted in place of a speedometer check:
a) If a speed limiter is required (which is sensed from the tachograph head): the presence of a seal, it is complete
and of a mandatory type.
b) If a speed limiter is not required: the presence of a seal (within the tachograph head) and it is complete. Note:
There is no requirement for the gearbox sender unit to be sealed.
12. Check that the speedometer can be illuminated.
Odometer
13. Record the odometer reading at the time of the test where an odometer is fitted. After completion of the CVR test, the
presenter/owner shall be given the opportunity to verify the odometer reading recorded (see Introduction).
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69
TACHOGRAPH/SPEEDOMETER Cont…
ITEM REASONS FOR FAILURE MiD MaD DD
01 Speedometer (including
Tachograph speedometer
function)
(1) Missing or not working properly.
(2) Cannot be seen by driver at all times.
X
X
X
X
02 EC Approved
Tachograph (if required)
(1) Not fitted (where no “tachograph declaration form” is available).
(2) Not working.
(3) Tachograph not positioned so that the driver has a clear view from
his seat of speedometer, distance recorder and clock.
X
X
X
(4) Tachograph not positioned so that all parts are protected against
accidental damage.
X
(5) Not recording time and/or speed and/or distance.
(6) Stylus bent or damaged.
(7) No installation plaque.
(8) Installation plaque more than six years old.
X
X
X
X
X
X
X
(9) No current two-year inspection plaque.
(10) Incomplete details on installation or two year plaque.
(11) Seals missing or broken.
X
X
X
(12) Digital tachograph outside 2-year calibration requirement.
X
(13) On digital tachograph, tyre size does not match tachograph printout.
(14) Vehicle registration number or VIN not recorded in the digital
tachograph vehicle unit.
X
X
(15) Any vehicle first registered on or after 1 st May 2006 that is not
equipped with a digital tachograph.
X
(16) Unable to obtain printout from digital tachograph.
X
03 Lighting of
Speedometer or
Tachograph
04 For vehicles not
required to be fitted with a
tachograph, where a
tachograph is fitted in
place of a speedometer:
(1) Not working. X X
If a speed limiter is required ( which is sensed from the tachograph
head):
(1) Seal missing, broken or where a clearly “non-mandatory seal
has been fitted in place of an “official seal”.
If speed limiter is not required:
(2) A seal (within the tachograph head) missing, broken, or where a
clearly “non mandatory” seal has been fitted in place of an
“official” seal.
X
X
X
X
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70
SPEED LIMITER
Method of Testing
NOTES
(1) A speed limitation device is not required on a motor caravan nor on an ambulance having not
more than eight passenger seats plus driver.
(2) In the case of a goods vehicle incapable of exceeding 90km/hr due to its design, or a passenger
vehicle incapable of exceeding 100km/hr due to its design, then a speedlimiter is not required
to be fitted. In such a case certification must be provided by the manufacturer or his authorised
Irish Distributor detailing the vehicle’s maximum design speed and any relevant construction
characteristics (e.g. engine, transmission, axles and tyres).
With reference to S.I. No. 831of 2005 and for the purpose of the vehicle roadworthiness test scheme a speed limiter is
required on the following vehicles:
First registered on or after 1 st January 1988:
Goods vehicles exceeding a GVW of 12,000kg,
Passenger vehicles exceeding a GVW of 10,000kg with passenger accommodation for more than 8 passengers (not
including driver’s seat).
First registered on or after 1 st October 2001 and before 1 st January 2005:
(a)
(b)
Goods vehicles with diesel engines exceeding a GVW of 3,500kg but not exceeding a GVW of 12,000kg.
Passenger vehicles with diesel engines not exceeding a GVW of 10,000kg with more than 8 passenger seats*
(not including driver’s seat).
First registered on or after 1 st January 2005:
(a)
(b)
Goods vehicles exceeding a GVW of 3,500kg,
Passenger vehicles not exceeding a GVW of 10,000kg with more than 8 passenger seats* (not including driver’s
seat).
* NOTE: on a passenger vehicle in this category where the operation, speed set point or speed limiter device cannot be
verified, e.g. where no tachograph is fitted, then the speed limiter test items 03, 04 and 05 (on the page that follows) do
not apply.
For vehicles required to be fitted with a speed limiter, check that a plate is fitted in a conspicuous position in the
driver’s compartment showing the following information:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
the words “speed limiter fitted”,
details of the type approval authority and the national or international approval mark,
the type approval number,
the name of the authorised sealer and the code number assigned to the authorised sealer by the approved body,
i.e. NSAI,
the set speed, expressed in kilometres per hour, to which the speed limitation device has been set,
the tyre size on the axle feeding the speed limiter,
the date on which the speed limitation device was most recently sealed; and,
the vehicle registration number or, in the case of an unregistered vehicle, the VIN.
Open the tachograph head, plug in the speed limiter check instrument, and, following the instrument manufacturer’s
instructions, note the speed at which the speed limiter operates and compare it with the permitted speed for the vehicle
type.
Check that the tyres fitted to the drive axle(s) are the same size as that stated on the speed limiter plate in the driver’s
compartment. Check where possible the integrity of the seals and that they are marked IR.
Check any other security arrangement at the electrical and mechanical connections within the speed limiter system.
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70
SPEED LIMITER
NOTES
(1) Seals may be in the form of lead, plastic, wax or paint.
(2) There will be a small % of vehicles for which the speed limiter check is not suitable. In such
cases check that the tachograph has not recorded a speed in excess of 95 kilometres per hour
in the case of a goods vehicle and 105 kilometres per hour in the case of a passenger vehicle.
ITEM REASONS FOR FAILURE MiD MaD DD
01 Speed Limiter (1) Not fitted where required by law.
(2) Actuating rods/cables disconnected or damaged so that the operation
is obviously affected.
(3) Wiring disconnected or can easily be disconnected by unauthorised
means.
(4) Incorrect Authorised Sealer number.
X
X
X
X
X
02 Speed Limiter Plate (1) Not fitted or not fitted in a conspicuous position.
(2) Required information not available.
X
X
03 Speed Limiter Setting (1) Speed Limiter Check Instrument shows speed in excess of that
permitted for vehicle type (above 90kph for goods vehicles and
100kph for buses).
04 Speed Limiter on
Vehicle with Digital
Tachograph
(1) Overspeed (above 90kph for goods vehicles and 100kph for buses) is
recorded for more than five consecutive minutes over the last twelve
months.
05 Tachograph Chart (1) Tachograph chart shows speed in excess of that permitted for vehicle
type (above 95kph for goods vehicles and 105kph for buses).
X
X
X
06 Tyres (1) Tyre size on drive axle(s) does not corresponded to tyre size stated
on speed limiter plate.
07 Seals (1) Broken or missing or other security arrangements interfered with.
(2) Not marked IR.
X
X
X
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71
MODIFICATIONS REPORT
Method of Testing
1. The vehicle’s owner (or the presenter on the owner’s behalf) shall confirm whether any repairs or
modifications have been carried out to a vehicle since its last CVR test which may adversely affect the
roadworthiness of one or more of the items to be tested (see Note 1).
2. In respect of vehicles modified since their last CVR Test, a modifications report must be provided in the
following cases;
1. The fitment of an extra axle or the removal of an existing axle.
2. Chassis work, including lengthening/shortening the wheel base or the replacement of chassis rails
3. A vehicle which has been converted. This includes (but is not limited to the following):
An M1, M2 or N2 converted to an N1 or motor caravan.
4. Modification to the steering system (this includes power steering and steering wheel).
5. Modification to the suspension system (including modifications to anti-roll bars).
6. Modification to the braking system including changing from disc to drum brakes (or vice versa) and
the addition or removal of equipment.
7. Modifications to seat belts (including anchorages), air bags or the addition of seats.
8. Major modifications to the cab or body work.
9. Modifications or repairs which may adversely affect the roadworthiness of one or more of the items to
be tested as part of the test including where “unsafe repairs or modifications” is specified in this
manual as a reason for failure.
3. Where during the CVR test, the CVR tester notices a repair or modification which may adversely affect the
roadworthiness of any of the test items including where unsafe “repairs or modifications” are specified in
this manual as a reason for failure, the CVR tester shall seek a modifications report in writing substantially
in the form outlined in 4 below. Where a historic report is provided, the CVR tester shall determine whether
this adequately addresses the issue and is in line with the form in 4 below and, if not, shall seek a new
modifications report. As the CVR test is essentially a maintenance and condition check, it is acknowledged
that a tester will not be removing or dismantling any parts in the course of a normal roadworthiness test and
that the finding of any modifications or repairs is based on a visual inspection of the vehicle only.
4. In the case of vehicles requiring a modifications report (as per 1, 2 or 3 above), this report shall be one
issued by the vehicle manufacturer (or his authorised distributor), an authorised representative of an NSAI
approved test centre (ATC) or by a Suitably Qualified Individual. This report shall be on headed notepaper
and must state;
a. Vehicle Make,
b. Vehicle Model and variant,
c. Description of body-type (not code) before and after modification (in the case of a modification). E.g.
flatbed to tipper, or van to motorcaravan,
d. Vehicle Registration Number,
e. VIN,
f. The purpose of the report,
g. The list of modifications or repairs made to the vehicle,
h. The standard of workmanship and specifications,
i. DGVW, & Gross Combination Weight (the original and new, where changed),
j. Unladen Vehicle Weight (the original and new, where changed),
k. That the vehicle is safe to use on the road and that the modification/repair does not diminish the
technical status or integrity of the vehicle or other vehicle components and safety features,
l. That the vehicle meets with the Road Traffic (Construction, Equipment and Use of Vehicles)
Regulations (as amended) and the Road Traffic (Lighting of Vehicles) Regulations as amended,
m. That the vehicle meets with the essential technical provisions of the EU Directives to which the
modification relates for the year of manufacture and category of vehicle concerned.
A template for the modifications report required to be presented can be found on page 152 of this manual.
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71
MODIFICATIONS REPORT
NOTES
(1) In accordance with the Road Traffic (Construction, Equipment and Use of Vehicles)
Regulations, S.I. 190 No. of 1963 (as amended), all vehicles on public roads must conform with
the general principles set down in these Regulations in relation to the condition and
maintenance of vehicles. All parts and equipment of every vehicle shall be in good and
efficient working order. It is each vehicle owner’s responsibility to ensure his or her vehicle is
in compliance with the law and maintained in a roadworthy condition at all times.
(2) A “suitably qualified individual” (SQI) means a mechanical or automotive engineer, an
automotive assessor or a person with similar qualifications who, by reason of his or her
competence, experience and independence, is an appropriate person to assess the fitness
and safety of a vehicle and who carries the appropriate indemnity relative to his or her
position.
(3) A modifications report is not required where:
(a)
a vehicle has been subject to a post registration modification scheme in another
Member State prior to being registered in Ireland and documentation (in English) is
provided from the competent authority in the Member State concerned, giving details
of the nature of the modifications carried out and the VIN of the vehicle.
However, where such documentation has been provided but does not correspond to
modifications identified and which may adversely affect the roadworthiness of the
vehicle then a modifications report for the relevant modifications shall be required.
(b) a vehicle has been type approved and has one of the following certificates of approval
corresponding to the vehicle presented;
EC Certificate of Conformity (EC CoC) for a complete or completed vehicle.
National Small Series Type Approval Certificate of Conformity (Irish NSSTA CoC)
for a complete or completed vehicle.
Individual Vehicle Approval Certificate (Irish IVA Certificate).
However, where such documentation has been provided but does not correspond to
modifications identified and which may adversely affect the roadworthiness of the
vehicle then a modifications report for the relevant modifications shall be required.
ITEM REASONS FOR FAILURE MiD MaD DD
(1) Modifications Report (where
required)
(1) not presented.
(2) incomplete.
(3) not in the form (template) acceptable by CVR tester.
(4) does not correspond with modifications identified by CVR tester.
(5) not acceptable (e.g. expired).
X
X
X
X
X
X
X
X
X
X
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RSA MODIFICATIONS REPORT TEMPLATE (HCV)
(Use Block Capitals Throughout)
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