This instrument is the Vehicle Standard (Australian Design Rule 4/02 , Seatbelts) 2006, made by the Minister under subsection 7(1) of the Motor Vehicle Standards Act 1989 (preamble). It sets technical design, construction, marking, testing and documentation requirements for seatbelt assemblies fitted to vehicles within the ADR category matrix (clause 1.1; clause 2; clause 3). The Standard commences the day after registration (clause 1.2) and expressly repeals earlier instruments bearing the same ADR name that were in force at commencement (clause 1.3.1 and 1.3.2). The instrument is dated 31 July 2006 and signed by the Minister (cover pages).

Mechanically, the Standard prescribes:

which vehicle categories must comply and from what manufacture dates (clause 3.1 and the Applicability Table);
the mandatory types of seatbelt assemblies and retractor types for particular seating positions (clause 5.3; clause 9);
construction and marking obligations for seatbelt components and assemblies (clauses 5.4-5.8; 5.7);
adjustment, buckle and accessibility design criteria expressed by dimensional boundaries and occupant anthropometry (clauses 6, 7, 16; Figure 2 and table);
dynamic, durability and environmental preconditioning and performance testing procedures including retractor durability, dynamic test rig calibration, dummy calibration and dynamic test preconditioning (clauses 10-15);
special, more stringent options for larger vehicle categories (MD3, MD4, ME, NB2, NC) including salt-fog corrosion conditioning, and acceptance of a small set of alternative standards where equivalence conditions are met (clauses 17-19; 20; Appendix A).

The Standard allows conformity to specified Australian Standards (AS 2596-1983 and associated AS 2597 series) or other Approved equivalent standards (clause 5.8.1-5.8.2; clause 17.2; clause 20.1). It also deems compliance with ECE Regulation 16/04 acceptable provided particular additional Australian requirements are met (clause 20.1). Appendix A reproduces modified ECE 16/04 text for the special class of ‘Type 4N Retractors’.

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Vehicle Standard (Australian Design Rule 4/024/02 – SeatbeltsSeatbelts) 20062006

I, JAMES ERIC LLOYD, Minister for Local Government, Territories and Roads, determine this vehicle standard under subsection 7 (1) of the Motor Vehicle Standards Act 1989.

Dated 31 July 2006

[SIGNED]

James Eric Lloyd

Minister for Local Government, Territories and Roads

CONTENTS

1. legislative provisions..............................................

2. function and SCOPE..............................................

3. APPLICABILITY................................................

4. DEFINITIONS...................................................

5. REQUIREMENTS................................................

6. ADJUSTMENT REQUIREMENTS..................................

7. BUCKLE REQUIREMENTS.......................................

8. GENERAL REQUIREMENTS FOR SEATBELT COMPONENTS.........

9. RETRACTORS (other than ‘TYPE 4N RETRACTORS’ )..................

10. DYNAMIC TEST REQUIREMENTS................................

11. RETRACTOR DURABILITY TEST.................................

12. DYNAMIC TESTING PROCEDURE................................

13. TEST DUMMY REQUIREMENTS..................................

14. DUMMY CALIBRATION.........................................

15. TEST RIG CALIBRATION........................................

16. COMPONENT BOUNDARY LOCATION............................

17. DETAILED REQUIREMENTS FOR VEHICLE CATEGORIES MD3, MD4, ME, NB2 AND NC ONLY

18. CORROSION CONDITIONING PROCEDURE FOR SEATBELT ASSEMBLIES FITTED IN ACCORDANCE WITH CLAUSE 17

19. ADJUSTMENT REQUIREMENTS FOR VEHICLE CATEGORIES MD3, MD4, ME, NB2 AND NC ONLY

20. ALTERNATIVE STANDARDS.....................................

Appendix A............................................................

legislative provisions
NAME OF STANDARD 1. This Standard is the Vehicle Standard (Australian Design Rule 4/02 – Seatbelts) 2006. 2. This Standard may also be cited as Australian Design Rule 4/02 — Seatbelts.
COMMENCEMENT 1. This Standard commences on the day after it is registered.
REPEAL 1. This Standard repeals each vehicle standard with the name Australian Design Rule 4/02 — Seatbelts that is:

(a) made under section 7 of the Motor Vehicle Standards Act 1989; and

(b) in force at the commencement of this Standard.

1.3.2. This Standard also repeals each instrument made under section 7 of the Motor Vehicle Standards Act 1989 that creates a vehicle standard with the name Australian Design Rule 4/02 — Seatbelts, if there are no other vehicle standards created by that instrument, or amendments to vehicle standards made by that instrument, that are still in force at the commencement of this Standard.

2. function and SCOPE

The function of this Australian Design Rule is to specify requirements for seatbelts to restrain vehicle occupants under impact conditions, to facilitate fastening and correct adjustment, to assist the driver to remain in his ‘Seat’ and thus maintain control of the vehicle in an emergency situation, and to provide protection against ejection in an accident situation.

3. APPLICABILITY

3.1. Applicability Summary

3.1.1. Subject to clause 3.1.2, this ADR applies to the design and construction of vehicles as set out in the table below.

3.1.2. Where ECE 16/04 was used as the Alternative Standard, vehicles meeting the requirements of any of the Acceptable Prior Rules shown below in the Applicability Table for a particular category are deemed to comply with this rule.

3.1.3. For omnibuses complying with ADR 68/.. only the driver’s seatbelt is required to comply with clauses 17 to 19 of this rule

3.2. Applicability Table

Vehicle Category ADR Category Code [*] UNECE Category Code * Manufactured on or After Acceptable Prior Rules
Moped 2 wheels LA L1 Not Applicable
Moped 3 wheels LB L2 Not Applicable
Motor cycle LC L3 Not Applicable
Motor cycle and sidecar LD L4 Not Applicable
Motor tricycle LE L5
LEM Not Applicable
LEP 1 July 1996 /01
LEG 1 July 1996 /01
Passenger car MA M1 1 July 1996 /00 /01
Forward-control passenger vehicle MB M1 1 July 1996 /00 /01
Off-road passenger vehicle MC M1 1 July 1996 Nil
Light omnibus MD M2
up to 3.5 tonnes ‘GVM’ and up to 12 seats MD1 1 July 1996 /00 /01
up to 3.5 tonnes ‘GVM’ and more than 12 seats MD2 1 July 1996 /01
over 3.5 tonnes and up to 4.5 tonnes ‘GVM’ MD3 1 July 1996 /01
over 4.5 tonnes and up to 5 tonnes ‘GVM’ MD4 1 July 1996 /01
Heavy omnibus ME M3 1 July 1996 /01
Light goods vehicle NA N1 1 July 1996 Nil
Medium goods vehicle NB N2
over 3.5 tonnes up to 4.5 tonnes ‘GVM’ NB1 1 July 1996 /00 /01
over 4.5 tonnes up to 12 tonnes ‘GVM’ NB2 1 July 1996 /01
Heavy goods vehicle NC N3 1 July 1996 /01
Very light trailer TA O1 Not Applicable
Light trailer TB O2 Not Applicable
Medium trailer TC O3 Not Applicable
Heavy trailer TD O4 Not Applicable

4. DEFINITIONS

4.1. Refer to Vehicle Standard (Australian Design Rule Definitions and Vehicle Categories) 2005.

5. REQUIREMENTS

5.1. General

5.1.1. Vehicle categories LEP, MA, MB, MC, NA and MD1 must comply with clauses 5.2 to 16.

5.1.2. Vehicle categories LEG, MD2 and NB1 must comply with either:

5.1.2.1. clauses 5.2, 5.3.1 (excluding 5.3.1.3 and 5.3.1.4) and 5.4 to 16 (excluding 10.2 and 10.3, for omnibuses); or

5.1.2.2. clause 5.1.1.

5.1.3. Vehicles categories MD3, MD4, ME, NB2 and NC must comply with either:

5.1.3.1. clauses 5.2, 5.3.1 (excluding 5.3.1.3 and 5.3.1.4), 5.3.2, 5.3.3 and 17 to 19; or

5.1.3.2. clause 5.1.1.; or

5.1.3.3. clause 5.1.2 (except that cl. 5.3.2 and 5.3.3 must be complied with).

5.2. ‘Seatbelts Assemblies’ of a type determined by the ‘Anchorage’ system must be fitted to each seating position for which seatbelt ‘Anchorages’ are required in accordance with ADR 5/... .

5.2.1. Threaded steel bolts of 7/16 inch - 20 UNF - 2A are recommended for attachment to the vehicle.

5.3. Type of ‘Seatbelt Assembly’

5.3.1. A ‘Lap-Sash Belt’ or ‘Harness Belt’ must:

5.3.1.1. when fitted to the driver’s seating position incorporate an ‘Emergency Locking Retractor’.

5.3.1.1.1. Where the driver’s ‘Seat’ is a ‘Suspension Seat’ and not all the ‘Anchorages’ are mounted on the moving part of the ‘Seat’, the retractor must be a ‘Type 4N Retractor’.

5.3.1.2. when fitted to the other front ‘Outboard Seating Position’, incorporate an ‘Emergency Locking Retractor’ or an ‘Automatic Length Adjusting and Locking Retractor’;

5.3.1.3. when fitted to any ‘Outboard Seating Position’ of a ‘Second Row Seat’ incorporate an ‘Emergency Locking Retractor’ or an ‘Automatic Length Adjusting and Locking Retractor’; and

5.3.1.4. when fitted to any ‘Outboard Seating Position’ other than the driver’s seating position in a forward-control passenger vehicle (MB); or an omnibus (MD1) incorporate an ‘Emergency Locking Retractor’ or an ‘Automatic Length Adjusting and Locking Retractor’.

5.3.2. For an ME or NC vehicle, a ‘Lap Belt’ must incorporate an ‘Emergency Locking Retractor’ when fitted to the driver’s seating position.

5.3.3. For an ME or NC vehicle, a ‘Lap Belt’ must, incorporate either an ‘Emergency Locking Retractor’ or an ‘Automatic Length Adjusting and Locking Retractor’ when fitted to the other front ‘Outboard Seating Position’.

5.4. Removal of the ‘Seatbelt Assembly’ from the vehicle or separation of any ‘Functional Components’ must not be possible without the use of tools except in the case of:

5.4.1. the unlatching of the ‘Buckle Components’;

5.4.2. a ‘Sash Guide’ device which is both:

5.4.2.1. designed to separate from its supporting structure or fail to retain the strap upon application of the ‘Anchorage’ test loads ADR 5/... ; and

5.4.2.2. for which more than one point of attachment to the vehicle is available to provide the occupant with a choice of sash ‘Strap’ positions relative to his shoulder; or

5.4.3. the torso ‘Strap’ of a ‘Lap-Sash Belt’ ‘Seatbelt Assembly’ fitted to an ‘Outboard Seating Position’ where the seat is designed to provide adjustment for conversion of occupant space to luggage or goods space and such seating position is not the driver’s or front ‘Seat’ passenger’s seating position or the seating position immediately to the rear thereof.

5.4.4. The provisions of clause 5.4.3 above must apply notwithstanding the requirements of clause 5 of AS 2596-1983 “Seat Belt Assemblies for Motor Vehicles”.

5.5. In the case where a ‘Lap-Sash Belt’ ‘Seatbelt Assembly’ is provided with a torso ‘Strap’ designed to be removed or separated from the ‘Seatbelt Assembly’ in accordance with the provisions of clause 5.4 the requirements of this rule must apply to the ‘Seatbelt Assembly’ as:

5.5.1. a ‘Lap-Sash Belt’ with the torso ‘Strap’ operative; or

5.5.2. a ‘Lap Belt’ with the sash ‘Strap’ so removed or separated.

5.6. Any single component of the ‘Seatbelt Assembly’ having a mass in excess of 75 g other than a ‘Strap’, ‘Anchor Fitting’ or ‘Sash Guide’ device must be located in areas other than that area forward of the ‘Torso Reference Line’ and between Line A and Line B when the assembly is correctly fitted for a ‘95th Percentile Adult Male’ and ‘50th Percentile 6 Years Old Child’ independently.

5.7. Each ‘Seatbelt Assembly’ must be permanently and legibly marked with at least the manufacturer’s name or trade mark, date of manufacture by month and year, and identification code. The identification code must be a number and/or symbol which uniquely identifies the ‘Seatbelt Assembly’ or sub-assembly design.

5.7.1. The same identification code may be used on two or more assembly or sub-assembly designs which are identical except for variations in ‘Strap’ length which do not exceed:

5.7.1.1. 25 mm in the case of a ‘Strap’ which has a length critical to the correct location of the ‘Lap-Sash Point’; or

5.7.1.2. 100 mm in the case of other ‘Straps’.

5.7.2. Furthermore, where a manufacturer, for “in-service” replacement purposes, provides for replacement of parts of a ‘Seatbelt Assembly’ rather than the assembly as a whole, each of the 2 sub-assemblies of the ‘Seatbelt Assembly’ which can be separated from each other by the normal unlatching process must be permanently and legibly marked in accordance with the requirements of this clause.

5.8. ‘Seatbelt Assemblies’ must comply with either:

5.8.1. The AS 2596 referred to in clause 5.4.4 of this rule but excluding clauses 1,2,4,15,16,17,18 and AS 2597.13 - 1983: “Determination of Dynamic Performance”;

5.8.1.1. the maximum dummy displacement limit in AS 2596-1983 section 14.1 (c), does not apply to ‘Seatbelt Assemblies’ required to comply with ADR 69/...

5.8.1.2. ‘Seatbelt Assemblies’ required to comply with ADR 69/... need not comply with the elongation and Hysteresis requirements specified in section 6.5 of AS 1753 - 1990; or

5.8.2. any other ‘Approved’ standard accepted as equivalent.

5.9. Instructions for use of ‘Seatbelt Assemblies’ must be included in the vehicle handbook, or otherwise supplied with the vehicle. The instructions must include the following text:

5.9.1. “WARNING: Seatbelts are designed to bear upon the bony structure of the body, and should be worn low across the front of the pelvis or the pelvis, chest and shoulders, as applicable; wearing the lap section of the belt across the abdominal area must be avoided.

“Seatbelts should be adjusted as firmly as possible, consistent with comfort, to provide the protection for which they have been designed. A slack belt will greatly reduce the protection afforded to the wearer.

“Care should be taken to avoid contamination of the webbing with polishes, oils and chemicals, and particularly battery acid. Cleaning may safely be carried out using mild soap and water. The belt should be replaced if webbing becomes frayed, contaminated or damaged.

“It is essential to replace the entire assembly after it has been worn in a severe impact even if damage to the assembly is not obvious.

“Belts should not be worn with straps twisted.

“Each belt assembly must only be used by one occupant; it is dangerous to put a belt around a child being carried on the occupant’s lap.”

5.9.2. In the case where a ‘Seatbelt Assembly’ incorporates an ‘Automatic Length Adjusting and Locking Retractor’ or an ‘Emergency Locking Retractor’:

5.9.2.1. “WARNING: No modifications or additions should be made by the user which will either prevent the seat belt adjusting devices from operating to remove slack, or prevent the seat belt assembly from being adjusted to remove slack.”; plus

5.9.2.2. a description of the adjustments necessary to ensure that the lap and sash portions of the ‘Seatbelt Assembly’ fit as firmly as possible consistent with comfort; and

5.9.2.3. instructions on the correct use of any device or devices included in the ‘Seatbelt Assembly’ which, upon manual or automatic operation, prevent the belt from being retracted.

5.10. When installed the ‘Seatbelt Assembly’ webbing must not contact any sharp edges which could abrade or cut the webbing during normal use or in an accident. If necessary, the webbing must be protected.

6. ADJUSTMENT REQUIREMENTS

6.1. Each ‘Seatbelt Assembly’ must be so designed that, with the adjustment provided, it must be capable of being ‘Correctly Fitted’ for:

6.1.1. in the case of the driver’s seating position, a ‘5th Percentile Adult Female’ with the seat in the rearmost driving position and a ‘95th Percentile Adult Male’ with the ‘Seat’ in the foremost driving position; and

6.1.2. if installed at any other seating position, a ‘50th Percentile 6 Years Old Child’ with the ‘Seat’ in the rearmost riding position and a ‘95th Percentile Adult Male’ with the ‘Seat’ in the foremost riding position.

6.1.3. Furthermore, in the case of the fittings to the ‘95th Percentile Adult Male’ in 6.1.1 and 6.1.2 above, the design must provide for at least 75 mm of additional ‘Strap’ in a ‘Lap Belt’ and at least 75 mm of additional ‘Strap’ in both the lap ‘Strap’ and upper torso ‘Strap’ of a ‘Lap-Sash Belt’ or ‘Harness Belt’. The purpose of this clause is to accommodate a stouter person than represented by the 95th percentile anthropometric dimensions.

6.2. In the case of a ‘Seatbelt Assembly’ incorporating a manual adjusting device, the following requirements must be met when the assembly is correctly fitted for a ‘95th Percentile Adult Male’ and a ‘50th Percentile 6 Years Old Child’ independently, when the ‘Seat’ is in the foremost riding or driving position (Figure 2 refers):

6.2.1. for tightening, the adjustment must be by a single action at an ‘Accessible’ point which lies between Line C and Line E and ‘Forward’ of Line FOS; and

6.2.2. for loosening, the entire adjusting device must lie between Line C and Line D and ‘Forward’ to Line KPS and there must be one point on the device which is ‘Accessible’.

6.2.3. For the purpose of determining whether the point is ‘Accessible’, the dummy or occupant may be removed.

6.3. Any free end of a ‘Strap’ must:

6.3.1. be designed so as to prevent it from passing through the adjuster under normal adjustment operations, and with the strap fully extended the ‘Strap’/adjuster combination must be capable of withstanding, for not less than 30 seconds a static tensile load of 9 kN applied to the load bearing end of ‘Strap’ with the adjuster restrained as in the vehicle; and

6.3.2. be restrained by a positive design feature to adopt a position against another ‘Strap’. The free end of a ‘Strap’ on any seat belt for a centre seating position or for an ‘Outboard Seating Position’ not adjacent to a vehicle door need not meet this requirement.

6.3.3. Further, with the ‘Strap’ fully extended, there must be not less than 25 mm of material extending from the device to provide a grip for adjustment purposes. The material may either be attached to or form part of the free end of the ‘Strap’.

7. BUCKLE REQUIREMENTS

7.1. It must not be possible to adjust a ‘Lap-Sash Belt’ so that when correctly fitted for a ‘5th Percentile Adult Female’, the ‘Lap Sash Point’ is less than 125 mm in the case of ‘Seats’ with ‘Forward’ and ‘Rearward’ adjustment, or 175 mm in the case of fixed ‘Seats’, from the ‘Seating Reference Plane’ when measured along the centreline of the pelvic restraint section of the belt. This requirement must be met with the ‘Seat’ in its foremost and rearmost driving or riding position and with the ‘Seat’ back at the design ‘Seat Back Angle’.

7.2. In cases where the ‘Buckle Component’ of a ‘Lap-Sash Belt’ ‘Strap’ can be latched with part of an assembly intended for an adjacent seating position, the design must be such that the requirements of clause 7.1 are met irrespective of the combination used.

7.3. In cases where the ‘Buckle Component’ of a ‘Seatbelt Assembly’ can be engaged either wholly or partially with the ‘Buckle Component’ of a ‘Seatbelt Assembly’ intended for an adjacent seating position, the design must be such that the ‘Seatbelt Assembly’ so formed must comply with the requirements of clause 14 of the AS 2596 - 1983 “Seat Belt Assemblies for Motor Vehicles”.

7.3.1. This requirement must apply irrespective of whether the wholly or partially engaged components will separate without operation of the unlatching device.

7.3.2. This requirement must not apply in cases where ‘Seatbelt Assemblies’ fitted to adjacent seating positions are from the same manufacturer and have the same buckle design.

7.4. In the case of a ‘Lap-Sash Belt’ incorporating a retractor, the design must be such that in the fully retracted position, the ‘Buckle Component’ associated with the retracting ‘Strap’ must adopt a position that is either:

7.4.1. ‘Accessible’; and

7.4.2. within 300 mm of both foremost and rearmost points on the ‘Seating Reference Locus’ when viewed in side elevation or within 300 mm of Point 0 and Point N when viewed in side elevation; and

7.4.3. within 400 mm of the ‘Seating Reference Plane’ when viewed in plan; or

7.4.4. can be moved to a position which meets the requirements of clauses 7.4.1 to 7.4.3 above by a manual operation applied to the assembly at points which meet the requirements of clauses 7.4.1 to 7.4.3.

7.4.5. This requirement must not apply to a seating position adjacent to an access door, where the ‘Seat’ must hinge or fold to permit access to another seating position.

7.5. In the case of a vehicle with one front seating position only, or with 2 front ‘Seats’ each providing for one seating position only, the ‘Buckle Component’ on that part of a ‘Lap-Sash Belt’ which does not include the retracting ‘Strap’ must be supported by a rigid member which may pivot, or in such a manner that after being correctly fitted for a ‘95th Percentile Adult Male’ with the ‘Seat’ in the foremost driving or riding position, unlatching of the buckle assembly and removal of the occupant from the seating position does not result in any point on the component moving downwards such that the vertical component of movement is more than 50 mm.

7.5.1. When unlatched after the assembly has been correctly fitted for a ‘95th Percentile Adult Male’ with the ‘Seat’ in the foremost driving or riding position and a ‘5th Percentile Adult Female’ with the ‘Seat’ in the rearmost driving or riding position, independently, there must be a point on the component which is:

7.5.1.1. ‘Accessible’;

7.5.1.2. within 300 mm of both the foremost and rearmost points on the ‘Seating Reference Locus’ when viewed in side elevation; and

7.5.1.3. within 150 mm to 400 mm of the ‘Seating Reference Plane’ when viewed in plan.

7.5.2. For the purpose of determining whether the point is ‘Accessible’, the dummy or occupant may be removed.

7.6. In the case of outboard seating positions not provided for in clause 7.5 the part of the assembly which does not include the ‘Strap’ designed to pass over the torso of the occupant must be so restrained by a positive design feature that one point at least cannot pass ‘Rearward’ of the line of contact of the ‘Seat’ cushion with the ‘Seat’ back.

7.6.1. The line of contact of the ‘Seat’ cushion with the ‘Seat’ back is the front boundary of the area of contact across the ‘Seat’ width of the ‘Seat’ cushion with the ‘Seat’ back when the ‘Seat’ cushion is unoccupied.

7.6.2. The requirements of clause 7.6 must be met when a folding or hinged ‘Seat’ is in its normal position. Re-establishment of such a ‘Seat’ may include a manual operation to re-establish part of the ‘Seatbelt Assembly’.

7.7. In the case of ‘Lap-Sash Belt’ assemblies not incorporating ‘Emergency Locking Retractors’, or ’Automatic Length Adjusting and Locking Retractors’ fitted to outboard seating positions vehicles.

7.7.1. The design must provide for a stowage feature for the part of the assembly which includes the ‘Strap’ designed to pass over the pelvis or torso of the occupant, to facilitate that part of the assembly, when unlatched, being kept clear of the vehicle floor and the lower edge of the door opening.

7.8. The area of vehicle floor does not include areas which are inaccessible to the occupant’s feet during travel or during entry and exit.

8. GENERAL REQUIREMENTS FOR SEATBELT COMPONENTS

8.1. In all cases where the ‘Strap’ passes through another component, other than a ‘Sash Guide’ used in conjunction with an ‘Emergency Locking Retractor’, and there is relative movement between the ‘Strap’ and the component as a result of adjusting operations, the tensile strength of the webbing must not be reduced to less than 14.7 kN or 75% of the ‘Dry Breaking Strength’, whichever is the greater, after 2,500 cycles of relative movement under the following test conditions:

8.1.1. the tensile load in all parts of the test ‘Strap’ during the working stroke of the 2 strokes of each cycle must be not less than 13 N;

8.1.2. the working stroke must be not less than 150 mm nor more than 200 mm; and

8.1.3. the angle which the centreline of each end of the test ‘Strap’ makes with the component must be not less critical to ‘Strap’ abrasion than that nominated by the vehicle ‘Manufacturer’ as representative of such angle of the ‘Strap’ in use, when the assembly is correctly fitted for a ‘5th Percentile Adult Female’ with the ‘Seat’ in the rearmost driving or riding position, except that in the case where the design provides for the centrelines of the straps to be separated when viewed normal to the plane of one ‘Strap’, then such angle of separation in the test may be any angle greater than 25°, and the angle of separation of the centrelines of the ‘Straps’ when viewed in the plane of one ‘Strap’ may be any angle less than l0°.

8.2. In the case of a ‘Lap-Sash Belt’ incorporating an ‘Emergency Locking Retractor’ (other than a ‘Type 4N Retractor’), where, during the wearing and retracting operations, there is relative movement between the retracting ‘Strap’ and the ‘Sash Guide’ system other than the retractor itself the tensile strength of the webbing must not be reduced to less than 14.7 kN or 75% of the ‘Dry Breaking Strength’, whichever is the greater, after the retracting ‘Strap’ has been drawn through the ‘Sash Guide’ system for 50,000 cycles under the following test conditions:

8.2.1. the tensile load in all parts of the test ‘Strap’ during the working stroke of the 2 strokes of each cycle must not be less than 18 N;

8.2.2. the tensile load in the test ‘Strap’ at one point in the cycle must be reduced to zero;

8.2.3. the working stoke must be not less than 200 mm;

8.2.4. the orientation of the test ‘Strap’ relative to the ‘Sash Guide’ must be such that:

8.2.4.1. the ‘Sash Guide’ must be in its design configuration except that, for ‘Sash Guides’ designed to pivot, the angle of the axis of rotation may vary from its design configuration provided that such variation is not greater than 5°.

8.2.4.2. the part of the test ‘Strap’ which simulates the ‘Strap’ passing from the ‘Sash Guide’ to the next ‘Sash Guide’ or to the retractor, must be in the design configuration; and

8.2.4.3. the part of the test ‘Strap’ which simulates the torso ‘Strap’ must be pulled in a vertical plane not more than 45° or a longitudinal plane when viewed in plan, and the direction of pull in that plane must vary over a range of not less than 65° during the working stroke of each cycle; and

8.2.5. all ‘Sash Guides’ for the one assembly must be tested simultaneously.

8.2.6. The requirements of this clause must not apply to relative movement between the ‘Strap’ and the retractor, at the retractor.

8.3. Buckle-Spring Fatigue Resistance

8.3.1. In the case where a spring is incorporated in the unlatching mechanism of a buckle, the load required to operate the spring must not be reduced by more than 20% after the spring has been subjected to 50,000 operations each involving a movement not less than 95% of the design movement for buckle unlatching.

9. RETRACTORS (other than ‘TYPE 4N RETRACTORS’ )

9.1. All retractors incorporated in ‘Seatbelt Assemblies’ must comply with the requirements of clause 9.2 and either clause 9.3 or 9.4.

9.2. General Requirements for Retractors

9.2.1. After being subjected to the retractor durability test of clause 11, the retractor must:

9.2.1.1. when locked, either:

9.2.1.1.1. withstand a tensile load of not less than 9 kN applied to the ‘Strap’; or

9.2.1.1.2. be subjected to the strength of assembly test of clause 14.1 of AS 2596-1983 “Seat Belt Assemblies for Motor Vehicles”.

9.2.1.2. withstand a tensile load of not less than 9 kN applied to the ‘Strap’. For the purpose of this test the ‘Strap’ must be fully withdrawn and the locking mechanism must be rendered inoperative.

9.2.2. In cases where the retracting ‘Strap’ of a ‘Lap-Sash Belt’ is the torso ‘Strap’, the retraction force in the ‘Strap’ before and after the retractor has been subjected to the retractor durability test of clause 11, must be not less than 2 N nor more than l0 N, under the following test conditions:

9.2.2.1. the ‘Sash Guide’ system and the retractor must be in the design configuration. In the case of a ‘Sash Guide’ system with an adjustable ‘Sash Guide’ the retractor must be capable of meeting the requirements of this clause with the ‘Sash Location Point’ set in any position of adjustment;

9.2.2.2. the part of the test ‘Strap’ which simulates the torso ‘Strap’ must be withdrawn through the ‘Sash Guide’ system until it is within 430 mm of its fully extended condition;

9.2.2.3. the ‘Strap’ must be allowed to retract until a point on the ‘Strap’ is 450 ± 20 mm, measured along the ‘Strap’ from its position when the ‘Strap’ is fully extended. It must then be held stationary at this extension by a force applied in a downward direction at 20 ±10° to the vertical in a vertical plane which is at 35 ±10° to a longitudinal plane when viewed in plan, and must not be withdrawn again until the retracting force has been determined;

9.2.2.4. the retraction force must be measured in the test ‘Strap’ ‘Forward’ of the point where it would contact the first ‘Sash Guide’ device after passing over the shoulder of the wearer; and

9.2.2.5. where the assembly incorporates a device that upon manual or automatic operation, prevents the belt from being completely retracted, such a device must not be operating when this requirement is assessed.

9.3. ‘Automatic Length Adjusting and Locking Retractors’

9.3.1. The locking mechanism of an ‘Automatic Length Adjusting and Locking Retractor’ must be designed to provide a locked position for at least every 30 mm of ‘Strap’ extension from the position when the ‘Seatbelt Assembly’ is correctly fitted for a ‘50th Percentile 6 Years Old Child’, with the ‘Seat’ in the rearmost riding position.

9.4. ‘Emergency Locking Retractors’ (other than ‘Type 4N Retractors’, see Appendix A).

9.4.1. ‘Emergency Locking Retractors’ must lock when the retractor and any associated devices to sense acceleration are accelerated at not more than 5 m/s2, the peak acceleration being attained in not less than 40 milliseconds.

9.4.2. Furthermore with a point on the external ‘Strap’ fixed the locking device must limit ‘Strap’ movement, measured from the time of application of the acceleration, to not more than:

9.4.2.1. 30 mm, when the ‘Strap’ is withdrawn to a point which is 150 ± 5 mm from the fully extended position; and

9.4.2.2. 80 mm, when the ‘Strap’ is withdrawn to points 450 ± 5 mm and 760 ± 5 mm from the fully extended position, if the ‘Seatbelt Assembly’ includes sufficient ‘Strap’ to attain these extensions.

9.4.3. This requirement must be met under positive and negative acceleration in longitudinal, transverse and vertical directions, except that in cases where the device is designed to lock when tilted to any angle in excess of 45° then the locking requirement need be met for longitudinal and transverse directions only.

9.4.4. Sensing of acceleration to meet the requirements of this clause must not be dependent upon rate of withdrawal of ‘Strap’ from the retractor. In demonstrating this requirement, any device dependent for sensing of acceleration on withdrawal of ‘Strap’ from the retractor may be rendered inoperative.

9.4.5. ‘Emergency Locking Retractors’ must be designed in such a way that when the ‘Strap’ is extended at an acceleration of not more than 20 m/s2 locking occurs within 25 mm of ‘Strap’ extension. This requirement must be met at an extrapolated point representing full extension based on test results achieved at points of extension which are less than the full extensions by 150 ± 5 mm, 450 ± 5 mm, and 750 ± 5 mm (if available), respectively.

9.4.6. An ‘Emergency Locking Retractor’ must be designed to lock automatically, or meet the requirements of clauses 9.4.1 and 9.4.5 upon any single mechanical failure of a spring which is part of the locking mechanism.

9.4.7. In cases where the operation of a retractor depends on an external signal or power source, the design must ensure that the retractor locks automatically upon failure or interruption of that signal or power source.

9.4.8. The design of an ‘Emergency Locking Retractor’ must ensure that it remains unlocked when the vehicle is tilted up to 12°, longitudinally or transversely, from the horizontal.

10. DYNAMIC TEST REQUIREMENTS

10.1. ‘Seatbelt Assemblies’ for front facing ‘Seats’ must not separate within themselves or from any ‘Anchorage’, when tested in accordance with the dynamic test procedure of clause 12.

10.2. Prior to the dynamic test, each ‘Seatbelt Assembly’ must be subjected to the preconditioning requirements of clause 10.3.

10.3. Dynamic Test Preconditioning

10.3.1. Any ‘Buckle Component’ or manual adjusting device which can take up a position in a door opening, or under a pivoting ‘Seat’, must be placed on a flat surface in its most stable position and subjected to a force of not less than 1.8 kN for a period of not less than 10 seconds. The force must be applied through a rigid bar of diameter not more than 20 mm formed to an arc of radius not more than 150 mm, with the bar in line with the ‘Strap’ when viewed in plan, and the test must be repeated with the bar normal to the direction of the ‘Strap’ when viewed in plan.

10.3.2. The buckle assembly must be subjected to not less than 20,000 unlatching operations. During each unlatching operation a tensile load of not less than 20 N must be applied to the assembly.

10.3.3. Each ‘Seatbelt Assembly’ which contains non-metallic material (other than a webbing ‘Strap’) must be exposed to environment over a water surface within a closed space, the environment having a temperature of not less than 80°C, for a continuous period of not less than 24 hours and then cooled in an environment having a temperature not exceeding 23°C. The cooling period must immediately be followed by three consecutive 24 hour cycles with each cycle comprising the following consecutive sequences:

10.3.3.1. an environment having a temperature of not less than l00°C must be maintained for a continuous period of 6 hours and this environment must be attained within 80 minutes of commencement of the cycle; then

10.3.3.2. an environment having a temperature of not more than 0°C must be maintained for a continuous period of 6 hours and this environment must be attained within 20 minutes; then

10.3.3.3. an environment having a temperature of not more than 23°C must be maintained during the remainder of the 24 hour cycle.

11. RETRACTOR DURABILITY TEST

The ‘Seatbelt Assembly’ must be prepared, conditioned and tested to AS 2597.9-1983 “Preparation and Conditioning of Test Specimens for Retractor Function”.

12. DYNAMIC TESTING PROCEDURE

12.1. The test rig must have a mass of not less than 380 kg and must meet the requirements of clause 15 for test rig calibration. It must comprise either:

12.1.1. a trolley and ‘Seat’ as specified in clauses 14.1 and 14.2 for dummy calibration, and with ‘Anchorages’ and ‘Sash Guide’ devices within l00 mm of their design positions with the test seat datum point assumed to coincide with the ‘Seating Reference Point’; or

12.1.2. a trolley and a vehicle body shell complete with a representative ‘Seat’ adjusted to the rearmost driving or riding position.

12.2. A dummy meeting the requirements of clause 13 must be placed in the appropriate seating position so that its centre-line lies in the ‘Seating Reference Plane’ and such that it is restrained by the ‘Seatbelt Assembly’ as follows:

12.2.1. in the case of ‘Seatbelt Assemblies’ incorporating retractors, the belt must be manually adjusted around the dummy to eliminate slack; and

12.2.2. in the case of other ‘Seatbelt Assemblies’, a spacer of flexible but substantially incompressible material not less than 25 mm thick and at least as wide and as long as the dummy’s back must be placed behind the back of the dummy. The assembly must be adjusted to eliminate slack and the spacer then removed. The dummy must be re-positioned so that its back is in contact with the ‘Seat’ back.

12.3. The rig must be operated in a manner identical in all operational respects to that specified in clause 15.1 for rig calibration except that in this case the dummy replaces the inert mass.

13. TEST DUMMY REQUIREMENTS

13.1. The dummy must have a mass of 74 ± 2 kg.

13.2. When tested in accordance with the requirements of clause 14 for dummy calibration, the test dummy must give rise to ‘Seatbelt Assembly’ loads such that the sum of the peak restraining forces in each length of the sash ‘Strap’ which is not in contact with the dummy is not less than l0 kN, and also that the sum of the peak restraining forces in each length of the lap ‘Strap’ which is not in contact with the dummy is not less than l0 kN.

14. DUMMY CALIBRATION

14.1. The test rig must have a mass of not less than 380 kg and, must meet the requirements of clause 15 for test rig calibration. It must comprise a trolley, test ‘Seat’, foot rest, and structure for providing seatbelt ‘Anchorages’, meeting the dimensional requirements indicated in Figure 1.

14.2. The ‘Seat’ base surface must not be designed with energy absorbing characteristics and must present a smooth surface for the dummy.

14.3. The dummy must be restrained by separate ‘Lap Belts’ and sash belts, each of which comprises load bearing material having an elongation of not less than 12% when subjected to a load of 11 kN. The method of test of elongation must be determined by the method described in AS 1753-1975: “Webbing for Restraining Devices for Occupants of Motor Vehicles”, except that the specimen must be loaded to 11 kN in lieu of the load specified in the Australian Standard.

14.4. The ‘Lap Belts’ and sash belts must be adjusted to eliminate slack.

14.5. The rig must be operated in a manner identical in all operational respects to that specified in clause 15.2 for rig calibration except that in this case the dummy replaces the inert mass.

15. TEST RIG CALIBRATION

15.1. In the case of calibration prior to seat belt testing, the test rig, to which a mass of 74 ± 2 kg is rigidly attached, when subjected to a velocity change of not less than 49 km/h, must achieve within 30 milliseconds a ‘Forward’ deceleration measured in the vicinity of a lap ‘Anchorage’ of at least 235 m/s2 and must maintain this deceleration, except for periods of less than one millisecond, for not less than 20 milliseconds.

15.2. In the case of calibration prior to proving the dummy, the test rig, to which a mass of 74 ± 2 kg is rigidly attached, when subjected to a velocity change of not less than 49 km/h, must achieve within 30 milliseconds, a ‘Forward’ deceleration measured in the vicinity of a lap ‘Anchorage’, within the range 235 to 335 m/s2 and must maintain this deceleration, except for periods of less than one millisecond, for not less than 20 milliseconds.

16. COMPONENT BOUNDARY LOCATION

16.1. The lines shown in Figure 2 in side elevation are established as follows:

16.1.1. Line A is a horizontal line 850 mm above the ‘Seating Reference Point’;

16.1.2. Line B is a horizontal line 330 mm above the ‘Seating Reference Point’;

16.1.3. Line C is a horizontal line 680 mm above the ‘Seating Reference Point’;

16.1.4. Line D is a horizontal line 150 mm below the ‘Seating Reference Point’;

16.1.5. Line E is a horizontal line 75 mm below the ‘Seating Reference Point’;

16.1.6. Line FOS consists of 2 lines FO and OS and is constructed as follows:

16.1.6.1. draw line FO parallel to the ‘Torso Reference Line’ and intersecting Line G at Point 0, such that the extension of Line FO passes through the most ‘Forward’ point on the ‘Seating Reference Locus’; and

16.1.6.2. draw a vertical Line OS intersecting Line G at Point 0;

16.1.7. Line KPS consists of 2 Lines KP and PS and is constructed as follows:

16.1.7.1. draw Line KP parallel to and l00 mm ‘Rearward’ of Line FO (established above) intersecting Line OS at P; and

16.1.7.2. Line PS is coincident with Line OS,

16.1.8. Line G is a horizontal Line 380 mm above the ‘Seating Reference Point’, intersecting the ‘Torso Reference Line’ at Point N; and

16.1.9. Line J is a horizontal Line 230 mm above the ‘Seating Reference Point’.

17. DETAILED REQUIREMENTS FOR VEHICLE CATEGORIES MD3, MD4, ME, NB2 AND NC ONLY

17.1. Separation of any ‘Functional Components’ of the ‘Seatbelt, Assembly’, other than unlatching of the ‘Buckle Components’, must not be possible without the use of tools.

17.2. ‘Seatbelt Assemblies’ must comply with either:

17.2.1. AS 2596-1983, as referenced in clause 5.8.1 but excluding clauses 1,2,4,15,16,17,18 of AS 2596 and excluding dynamic testing to the AS 2597 referred to in clause 5.8.1 provided that the maximum test load must not be less than 9 kN and the corrosion conditioning procedure must be that specified in clause 18;

17.2.2. Federal Motor Vehicle Safety Standard No. 209, “Seat Belt Assemblies” current as at 13 December 1979 except that the use of non-locking retractors as defined in that Standard are not allowed;

17.2.3. ECE Regulation 16/04, “Safety Belts” (except that the use of a non-locking retractor as defined in that Regulation IS not allowed.); or

17.2.4. Any other ‘Approved’ standard accepted as equivalent.

17.3. The operation of any ‘Emergency Locking Retractor’ (including a ‘Type 4N Retractor’) incorporated in a ‘Seatbelt Assembly’ must not be dependent solely upon rate of withdrawal of ‘Strap’ from the retractor.

17.4. In the case of a non-’Suspension Seat’ where the ‘Seatbelt Assembly’ is not mounted on the ‘Seat’ the ‘Buckle Component’ which does not include the retracting ‘Strap’ must comply with the accessibility requirements of clause 7.5.1.

18. CORROSION CONDITIONING PROCEDURE FOR SEATBELT ASSEMBLIES FITTED IN ACCORDANCE WITH CLAUSE 17

18.1. The ‘Seatbelt Assembly’ must be conditioned by the procedure specified in the ASTM B117-64 “Standard Method of Salt Spray (Fog) Testing”.

18.2. The period of conditioning must be not less than 50 hours, and at the end of the conditioning procedure specified in clause 18.1 the ‘Seatbelt Assembly’ may be washed thoroughly with water to remove the salt. If washed, the webbing must be fully extended and allowed to dry for at least 24 hours in an atmosphere having a relative humidity of not less than 48% nor more than 67% and a temperature of not less than 21°C nor more than 25°C. The webbing must then be withdrawn manually and allowed to retract for 25 cycles.

19. ADJUSTMENT REQUIREMENTS FOR VEHICLE CATEGORIES MD3, MD4, ME, NB2 AND NC ONLY

19.1. With the ‘Seatbelt Assembly’ in the unlatched condition, a point on each separate portion of the seat belt must be located by a design feature to adopt a position not more than l00 mm below the top edge of the seat cushion measured in the immediate vicinity of such a design feature.

19.2. Any free end of a ‘Strap’ must be restrained by a design feature to adopt a position against another ‘Strap’.

19.3. With the ‘Strap’ fully extended, there must be not less than 25 mm of material extending from the adjusting device to provide a grip for adjustment purposes. The material may either be attached to or form part of the free end of the ‘Strap’.

20. ALTERNATIVE STANDARDS

20.1. The technical requirements of ECE R 16/04 “Safety Belts” must be deemed to be equivalent to the technical requirements of this rule, provided that

20.1.1. for clauses 17 to 19 non-locking retractors must not be employed; and

20.1.2. the sunlight exposure requirement of the Australian Standards referred to in clause 5.8 and the dust and preconditioning (before any dynamic testing) requirements of this rule are met; and

20.1.3. the free end requirements of clauses 6.3.2 or 19.2 of this rule are met.

TABLE 1DUMMY DIMENSIONS ##
‘95th Percentile Adult Male’ ‘5th Percentile Adult Female’ ‘50th Percentile 6 Years Old Child’
Mass 97.5 + 5 kg 46 + 5 kg 21.4 + 3 kg
Erect sitting height 965 mm 785 mm 645 mm
Hip breadth (sitting) 415 mm 325 mm 215 mm
Hip circumference (sitting) 1200 mm 925 mm 605 mm
Waist circumference (sitting) 1080 mm 600 mm 530 mm
Chest depth 265 mm 190 mm 160 mm
Chest circumference 1130 mm 775 mm (nipple)755 mm (upper)675 mm (lower) 595 mm
Shoulder height 680 mm 520 mm 415 mm
Tolerance on all length dimensions + 5 percent

FIGURE 1

TEST SEAT and ANCHORAGES

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FIGURE 2

COMPONENT BOUNDARY LOCATION

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Appendix A

REQUIREMENTS FOR TYPE 4N RETRACTORS

The following text is from ECE Regulation 16/04 “Safety Belts”, with text not applicable in Australia struck through. The text has been modified slightly, to make it clear that it only applies to ‘Type 4N Retractors’.

6.2.5.3 Emergency locking retractors ‘TYPE 4N RETRACTORS’

6.2.5.3.1 A n emergency locking ‘Type 4N Retractor’, when tested in accordance with paragraph 7.6.2 must satisfy the conditions below:

4.6.2.5.3.1 FOR AUSTRALIA WHERE A VEHICLE CATEGORY IS REQUIRED, OR A MANUFACTURER ELECTS, TO COMPLY WITH CLAUSES 5.1.1 OR 5.1.2 WHICH INVOKE DYNAMIC TESTING, THE REQUIREMENTS OF CLAUSE 10 MUST BE COMPLIED WITH.

6.2.5.3.1.1 The locking must have occurred when the deceleration of the vehicle reaches 0.45 in the case of type 4 and 0.85 g1 in the case of ‘Type 4N Retractors’.

6.2.5.3.1.2 It must not lock for values of acceleration of the strap measured in the direction of the extraction of the strap of less than 0.8 g in the case of type 4 or less than 1.0 g1 in the case of ‘Type 4N Retractors’.

6.2.5.3.1.3 It must not lock when its sensing device is tilted 12o or less in any direction from the installation position specified by its manufacturer.

6.2.5.3.1.4 It must lock when its sensing device is tilted by more than 27o in the case of type 4 or 40o in the case of ‘Type 4N Retractors’ in any direction from the installation position specified by its manufacturer.

6.2.5.3.1.5 In cases where the operation of a retractor depends on an external signal or power source, the design must ensure that the retractor locks automatically upon failure or interruption of that signal or power source.

6.2.5.3.2 A retractor with multiple sensitivity must satisfy the specification above, when tested in accordance with paragraph 7.6.2. In addition if one of the sensitivities relates to strap extraction, locking must have occurred at a strap acceleration equal to or more than 1.5 g in the case of type 4 or more than 2.0 g1 in the case of ‘Type 4N Retractors’, when measured along the line of the extraction of the strap.

6.2.5.3.3 In the case of the tests mentioned in paragraphs 6.2.5.3.1 and 6.2.5.3.2 above the amount of strap movement which may occur before the retractor locks must not exceed 50 mm starting at the length given in paragraph 7.6.2.1. In the case of the test mentioned in paragraph 6.2.5.3.1.2 above locking must not occur during the 50 mm of strap movement starting at the length given in paragraph 7.6.2.1.

6.2.5.3.4 If the retractor is part of a lap belt, the retracting force of the strap must be not less than 0.7 daN when measured in the free length between the dummy and the retractor in accordance with paragraph 7.6.4. If the retractor is part of an upper torso restraint, the retracting force of the strap must be not less than 0.2 daN and not more than 0.7 daN when similarly measured. If the strap passes through a guide or pulley, the retractor force must be measured in the free length between the dummy and the guide or pulley. If the assembly incorporates a device that upon manual or automatic operation prevents the strap from being completely retracted, such a device must not be operated when these requirements are assessed.

6.2.5.3.5 The strap must be withdrawn from the retractor and allowed to retract repeatedly by the method described in paragraph 7.6.1 until 40,000 cycles have been completed. The retractor must then be subjected to the corrosion test given in paragraph 7.2 and after that to the dust test prescribed in paragraph 7.6.3. It must then satisfactorily complete a further 5,000 cycles (making 45,000 in all). After the above tests, the retractor must operate correctly and still meet the requirements of paragraphs 6.2.5.3.1, 6.2.5.3.2, 6.2.5.3.3 and 6.2.5.3.4 above.

7.6 ADDITIONAL TESTS FOR SAFETY BELTS WITH RETRACTORS

7.6.1 Durability of retractor mechanism

7.6.1.1 The strap must be withdrawn and allowed to retract for the required number of cycles at a rate of not more than 30 cycles per minute. In the case of emergency locking ‘Type 4N Retractors’, a snatch to lock the retractor must be introduced at each fifth cycle. The snatches must occur in equal numbers at each of five different extractors, namely, 90, 80, 75, 70 and 65 per cent of the total length of the strap remaining wound on the retractor. However, where more than 900 mm is provided the above percentages must be related to the final 900 mm of strap which can be withdrawn from the retractor.

7.6.1.2 A suitable apparatus for the tests specified in paragraph 7.6.1.1 above is shown in annex 3 to this Regulation.

7.6.2 Locking of ‘Type 4N Retractors’

7.6.2.1 The retractor must be tested once for locking when the strap has been unwound to full length less 300 ± 3 mm.

7.6.2.1.1 In the case of a retractor actuated by strap movement, the extraction must be in the direction in which it normally occurs when the retractor is installed in a vehicle.

7.6.2.1.2 When retractors are being tested for sensitivity to vehicle deceleration they must be tested at the above extraction along two perpendicular axes, which are horizontal if the retractor is installed in a vehicle as specified by the safety belt manufacturer. When this position is not specified, the testing authority must consult the safety belt manufacturer. One of these axes must be in the direction chosen by the technical service conducting the approval test to give the most adverse conditions with respect to actuation of the locking mechanism.

7.6.2.2 A suitable apparatus for the tests specified in paragraph 7.6.2.1 above is described in annex 4 to this Regulation. The design of any such test apparatus must ensure that the required acceleration is given at an average rate of increase of acceleration at least 25 g[1] per second.

7.6.2.5 To check conformity with the requirements of paragraph 6.2.5.3.1.3 and 6.2.5.3.1.4, the retractor must be mounted on a horizontal table and the table tilted with speed not exceeding 2o per second until locking has occurred. The test must be repeated with tilting in other directions to ensure that the requirements are fulfilled.

7.6.3 Dust resistance

7.6.3.1 The retractor must be positioned in a test chamber as described in annex 5 to this Regulation. It must be mounted in an orientation similar to that in which it is mounted in the vehicle. The test chamber must contain dust as specified in paragraph 7.6.3.2 below. A length of 500 mm of the strap must be extracted from the retractor and kept extracted, except that it must be subjected to ten complete cycles of retraction and withdrawal within one or two minutes after each agitation of the dust. For a period of five hours, the dust must be agitated every twenty minutes for five seconds by compressed air free of oil and moisture at a gauge pressure of 5.5  105 ± 0.5  105 Pa entering through an orifice, 1.5 ± 0.1 mm in diameter.

7.6.3.2 The dust used in the test described in paragraph 7.6.3.1 above must consist of about 1 kg of dry quartz. The particle size distribution is as follows:

(a) passing 150 m aperture, 104 m wire diameter: 99 to 100 per cent;

(b) passing 105 m aperture, 64 m wire diameter: 76 to 86 per cent;

7.6.4 Retracting force

7.6.4.1 withdrawal and retracting force must be measured with the safety belt assembly fitted to a dummy as for the dynamic test prescribed in paragraph 7.7. The strap tension must be measured at the point of contact with (but just clear of) the dummy while the strap is being retracted at the approximate rate of 0.6 metres per minute.

Annex 3

DIAGRAM OF AN APPARATUS TO TEST DURABILITY OF RETRACTOR MECHANISM

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Annex 4

DIAGRAM OF AN APPARATUS TO TEST LOCKING OF EMERGENCY LOCKING ‘TYPE 4N RETRACTORS’

A suitable apparatus is illustrated in the figure and consists of a motor-driven cam, the follower of which is attached by wires to a small trolley mounted on a track. The cam design and motor speed combination is such as to give the required acceleration at a rate of increase of acceleration as specified in paragraph 7.6.2.2 of this Regulation Annex and the stroke is arranged to be in excess of the maximum permitted webbing movement before locking.

On the trolley a carrier is mounted which can be swivelled to enable the retractor to be mounted in varying positions relative to the direction of movement of the trolley.

When testing retractors for sensitivity to strap movement the retractor is mounted on a suitable fixed bracket and the strap is attached to the trolley.

When carrying out the above tests any brackets, etc. supplied by the manufacturer or his accredited representative shall be incorporated in the test installation to simulate as closely as possible the intended installation in a vehicle.

Any additional brackets, etc. that may be required to simulate the installation as intended in the vehicle shall be provided by the manufacturer or his accredited representative.

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Annex 5

DIAGRAM OF AN APPARATUS FOR DUST-RESISTANCE TEST

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[*] The category code may also be in the format L1, LA etc.

[1] g = 9.81 m/s2

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Vehicle Standard (Australian Design Rule 4/024/02 – SeatbeltsSeatbelts) 20062006

I, JAMES ERIC LLOYD, Minister for Local Government, Territories and Roads, determine this vehicle standard under subsection 7 (1) of the Motor Vehicle Standards Act 1989.

Dated 31 July 2006

[SIGNED]

James Eric Lloyd

Minister for Local Government, Territories and Roads

CONTENTS

1. legislative provisions..............................................

2. function and SCOPE..............................................

3. APPLICABILITY................................................

4. DEFINITIONS...................................................

5. REQUIREMENTS................................................

6. ADJUSTMENT REQUIREMENTS..................................

7. BUCKLE REQUIREMENTS.......................................

8. GENERAL REQUIREMENTS FOR SEATBELT COMPONENTS.........

9. RETRACTORS (other than ‘TYPE 4N RETRACTORS’ )..................

10. DYNAMIC TEST REQUIREMENTS................................

11. RETRACTOR DURABILITY TEST.................................

12. DYNAMIC TESTING PROCEDURE................................

13. TEST DUMMY REQUIREMENTS..................................

14. DUMMY CALIBRATION.........................................

15. TEST RIG CALIBRATION........................................

16. COMPONENT BOUNDARY LOCATION............................

17. DETAILED REQUIREMENTS FOR VEHICLE CATEGORIES MD3, MD4, ME, NB2 AND NC ONLY

The Standard organises seatbelt requirements around four principal legal-technical concepts: applicability by vehicle category, the type and function of seatbelt components, performance/testing requirements, and equivalence/alternative standards.

Applicability by vehicle category

Clause 3 sets the ADR categories which are in or out of scope and ties them to manufacture dates in the Applicability Table. Typical passenger and light commercial vehicle categories (MA, MB, MC, NA, LEP, LEG, MD1 etc.) and heavier categories (MD3, MD4, ME, NB2, NC) are listed with the dates on or after which the Standard applies. Clause 3.1.3 provides a narrow concession for omnibuses complying with ADR 68/.. where only the driver’s seatbelt must meet clauses 17-19.

Type and function of seatbelt components

Defined types: ‘Lap-Sash Belt’, ‘Harness Belt’, ‘Lap Belt’, ‘Emergency Locking Retractor’, ‘Automatic Length Adjusting and Locking Retractor’, and ‘Type 4N Retractor’ (clauses 4 and 5.3; Appendix A). The Standard prescribes which combinations must be fitted to which seating positions (clause 5.3.1-5.3.3). For example, driver positions must incorporate an Emergency Locking Retractor, with the additional requirement that suspension-seat drivers use a Type 4N retractor if the anchorages are not all mounted on the moving part of the seat (clause 5.3.1.1 and Appendix A).

Performance and component constraints

Mandatory performance thresholds for strength, locking distances, deceleration and strap movement are specified. Examples: retractors when locked must withstand 9 kN (clause 9.2.1.1; clause 9.2.1.2); emergency-locking retractors must lock under defined acceleration envelopes and limit strap movement to 30 mm or 80 mm depending on extension points (clauses 9.4.1-9.4.2); webbing abrasion tests require a post-cycle tensile strength floor of 14.7 kN or 75% of dry breaking strength (clause 8.1).

Testing, preconditioning and calibration concepts

The Standard defines detailed preconditioning requirements (clause 10.3) including mechanical loading of buckle components, a minimum number of unlatching cycles (20,000), and thermal cycling for non-metallic parts (10.3.3). Retractor durability and dynamic testing procedures are specified (clauses 11-15); dynamic test rig calibration demands a massed rig and specific deceleration pulses (clauses 12, 15). Dummy specifications and calibration requirements are set out (clauses 13, 14; Appendix table and notes).

Equivalence and alternative standards

The Standard admits alternative compliance paths by permitting the use of AS standards (clause 5.8.1), ECE R16/04 (clause 20.1), FMVSS No. 209 (clause 17.2.2) for certain heavy categories, and any other Approved standard accepted as equivalent (clauses 5.8.2; 17.2.4). Where ECE R16/04 is used, the Standard requires additional Australian-specific preconditioning, free-end and retractor locking restrictions (clauses 3.1.2; 20.1; Appendix A).

Interplay of structure and objectives

The declared function is to specify requirements that restrain occupants, facilitate correct fastening/adjustment, assist the driver to remain in the driver’s seat and provide ejection protection (clause 2). The instrument converts that purpose into engineering tolerances, component tests, and human-fit ranges based on anthropometry (clauses 6, 16; Figure 2; dummy table).

Terminology and boundaries

The Standard depends on ADR definitions and categorisations, referring readers to the Vehicle Standard (Australian Design Rule Definitions and Vehicle Categories) 2005 for defined terms (clause 4.1). It also establishes component boundary lines by reference to Figure 2 (clause 16) so that many accessibility and positioning rules can be applied objectively.

Primary actors directly affected by the Standard are manufacturers of vehicles and seatbelt systems, component suppliers (retractors, buckles, webbing, sash guides), vehicle certification agents, testing laboratories, and vehicle importers who supply to the Australian market. Secondary actors include fleet operators, vehicle modifiers, and vehicle handbook authors.

Manufacturers and suppliers

Vehicle manufacturers must design and fit seatbelt assemblies that meet the requirements for the vehicle category concerned (clause 5.1; clause 5.2). Supply-chain actors who produce webbing, retractors, buckles and sash guides must meet the component-level durability, marking and strength criteria (clauses 5.6-5.8; clause 8; clause 9).

Testing and accreditation service providers

Qualification to the Standard requires calibrated test rigs, thermal chambers, salt-fog apparatus, cyclic test rigs for retractors and buckles, and anthropometric dummies in specified configurations (clauses 10-15; clause 18). Laboratories and certifiers performing ADR conformity assessment will bear the burden of providing facilities and protocols to meet the specified calibration and test cycles (clause 15 provides the deceleration pulse, clause 11 and Appendix A require tens of thousands of retractor cycles).

Importers and compliance certification

Since the Standard is an ADR adopted under the Motor Vehicle Standards Act 1989, importers who seek approval to supply vehicles to the Australian market must demonstrate compliance for the vehicle categories concerned (clause 3; preamble). Compliance can be shown by adherence to the Standard itself or to approved alternative standards where the instrument permits equivalence (clause 20.1).

End users and fleet operators

The Standard imposes obligations on vehicle suppliers to provide seatbelt instructions in the vehicle handbook containing specified warning and usage text (clause 5.9). That affects what information must be provided to end users and is relevant to fleet compliance documentation.

Regulators and certifiers

The instrument is fixed under a Ministerial determination (preamble). The Standard does not itself set enforcement sanctions, so regulators enforcing motor vehicle standards and vehicle registration agencies will act under the Motor Vehicle Standards Act 1989 or other delegated instruments for compliance and enforcement (preamble; note absence of penalty clauses).

Special-category manufacturers

Heavier and omnibus-type vehicles (MD3, MD4, ME, NB2, NC) can choose more specific heavy-vehicle compliance routes including AS 2596-1983 with a higher minimum test load and a dedicated corrosion conditioning (clauses 17.2 and 18). These categories also face stricter requirements on component separation and retractor operation (clauses 17.1, 17.3).

Designers and vehicle modifiers

Vehicle modifiers who alter seating, seat mounting, suspension seats or anchorages must comply with the clauses that address suspension seat retractor types and assembly mounting. For example, a driver’s suspension seat with anchorages not on the moving part means a Type 4N retractor is required (clause 5.3.1.1; Appendix A). Modifiers must ensure buckle accessibility and positions under clauses 7 and 19.

Other affected stakeholders

Standards bodies and testing equipment suppliers will see demand from the need to meet the detailed test cycles and specific apparatus (e.g., Annex diagrams for Type 4N retractor testing, clause 7.6 and Annexes in Appendix A). Vehicle handbook authors and technical communicators must include specified warning text (clause 5.9.1 and 5.9.2).

Who pays and who decides

Manufacturers and suppliers pay for design, testing, preconditioning, calibration and marking. The Minister (and ultimately the Commonwealth under the Motor Vehicle Standards Act 1989) decides the content of the ADR, as recorded in the instrument’s opening paragraph and signature block. Enforcement action and any penalties would flow from the Act and enforcement agencies, not from this Standard text itself.

Duties placed on manufacturers and vehicle suppliers

Fit the required types of seatbelt assembly to each seating position for which anchorages are required by ADR 5/... (clause 5.2). This is a duty to fit the correct assembly type by seating position as set out in clause 5.3.
Ensure components and whole assemblies cannot be separated without tools except where expressly permitted (clause 5.4; clause 17.1 for heavy vehicles). This is a construction duty to prevent unintended in-service disassembly.
Comply with marking and identification obligations: each assembly must be permanently and legibly marked with manufacturer name/trademark, month and year of manufacture, and a unique identification code (clause 5.7). Sub-assemblies used for in-service replacement also require marking (clause 5.7.2).
Meet adjustment and fitment range duties so assemblies can be correctly fitted for specified anthropometric extremes (clause 6.1). The Standard requires accommodation for a 5th percentile female and a 95th percentile male in driver position, and a 50th percentile 6-year-old child and 95th percentile adult male in other positions (clause 6.1.1-6.1.2).
Provide seatbelt instructions in the vehicle handbook or supply them with the vehicle, using prescribed warning language and, where retractors are fitted, additional specified warnings and adjustment instructions (clause 5.9.1-5.9.2).
Meet specific performance requirements on retractors and buckles, such as locking characteristics, retraction force ranges, and spring fatigue resistance (clauses 9.2.1; 9.2.2; 8.3).

Testing, preconditioning and calibration duties

Subject assemblies to preconditioning and dynamic testing where required (clause 10.2-10.3). For certain vehicle categories and for some retractor types, extensive durability cycles, corrosion conditioning and dust testing are mandatory (clauses 11; 18; Appendix A 7.6).
Provide and maintain test rigs that meet specified calibration targets including mass and deceleration pulses (clauses 12.1; 15.1-15.2). Test dummies must meet mass and force generation specifications (clauses 13-14).

Rights and permitted alternatives

Manufacturers may elect to comply with specified Australian Standards (AS 2596-1983 and related AS 2597 parts) or other Approved equivalent standards (clause 5.8.1-5.8.2). For heavier categories the Standard lists AS 2596, FMVSS No. 209 (as at 13 December 1979) and ECE R16/04 as acceptable alternatives subject to exclusions and additional Australian conditions (clause 17.2; 20.1).
Where ECE R16/04 is used as the Alternative Standard, vehicles meeting listed Acceptable Prior Rules in the Applicability Table can be taken to comply (clause 3.1.2). Clause 20 articulates the equivalence conditions and additional Australian preconditioning, sunlight exposure and free-end requirements that must be observed.

Decision points left to manufacturer judgement

The Standard sets functional thresholds and boundaries but allows manufacturers flexibility in design choices that meet those thresholds. For example, clause 5.8.2 permits “any other Approved standard accepted as equivalent,” leaving scope for technical assessment and approval by the competent authority.
Several requirements depend on measuring positions and accessibility relative to lines defined in Figure 2 and clause 16, which requires manufacturers to determine design compliance in relation to the seating reference points and lines.

Limited discretion regarding exceptions

Specific exceptions are carved out, e.g., sash guides intended to be removable for adjustment purposes and certain seat conversion designs can permit separation without tools (clause 5.4.2-5.4.3). Omnibus driver seats have a limited carve-out in clause 3.1.3 for compliance with clauses 17-19. Such exceptions must be applied in line with the textual conditions provided.

No penalty or sanctioning powers in the Standard itself

The instrument does not create fines, criminal sanctions or administrative penalty regimes within its text. Any enforcement, registration refusal, or corrective action would be taken under the Motor Vehicle Standards Act 1989 and associated regulatory instruments outside this Standard (preamble). The Standard therefore imposes duties and standards but not within-text enforcement mechanisms.

The Standard itself contains no penalty clauses and does not specify enforcement processes or sanctions. It is a technical ADR determined by the Minister under the Motor Vehicle Standards Act 1989 (preamble). Consequences for non-compliance , including administrative action, refusal of type approval, importation restrictions or penalties , are functions of the Motor Vehicle Standards Act 1989 and the administrative agencies and regulations that implement that Act, not provisions within this instrument.

What the Standard prescribes that is enforceable through compliance assessment

The Standard provides objective test methods, cycles and numerical thresholds (for example, deceleration pulses for rig calibration in clause 15, tensile strengths in clauses 8.1 and 9.2, retractor locking distances in clauses 9.4.2, preconditioning cycles in clause 10.3). A compliance assessor or regulator will use these objective benchmarks when testing products or assessing a manufacturer’s test reports.

Mechanisms by which enforcement will be operationalised (implied by the Standard)

Certification bodies, testing laboratories and vehicle regulatory agencies will need to rely on the Standard’s test procedures and calibration requirements to determine whether assemblies meet ADR 4/02. For example, dynamic testing requires a calibrated rig achieving a forward deceleration of at least 235 m/s2 within 30 ms and maintaining it for not less than 20 ms (clause 15.1). A failure to meet the specified test outcomes would furnish the evidential basis for non-compliance actions taken under enabling statutes.

Practical enforcement signals embedded in the text

Detailed marking and documentation requirements (clause 5.7 and 5.9) allow inspectors to rapidly check traceability, date of manufacture and conformity to the identification code requirements as part of any compliance audit.
The Standard’s inclusion of alternative compliance routes (e.g., clause 20, clause 17.2) creates an evidentiary path for suppliers who rely on recognised foreign standards, but requires demonstrable fulfilment of the additional Australian conditions specified.

Limitations and implementation risk

Because the Standard does not itself prescribe penalties, the deterrent effect depends on external enforcement capacity under the Motor Vehicle Standards Act 1989 and related administrative practice. The text does not specify inspection frequency, sampling regimes, or administrative processes for recall or market withdrawal. Those procedural and sanctioning elements are therefore implementation-dependent and rest with relevant enforcement agencies.

Record-keeping and audit implication

Manufacturers and importers will need to retain test records, marking details and documentation demonstrating compliance with preconditioning and durability cycles (clauses 10-12; clause 11; clause 18) to defend conformity claims in regulatory audits. Absent those records, a regulator applying the Motor Vehicle Standards Act 1989 could treat the product as non-compliant.

Cross-reference to ADR Definitions and Categories

Clause 4.1 explicitly directs users to the Vehicle Standard (Australian Design Rule Definitions and Vehicle Categories) 2005 for defined terms used throughout the instrument. Consequently, how terms such as ‘Seat’, ‘Anchorage’, and vehicle category codes are interpreted depends on that Definitions ADR.

Dependent operation within the Motor Vehicle Standards Act 1989 framework

The Standard is made under subsection 7(1) of the Motor Vehicle Standards Act 1989 (preamble). The Standard’s legal force therefore operates within the legal and administrative framework established by the Act. Enforcement powers, offences and penalties for non-compliance will originate from the Act and subordinate instruments, not from this Standard itself.

Interplay with Australian Standards and overseas regulations

Clause 5.8 permits compliance to AS 2596-1983 and selected parts of AS 2597 to satisfy technical requirements. Clauses 17.2 and 20.1 explicitly accept FMVSS No. 209 (as at 13 December 1979) and ECE Regulation 16/04 as alternative standards for certain vehicle categories, subject to exclusions. Clause 20.1 also adds Australian-specific preconditioning, sunlight exposure and free-end requirements that must be met in addition to ECE R16/04.

Referencing ADR 5 and ADR 69

Clause 5.2 requires seatbelt assemblies in relation to anchorages required under ADR 5/..., linking the present Standard to the anchorage requirements set by ADR 5 (the exact ADR 5 instrument is referenced but not reproduced). Clause 5.8.1.1 notes a particular non-application of an AS 2596 limit for assemblies required to comply with ADR 69/..., which shows cross-dependency with ADR 69 for some tests or vehicle uses.

Standards and tests that supplement or modify overseas norms

Appendix A imports ECE Regulation 16/04 text for Type 4N retractors but with modifications and struck-through non-applicable text for Australia. Clause 20.1 establishes equivalence but imposes Australian preconditioning and other requirements, illustrating that overseas standards are accepted only when augmented to meet Australian-specified environmental or operational exposures such as salt-spray and dust tests (clauses 18; Appendix A 7.6.3).

Consumer-protection, occupational health and safety, and registration regimes

The Standard mandates that safety-critical components be marked and that instructions and warnings be supplied (clause 5.7; clause 5.9). Those obligations overlap with consumer-protection obligations and may be relevant to product-liability inquiries or obligations under consumer law, but the Standard itself does not assign civil liability. Registration and roadworthiness authorities will use ADR compliance as an input into registration and import approval processes under the Motor Vehicle Standards Act 1989.

Potential interactions not resolved in the text

The Standard does not address recalls, remedial measures or liability. Any recall powers or civil consequences will be governed by other statutes and common law. The Standard does not displace those obligations but provides the technical baseline used by regulators and courts when assessing conformity and safety.

International trade and type approval

By admitting ECE and FMVSS standards as alternatives (subject to conditions), the Standard creates pathways for manufacturers using internationally-harmonised test regimes to obtain Australian compliance without duplicative testing, provided they meet any additional Australian conditioning and documentation requirements (clauses 17.2; 20.1). This affects importers, global manufacturers and homologation strategies.

What this instrument records about its own history

Clause 1.3.1 expressly states that this Standard repeals each vehicle standard with the name Australian Design Rule 4/02 , Seatbelts that was made under section 7 of the Motor Vehicle Standards Act 1989 and was in force at the commencement of this Standard. Clause 1.3.2 extends repeal to any instrument made under section 7 that creates an ADR with that name, subject to the condition that the instrument contains no other still-effecting standards or amendments. The commencement clause states the Standard commences on the day after it is registered (clause 1.2). The instrument is dated and signed 31 July 2006.

No subsequent amendments recorded in the text provided

The text supplied contains no later amendment notes, expiry dates, or consolidated amendment history beyond the repeal of prior 4/02 ADR instruments by this 2006 Standard. The instrument itself therefore represents the 2006 determination and its stated effect on earlier 4/02 ADRs.

Indicative amendment pathways implied by the instrument

Clause 20.1 and Appendix A indicate an openness to alignment with ECE R16/04 and other Approved standards, which can function as a mechanism for technical updates without changing the ADR text, subject to the conditions imposed in clauses 17-20. Such equivalence clauses are a common route for the ADR regime to keep technical requirements aligned with evolving international norms without frequent textual amendment of the ADR itself.

Administrative record to check for later updates

Because the instrument repeals prior ADRs and establishes the 2006 rule, users should check the official ADR register and subsequent Gazette notices or the Motor Vehicle Standards Act 1989 legislative instruments register for any later variations, revocations, or consolidations that post-date the provided document. The instrument itself does not record subsequent changes.

Interpretation implications of repeal language

The mechanism in clause 1.3 that repeals prior ADR 4/02 standards while preserving other instrument elements implies a clean replacement approach. If a prior instrument created additional ADRs or amendments still in force, clause 1.3.2 preserves those other standards by excluding them from repeal. This may affect how historical compliance and grandfathering operate and should be reviewed against the full legislative register.

Timing and effective date relevance

The commencement timing provision (clause 1.2) requires attention when determining which vehicles are captured by the rule. The Applicability Table (clause 3) lists manufacture dates for each category; linking those manufacture dates to the ADR commencement and any later amendments is necessary for compliance mapping across fleet years.

The instrument as provided contains no litigation history. It does not reference judicial decisions, appeal outcomes, or administrative tribunal determinations. The text does not cite any case law or provide dispute-resolution procedures linked to the Standard. Therefore, based solely on the instrument provided, there are no proceedings or court interpretations incorporated into or affecting the text.

What that means practically

Any legal disputes about the Standard’s interpretation, compliance, or the sufficiency of test evidence would be resolved under the Motor Vehicle Standards Act 1989, consumer protection or product liability law, or administrative review mechanisms. The Standard provides technical criteria which courts or tribunals would rely on as expert benchmarks, but the instrument itself does not provide guidance on litigation process, burden of proof, or evidentiary admissibility.

Recommended steps for practitioners

For litigation or regulatory enforcement work, a practitioner should obtain:
- the authoritative version of ADR 4/02 2006 from the government register to confirm any later amendments;
- associated ADRs and the Motor Vehicle Standards Act 1989 to establish the statutory enforcement framework;
- test reports and calibration certificates produced under the clauses in the Standard (clauses 10-15; clause 11; clause 18) as primary technical evidence;
- the vehicle handbook and marking information required by clauses 5.7 and 5.9 when advising on compliance with documentation obligations.

Limits of the available text

Because no cases or interpretations are provided in the instrument, there is no source-grounded judicial development to summarise. Any legal analysis of enforcement outcomes or dispute trends must therefore be based on external material beyond the provided Standard.

Several specific provisions present traps for designers, certifiers and compliance officers if read too generally. These are mechanical features, exceptions and test details in the text that commonly cause non-compliance or operational confusion.

Multiple compliance routes and choice of standard

For many vehicle categories the Standard permits different compliance paths. For MD3/MD4/ME/NB2/NC vehicles a manufacturer may choose clause 5.1.3.1 (which invokes clauses 5.2, 5.3.1 except certain subclauses, 5.3.2, 5.3.3 and 17-19) or clause 5.1.3.2 (comply with clause 5.1.1) or clause 5.1.3.3 (comply with 5.1.2 subject to parts). Choosing the wrong route or misunderstanding exclusions (for example the exclusion of clauses 5.3.1.3-5.3.1.4 in some paths) will produce non-conformity (clause 5.1.3). Practitioners must map the chosen compliance route in writing.

Anchorages and integration with ADR 5

Clause 5.2 requires seatbelt assemblies to be fitted where anchorages are required in ADR 5/..., so anchorages not required by ADR 5 may not trigger seatbelt fitment obligations under this Standard. Misreading this cross-reference may misidentify required fitment positions.

Type 4N retractor special rules

Suspension-seat driver arrangements where not all anchorages are mounted on the moving part require a Type 4N retractor (clause 5.3.1.1). Appendix A modifies ECE 16/04 text to set different locking thresholds and cycling requirements. Type 4N retractors have specific test positioning, acceleration thresholds and snatch cycle requirements (Appendix A paragraphs 6.2.5.3 and 7.6). Using a different retractor without recognising this obligation is a compliance risk.

Marked contradictions in dummy mass and anthropometry

Clause 13.1 mandates a test dummy mass of 74 ± 2 kg for the test dummy used in test procedures. The Appendix table labelled “TABLE 1 DUMMY DIMENSIONS” lists masses for ‘95th Percentile Adult Male’ as 97.5 +5 kg, ‘5th Percentile Adult Female’ 46 +5 kg and ‘50th Percentile 6 Years Old Child’ 21.4 +3 kg. The table is anthropometric. The Standard requires the test dummy mass at clause 13.1 and at clause 14.3 specifies separate dummy-belt parameters. Users must carefully apply the clause 13.1 mass for rig calibration and dynamic tests and use the anthropometric table only for fit/adjustment requirements.

Extensive preconditioning and high cycle counts

Preconditioning steps are onerous: 20,000 unlatching operations with 20 N load on the buckle (clause 10.3.2); sash guide relative movement 50,000 cycles for webbing abrasion (clause 8.2); retractor cycle counts in Appendix A require 40,000 cycles plus further cycles plus corrosion and dust tests to reach 45,000 total cycles for Type 4N (Appendix A paragraph 6.2.5.3.5). Many small or in-house test facilities lack equipment or capacity to perform these cycles to the precision required.

Specific retractor locking test envelopes

Emergency locking retractors must lock with accelerations not exceeding specified thresholds, limit strap movement to defined millimetres at particular extension points, and be designed to lock on power or signal failure (clauses 9.4.1-9.4.8). The Standard disallows designs dependent on strap withdrawal rate for acceleration sensing, and in tests such devices may be rendered inoperative (clause 9.4.4). Manufacturers relying on withdrawal-dependent mechanisms must redesign.

Marking and identification granularity

Identification codes must be unique to assembly or sub-assembly design; identical codes may apply only to assemblies identical except for strap length variations within defined tolerances (clause 5.7 and 5.7.1). For in-service replacement strategies where parts are provided separately, both sub-assemblies must be marked (clause 5.7.2). Loose marking practices or batch-level marking without design codes will not satisfy clause 5.7.

Buckle engagement with adjacent seating positions

If a buckle can latch with an assembly intended for an adjacent seat, clause 7.3 requires the combined assembly to comply with clause 14 of AS 2596-1983, irrespective of whether the engaged components separate without operating the unlatching device. Exception exists only where adjacent assemblies are from the same manufacturer and have the same buckle design (clause 7.3.2). This produces design constraints for multi-seat buckle compatibility.

Component mass placement rule

Any single seatbelt component weighing more than 75 g other than a strap, anchor fitting or sash guide must not be located forward of the torso reference line and between Lines A and B when correctly fitted for a 95th percentile adult male and 50th percentile 6-year-old child independently (clause 5.6). This spatial restriction can constrain mounting of sensors or electronic units incorporated in assemblies.

Accessibility and free-end requirements

Multiple clauses (6.2 on manual adjusters; 7.4 on buckle accessibility; 7.5 on single-seat front seating) prescribe tight spatial access envelopes relative to lines in Figure 2 (clauses 6.2; 7.4; 7.5; 16). Ensuring required accessibility after retraction and with different seat positions requires detailed measurement and validation.

Corrosion conditioning for heavy vehicles

Heavy categories intending to use AS 2596 must comply with ASTM B117-64 salt-spray conditioning for not less than 50 hours followed by specified drying and retraction cycles (clause 18). Failure to include the salt-spray conditioning will prevent reliance on clause 17.2.1 for these categories.

Equivalence is conditional not automatic

Using ECE R16/04 is only acceptable if clause 20.1 conditions are met. That means manufacturers cannot assume foreign certification alone suffices , they must additionally demonstrate meeting sunlight exposure, dust, preconditioning and free-end requirements specified in the ADR (clause 20.1.1-20.1.3).

This section sets out practical compliance steps, tied to the relevant clauses, for designers, manufacturers, and compliance officers preparing to demonstrate conformity with ADR 4/02 2006.

Step 1 , Determine applicability and compliance path

Identify the vehicle category from the Applicability Table in clause 3 and confirm the manufacture-on-or-after date from the table. Note special omnibus driver-seat exception in clause 3.1.3. Decide which compliance route the vehicle will follow under clause 5.1 (for MD3/MD4/ME/NB2/NC, choose among the three permissible routes in clause 5.1.3; for other categories follow clause 5.1.1 or 5.1.2 as applicable).

Step 2 , Select the technical standard or Approved alternative

Choose whether to comply directly with the ADR test and performance clauses (5-19) or to adopt an Approved alternative standard. If using AS 2596-1983 or AS 2597 parts, ensure excluded clauses are accounted for (clause 5.8.1). If using ECE R16/04, ensure clause 20.1 conditions are satisfied (sunlight exposure, dust and preconditioning requirements). For heavy categories, confirm whether FMVSS No. 209 or ECE R16/04 is acceptable as per clause 17.2, and remember the prohibition on non-locking retractors (clause 17.2.2-17.2.3).

Step 3 , Design to fit and adjust for specified anthropometry and accessibility

Design belt routing, adjusters and sash guides so assemblies can be correctly fitted for the anthropometric bounds stated in clause 6.1 (5th percentile adult female and 95th percentile adult male in the driver position; 50th percentile 6-year-old child and 95th percentile adult male in other positions).
Provide minimum spare strap allowances (75 mm extra for lap belt and sash belt at the 95th percentile fit, clause 6.1.3).
Ensure manual tightening and loosening points are within the accessibility lines defined by clause 6.2 and clause 16; check adjuster positions relative to Figure 2.

Step 4 , Choose retractor and locking system and verify locking envelopes

For driver positions ensure Emergency Locking Retractors (ELRs) are fitted (clause 5.3.1.1). For suspension seats where anchorages are not all on the moving part, specify Type 4N retractors (clause 5.3.1.1.1 and Appendix A).
Design or select retractors to meet the locking characteristics in clauses 9.4.1-9.4.8 (locking acceleration thresholds, strap movement limits at specified extensions, automatic locking on power failure).

Step 5 , Component-level design to meet strength and durability tests

Ensure webbing and strap assemblies meet the tensile strength retention requirements after abrasion cycles (clauses 8.1-8.2). Implement sash guide designs that accommodate the 50,000 cycle sash-guide abrasion test where required (clause 8.2).
Specify buckle springs and mechanisms capable of resisting fatigue , load to operate must not reduce by more than 20% after 50,000 operations (clause 8.3).

Step 6 , Marking, replacement and documentation

Mark each seatbelt assembly with manufacturer’s name or trade mark, month and year of manufacture, and a unique identification code as required by clause 5.7. Where sub-assemblies are provided for in-service replacement, mark each separable sub-assembly (clause 5.7.2).
Prepare the prescribed handbook text and additional warnings for retractors and automatic devices as required in clause 5.9. Ensure text is included in the vehicle handbook or otherwise supplied with the vehicle.

Step 7 , Preconditioning and laboratory testing

Conduct the preconditioning steps in clause 10.3 before dynamic testing: mechanical loading of buckle positions that could be in door openings (10.3.1), 20,000 unlatch operations with a 20 N applied load (10.3.2), and thermal cycling for non-metallic components (10.3.3).
Perform retractor durability tests as stated in clause 11, referencing AS 2597.9-1983, and apply the specific retractor cycle regimes in Appendix A where Type 4N retractors are used. For heavy-vehicle assemblies bound to clause 17, perform the corrosion conditioning procedure in clause 18 (ASTM B117-64 for minimum 50 hours and subsequent drying and cycling).
For dynamic testing, use a test rig conforming to clause 12.1 and ensure rig calibration meets clause 15 targets (e.g., 74 ± 2 kg mass fixture achieving at least 235 m/s2 within 30 ms and maintaining it for 20 ms per clause 15.1-15.2). Use a test dummy that meets clause 13.1 (74 ± 2 kg) and ensure the dummy produces the required peak loads in sash and lap straps in clause 13.2.

Step 8 , Record-keeping and traceability

Retain test records, calibration certificates, preconditioning logs, cycle counts, corrosion/dust conditioning certificates, manufacturing batch numbers and marking records. The Standard’s marking and identification obligations mean that traceability is primary evidence of design continuity and conformity (clause 5.7).

Step 9 , Use of alternative standards and equivalence demonstrations

If relying on an Approved alternative standard, prepare a technical equivalence dossier demonstrating how the alternative meets or exceeds ADR thresholds, and document how any additional Australian conditioning (sunlight exposure requirement, preconditioning and dust requirements) has been met (clause 20.1). Where ECE R16/04 is adopted, identify and apply the Appendix A modifications.

Step 10 , Ongoing quality control and in-service replacement strategy

Establish production monitoring to ensure retractor and buckle manufacturing processes produce units that meet fatigue and durability testing. For in-service replacement parts, ensure sub-assemblies are marked and meet the same design codes as the original assembly (clause 5.7.2).
Implement a documented process for handling design changes that could affect the identification code or require retesting.

Practical compliance resource implications

Budget for capital-intensive test equipment: thermocycles (10.3.3), salt-fog chambers for clause 18, retractor cyclic rigs for tens of thousands of cycles (clause 8.2; clause 11; Appendix A 7.6.1), dynamic test rigs meeting clause 15 deceleration pulses and dummy calibration rigs (clauses 12-15). Where in-house capability is absent, plan for accredited external laboratory use and the associated time and cost.

Final verification

Before deployment, perform a documentary and physical audit against clause checklists: fitment matrix (clause 5.3), marking (clause 5.7), handbook text (clause 5.9), preconditioning logs (clause 10.3), retractor durability tests (clause 11/Appendix A), dynamic test records (clauses 12-15) and corrosion conditioning where required (clause 18). Obtain written approval or certification from the relevant authority per the Motor Vehicle Standards Act 1989 processes outside the ADR text.

Vehicle Standard (Australian Design Rule 4/02 – Seatbelts) 2006

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Vehicle Standard (Australian Design Rule 4/02 – Seatbelts) 2006

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Tolerance on all length dimensions + 5 percent

7.6 ADDITIONAL TESTS FOR SAFETY BELTS WITH RETRACTORS

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