ANNEX VII

TYPE-APPROVAL OF REPLACEMENT CATALYTIC CONVERTER AS SEPARATE TECHNICAL UNIT FOR TWO OR THREE-WHEEL MOTOR VEHICLES

This Annex applies to the type-approval, as separate technical units within the meaning of Article 2(5) of Directive 2002/24/EC, of catalytic converters to be fitted, on one or more types of two or three-wheel motor vehicles, as replacement parts.

1.   DEFINITIONS

For the purposes of this Annex, the following definitions shall apply:

1.1.   “original equipment catalytic converter” means a catalytic converter or an assembly of catalytic converters covered by the type approval delivered for the vehicle;

1.2.   “replacement catalytic converter” means a catalytic converter or an assembly of catalytic converters intended to replace an original equipment catalytic converter on a vehicle type-approved in accordance with this Chapter which can be type-approved as a separate technical unit as defined in Article 2(5) of Directive 2002/24/EC;

1.3.   “original replacement catalytic converter” means a catalytic converter or an assembly of catalytic converters whose types are indicated in section 5 of Annex VI but are offered on the market as separate technical units by the holder of the vehicle type-approval;

1.4.   “type of catalytic converter” means catalytic converters which do not differ in such essential respects as the following:

1.4.1.

number of coated substrates, structure and material;

1.4.2.

type of catalytic activity (oxidising, three-way, etc.);

1.4.3.

volume, ratio of frontal area and substrate length;

1.4.4.

catalyst material content;

1.4.5.

catalyst material ratio;

1.4.6.

cell density;

1.4.7.

dimensions and shape;

1.4.8.

thermal protection;

1.5.   “vehicle type with regard to the emission of gaseous pollutants from the engine” means two or three-wheel motor vehicles which do not differ in such essential respects as the following:

1.5.1.

the equivalent inertia determined in relation to the reference mass, as laid down in section 5.2 of Appendix 1 of Annex I or Annex II (depending upon the type of vehicle);

1.5.2.

the characteristics of the engine and the two or three-wheel motor vehicle as defined in Annex V;

1.6.   “gaseous pollutants” means carbon monoxide, hydrocarbons and oxides of nitrogen expressed in terms of nitrogen dioxide (NO2) equivalence.

2.   APPLICATION FOR TYPE-APPROVAL

2.1.   An application for type-approval of a type of replacement catalytic converter as a separate technical unit shall be submitted by the manufacturer of the system or by his authorised representative.

2.2.   A model for the information document is given in Appendix 1.

2.3.   For each type of catalytic converter for which approval is requested, the type-approval application must be accompanied by the following documents in triplicate, and by the following particulars:

2.3.1.

description of the type(s) of vehicle for which the device is intended, in respect of the characteristics referred to in section 1.1 of Annex I or Annex II (depending upon the type of vehicle);

2.3.2.

the numbers and/or symbols specific to the type of engine and vehicle;

2.3.3.

description of the replacement catalytic converter stating the relative position of each of its components, together with the fitting instructions;

2.3.4.

drawings of each component to facilitate location and identification, and statement of materials used. These drawings must also indicate the intended location of the mandatory type-approval number.

2.4.   The following must be submitted to the technical service responsible for the type approval test:

2.4.1.

Vehicle(s) of a type approved in accordance with this Chapter equipped with a new original equipment catalytic converter. This (these) vehicle(s) shall be selected by the applicant with the agreement of the technical service. It (they) shall comply with the requirements of Section 3 of Appendix 1 to Annex I, II or III (depending upon the type of vehicle). The test vehicle(s) shall have no emission control system defects; any excessively worn out or malfunctioning emission-related original part shall be repaired or replaced. The test vehicle(s) shall be tuned properly and set to the manufacturer's specification prior to emission testing.

2.4.2.

One sample of the type of the replacement catalytic converter. This sample shall be clearly and indelibly marked with the applicant's trade name or mark and its commercial designation.

3.   GRANTING OF TYPE-APPROVAL

3.1.	Upon completion of the tests laid down in this Annex, the competent authority shall issue a certificate based on the model set out in Appendix 2.

3.2.

An approval number in accordance with Annex V to Directive 2002/24/EC shall be assigned to each type of replacement catalytic converter approved. The same Member State shall not assign the same number to another replacement catalytic converter type. The same type-approval number may cover the use of that replacement catalytic converter type on a number of different vehicle types.

4.   MARKING REQUIREMENT

4.1.   Every replacement catalytic converter conforming to the type approved under this Directive as a separate technical unit, but not the mounting parts and pipes, shall bear a type-approval mark composed in accordance with the requirements of Article 8 of Directive 2002/24/EC, supplemented by further information as referred to in section 4.2 of this Annex. The type-approval mark must be affixed in such a way as to be legible and indelible and also visible (where possible) in the position at which it is to be fitted.

The dimensions of “a” must be ≥ 3 mm.

4.2.   Further information contained in the type-approval mark

4.2.1.   Every replacement catalytic converter, but not the mounting parts and pipes, must bear, in the type-approval mark, the number of the Chapter(s) under which the type approval has been granted.

4.2.1.1.   Replacement catalytic converter which consists of a sole part integrating both the catalytic converter and the exhaust system (silencer)

The type-approval mark referred to in section 4.1 must be followed by two circles surrounding a number 5 and a number 9, respectively.

4.2.1.2.   Replacement catalytic converter separated from the exhaust system (silencer)

The mark of the type-approval referred to in section 4.1 affixed to the replacement catalytic converter must be followed by a circle surrounding a number 5.

Examples of type-approval marks are given in Appendix 3.

5.   REQUIREMENTS

5.1.   General requirements

The design, construction and mounting of the replacement catalytic converter must be such that:

5.1.1.

the vehicle complies with the requirements of the Annex under normal conditions of use, and in particular regardless of any vibrations to which it may be subjected;

5.1.2.

the replacement catalytic converter displays reasonable resistance to the corrosion phenomena to which it is exposed, with due regard to the normal conditions of use of the vehicle;

5.1.3.

the ground clearance available under the original equipment catalytic converter, and the angle at which the vehicle can lean over, are not reduced;

5.1.4.

the surface does not reach unduly high temperatures;

5.1.5.

the outline has no projections or sharp edges;

5.1.6.

shock absorbers and suspension have adequate clearance;

5.1.7.

adequate safety clearance is provided for pipes;

5.1.8.

it is impact-resistant in a way that is compatible with clearly-defined maintenance and installation requirements;

5.1.9.

if the original equipment catalytic converter includes thermal protection, the replacement catalytic converter shall include equivalent protection;

5.1.10.

if (an) oxygen probe(s) and other sensors are originally installed on the exhaust line, the installation of the replacement catalytic converter shall be at the exact position of the original equipment catalytic converter, and the position on the exhaust line of the oxygen probe(s) and other sensors, shall not be modified.

5.2.   Requirements regarding emissions

5.2.1.   The vehicle referred to in section 2.4.1, equipped with a replacement catalytic converter of the type for which type-approval is requested, shall undergo the tests laid down in Appendices 1 and 2 to Annexes I, II or III (according to the type-approval of the vehicle) (1).

5.2.1.1.   Evaluation of the emission of pollutants of vehicles equipped with replacement catalytic converter

Requirements regarding emissions are deemed to be complied with if the test vehicle equipped with the replacement catalytic converter complies with the limit values according to Annex I, II or III (according to the type-approval of the vehicle) (2).

Where type-approval is applied for different types of vehicles from the same manufacturer, and provided that these different types of vehicle are fitted with the same type of original equipment catalytic converter, the type I test may be limited to at least two vehicles selected after agreement with the technical service responsible for approval.

5.2.2.   Requirements regarding permissible sound level

The vehicle referred to in section 2.4.1, equipped with a replacement catalytic converter of the type for which type-approval is requested, shall satisfy the requirements of section 3 to Annex II, III or IV to Chapter 9 (according to the type approval of the vehicle). The test result for the vehicle in motion and for the stationary test shall be mentioned in the test report.

5.3.   Testing of vehicle performance

5.3.1.

The replacement catalytic converter must be such as to ensure that the vehicle’s performance is comparable to that achieved with the original equipment catalytic converter.

5.3.2.

The replacement catalytic converter must be compared with an original equipment catalytic converter, also in new condition, fitted in turn to the vehicle referred to in section 2.4.1.

5.3.3.

This test is carried out by measuring the engine power curve. The net maximum power and the top speed measured with the replacement catalytic converter must not deviate from the net maximum power and top speed measured under the same conditions with the original equipment catalytic converter by more than ± 5 %.

6.   CONFORMITY OF PRODUCTION

The provisions of Annex VI to Directive 2002/24/EC apply to the checking of conformity of production.

In order to test conformity as required above, a sample replacement catalytic converter must be taken from the production line of the type-approved, pursuant to this Annex.

Production will be regarded as being in conformity with the provisions of this Annex if the requirements of section 5.2 (Requirements regarding emissions) and section 5.3 (Testing of vehicle performance) are satisfied.

7.   DOCUMENTATION

7.1.   Each new replacement catalytic converter shall be accompanied by the following information:

7.1.1.

the catalyst manufacturer's name or trade mark;

7.1.2.

the vehicles (including year of manufacture) for which the replacement catalytic converter is approved;

7.1.3.

installation instructions, where necessary.

7.2.   This information shall be provided either on a leaflet accompanying the replacement catalytic converter, or on the packaging in which the replacement catalytic converter is sold, or by any other applicable means.