EPA 460/3-81-019
A Study of Emissions from Light Duty
Vehicles in San Antonio, Texas
EPA Contract No. 68-03-3024
prepared by:
Maurice Forshee
Mark D. Da I en
L. Kevin Kott
EG&G Automotive Research, Inc.
5404 Bandera Road
San Antonio, Texas 78238
(512) 684-2310
prepared for:
Environmental Protection Agency
2565 Plymouth Road
Ann Arbor, Michigan 48105
Thomas C. Bejma
EPA Project Officer
Date: September, 1981
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This report is issued by the U.S. Environmental Protection Agency to
convey technical information to those interested in the subject matter.
Copies of this report are available without charge to employees of the
U.S. Government, contractors, grantees and nonprofit organizations
currently doing business with the Government from the EPA Library,
2565 Plymouth Road, Ann Arbor, Michigan 48105. Copies are also avail-
able commercially from the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
EG&G Automotive Research, San Antonio, Texas in fulfillment of Contract
No. 68-03-3024. The contents of this report are reproduced herein as
received from EG&G Automotive Research, San Antonio, Texas. The opinions,
findings, and conclusions expressed are those of the author and not
necessarily those of the Environmental Protection Agency. Mention of
company or product names is not to be considered as an endorsement by the
Environmental Protection Agency.
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ABSTRACT
Three hundred 1978 through 1981 in-use light duty vehicles were obtained
from the public, in the San Antonio Metropolitan Area. These vehicles were
tested, as received, for exhaust emissions utilizing the Federa Test Pro-
cedure, the Highway Fuel Economy Test, and four short mode tests. Al I vehicles
were subjected to a thorough emissions control component inspection. Fifty
vehicles which failed to meet applicable standards received maintenance and
a retest.
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TABLE OF CONTENTS
A STUDY OF EMISSIONS FROM LIGHT-DUTY
VEHICLES IN SAN ANTONIO, TEXAS
EPA CONTRACT NUMBER 68-03-3024
PAGE
ABSTRACT i i i
TABLE OF CONTENTS v
LIST OF FIGURES AND TABLES vii
SECTION 1 - BACKGROUND ..... 1
SECTION II - INTRODUCTION 3
SECTION III - PROCUREMENT OF VEHICLES 5
A - PROCUREMENT METHODS 5
B - SUMMARY OF RESULTS 6
SECTION IV - VEHICLE PREPARATION, INSPECTION AND MAINTENANCE 17
A - INITIAL MECHANICAL NSPECTION 17
B - POST TEST INSPECTION 17
C - RESTORATIVE MAINTENANCE 17
SECTION V - VEHICLE EMISSION TESTING 27
A - TEST LABORATORY 27
B - EQUIPMENT CHANGES 27
C - TEST PROCEDURES 29
D - CALIBRATIONS 31
SECTION VI - TEST RESULTS 35
SECTION VII - DATA HANDLING 37
A - EMISSION TEST AUDITING AND VAL DAT I ON 37
B - TEST DATA TRANSMITTAL 37
C - CALIBRATION DATA TRANSMITTAL 37
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TABLE OF CONTENTS
(conti nued)
PAGE
APPENDIX A - SAMPLE PROCUREMENT PACKET 39
APPENDIX B - EPA VEHICLE DATA PACKET 53
APPENDIX C - LAB QUALIFICATION WORKSHEETS 65
APPENDIX D - CALIBRATION FORMS 79
APPENDIX E - AUDIT FORMS 95
v i
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LIST OF TABLES AND FIGURES
TABLE II1-1 ORIGINAL VEHICLE REQUIREMENTS
TABLE III-2 VEHICLE SUBSTITUTIONS
FIGURE I I 1-1 VEHICLE PROCUREMENT FLOW CHART
1981 MODEL YEAR EXAMPLE
TABLE III-3 VEHICLES OBTAINED BY ALTERNATE
PROCUREMENT METHODS
TABLE IV-1 RESTORATIVE MAINTENANCES
FIGURE V-1 EG&G AUTOMOTIVE RESEARCH, INC.
CHASSIS DYNAMOMETER TESTING LABORATORY.
PAGE
7
14
15
19
28
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SECTION I
BACKGROUND
The United States Environmental Protection Agency (EPA) has the authority
under the provisions of the Clean Air Act to develop, implement, and admin-
ister programs designed to quantify and reduce the pollution of the nation's
resources. Authority in part for this objective is assigned to EPA's Emis-
sion Control Technology Division (ECTD). ECTD is responsible for assessing,
quantifying and ultimately reducing air pollution from in-use motor vehicle
sources. One of the major test projects that is utilized to attain this
goal is the Emissions Factor (EF) Program.
The first EF Program was conducted in EPA's Fiscal Year (FY) 1971. Sub-
sequent Programs were conducted in FY's 1972, 1973, 1974, 1975, 1977 and
1979. The programs conducted in FY's 1975 and 1977 were extended to include
the following year. These EF Programs were specifically designed to obtain
exhaust emissions data from in-use vehicles operated in a wide range of topo-
graphical and climatogical conditions. During the course of EF Programs,
vehicles located in the following U.S. cities have been tested: Chicago,
Houston, San Antonio, Denver, Los Angeles, Detroit, Phoenix, St. Louis and
Washington, D.C.
The number of model years, number of vehicles to be tested, and any other
specific vehicle requirements for each EF Program was established by ECTD.
Some of the factors which affected the vehicle requirements were, sales per-
centages by manufacturer for each model year, changes in emissions standards,
advancements in emission control technology and revisions in Federal Testing
Procedures.
In the recent EF Programs special short mode testing procedures have been
incorporated. These short mode tests are designed to correlate with the more
extensive certification tests. These methods are under consideration for use
by state governments in vehicle emissions inspection and maintenance programs.
The portion of the FY 1980 Emission Factor Study which was conducted in
San Antonio, Texas, is the subject of this report. In order to accomplish
this study EPA contracted EG&G Automotive Research, Inc. (EG&G-AR) to provide
data on vehicles operated in the San Antonio metropolitan area.
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SECTION I I
INTRODUCTION
In September of 1980, EG&G Automotive Research, Inc. was awarded a contract
to procure and test three hundred vehicles in the San Antonio area. Model
year 1978 through 1981 vehicles were procured from registration listings.
In accordance with the contract terms a limited number of 1981 vehicles were
obtained through car rental agencies. Only light duty, gasoline powered
vehicles were included in the program. The contract period was from September
1980 to July 1981.
AM three hundred vehicles were tested as received. The test sequence con-
sisted of the FTP emissions test, Highway Fuel Economy Test and four short
cycle tests. After the test sequence, each vehicle received an extensive
inspection of emission-related components and adjustments.
The first fifty vehicles that exhibited high exhaust emissions levels received
a restorative maintenance procedure, followed by an additional test sequence.
After validation of the test results, each vehicle was returned to the owner
along with the participation incentives.
All test data was supplied to either the Project Officer or the EPA's data
contractor, with calibration and maintenance data supplied to the Project
Officer on a weekly basis.
This program is detailed in Sections III through VII.
o Section III contains a brief narrative of the procurement methods
utilized. It also includes a summary of the procurement activity.
o Section IV outlines the methods and procedures used in vehicle prep-
aration, inspection and maintenance.
o Section V describes the emission testing equipment that was used.
It also explains calibration procedures. A brief description of the
different testing modes is also found in this section.
o Section VI is an explanation of how test results were processed.
o Section VII explains the process that was used in auditing and trans-
mitting test results and equipment calibration data.
-3-
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SECTION I I I
PROCUREMENT OF VEHICLES
A. PROCUREMENT METHODS
The EPA supplied a list of three hundred vehicles to be procured and tested.
This ist is found in Table I I 1-1. Substitutions were made by the EPA for
some models that were unavailable. Table III-2 lists these substitutions
and the reasons why they were made.
Total requirements by model year were as follows:
MODEL YEAR NUMBER OF VEHICLES
1978 25
1979 25
1980 100
1981 150
TOTAL 300
Each of the model year lists specified the vehicle number, number of units
required, make, model, and in some cases engine size. Individual vehicle
requirements for each model year were based on sales volumes for that year.
The Wilson Publishing Company in Houston, Texas was contracted to supply
vehicle registration lists for all the required year models. Registration
listings were limited by U.S. Postal codes for the immediate San Antonio met-
ropolitan area.
A random number table was used to randomize the registration listing for the
1978, 1979 and 1980 model years. The list for the 1981 model year which was
supplied later, was randomized prior to printing by the Wilson Publishing
Company.
Procurement maiI ings were then made from these randomized I ists. The maiI ing
consisted of an EPA supplied letter briefly describing the project, a list of
normally asked questions and answers and a reply card. Positive response
cards were followed up with telephone interviews. Appendix A contains copies
of alI of the forms and documents that were uti I ized in the procurement process.
Each of the procurement mailings were recorded in the Sample Vehicle Control
Logs. These logs were supplied by EPA and used for tracking each vehicle from
initial solicitation to the conclusion of the procurement process.
-5-
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Figure I I 1-1 is a Vehicle Procurement Flow Chart which shows the procurement
method that was utilized. This flow chart reflects the 1981 year model
requirements for percentage of high mileages, number of rental vehicles, etc.
The same sequence of events applies for all year models.
B. SUMMARY OF RESULTS
Of the three hundred vehicles procured, 268 (89$) were obtained in accor-
dance with the prescribed random method. The remaining 32 (11%) vehicles
were procured using alternate methods that were either specified in the
contract or specifically approved by the EPA. The methods included rentals
(1981 models only), EG&G-AR employee owned vehicles, leased vehicles, etc.
Table I I 1-3 lists these vehicles and shows the alternate methods that were
utiIized.
In order to obtain the 268 vehicles that were procured from the randomized
listings, a total of 1,665 procurement packets were mailed.
-6-
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emission Factor Program
1981 Model Year
Veh. No.
001-007
008-014
015-019
020-022
023-024
025-026
027
028-034
035-037
038-040
041-044
045-049
050-051
052-054
055
056-057
058-059
060
061
062-063
064
065-069
070-073
074-077
078-079
080
081-082
083-084
085
086
087-088
089-090
091-092
093-094
095-096
097-099
100-101
102-104
105-107
108-109
110
111-113
114-115
1 16-117
Quantity
7
7
5
3
2
2
1
7
3
3
4
5
2
3
1
2
2
1
5
4
4
2
2
1
1
2
2
2
2
2
3
2
3
3
2
1
3
2
2
Make
Model
Chev
Chev
Chev
Chev
Chev
Chev
Chev
Olds
Olds
Olds
Buick
Buick
Buick
Pont iac
Pontiac
Pont iac
Pontiac
Pontiac
Pontiac
Cadi I lac
Cadi I lac
Ford
Ford
Ford
Ford
Ford
Mercury
Mercury
Mercury
Mercury
PI ymouth
PI ymouth
Dodge
Dodge
Chrys I er
Vol kswagen
of America
AMC
Toyota
Toyota
Toyota
Toyota
Datsun
Datsun
Datsun
TABLE I I 1-1
Page 1 of 6
Chevette
Citation-four 4-cylinder, three
Malibu-three V-6, two V-8
Cava I ier
Camaro
Impa I a/Caprice
Monte Carlo
Cut I ass/Supreme-four V-6, three
88/98
Omega-two 4-cylinder, one V-6
Skylark-two 4-cylinder, two V-6
Regal /Century-three V-6, two V-8
LeSabre/EI ectra
Phoenix-two 4-cylinder, one V-6
Fi reb i rd
Grand Prix
Cata I i na/Bonnevi I le
LeMans
"J-Car"
DeVi lie, Fleetwood
Eldorado or Seville (non-diesel)
Escort
Fa i rmont
Mustang
Thunderb i rd
Granada
Lynx
Zephyr
Capri
Marqu i s
Rel iant
Hor i zon
Aries
Omn i
LeBaron /Cordoba
Rabbit
Concord/Sp i r it
Corol I a
Tercel
Cel ica
Corona
210
310
510
V-6
-7-
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emission Factor Program
1981 Model Year
Veh. No.
1 18
119-121
122-123
124-125
126-127
128-129
130-131
132
133
134
135
136-140
141-145
146-148
149
350
Quanti ty
1
3
2
2
2
2
2
1
1
Make Model
Datsun 200SX/280ZX
Honda Civic
Honda Accord
Mazda GLC/626/RX-7
Mitsubishi Colt/Arrow
Subaru Any model except "Brat"
Volkswagen Dasher
Ford Fiesta
Fiat Strada/Brava
Volvo Any model
Audi Any model
Chev/GMC P/U
Ford P/U
Dodge P/U
Datsun P/U
Toyota P/U
TABLE 111-1
Page 2 of 6
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emission Factor Program
1980 Model Year
Veh. No.
151-154
155-156
157-161
162
163-165
166-167
168-170
171
172-176
177-178
179-180
181-182
183-184
185
186
187
188
189
190
191
192
193-195
196-198
199
200
201
202-203
204
205
206-207
208
209
210
21 1
212-213
214-215
216-217
218-219
220
221-222
223-224
225
226-227
228-229
Quantity
4
2
5
1
3
2
3
1
5
2
2
2
2
1
1
3
3
1
1
1
2
2
2
2
1
2
2
1
2
2
Make
Chev
Chev
Chev
Chev
Chev
Chev
Chev
Olds
Olds
Olds
Buick
Buick
Buick
Buick
Ponti ac
Pontiac
Pont iac
Pontiac
Ponti ac
Cadi I lac
Ford
Ford
Ford
Ford
Ford
Ford
Mercury
Mercury
Li ncoln
PIymouth
PIymouth
Chrysler
Dodge
Dodge
VoIkswagen
of America
AMC
Toyota
Toyota
Toyota
Datsun
Datsun
Datsun
Honda
Honda
TABLE I I 1-1
Page 3 of 6
Mode I
Chevette .
Monza
Citation-three 4-cylinder, two V-6
Camaro
Ma I i bu
Monte Carlo
Impala/Caprice
Omega
Cutlass/Supreme-three V-6, two V-8
88/98
Skylark
Century
Regal
LeSabre
Sunb i rd
Phoen ix
Fi rebi rd/LeMans
Grand Prix
CataI ina/BonneviI Ie
Any model
Pinto
Mustang
Fa i rmont
Granada
Thunderb i rd
LTD
Zephyr
Capri
ContinentaI/Mark VI
Hori zon
VoI are
Cordoba/LeBaron
Omn i
Aspen
Rabbit
Concord/Sp i rit
Corol I a
TerceI
CeI i ca
210
310
510
Civic
Accord
-9-
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emissions Factor Program
1980 Model Year
Veh. No. Quanti ty Make Mode I
230 1 Mazda GLC
231 1 Mazda 626
232-233 2 Subaru Any model except "Brat"
234-235 2 Volkswagen Dasher
236-237 2 Mitsubishi Colt/Arrow
238 1 Volvo Any model
239 1 Ford Fiesta
240 1 Mercedes Benz Any model
241-244 4 Chev/GMC P/U
245-246 2 Ford P/U
247-248 2 Toyota P/U
249 1 Dodge P/U
250 1 Datsun P/U
TABLE I 1-1
Page 4 of 6
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emission Factor Program
1979 Model Year
Veh. No.
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1.
1
Make
Chev
Chev
Chev
Chev
Olds
Olds
Buick
Pont iac
Pont i ac
Ford
Ford
Ford
Mercury
Dodge
PI ymouth
Datsun
Datsun
Toyota
Toyota
Vo I kswagen
Honda
Mazda
Chev
Ford
Dodge
Model
Chevette
Monza
Ma Ii bu
Camaro
Cut I ass/Supreme
88/98
RegaI/Century
Sunbi rd/Phoen ix
Firebird/Grand Prix
Mustang
Fa i rmont
LTD/Thunderbird
Monarch
Omn i
Hori zon
B210
510/280Z
Corona/CoroI I a
Gel i ca/Cress i da
Rabbit
Civ ic/Accord
GLC/626/RX7
P/U
P/U
P/U
TABLE
Page 5 of 6
-11-
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ORIGINAL VEHICLE REQUIREMENTS
FY80 Emission Factor Program
1978 Model Year
Veh. No.
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
Quantity
Make
Mode I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Chev
Chev
Chev
Chev
Chev
Olds
Olds
Buick
Pont iac
Pont i ac
Ford
Ford
Ford
Ford
Mercury
Dodge
PI ymouth
Datsun
Datsun
Toyota
Toyota
Vol kswagen
Honda
Chev
Ford
Chevette
Monza
Camaro
Ma I i bu
Monte Carlo
Cut I ass/Supreme
88/98
Rega I /Century
Sunb i rd
LeMans/Fi rebi rd
Pinto
Mustang
Fa i rmont
Granada
Zephyr
Aspen
Horizon
B210
510
Corona/Coro I I a
Cel ica
Rabbit
Accord
P/U
P/U
TABLE II1-1
Page 6 of 6
-12-
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VEHICLE SUBSTITUTIONS
ORIGINAL REQUIREMENTS
Veh. No. of
No. Veh. Year Make/Model
132 1 1981 Ford/Fiesta
133 1 1981 Fiat/Strada
Brava
*130 1 1981 Volks/Dasher
*097- 3 1981 Volks/
099 Rabbit
063 1 1981 Cadillac/
DeVi 1 ie
157 1 1980 Chev/
Ci tation
103 1 1981 Toyota/
Corol I a
127 1 1981 Mitsubishi/
Arrow
*131 1 1981 Volks/Dasher
Veh. No. of
Engine No. Veh. Year Make/Model
Any
Any
Any/
gaso 1 i ne
Any/
gasol i ne
Any
V-6
Any
Any
Any
gasol i ne
132 1 1982 Merc/LN7
133 1 1982 Ford/EXP
130 1 1982 Ford-Merc/
EXP-LN7
097- 3 1982 Ford/Merc/
099 EXP-LN7
063 1 1981 Cadillac/
El dorado
157 1 1980 Chev/
Citation
103 1 1981 Toyota/
Tercel
127 1 1981 Dodge/
Aries
131 1 1982 Merc/LN7
SUBSTITUT
Eng i ne
Any
Any
Any
Any
Any
4-Cyl
Any
Any
Any
IONS
Reason
1980 was the last production
year for the Ford Fiesta.
Registration list supplier
could not locate 1981 vehicles
Registration list supplier and
local dealer stated that the
1981 VW Dasher is avai lable
with diesel engines only.
Al 1 registration of 1981 VW
were used with no positive
responses.
Could not obtain required
model. Substitution approved
by the Project Officer.
Contract al lows that 10$ (30
vehicles) of the vehicles do
not have to be an exact match
for engine displacement.
Could not obtain required
model. Substitution approved
by the Project Officer.
Could not obtain required
model. Substitution approved
by the Project Officer.
Could not obtain required
model. Substitution approved
by the Project Officer
*A1I available registration listings for '981 Volkswagens were solicited, but the majority of positive responses were
diesel powered units. Attempts to obtain these vehicles through local dealers and other sources were unsuccessful.
TABLE I I I-2
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VEHICLE PROCUREMENT FLOW CHART
1981 MODEL YEAR EXAMPLE
Obtain Local Venicle
Reg i s t rat ion List
Obtain Vehicle
List crom Loca
Car Rental
Agencies 'l°8l
Models Only)
Random! ze List
if not done by
L st Suop 1 i er
Ma i 1 Procure-
ment Packets
Place Phone
Ca 1 1 s for Pos i -
t ve Responses
Screen Candidate
Vehicle
Screen 1978/79
Model Year
Vehicles
Was Vehicle
Owner Contacted
Within Two
Phone CalIs?
J El inn nate
Candidate
Screen 1981 Model
Year Vehicles
(Con t i nue s imi
to 1981 M Y.
Strategy)
Is Vehicle Odometer
>; <*,000 miles?
No
El im i nate
Cand idate
i Yes
Is the ^ of 1981
M.Y. Non-"High
Mi 1 eage" Veh i cl es
Selected to Date
^ 120?
No
Is Candidate
Vehicle Source
a Lease or
Rental Agency?
Veri fy Make, Model ,
Type and Model Year
Yes
Is ^ of Vehicles
Wh I ch are Not an
Exact Match on
Al 1 Parameters
Yes
is -
Wh I ch
Exact
Make,
of Vehi c 1 es
are Not an
Match on
Model and
Eng i ne D i sp 1 ace-
ment
>: 15?
Yes
Schedule Vehicle
Droo at Lab and
Test i no
Is = of 1981 MY
Veh f c les Se 1 ected/
Testea =- 150?
Yes
Ven i c 1 e Procu re-
ment Comp 1 ete for
1981 M Y. Vehicles
Screen 1980
Model Year
Vehicles
(Cont inue similar
1981 M. Y.
Strategy)
Is the = of 1981
M.Y. Vehicles
Selected from
Thi s Source i 30?
Yes
El imi na te
Candidate
1 s Loan/ 1 ncent i ve
Agreeable or Lease
Obtainable/Accept-
able to Owner9
NO|
El i m i na te
Cand i date
FIGURE I I 1-1
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VEHICLES OBTAINED BY ALTERNATE
PROCUREMENT METHODS
Veh.No. Year
Make/Model
Alternate Method
Reason
020
021
022
032
036
041
045
056
057
078
081
083
087
089
101
11 1
132
133
145
127
240
287
103
105
130
131
061
075
016
097
098
099
1982
1982
1982
1981
1981
1981
1981
1981
1981
1981
1981
1981
1981
1981
1981
1981
1982
1982
1981
1980
1980
1978
1981
1981
1982
1982
1982
1981
1981
1982
1982
1982
Chev/Cava I ier
Chev/Cava I i er
Chev/Cava I ier
. Olds/Cutlass
Olds/Delta 88
Bu ick/Sky I ark
Bu ick/Century
Pontiac/Grand Prix
Pontiac/Grand Prix
Ford/Thunderb i rd
Merc/Lynx
Merc/Zephyr
PI ymouth/Re I iant
PI ymouth/Horizon
AMC/Concord
Datsun/210
Merc/LN7
Ford/EXP
Ford/Pick Up
Chev/Citation
Mercedes/450 SL
Ford/Mustang
Toyota/Terce I I
Toyota/Terce I I
Ford/EXP
Merc/LN7
Pont iac/J 2000
Ford/Mustang
Chev/Mal ibu
Merc/LN7
Merc/LN7
Merc/LN7
Rental
Rental
Rental
Rental
Rental
Renta I
Rental
Renta I
Employee reference
Employee reference
Renta I
Renta I
Rental
Renta I
Rental
Rental
Rental
Participant reference
Emp loyee
Emp I oyee
Obtained thru Dealer
Emp loyee
Employee reference
Renta I
Employee reference
Renta I
Rental
Renta I
Rental
Rental
Renta I
Renta I
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Approved by Project Officer
Approved by Project Officer
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Approved by Project Officer
Approved by Project Officer
Approved by Project Officer
Approved by Project Officer
Approved by Project Officer
Approved by Project Officer
Per terms of contract
Approved by Project Officer
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
Per terms of contract
TABLE I I I-3
-15-
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SECTION IV
VEHICLE, PREPARATION, INSPECTION AND MAINTENANCE
A. INITIAL MECHANICAL INSPECTION
After a vehicle was screened by telephone, the owner was asked to deliver it
to the laboratory for testing. On arrival, the vehicle was checked for
exhaust leaks and the Vehicle Information Data Sheet and the Engine Parameter
Data Sheet (Appendix B) were completed. During this process, all emission
control systems and sub systems were checked to verify that they matched
those listed in the Gas Mileage Guide for that model year. Variances were
noted when found.
A fuel sample was taken from the vehicle fuel tank for lead content analysis.
The vehicle was then delivered to the Chassis Dynamometer Testing Laboratory
for preconditioning and testing.
B. POST TEST INSPECTION
On completion of the "as received" emissions test, each vehicle received a
thorough engine and emission control systems inspection. Appendix B of this
report contains a copy of the data sheets that were used to record the inspec-
tion information. The methods for inspection and specifications for operating
parameters on each system were obtained from Manufacturer's shop manuals or
Chi I ton's Automotive Manuals for the appropriate model. Information from the
emissions data sticker, which is found in the engine compartment, was used
when available. Observed values, (i.e. basic timing, idle speeds, idle HC
and CO levels, etc.) were recorded on the Inspection Data Sheets (Appendix B).
The Comments Data Sheet (Appendix B) was used to note any maladjustments,
disabled systems or abnormal operating conditions that were found during the
i nspection.
Representatives from General Motors and the Chrysler Corporation actively
participated in the inspection and maintenance portions of this project. The
EPA Project Officer allowed these representatives to receive copies of emissions
test data and observe and/or assist in the inspection and maintenance procedures
for their companies respective vehicles. On numerous occasions this partici-
pation was beneficial in locating parts, and supplying technical information
for emission control systems.
C. RESTORATIVE MAINTENANCE
The first fifty vehicles which failed the "as received" tests were subjected
to a restorative maintenance procedure and a retest.
-17-
-------
Pass/fail criteria for the various model years were established by the EPA
as follows:
1. Emission results which were within two times the standard for that model
year were considered a pass with the following exception. If, during the
inspection procedure a problem was found that could account for excessive
emissions, a maintenance procedure and retest was recommended. These
maintenance procedures and retests were authorized by the EPA in some
instances, although the results did not exceed the two times limit.
2. In order to simplify the complexity of 1981 standards (due to the various
waivers that were granted), the following standards are used as a guide-
line for all 1981 vehicles:
HC gm/mi CO gm/nni *NOx gm/mi
.41 7.0 1.0
* A 2.0 NOx gm/mi standard applied to all 1981 American Motors Corporation
veh icles.
3. Idle test results greater than 200 PPM Hexane or 1.2$ CO were considered a
failure. This was based on the sample taken at the second idle in neutral
during the four mode test (immediately after 2,500 RPM in neutral mode).
Once a failure was identified, the inspection-maintenance procedure was
initiated. The first step was to review the manufacturer'^ recommended main-
tenance intervals. Each item listed for the last interval was inspected and
a determination was made as to whether or not the required maintenance had
been performed. Any part replacements, adjustments or checks required at the
last interval that had not been performed were accomplished during the restor-
ative maintenances.
A complete diagnostic performance check was made on the emission control
systems and sub systems in order to locate the problems. Adjustments and/or
replacements were made as necessary to bring all systems back to manufacturer's
spec!f i cations.
When the problem was diagnosed as a malfunction in a major component (any single
item which would cost in excess of $100.00 to repair or replace) no restorative
action was taken. The EPA was notified in these cases. Any further action
on vehicles in this category was at the EPA's discretion. In all cases the
restorative maintenance activities were documented in detail on the Comment
Data Sheet (Appendix B) in the After Maintenance Data Packet (Appendix B).
Table IV-1 lists each of the restorative maintenances, what problems were
found, and the corrective action taken.
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
214
267
196
251
289
255
258
198
Year
1980
1978
1980
1979
1978
1979
1979
1980
Odometer
11,183
36,261
6,442
27,956
30,964
34,118
17,845
19,531
Make/Model
AMC/Concord
Datsun/280Z
Ford/Futura
Chev/Chevette
Ford/Granada
Olds/Cutlass
Pontiac/Sunbird
Ford/Fairmont
As Rec 'd Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
HC gm/mi 1.07
CO gm/mi 38.0
HC gm/mi 7.58
CO gm/mi 172.
HC gm/mi 2.03
HC gm/mi 1.46
CO gm/mi 22.3
HC gm/mi 1.64
CO gm/mi 34.0
HC gm/mi 1.64
CO gm/mi 24 . 5
HC gm/mi 3.01
CO gm/mi 33. 2
HC gm/mi 6.32
CO gm/mi 89.6
Corrective Actions
Found broken wire on the open loop
close loop switch. Repaired wire.
Changed EGR valve and spark plugs.
Major problem with the fuel injec-
tion system. Repair cost would have
exceeded contractual limitations.
(Not retested)
Spark plugs appeared oil fouled.
Conducted cylinder compression and
leakdown test; results within manu-
facturer's specification. Problem
was diagnosed as oil leak in valve
guides and seals. Repair cost
would have exceeded contractual
limitations. (Not retested)
Spark plugs fouled; no other
problems found. (Not retested)
Reset idle mixture to manufacturer's
specs. Replaced spark plugs and
air filter element.
Reset choke index to manufacturer's
specs.
Reset idle mixture to manufacturer's
specs and replaced spark plugs.
Reset idle mixture to manufacturer's
specs (one mixture screw was damaged
and had to be replaced) . Reconnected
vacuum supply line to air diverter
valve.
After Maint. Test Results
Test
Type
CVS-CH
-
-
-
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
HC gm/mi .409
CO gm/mi 6.29
N/A
N/A
N/A
N/A
N/A
HC gm/mi .707
CO gm/mi 6.78
HC gm/mi 1 . 51
CO gm/mi 20. 1
HC gm/mi .090
CO gm/mi 7.75
HC gm/mi . 508
CO gm/mi 5. 18
% A
- 62%
- 83%
-
-
-
- 57%
- 80%
- 8%
- 18%
- 97%
- 77%
- 92%
- 94%
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RESTORATIVE MAINTENANCES
1
M
O
1
Vehicle
Number
197
171
221
203
265
284
285
271
292
263
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year
1980
1980
1980
1980
1979
1979
1978
1979
1978
1979
2. "f
CO
Odometer
11,915
17,812
10,856
11, 128
23,413
39,308
55,945
49, /53
26,534
23,743
Make/Model
Ford /Fairmont
Olds/Omega
Uatsun/210
Merc/Zephyr
Ply/Horizon
Ponticic/Sunbird
Pontiac/Lenians
Honda/Accord
Ply/Horizon
Merc. /Monarch
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
HC gm/mi .809
CO gm/mi 34.7
NOX gin/mi 4.70
CO * 378.
HC gm/mi 1 . 51
CO gm/mi 43.0
HC gm/mi 2.59
CO gm/mi 28 . 0
HC gm/mi 3 . 61
CO gm/mi 54 . 9
HC gm/mi 3.12
CO gm/mi 43.4
HC gm/mi 1 . 51
CO gm/mi 11.0
HC gm/mi 2. 32
CO gm/mi 49. 5
HC gm/mi 1 . 14
CO gm/mi 17.0
Corrective Actions
Reset idle mixture to manufacturer's
specs.
Removed vacuum delay valve from EUR
vacuum supply line. The delay valve
was not shown on the manufacturer's
schematic.
Reset idle mixture to manufacturer's
specs.
Reset idle mixture to manufacturer's
specs and changed spark plugs
Reset idle mixture to manufacturer's
specs, changed spark plugs and PCV
valve.
Reset idle mixture to manufacturer's
specs and performed 24K maintenance
interval (oil & filter change, spark
plugs and PCV valve change) .
Reset idle mixture to manufacturer's
specs. Changed air filter, PCV
valve, PCV hose and PCV filter.
Reset idle mixture to manufacturer's
specs.
Reset idle mixture to manufacturer's
specs. Changed spark plugs and PCV
valve.
Reset idle mixture to manufacturer's
specs. Changed spark plugs, and
EGR valve.
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
HC gm/mi .282
CO gm/mi 12.0
NOX gm/mi 1 . 92
CO "„ .013
HC gm/mi .484
CO gm/mi 17 .4
HC gm/mi i . 74
CO gm/mi 6.36
HC gm/mi L. 56
CO gm/mi 21.1
HC gm/mi 1.48
CO gm/mi 12.0
HC gm/mi 1.04
CO gm/mi 6.21
HC gm/mi .359
CO gm/mi 6.48
HC gm/mi . 557
CO gm/mi 5.28
% A
- 65%
- 66%
- 59*
- 99. 94
- 68*
- 60%
- 33%
- 77%
- 57%
- 62%
- 53%
- 72'i
- 31%
- 44%
- 85*
- 87%
- 51%
- 69*
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
161
253
286
lay
030
036
276
190
300
Vear
1980
1979
1978
1980
19B1
1981
1978
1900
1978
Odometer
23,297
22,958
26,865
18 ,862
4, 121
6,880
56,615
1 3,525
49,950
Make/Model
Chev/Citation
Chev/Malibu
Ford/Pinto
Ford/Granada
Olds/Cutlass
Olds/Uelta 88
Chev/Chevette
Pontiac/
Bonnevllle
Ford/Fl 50
As Rec'd Test Results
Teat
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
Idle
Emissions Results
(Failed Standards)
NOX gm/ml 4.42
NOx gm/mi 5.30
HC gm/mi 9.46
CO gm/mi 90.0
CO gm/mi 12.0
HC ppm 239.
CO % 4.98
HC gm/mi .723
CO gm/mi 10.8
CO gm/mi 8.14
CO gm/mi 19.4
CO % 1.94
NOX gm/mi 4 . 28
HC gm/mi 7. 29
HC ppm 1190.
Corrective Actions
Pulse air system was disabled.
Reactivated pulse air system,
changed spark plugs and EGR valve.
Changed EGR valve and spark plugs.
Reset idle mixture to manufacturer's
specs. Changed air filter element
and spark plugs.
Reset idle mixture to manufacturer's
specs.
Idle mixture control solenoid was
defective. With approval of the EPA,
GM supplied new carburetor assembly.
Installed new carburetor.
Reset basic timing to manufacturer's
specs. (10° advanced as received)
Reset idle mixture to manufacturer's
specs. Changed spark plugs, PCV
valve and fuel filter.
Reconnected EGR vacuum supply line.
Replaced vacuum operated choke pull
off, repaired carb. leaks, changed
spark plugs, PCV valve and reset
idle RPM. Also diagnosed engine mis-
fire due to burned exhaust valve.
Repair of the problem would have
exceeded contractual limitations.
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
Idle
Emissions Results
NOX gm/mi 2. 21
NOx gm/mi 1 . 21
HC gm/mi 4.74
CO gm/mi 36.4
CO gm/mi 2.16
HC ppm 5.77
CO % .009
HC gm/mi .253
CO gm/mi 2.82
CO gm/mi 4.22
CO gm/mi 9.11
CO % .006
NOx gm/mi 1.93
HC gm/mi 6.45
He ppm 284.
% A
- 50%
- 77*
- 50%
- 60%
- 82%
- 98%
- 99.8%
- 65%
- 74%
- 48%
- 53%
- 99.7%
- 55%
- 12%
- 76%
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RESTORATIVE MAINTENANCES
1
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Vehicle
Number
186
OO7
104
260
211
093
264
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CD
Year
1980
1981
1 98 1
1979
1980
1981
1979
— 1
33
Odometer
5,453
6,983
3,747
14,879
9,011
3,160
26,261
Make/Model
PonLiac/Sunbird
Chev/Chevette
Toyota/Corolla
Ford/Mustang
Dodge/Aspen
Dodge/Unm
Uodye/Omni
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
NOx gm/mi 5.83
HC gm/mi 1 . 17
CO gm/mi 12.8
CO % 2.53
HC gra/mi 2.21
CO gm/mi 22.0
HC ppm 400.
CO gm/mi 35.2
HC gm/ml .812
CO gm/mi 12.7
HC gm/mi .307
CO gm/mi 4. 55
NOx gm/mi 4 . 56
Corrective Actions
Reset idle mixture to manufacturer's
specs and unplugged EGR vacuum supply
line .
Signal from O2 sensor was within
limits, but signal was erratic.
The EPA approved 02 sensor change
(GM provided) and retest.
Owner admitted using leaded fuel.
Reconnected air pump supply line to
air cleaner and reconnected hot air
tube to air cleaner.
Reset idle mixture to manufacturer's
specs and changed spark plugs.
Reset idle mixture, idle RPM's and
basic timing to manufacturer's specs
Vehicle passed standards as received
but during the inspection it was
discovered that the emission control
module was improperly wired. The
lead wire to the O2 sensor was also
disconnected. This was apparently
done when an after market A/C was
installed. The EPA authorized repair
and retest.
Reset idle mixture to manufacturer's
specs. Repaired tampering change
made to idle solenoid plunger assem-
bly and removed plug from EGR vacuum
supply line. Changed spark plugs and
PCV filter.
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
NOx gm/mi 1.21
HC gm/mi 1.05
CO gm/mi 9.26
CO % " 1 . 04
HC gm/mi 1. 78
CO gm/mi 13.0
HC ppm 355.
CO gm/mi 2. 56
HC gm/mi .704
CO gm/mi 9.61
HC gm/mi .224
CO gm/mi 1.22
NOX gm/mi 1.31
% A
- 79%
- 10%
- 28%
- 59%
- 20*
- 42%
- 11%
- 93%
- 13%
- 24%
- 27%
- 73%
- 71%
O
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
237
291
209
229
234
Year
1980
1978
1980
1980
19BO
Odometer
10,668
46,376
22,045
b , 900
11, 200
Make/Model
Uodtje/Colt
Dodge/Aspen
Chrylser/
Le Baron
Ho ndd/ Accord
Volks/Uasher
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Idle
Emissions Results
(Failed Standards)
HC gm/mi .535
CO gm/mi 23.0
HC gm/mi 2.18
CO gm/mi 21.0
NOx gm/mi 4 . 06
HC ppm 309.
CO % .161
HC gm/mi .685
CO gm/mi 24 . 0
CO % 1.34
HC gm/mi 1.37
CO gm/mi 19.0
CO % 1.80
Corrective Actions
Reset idle mixture and idle RPM's
to manufacturer's specs. Changed
spark plugs. Restorative maintenance
did not cause any substantial change
in emissions results. Chrysler
representative assisted in this
maintenance procedure and could
offer no further suggestions other
than catalyst damage. Replacement of
catalyst would exceed contractual
limitations.
Reset idle mixture. Idle RPM's and
basic timing. Changed spark plugs.
PCV valve, evap. canister purge line,
evap. canister vent line, EGR vacuum
supply hose, vacuum amplifier,
fuel filter and carburetor base
gasket. Restorative maintenance
resulted in increases on some
emissions. A Chrysler representative
assisted in this maintenance pro-
cedure and the increases were
attributed to the overall poor con-
dition of this vehicle.
Reset idle mixture to manufacturer's
specs.
Reset idle mixture to manufacturer's
specs.
Reset fuel injector limiting device
to manufacturer's specs.
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Idle
Emissions Results
HC gm/mi .654
CO gm/mi 2b.O
HC gm/mi 2.38
CO gm/mi 12.8
NOX gm/mi 2 . 64
HC ppm 612.
CO * .026
HC gm/mi .402
CO gm/mi 8.36
CO % .232
HC gm/mi .436
CO gm/mi 3.90
CO % .006
* A
+ 22H,
1 9
+ 9%
- 39
- 35*
+ 98%
- 84*
- 41*
- 65*
- 83*
- 68*
- 80*
- 99.6*
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CD |-
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RESTORATIVE MAINTENANCES
Vehicle
Number
152
005
048
019
149
254
156
Year
1980
1981
1981
1982
1981
1979
1980
Odometer
33,020
6,282
10,529
6,727
7,373
33,708
18,250
Make/Model
Chev/Chevette
Chev/Chevette
Buick/Regal
Chev/Malibu
Datsun/Pickup
Chev/Camaro
Chev/Monza
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Emissions Results
(Failed Standards)
CO gm/mi 31.6
HC gm/mi .834
CO gm/mi 9.91
CO gm/mi 6.52
NQx gm/mi 1.20
HC ppm 275.
CO % 1.77
HC gm/mi 3.99
CO gm/mi 108.
HC ppm 211.
CO % 2.89
NOx gm/mi 3 .07
Corrective Actions
Replaced pulse air distribution
element and purge valve for pulse
air system. Changed spark plugs, PCV
valve in accordance with manufac-
turer's recommendations for last
regular schedule maintenance inter-
val.
Engine would not respond to propane
enrichment. GM representative
diagnosed the problem an improperly
set idle mixture (sealed carb. ) The
EPA authorized a carburetor assembly
change (GM supplied) and retest.
Reset choke plate opening angle to
manufacturer's specs.
Reconnected vacuum supply line to
EGR valve.
Reset idle mixture to manufacturer's
specs and changed spark plugs.
Reset idle mixture and idle RPM's
to manufacturer's specs. Changed
fuel filter, air filter, PCV filter.
PCV valve, PCV supply line.
Rerouted vacuum lines in accordance
with manufacturer's specs. Reset
idle RPM's and basic timing to manu-
facturer's specs.
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Emissions Results
CO gm/mi 18. 5
HC gm/mi .336
CO gm/mi 4.12
CO gm/mi 2. 36
NOX gm/mi .631
HC ppm 64.8
CO % .009
HC gm/mi .881
CO gm/mi 6.31
HC ppm 78.7
CO % .007
NOx gm/mi 1.85
% A
- 41%
- 60%
- 58%
- 64%
- 47%
- 76%
- 99.5%
- 78%
- 94%
- 63%
- 99.8%
- 40%
I
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CD |—
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RESTORATIVE MAINTENANCES
Vehicle
Number
299
279
280
178
168
236
069
Year
1978
1979
1978
1980
1980
1980
1981
Odometer
33,763
68,593
40,951
26,384
31,670
19,652
3,652
Make/Model
Chev/C-10
Pickup
Chev/Malibu
Chev/Monte
Carlo
Olds/Delta 88
Chev/Impala
Dodge/Colt
Ford/Escort
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
HC gin/mi 4.96
CO gin/mi 68 . 2
HC gin/mi 6.10
CO gm/mi 84.53
HC ppm 641.
CO % 5.15
HC gm/mi 2.11
CO gm/mi 36.1
HC ppm 261.
CO % 3.07
CO gm/mi 11.3
HC gm/mi 2.91
CO gm/mi 56.8
CO gm/mi 53 .6
HC gm/mi 1.04
CO gm/mi 15.0
Corrective Actions
Diagnosis indicated a defective
power valve in the carburetor.
installed carburetor kit. Reset basic
timing and set carburetor to specs.
Reset idle mixture, curb idle, fast
idle and basic timing to specs.
Reset idle mixture to manufacturer's
specs. Changed spark plugs, air
filter, PCV valve, PVC filter, EGR
valve and fuel filter.
Reset primary choke vacuum break and
curb idle speed to manufacturer's
spec s .
Reset idle mixture and basic timing
to manufacturer's specs. Changed
spark plugs, air filter and PCV
filter.
Reset idle mixture to manufacturer's
specs. Changed spark plugs.
Reconnected hot air stove pipe from
the exhaust manifold to the air
intake .
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
HC gm/mi 3.42
CO gm/mi 52.6
HC gm/mi 2.32
CO gm/mi 32.0
HC ppm 25.6
CO % .009
HC gm/mi .887
CO gm/mi 14.3
HC ppm 28.7
CO % .009
CO gm/mi 9.60
HC gm/mi 2.73
CO gm/m i 45.6
CO gm/mi 19.7
HC gm/mi . 918
CO gm/mi 12.2
% fl
- 3i%
- 23%
- 62%
- 62%
- 96%
- 99.8%
- 58%
- 60%
- 89%
- 99.7%
- 15%
- 6%
- 20%
- 63%
- 12%
- 19%
M
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DJ >
CQ CD
Ct> I—
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CD
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RESTORATIVE MAINTENANCES
Vehicle
Number
*063
*058
* Vehic
agree
Year
1981
1981
les 06:
d to a:
Odometer
9,645
5,669
and 058 were
low retest or
Make/Model
Cadillac/
Barritz
Pontiac/
Bonneville
tested after tl
the vehicles.
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
e requiret
These ret<
Emissions Results
(Failed Standards)
CO gm/mi 8.15
NOx gm/mi 4.00
HC gm/mi 8.88
CO gm/mi 205 .
NOx gm/mi .325
HC ppm 354.
CO % 4.03
50 I/M procedures 1
sts will be applied
Corrective Actions
During bags one and two of the "as
received" FTP CVS-CH test the engine
would not come off of fast idle.
The G.M. representative diagnosed
the problem as a faulty ECM and
malfunctioning fuel injectors.
These components were replaced.
While attempting to retest, the
check engine light came on and
problem codes were found. With the
approval of the Project Officer the
vehicle was then taken to a local
Cadillac dealer for repairs. The
throttle position sensor was re-
placed by the dealer.
Replaced 02 sensor. A G.M. repre-
sentative assisted in this
diagnosis and repair.
ad been completed. At the manufactur
to the contractual requirements for t
After Maint. Test Results
Test
Type
CVS-CH
CVS-CH
Idle
;r's reque
le FY81 pr
Emissions Results
CO gm/mi 2.96
NOX gm/mi .751
HC gm/mi 4.53
CO gm/mi 27.4
NOX gm/mi 3 . 94
HC ppm 152.
CO % .526
;t, the Project Offi
>ject.
% A
- 64%
- 81%
- 49%
- 87%
+1112%
- 57%
- 87%
:er
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CQ CD
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SECTION V
VEHICLE EMISSION TESTING
A. TEST LABORATORY
EG&G-AR Chassis Dynamometer Testing Laboratory is located at 5404 Bandera
Road, San Antonio, Texas. A floor plan of this lab is included as Figure
V-1. This lab presently consists of two automotive test cells with chassis
dynamometers, one motorcycle chassis dynamometer test cell, emissions analyt-
ical equipment, soak area and support equipment. Details on most equipment
are available in Appendix C, EPA Laboratory OuaI ificat ion Worksheets.
Test Cell Number One was exclusively used for the data generated in the
Emission Factor Program. This cell contains a Clayton ECE-50 chassis
dynamometer with an inertia range from 1000 Ibs. to 8875 Ibs. in 125 Ib.
increments. The drivers aid is a Hewlett Packard 7133A recorder. A Hartzell
N24D WW fan was used in this cell.
A CFV-CVS System was utilized for testing under this contract. The system
is a Horiba Model 20-B-CFV-CVS with a flow capacity of 325 CFM. Details may
be found in Appendix D.
The Emission Analytical Console used was constructed by Horiba Instruments
according to EG&G-AR specifications. The console contains a total of seven
analyzers on two sample trains for both dilute and raw exhaust gas analysis.
Details on this console may be found in Appendix D. Additionally, a Horiba
Mexa 321 E was used for undiluted HC (Hexane) measurements.
EG&G-AR's Chassis Dynamometer Testing Laboratory has a soak area capacity of
approximately 14 vehicles, dependent upon vehicle size. Soak area temperature
is control led year-round to a target 74 +_ 3 F.
A full complement of support equipment is located in the Chassis Dynamometer
Testing Laboratory. This equipment is detailed in Appendix D but essentially
consists of temperature and humidity recorders, a barometer, clocks timers
calibration equipment, lead (Pb) test kit and a zero gas generator.
B. EQUIPMENT CHANGES
At the start of the contract period, the Horiba Console was used to measure
undiluted HC, with results converted to Hexane equivalent. Later the Mexa
321 E was used, beginning with run number 61.
The only other equipment change was the initiation of the use of Plumbtesmo
kits. Beginning with run number 134, these kits were used to detect the
presence of lead traces in the test vehicle tailpipes.
-27-
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EG&G AUTOMOTIVE RESEARCH, INC.
CHASSIS DYNAMOMETER TESTING LABORATORY
CD
oo
I
•M«t
11
ellic*
Cell #2
«r>«> (New)
Analyt
Console
Cell #1
gn cyfmtfar ttorog*
Motorcycle
Test Cell
Office
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C. TEST PROCEDURES
1. Preconditioning Procedures
On all vehicles the "as received" fuel was drained and the tank
refilled to tank-fuel volumes (40% of tank capacity) with the
appropriate test fuel. The vehicles were run on the dynamometer
for the first 505 seconds of the Federal Cycle. During precondi-
tioning and the cold transient phase of the FTP, a vehicle drive-
ability evaluation form was completed. The preconditioning ensured
that the test fuel had purged the vehicle's fuel system and the
engine had achieved a normal operating temperature. Test vehicles
were then placed in the soak area. The required ambient temper-
ature in the soak area was maintained and the prescribed 12 to
36 hour soak began. The ignition was not turned on again until
the beginning of the emissions test.
2. FTP Procedure
The basic test performed on each vehicle was the Federal Test Pro-
cedure for exhaust emissions as described in Federal Register
Vol. 42, No. 125 - Tuesday, June 28, 1977 and as amended in Vol. 43,
No. 220 - Tuesday, November 14, 1978. This procedure was modified
and expanded by EPA guidelines contained in the subject contract.
3. Highway Fuel Economy Test Procedures and Requirements
After the FTP the vehicle was operated on the chassis dynamometer
at 50 miles per hour for a period of three minutes. The "50 cruise"
short cycle test was performed at this time. Within one minute of
this cruise period, the vehicle commenced operation over the 10.242
mile, 765 second driving schedule. The CVS system was used to
gather the dilute exhaust for the purpose of emission and fuel
economy calculations. The engine was at an idle condition at the
beginning of the sampling period.
The tolerance of this driving schedule was identical to those defined
in the basic FTP driving schedule.
Dynamometer loading and transmission shift points follow the pro-
cedures required for FTP tests.
4. Additional Test Cycles
This set of four short cycle tests included; 50 cruise, four-speed
idle test, two-mode loaded test and bagged idle test. Measurements
of diluted and undiluted HC, CO, C02 and NOx emissions were accom-
plished with instruments described in Section V-A. Test Laboratory.
The entire sequence was conducted with the hood open and the auxiliary
cool ing fan on. For the final test, the inertia was reduced to the
-29-
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lowest available setting (1,000 Ibs.). Each of the short cycle
tests began after a six (+_one) minute idle period with the trans-
mission in neutral. The idle period began immediately after the end
of the preceding test. If the time between tests was exceeded by
less than two hours, the vehicle was preconditioned by driving the
first 505 seconds of the FTP Driving Schedule. The test sequence
then resumed, beginning with a six minute idle. If the idle time
was exceeded by more than two hours, the vehicle was placed in soak
from 12-36 hours and retested from the beginning of the cold start
FTP. In each case, equilibrium of engine (or vehicle) speed and
analyzer outputs were achieved before the readings are taken. Only
in the case of the 50 Cruise Test, did the mode exceed 30 seconds
after the proper engine (or vehicle) speed and dynamometer load had
been reached. Emission values were monitored continuously on strip
chart recorders. Sample data sheets are located in Appendix C.
Details of the procedures for each of the short cycles are listed
be Iow.
a. The 50 Cruise Test was a high speed loaded test that takes advan-
tage of the three minute preconditioning run before the HFET.
Tailpipe emissions were measured and recorded continuously
throughout the period although the official sampling period
ended 30 seconds after speed and load had stabilized at 50 mph.
b. The Four-Speed Idle Test involved four steady state idle condi-
tions with the transmission in neutral. Emissions were measured
and recorded at basic idle, idle at 2500 rpm and after returning
to basic idle. The transmission was then placed in drive (with
brakes applied) for sampling in the fourth mode.
c. The Two-Mode Loaded Test consisted of two operating conditions.
At the end of the six minute idle period, the vehicle was
operated at 30 mph while setting 9.0 actual horsepower. Imme-
diately following sampling in this mode, the vehicle was returned
to the idle mode, the transmission placed in neutral and the
emissions sampled again.
d. The Bagged Idle Test followed the FTP and preceded the HFET. The
Bagged Idle Test required the use of the same instrumentation as
the FTP to measure di ute exhaust emissions during one steady
state of operation.
The test was preceded by an "engine-off" soak period of six (+_
one) minutes. At the end of this soak period, the vehicle was
restarted and operated for three minutes at idle with the trans-
mission in drive (manual transmission vehicles were operated in
neutral with the clutch engaged). The three minute sampling
period began at the time the starter was engaged so that the
engine cranking was included as part of the sample. During the
-30-
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three minute period, the exhaust sample was gathered through
the CVS.
D. CALIBRATIONS
The following calibrations were performed routinely during the contract
period. No changes in usual lab operations were required to meet the
requirements of the subject contract.
1. Chassis Dynamometer
The chassis dynamometer received the following calibrations: A complete
calibration was performed prior to initiation of testing. The cali-
bration included speed, load cell deadweight, deadband adjustment and
dynamometer coastdowns. This calibration was repeated after maintenance
was performed that could affect the calibration or whenever a weekly
verification exceeded the +_ 0.5 road load horsepower tolerance.
On a weekly basis coastdown times were verified on half of the inertia
weight and road load combinations used. The following week the remainder
of the inertia weight and road load combinations used were verified. A
speed check at 74.54 km/hr (46.3 mph), 1800 rpm was performed on a
weekly basis.
During the dynamometer warm-up and prior to the start of each test, the
indicated horsepower for the selected inertia weight was verified at
50 mph.
The dynamometers were lubricated and maintained in accordance with Clayton's
recommended maintenance schedule.
2. CVS System
The CFV-CVS System received a complete calibration, according to the guide-
lines set forth in Title 40, Code of Federal Regulations, Part 86, Section
86.199-78 (b) CFV calibration, prior to the start of the program, when
maintenance was performed that could have an effect on the calibration
or when deemed necessary by Quality Control personnel.
The flow computation board calibration was verified on a weekly basis. If
the variance of one counter exceeded ten counts from the average count
or the calculated SCFM and the indicated SCFM exceed five counts, the flow
computation board was adjusted.
On a daily basis a CVS System verification was performed using the propane
recovery method as outlined in Title 40, Code of Federal Regulations,
Part 86, Section 86.199-78 (c). If the recovery was outside of the + 2%
-31-
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tolerance, the problem was identified and repaired. Two successive
recoveries within +_ 2% were obtained before testing began.
3. Analytical Bench
Monthly calibrations on all used analyzer ranges were conducted using
seven gases spaced evenly over each range (e.g., zero, 15, 30, 45, 60,
75 and 90 percent of fulI scale). The gases used to caI ibrate the CO,
C02, and NOx analyzers are all single blend gases with nitrogen as the
diluent. The gases used for the FID were single blend gases using pro-
pane with air as the diluent. All of the above gases were purchased
from Scott Specialty Gases and were gravimetric blends with certified
analysis (+_ \%] and are traceable to NBS standards. An Aadco Model
737-13 pure air generator was used for a I I zero air requirements. The
operation of this generator was verified weekly by cross-checks with com-
pressed zero air with certified levels of impurities. A complete cali-
bration was performed following maintenance or when curve checks were
out of Iimi ts.
On a weekly basis all analyzer curves were checked using the span gas
and three of the gravimetrics (e.g. 90, 60, and 30$ of full scale). If
any of the readings exceeded +_ ]% of the concentration for gases, above
50% of meter, the instrument received a complete calibration. On alter-
nating weeks, 75, 45, and \5% gravimetrics were substituted in the pro-
cedure.
The entire analytical system was leak checked daily. Zero and span drift
on all ana yzer ranges measured and recorded, zero and span pot settings
were recorded, NOx converter efficiency was checked and CO analyzer vapor
interference was checked using C02 bubbled through water. Propane recov-
eries were performed, span gas cylinder pressures recorded, HC hangup
was checked and ambient HC and CO analysis was performed.
4. Soak Area Temperature Recorder and Wet Bulb/Dry Bulb Recorder
The temperature recorders were calibrated monthly by referencing the
temperature sensors to a certified thermometer. They were checked at
ambient, cool (approx. 60° F) and warm (approx. 90° F) temperatures.
Response time was recorded.
The recorder was checked daily at ambient temperatures.
5. Strip Chart Recorders
The chart speed and linearity of all emissions recorders and the driver's
aid were checked weekly. Response time and deadband adjustments were also
checked during this calibration. The data forms used for all calibrations
and functional checks are included in Appendix D.
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6. Qual ity Audit
In order to ensure that all calibrations were completed in a consistent
manner and that no procedural or operational errors had occured during
the calibrations, each completed data sheet was audited by the EG&G-AR
Quality Control Group.
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SECTION VI
TEST RESULTS
All test results were transferred to special data sheets (included in
Appendix B) provided by the EPA. After review by the EPA, these packets
were forwarded to Systex Inc. which was contracted by the EPA to process
all data supplied by the Emission Factor testing contractors.
Because of this arrangement, EG&G-AR's contract required that test data
not be included as part of the final report.
-35-
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SECTION VI I
DATA HANDLING
A. EMISSIONS TEST AUDITING AND VALIDATION
Upon completion of each vehicle test sequence, test data packets were re-
viewed by the Quality Control Department, independent from testing opera-
tions. This review consisted of:
1. Checks for errors, omissions and legibility.
2. Verification of time specifications.
3. Application of current calibration data and use of properly calibrated
equ ipment.
4. Compliance with FTP specifications.
To ensure consistency and completeness of audits, a group of checklists was
utilized. These checklists are located in Appendix E. When problems were
discovered in the data packets, the packet was returned to the appropriate
technician for corrections. If any inconsistencies could not be resolved,
the test was invalidated.
B. TEST DATA TRANSMITTAL
After completion and review of each data packet, the packet was forwarded to
the EPA via United Parcel Services. As directed by the EPA, on July 15, 1981
all data packets were sent to Systex, Inc., via United Parcel Services.
C. GAL I BRAT!ON DATA TRANSMITTAL
On a weekly basis a copy of all calibrations was sent to the EPA. This
packet also included daily work summary logs, daily instrument checks and the
barometric recording for the week. The packet included information generated
from Monday to Sunday of each week.
inning in mid July, the monthly analytical instrument calibration curves
were sent to Systex, Inc. as directed by the EPA. The remainder of the packet
continued to be sent directly to the EPA.
-37-
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APPENDIX A
Sample Procurement Packet
1) Letter of Introduction
2) Emission Factor Testing Program - Question and Answers
3) Telephone Questionnaire
4) Incoming Vehicles Inspection Sheet
5) Test Agreement
6) Standard Vehicle Loan Agreement
7) Savings Bond Information Sheet
8) Test Agreement Addendum
9) University of Michigan Questionnaire
10) EG&G-AR Letter of Appreciation
11) EG&G-AR Letter of Acknowlegement for Response
12) Vehicle Owner Questionnaire Data Sheet
-39-
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
ANN ARBOR MICHIGAN 48105
OFFICE OF
AIR. NOISE AND RADIATION
Dear Vehicle Owner:
As you may know, the Environmental Protection Agency and EG & G Automotive
Research are conducting an Important research program on air pollution fro™
motor vehicles In San Antonio. You have been selected by a random scientific
sampling procedure as a possible participant in this program, which involves
analyzing exhaust emissions from certain vehicle.. We hope you will agree to
take part in this important effort.
If your vehicle matches our research specifications, we will provide you with
a late-model loaner car for the several days that your car is being examined
by EG & G Both your vehicle and the one being loaned to you will be insured.
Your car will be returned to you with a full tank of gasoline and you will
also receive a $100 United States Savings Bond as our way of thanking you tor
your help. Your participation in this research will be an Important
contribution toward solving this country's air pollution problems.
Please fill out and mail the enclosed postage-paid card as soon as you can.
If you are willing to participate, a representative of EC & G will be in touch
with you to ask a few questions about your vehicle. The enclosed information
sheet answers some questions people often ask about this research program If
you have any additional questions about your participation, please feel free
to call Mr/Kevin Kott of EG & G at 684-2310. He will be happy to answer any
questions you may have.
We look forward to receiving your reply card very soon.
Sincerely,
Thomas C. Bejma, Pfro^ect Officer
Emission Control Technology Division
Enclosures
O
I
EMISSION FACTOR TESTING PROGRAMS
Questions and Answers
1. Must I participate In this program7
No, your cooperation in this research program Is completely voluntary. If, for
any reason, you decide not to participate, please let us know on the enclosed
postpaid reply card.
2. Why should I participate?
In addition to the free gasoline and a $100.00 U.S. Savings Bond, your
participation will benefit you Indirectly by helping EPA uudt'rst.-ind and Improve
the quality of the air in and around your city.
3. How long will the examination take?
While the examination itself takes only about an hour, the vehicle must be
completely cooled off before the examination can begin. This requires tint the
vehicle not be started for 12 to 36 hours to simulate overnight pnrking.
Therefore, we will need to have your vehicle at the laboratory for two or three
days. You will be contacted once the evaluation Is complete so that
arrangements can be made to pick up your vehicle. In general, we suggest th.it
you plan to use the loaner car for three to four days.
4. Will my vehicle be mistreated In any way?
No, every aspect of the evaluation has been designed to duplicate ovoryH.iy
operation.
5. Exactly what will be done to my vehicle?
Once the vehicle Is sufficiently cooled off, It will be pushed onto a
dynamometer. Although the vehicle does not actually move during the
examination, the dynamometer is a type of treadmill which simulates conditions
which would normally be encountered on the road. A hose is connected to the
exhaust pipe to collect the exhaust. A specially trained driver then starts the
vehicle and "drives" it through a "driving cycle" which represents typic.il
operation In urban, suburban, and rural areas. Throughout this time, H portion
of the exhaust gases are collected for subsequent analysis. This analysis
allows us to calculate the quantity of exhaust emissions emitted by vour
vehicle. Values for the city and highway fuel economy are also calculated. A
complete inspection of the emission control components is conducted .iftor tho
examination.
-------
6. How many miles will my vehicle be driven during the program?
Your vehicle will be driven approximately 50 odometer miles during the
examination. The majority of these miles will be accumulated indoors on the
dynamometer. A 10 minute drive will precede the examination.
7.
8.
10.
How will my vehicle be protected while in the contractor's possession?
In addition to the Insurance provided by the contractor, your vehicle will be
stored Indoors while the examination Is being conducted. If required to be
parked outside, your vehicle will be located in a secure area.
What determines whether or not my vehicle will be ultimately selected?
Your vehicle has been initially identified by a statistically random samplinR
procedure. In order to obtain a cross section of the population of vehicles on
the road, certain other criteria such as make, model and model year must be let
We are examining a limited number of vehicles that meet these particular
specifications. If your vehicle meets these criteria, the final decision on
whether your vehicle is selected will be based on a random process.
What happens to the information obtained from my vehicle?
The Information collected as a result of this program Is used to determine how
the entire population of in-use vehicles is affecting air quality. The data
from your vehicle are combined with data from several hundred other vehicles in
this area In order to obtain a statistically valid sample.
How can I obtain the results from your examination of my vehicle?
form to
After the completion of the examination you will be provided with a orm to
complete and return to us. This form has a space In which you may indicate your
desire to obtain the results on your vehicle. We will forward them to you as
soon as all the data have been processed. *
I out r o 1 Ho
DATA I OHM HO . !02.r.
Paqe 1 of 3
TTU.I'IIONL QULSTIONNAIRE
and t line
of contact •
If owner was not contacted, list (lie number of attempts that have been made
_ (eliminate after t liree attempts).
Individual Contacted:
If you were instructed to call hack later, obtain convenient: dati
and time
VEHICLE CONTROL NO.
you have been randomly selected from a list of
* Mr./Mrs.
19 vehicle owners living in the San Antonio Metropol i t
-------
DATA FORM NO.3024.2
To lephone puestioniuii re
Page 2 of 3
Pr lor to releasing your velncle into our possession you wi11 be given some
documents to sign. These documents, which will also he signed by an authorized
FXI&G Automotive Research representative, will define in detail these areas:
1) Initial Inspection form which will document the overall interior and
exterior condition of your vehicle when received.
2) Test Agreement form which explains what sequence of tests your vehicle
will he given and as-sign full liability responsibilities to EGSG
Automotive Research for your vehicle while in our possession.
3) Loaner Car Agreement explains the terms and 1 lability responsibilities
for hoth parties in relation to the loaner vehicle.
'1 ) Savings Bond information sheets. This form when completed will contain
dl 1 the information necessary for a Savings Bond to be issued in your
name .
[Jo you think you would he willing to participate in this program?
II' RESPONSE ]S POSITIVE
Yes
Tor the purpose of identifying your vehicle as a possible candidate for this study,
I am going to ask you a few quest ion. None of this information can be used against
you in any way and you should answer these questions to the best of your knowledge.
PI ease indicate when you are not sure of something.
1) What is the made, model, year, transmission type, vehicle identification
number and engine size?
MAKK
TRANS: AUTO
ENGINE
MODEL
MANUAL
YEAR
V.I.N.
?} What is the approximate odometer reading •
3} Mas your vehicle ever been involved in an accident?
If the answer is yes, and i crate the type and extent of damage, i.e. frame,
engine, drive train, cooling system, exhaust system, etc.
Telephone Questionnaire
DATA I'OKM NO . 3024.2
pd'ie 7 of T~
<\) Because this is an exhaust emissions test, it is cri ti cal that the
exhaust systems on the vehicle tested be in good condition. To your
knowledge, are the exhaust pipos, muffler and catalyst on your vein cle
in good condi tion with no 1 n.iks or holes . Yes Ho
IF NO
Would you consider maki ng the not essary repni rs or rep I .irem'Mits to your
exhaust system at your own expense in order to participate in this
program? Yes Ho
IF HO ELIMINATE
If Y_e_s_ try to obtain an estimate of when these repairs will be completed
This should supply all of the information needed to determine if your vehicle is
acceptable.
This l nformat ion wil 1 have to be rev Jewed by t he Project Manager
-------
INCOMING VEHICLE INSPECTION
SHEET PART II
Control Mo.
Form No. 3024.1
EGnG AUTOMOTIVE RESEARCH,,^
5404 BANDERA ROAD. SAN ANTONIO TEXAS 7B?38 • TEL(512>684-2310 TWX 910-871 107S
TEST AGREEMENT
TIRES: RADJAL OR
ENGINE SIZE:
BODY STYLE:
YEAR:
BIAS
MAKE/MODEL:
OR NONE A/C
CAR NO.:
* PLEASE GIVE JOHN R. INFORMATION
Your vehicle Is being loaned to EG&G AUTOMOTIVE RESEARCH, INC., for use
in a government-sponsored program for cleaner air. This executed Agreement
is your assurance of full protection against any loss sustained by accident
or damage to the vehicle while in the possession of EG&G AUTOMOTIVE RESEARCH,
INC., or Its designed representatives.
EG&G AUTOMOTIVE RESEARCH, INC., agrees to be fully responsible fol any
and all damage to the vehicle occurring while the vehicle Is in its posses-
sion. Possession is hereby defined as care, control, custody, operation,
inspection, or storage between the time the vehicle is received from the owner
by EG&G AUTOMOTIVE RESEARCH, INC., and the time the vehicle Is returned to the
owner.
EG&G AUTOMOTIVE RESEARCH, INC., agrees to indemnify and hold harmless
the vehicle owner of any repairs, damage, loss, or liability sustained by
the vehicle owner by reason of accident or damage to the vehicle while in
its possession.
EG&G AUTOMOTIVE RESEARCH, INC., agrees to provide primary automobile
insurance on the vehicle while in its possession.
EG&G AUTOMOTIVE RESEARCH, INC., agrees to exercise extreme care in the
use of the vehicle and agrees to return the vehicle to the owner in as good
exterior, interior, and operating condition, except for normal wear and tear,
as when the vehicle vas received by EMC AUTOMOTIVE RESEARCH, INC.
EG&G AUTOMOTIVE RESEARCH, INC., reserves the right to perform any repairs
and maintenance upon the vehicle, at its sole discretion, provided all such
repairs and maintenance are performed according to the manufactureres specifica-
tions.
(Year)
, agree to loan -ay vehicle,
(Hake and Model),
under License Plate No.
I,
described as a
registered in the State of
A to EG&G AUTOMOTIVE RESEARCH, INC., for a
period of approximately days for a series of tests.
I further agree that, should testing not be complrted within
the time period specified above, I will execute the Agree-
ment Renewal which is an addendum to this Agreement, for the
additional time required to complete testing. I understand
that I may refuse to loan the vehicle to EG&G AUTOMOTIVE
RESEARCH, INC., at any time and that I am under no obligation
whatsoever.
AGREED TO this
day of
198
VEHICLE OWNER:
By:
EG&G AUTOMOTIVE RESEARCH
By:
-------
Control No.
Data Form No.3024.4
STANDARD VEHICLE LOAN AGREEMENT
THIS STANDARD VEHICLE LOAN AGREEMENT (the "Agreement") is made and entered
into by and between Mr . /Mrs . /Miss/Mb . _________ of
____ County, State of Texas
TrefeYreT uTTrTThTr ^Agreement ab the "Participant"), and EGiG Automotive
Research, Inc., a Texas corporation having a usual place of business at 5404
Handera Road. City of San Antonio, Bexdr County, State of Texas (referred to
in this Agreement as "Automotive Research").
Ui!*?ESSETH THAT
WHERE*S: Automotive Research has entered Into a contract with the
UnitecT~sTat«;s Environmental Protection Agency under which Automotive
Research will borrow cars from the public and test those cars to deter-
mine the effectiveness of their emissions control systems; and
W1IFRLAS. Hie Participant has agreed to let Automotive Research test
the PaTtTcTpant 's car on the condition that Automotive Research lend the
Participant a car to use during the period of such tests; and
WlllREAS: Automotive Research is willing to lend a car to the Parti-
cipant and"the Participant is willing to accept the loan of such car
(such car being referred to in this Agreement as the "Car") all on the
terms and conditions hereinafter set forth,
NOW, THEREFORE. In consideration of the mutual covenants and agree-
ments~set~7o7th in thi Agreement, Participant and Automotive Research
do hereto contract, c -enant and agree as follows:
1. Automotive Research lends to and the Participant hereby accepts the
loan of the Car whose license number and condition are set forth In the
box at the bottom of the last page of this Agreement.
2. Participant agrees to exercise care in the use of the Car and agrees
to return the Car to Automotive Research within forty-eight (48) hours.
or two (2) working days, after notification of the completion of the tests
on the Participant's own car, but in no event later than ten (10) days
from the date of execution of this Agreement. Upon Its return, the Car
will have with it all tires, tools, and other accessories now contained in
or installed on the Car. The Car and all such tires, tools, and acces-
sories will, upon return, be In as good exterior and Interior repair and
operating condition as thty now are and as Is indicated in the box at the
bottom of the following page, except for wear and tear caused by normal
use and except for damage caused by casualty.
3 Participant agrees that the Car will not be operated to carry passengers
or property for any money or other consideration, expressed or Implied, or
to push or tow any other vetucle or trailer. The Car will be operated only
b> Participant and permitted members of his immediate family, and provided
that all such operators shall be duly qualified and licensed.
AUTOMOTIVE RESEARCH
4. Participant agrees to be liable for: (a) all charges, fines, and costs
for parking, traffic, or cither legal violations assessed against the Car,
Participant, or Automotive Research, except where caused through fault of
Automotive Research: (b) Automotive Research's costs Including reasonable
attorney's fees, where permitted by law, Incurred collecting payments due
from Participant hereunder; (c) Automotive Research's costs to repair
collision damages to the Car caused by the negligence or willful miscon-
duct of the operator; provided, however, that Participant's liability for
such damage will not exceed $100.00.
5. Participant and any authoriz
insured in benefits of an automo
which is available from Automoti
other insurance carried by Parti
bodilv injury or death liability
accident and Is subject to the f
all persons in each accident and
for each accident. Participant
limitations, and restrictions of
policy is a standard Texas motor
ed operator agree to participate as an
bile liability Insurance policy, a copy of
ve Research. Said policy comes before any
cipant or authorized operator and contains
limits of $250,000 for each person in each
ollowlng limitations: A $500,000 limit for
a property damage liability limit of $50,000
is bound by and agrees to the terms, conditions,
said policy; it being understood that the
vehicle policy.
6. Participant releases Automotive Research from any liability for loss of
or damage to any property left, stored, or transported by Participant or
any other person in or upon the Car, during the term of this loan, or after
return of the Car to Automotive Research.
TO WITNESS this Agreement, the Participant has signed below and Automo-
tive Research has caused Che Agreement to be executed by its authorized
representative, all under seal, as of the day of , 198
in the city of San Antonio, Texas.
PARTICIPANT:
EGJiG AUTOMOTIVE RESEARCH, INC.:
Driver's License l_
Expiration Date
By:
CAR AND CONDITION
DATE:
Loan Car License No:
Loan Car Condition: OUT_
DATE IN
_OK/lnitial
OK/Initial
Defects noted when Car was received by Participant:_
-------
Control No.
DATA FORM NO. 3024.6
EGSG AUTOMOTIVE RESEARCH, INC.
5404 Bandera Road
San Antonio, Texas 78238
TEST AliRlJtJlEHT ADDENDUM
SAVINGS BOND INFORMATION
NAME
SOCIAL SEC. NO.
STREET ADDRESS
CITY
HOME TELEPHONE NO.
STATE ZIP
BUSINESS TELEPHONE NO.
THE FOLLOWING PERSON, IF ANY, IS TO "",
NAME
OWNER
CO- OWNER
BENEFICIARY
SOCIAL SEC. NO.
MAILING ADDRESS (IF DIFFERENT THAN ABOVE)
CITY STATE ZIP
CLASS/SERIAL NO.
YEAR/MAKE OF VEHICLE
MODEL OF VEHICLE
ISSUE DATE
I,
owner! ) and/or
owner) ) and/or principal driver! ) of the vehicle described ,is n
("ear) (Make and Model)
registered in the state of
original testing agreement dated
period of days.
agree to extend
, 19 for a
VEHICLE OWNER
By
Dat e :
Ul
I
-------
VEHICLE HUMBER
family?
3. How many of these drivers are employed?
U. How many children do you have llv
with you) own or lease'
1 . ONE 2 . TWO 3 .
LnR at home?
THREE 4. FOUR 5. FIVE OR MORE
6. How often is the car we are testing tuned up; according to the ovner's manual, at
least every 6 months, every 7 to 12 months, or less than once a year, or what?
TURN TO P. 2, 7
t>a. How long ago was the last tune up, 6 months ago or less, 7 to 12 months, or
longer than 12 months?
6b. Was the tune up done by a car dealer, a service station, an Independent garage,
you (or another family member), or aomeone else?
1. CAR DEALER
2.
SERVICE
STATION
3.
INDEPENDENT
GARAGE
4.
SELF/OTHER
FAMILY MEMBER
OTHER (SPCCirY)
7.
7. We »re interested in the fuel economy people actually get with their cars. Hov
•any miles per gallon do you get with this car in city driving'
8. How about on the highway?
MPC
IN
CITY
MPG ON
HIGHWAY
9. Is unleaded gasoline usually used in this car7
1
YES
I
9a . la regular or premium used?
1. REGULAR
1
GO TO
2. PREMIUM
1
10
5. NO
9b. Is regular, premium, or some other fuel
used'
1. REGULAR
2. PREMIUM
TURN TO P. 3, 11
10. Unleaded gas is more expensive than leaded and at times has been hard to find. Have
you ever used leaded gasoline in this car?
1. YES
I TURN TO P. 3, 11
lOa. How often has leaded gasoline been used?
CTi
I
-------
11. Have any .peci.1 modification like installing high perforate, equipment been made
to this car to improve ita performance?
Ha. What has been done?
GO TO 12
SRC THUMBNAIL SKETCH
Uss)
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
ANN ARBOR MICHIGAN 48105
OFFICE or
AIR NOISE AND RADIATION
Dear Participant:
Th.m'rt you ve cy much fo r your part id pat ion in our vehicle emission testing
program. We are conducting a t ol low-up on this effort and vould like your
response to a few questions on the program. These may be answered aftei you
have had a few days to become reacqualntcd with your vehicle. You may use
this sr-lf-ad dressed franked envelope to subrai t your responses.
1. ""t.'er? you treated courteously and efficiently by the personnel at our
contractor's laboratory? "
Yes
D
2. "Do you feel that the performance of your vehicle is now different tha
when it was submitted for testing?"
Ko noticeable change I 1
Slightly better Q] Slightly worse Q
Much better j j Much worse I 1
3. "Are you satisfied with the present performance of your vehicle?"
Yes No
^'s appreciate the time you have spent In completing this questionnaire. If
you would like to receive a summary of the emission r. -suits on your vehicle,
please fill In the name and address for nailing in the sp
-------
AUTOMOTIVE RESEARCH,,*
5404 BANDEHA ROAD SAN ANTONIO TEXAS 78238 • TEL(512)684-2310 TWX 910-871-1075
Dear Partic ipant :
This letter is to express my thanks to you for your recent participation
in the exhaust emissions testing program which EG&G AUTOMOTIVE RESEARCH,
INC., is conducting on behalf of the Environmental Protection Agency.
In addition to the tank of gas , savings bond and use of a loan car which
you have received as incentives for your cooperation in this effort , we
may have performed maintenance items on your vehicle according to the
manufacturer ' s speci fi cat ions . Attached for your records is a detailed
summary of any maintenance performed on your car while in our laboratory.
Again, thank you very much for your kind cooperation in this important
effort.
Sincerely ,
Mark D. Dalen
Project Manager
MDD/bh
Attachment
CO
I
AUTOMOTIVE RESEARCH,,^
5404 BANDERA ROAD SAN ANTONIO TEXAS /fl?1B . TEl_(512)684 2310 T WX 910 871 107S
Dear Vehicle Owner:
Thank you for your response to our recent inquiry on your vohit-le.
This information will be valuable in our overall data gathering
process.
Unfortunately, your vehicle does not meet all of the specifications
and requirements for this particular study and can not be used iti
the actual testing phase at this time.
Again, we would like to express our appreciation for your timely
response.
Mark D. Dalen
Project Manager
MDD/bh
-------
VEHICLE UWNEH QUE&TIONNAI Rt
DATA SlltLT
VEIIICLC OWNEH QUESTIONNAIRE
DATA SHEET
1 *
If d
odoc in the vehi c It- uxli.ius t ?
the Chicle (*rfor».,..r^
fuel economy?
1 I 1 1 1
1 1 1 1 1
4 Ifitque.ill /)
S (don't Vno-l
) (occasional lyt
4 |frr>|uf>it l\ I
2 (prtf. is botirrt
I \\*tf \*. wv.i-.el
J (>.<• Ji ( frtcncet
2 |(uc> «coiuH«y tirttcrt
J If ttcl economy worsel
5 (dun* I know)
1 (0- J nniitl.- (
2 (3-1: RHIMtllSl
) (1-2 ft.»fH
EWTHIES FOR ./JESTICH
E.'.TER
A.-IOC
ABCO
AS ML,
aoriA
BP
CHCL
CITC
BRAND NAME
A.HOCO
APCO
ASHLAND
BONATIDE
BP
CHEVROM
C1TCO
ENTER
LAB
ONO
RUW
EHfl
HCO
SSO
XXO
BRAJ1D NAME
:LAWC
QNOCO
ROWN
ERBY
NCO
SSO
XtON
E^ER
riHA
CEMC
CULT
HESS
HUDS
HARS
KA»T
BRUfD HAHE
flNA
GEXO
HESS
HUOSOH
KAfiS
MAKT1H
EMTEB
HOB I
MOTO
PHIL
SCOT
SCAR
SHAM
BRWID 1IAME
MOBIL
MOTOR
PHILLIPS
SCOTT
SEAAS
SHAMROCK
ETTEB
HEL
INC
KEL
TAW
UNO
EKA
9 PA: ic NAME
SHELL
SINCLAI"
SK£U.y
STW^DARO
SL"OCO
TEXACO
E-ncR
USI3
vrct
ZEPK
**
u*na<
VAfU
fhA.ro
LMl , 1
VIC-£i»
UIJX;.OM
vf,--:ou
IF BRAND IS 'CfTHER' THEN tKTEB THE FULL BBAMD HAH£ VEHICLE
i hi 1 drl '
• t-K>nt *lli >75»
«o»C. 1S-SI\
.«—. so- 31*
nd f *
4lmo*t *1) : > 7r>%
•rtst: JS-5U
little or i.on«-<30* b) Slioppinq *nd «rr*nd«
-M Hou did yoo 9«C h«e« today?
AppCOM. «lt*»
1 (0-5)
2 (5-10)
1 (10-13)
* (iS-201
9 (20-30)
6 (ov«r 301
1 («lTO»t *U)
3 t*o*c)
3 1»OM|
4 (UttU or non«<
2 (ncjt)
7 (»OM|
4 (li.tla r
2 (•ott)
1 (io*«l
4 (Hcti» or non*)
3 (moat)
] (fO*«;
4 (Itctl* or non*)
1 («09At)
4 ' LLC.CV* QC ocncl
1 («lao«t *11)
] (*o»t)
I »l
I Inoiel
] (IDM|
4 'ilttl* or ncn«J
3 (B09tl
) (»OOI«|
J (licclt Jt nor*]
1 (cit/ itKe*t* Jnlyl
2 IIOB.* •«prenw*y)
) (pmanly *xp f «*»"•)'» '
c:
(10)
I1L1
(1)1
1141
US)
llul
ll1!
'18)
( 19!
CO)
IJ1
-------
VfllJCLE OIVNEK UUEST1ONNAJR£
DATA SHEET
VhlJJCLE UWNKR OlliVf JCN/JA J KL
DATA SHEET
almost Alt > 75\
most- 15-5U
some 50-21*
c> Orlv«r «nd 2 or mar* p4»**fjg«r«
O Towing * trailer
13. ,.o ,ou now .xp.ti.nc. *ny .nqin. .t H*rd it.rtinq
b) StalUnq
c) Rou^h tdl«
1 9 .
C) Stumblint)
9! M«sit*eion
"' En"" k"°ck "•""''
2 (motel
1 (son.)
4 (lltclc or nor.i
1 l«L*oac all)
2 l-o.tl
1 (son«)
4 (Utcle or non.t
i («Lno*c 4UI
2 (no>t) |
J (*om«f
4 (little or hond)
1 Uimot--: *U1
2 Inoat)
1 IIOIM]
4 (littl* or rone!
1 («LAOSt All)
2 (mo,U
3 (son* I
4 (little oi ion*)
1 Ulmoit «11)
2 (no>c)
3 UoMl
4 Ilittl* or none)
CD
1 I I
I (seldom*
2 (orce or twice)
3 'J-* :ijr*s>
4 icverv day)
I (y«»l
o
1 (y«)
: (noi
1
1 (y«»
2 (no)
1 (?•»>
2 (no)
1 (/•))
2 (no)
1 (yes)
2 (no)
1 (>esl
2 (no)
/ (not
the drii'^AUilicy problems?
Specify
1 h«d7
•vent,, or in hauling or ertn.porti,.., load, heavi.r than (or
ijn
1 (ye*/
2 (noil of the time)
1 (no)
1 (Coo new, not u«l
2 (due, but not et donel
} (0-6 oonths »q 1
4 (6-12 months a o)
5 (Over [ year * of
6 (don't know)
1 (C-ic.)
4 O or tote}
5 (don't know)
1 (no w«rrj ,ti F
? (t«call)
4 (driv«*±)i 1 ity I
5 (oth«r)
i (r*»
2 (no prohleml(
3 («ngiriel
t loth.r)
7 (don't -kni,-w|
2 IO-) Bwn;-,s)
3 C)-6 oontris)
4 |ov»r 6 rortfts)
1 Cro repair!
2 lyesl
) Lnot
1 (y*si
2 (no)
I
I
Ul
o
I
-------
VLIIICLE OWNER QUtSTlONNAI R£
DATA SHEET
VEHICLE OWNER QUIIST 1ONNAI RU
DATA SHEET
dny of the following dr««s?
b) Cooling iystu
c) Fuel ayatee)
• I Ho d*Mge
C) Don't know
2 (no)
1 (yea)
2 (no)
1 (ye.)
2 (no)
2 (no)
1
2 (no)
1 (y«»
2 (no)
L (no catalyst)
2 (yea)
J (no)
4 (don't know)
1 (yes)
2 (nol
1 (yeai
2 (nol
) (not tested)
1 (wirr&ncy)
2 (tone-up)
1 (nonel
•) (not teitedl
MM
UJJ
4 (tune-up clinic)
S (yourself)
6 (not texted)
Date of last city 01 sta
— don* I kitrw ~* •
111 Dii) your vvliicl* pjs* or tail th* Inspect Ion?
b) If no, specify
been driven
1 (ye*)
2 (no)
H
I
Ul
-------
APPENDIX B
EPA Vehicle Data Packet
1) Vehicle Information Data Sheet
2) Engine Parameter Data Sheet
3) Vehicle Information Data Sheet
4) Mechanic's Inspection Form
5) FTP Test Data
6) Highway Fuel Economy Test Data Sheet
7) Bag Idle and 50 MPH Cruise Test Data Sheet
8) Four Mode and Loaded Two Mode Test Data Sheet
9) Propane Gain Data Sheet
10) Comments Data Sheet
11) Driveability Evaluation Data Sheet
12) Emission Component Data Sheet
-53-
-------
VEHICLE INFORMATION DATA SHEET
gl I ACTUAL STANDARDS 1
jl I HC CO NOX
w I I gm/mi am/mi airvmi
"TH I I fl'l I l*fVl
TIRE PRESSURE lp».|
I j MEASURED SP
MANUFACTURER II I
EFT JUSTIFY) I 1. I F.F I in I HR FRONI
iniijiiijltiii
ENGINE PARAMETER DATA SHEET
-------
VEHICLE INFORMATION DATA SHEET
CARDV3
LLI i inn iru ii
EMISSION STICKER PAUT NUMBER
(LEFT JUSTIFY)
11 i.rnn.ri i; LI
Con t- ro 1 ;hi .
DATA FOHM NO . 302-1 .
Page 1 of 12
MECHANICS INSPECTION FORM
VEHICLE NO.
Fuel Filler Neck Uamaye
AXLE RATIO_
TIRE SIZE
1 - Yes, Unleaded fuel vohiclo
2 - No, Unleaded fuel vehicle
3 - N/A, Leaded fuel acceptable
TIRE MANUFACTURER
EGR VALVE PART NUMBER
CARBURETOR PART NUMBER
DISTRIBUTOR PART NUMBER
_( Includes all spaces,, slasho
dashes, etc.)
(Includes all spaces, slashe
dashe's, etc.)
(Includes all spaces, r 1 allie
dashes, etc.)
-------
FTP AND EVAP TEST DATA SHEET
FTP TEST DATA
Page (1 of 2)
I 1*1 I I N I I ITTBTRm
FTP AND EVAP TEST DATA SHEET
FTP TEST DATA (continued)
Page (2 of 2)
WET
BULB
•F
20 25 30
CONCENTRATION OF DILUTION AIR
DISTANCE
MILES
HC
ppm
SIKH
60 55 60 65
CONCENTRATION OF DILUTE EXHAUST SAMPLE
HC
CO
ppm
NOX
ppm
cm
ppm
HUE:
EVAP TEST DATA
MTlTTTMinTR"
-------
HIGHWAY FUEL ECONOMY TEST DATA SHEET
BAG IDLE AND 50 MPH CRUISE TESTS DATA SHEET
BAQ IDLE TEST DATA
90 25 30
CONCENTRATION OF DILUTION AIR -
50 55 «0
CONCENTRATION OF DILUTE EXHAUST SAMPLE -
NOX
ppm
CH4
ppm
IK
•El
CO
ppm
NOX
ppm
SO MPH CRUISE DATA
Ul
-J
I
-------
FOUR MODE IDLE AND LOADED TWO MODE TESTS DATA SHEET
FOUR MODE IDLE TEST DATA
PROPANE GAIN DATA SHEET
Page (1 of 2)
LOADED TWO MODE TEST DATA
3-WAY CLOSED LOOP
STEP1
STEP 2
STEPS
STEP 4
PRESET FLOW RATE
RECORD: a) FLOW RATE
b) RPM
c) IDLE %CO
INDUCE PROPANE. OBSERVE VEHICLE BEHAVIOR
RECORD ONE a) RPM RISES SMOOTHLY TO
b) RPM FALLS SMOOTHLY TO
c) ENGINE RUNS ROUGH AND THEN
STABILIZES (1 YES)
d) ENGINE DIES (1 YES)
e) RPM STAYS THE SAME (1 YES)
WHEN ENGINE STABILIZES, RECORD:
a) RPM
b) IDLE %CO
(Continual on Nan) Page)
IN
NEUTRAL
D
' 'J *
1 • 1
15
HE1
-i-iVa
TEEJ
35
43
D
45
D
47
IN
DRIVE
.Pu
•ILL
10
1 -1 1
20
M-^n-
tm
40
D
44
D
46
D
48
HLMHE
50 55
•I
HI
' "1 K
H"6
I
Ul
CD
I
-------
PROPANE GAIN DATA SHEET
Page (2 of 2)
i
ui
VD
I
3 WAY CLOSED LOOP (Conllnu.d)
STEPS
STEP 6
WITHDRAW PROPANE, OBSERVE VEHICLE BEHAVIOR
RECORD ONE: •) RPM RISES SMOOTHLY TO
b) RPM FALLS SMOOTHLY TO
c) ENGINE RUNS ROUGH AND THEN
STABILIZES (1 -YES)
d) ENGINE DIES (1-YES)
•) RPM STAYS THE SAME (1-YES)
WHEN ENGINE STABILIZES, RECORD:
•) RPM
b) IDLE%CO
IN
NEUTRAL
. . _^^
IN
DRIVE
__ , . —
TTTfc I I
s
TTTMTT
15
D
21
D
23
g
™- 1 1
D
22
D
24
D
26
\\im\\
30
!•
40
35
11*1
45
^^^^^^^^^^^| p
-|—
E
10
E
20
L
2
80
VEHICLES OTHER THAN 3-WAY CLOSED LOOP
I IN NEUTRAL
WIO PROPANE
IDLE
HC IDLE
| ppm %CO
• Mihrwr
n
1111 n 111111111111111 n 11111111 n 111 rro
n1
-------
DIUVI1AIII 1.1 TV EVALUATION llft'l'A S:ili:l.T
AMBIENT TEMPERATURE °F
EMISSION COMPONENTS DATA SUM: I
CONSTANT SPEED PHASE
NUMBER OF STALLS, PASS-OUTS UPON PART THROTTIE
ACCELERATION TO ROAD SPEED
ACCELERATION QUALITY
CRUISE QUALITY
SLIGHT ACCELERATION RESPONSE (PASSING)
IDLE QUALITY AT STOP KITH A/C 'ON*
IDLE QUALITY AT STOP WITH A/C 'OFF1
ACCELERATION FROM STOP PHASE
DUALITY OF ACCELERATION UNDER 1/4 THROTTLE
QUALITY OF ACCELERATION UNDER 1/2 THROTTLE
QUALITY OF ACCELERATION UNDEH 2/3 THROTTLE
QUALITY OF ACCELERATION UNDER 3/4 THROTTLE
RESTART PHASE
CRANKING TIME TO START AFTEH 10 HIN (IN SECONDS)
IDLE QUALITY AFTEK RESTART
D
345
12345
123459
12345
12345
2 3 4 5
COLD
START AND IDLE PHASE (DYNAMOMETER)
INITIAL CRANKING TIME (IN SECONDS)
NUMBER OF ENGINE IDLE-OUTS AFTER START
NUMBER OF ENGINE STALLS AFTER GEAR SELECTION
HESITATION, 1AG UPON SLIGHT ACCELERATION (1-YES 2-NO)
IDLE DUALITY _ —
PRIVE
-
, -
1 2
12345
AWAY PHASE (DYNAMOMETER)
NUMBER OF STALLS. PASS-OUTS UPON SLIGHT
ACCELERATION TO ROAD SPEED
ACCELERATION QUALITY
IDLE QUALITY AFTER 0.2 MILE FROM STOP
NUMBER OF STALLS, PASS-OUTS UPON SLIGHT
ACCELERATION TO ROAD SPEED
ACCELERATION DUALITY
IDLE QUALITY AFTER 0.4 MILES FROM STOP
D
12345
12345
u
123
12345
' • 'I 1 '
1 '" " hi)
1ALITY COUC L.r
9 = IF NOT L'OPD, S^EXCELLENT, 4=GOOD, 3=FAIK, 2=POOR, 1»FAIL
(45)
(46)
(47)
(4U)
(49)
(50)
(51)
(51)
(55-56
(57)
(5B-S<
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(66]
(b9)
(79-81
a) HEATED AIR DOOR ASSEMBLY
b) TEMPERATURE SENSORS
c) AIR FILTER ELEMENT
d) HOSES
e) OTHER
CARBURETOR AND FUEL SYSTEM - FUEL, SUBSYSTEM
a) CARBURETOR ASSEMBLY
b) IDLE MIXTURE ADJUSTMENT LIMITING DEVICE
C) IDLE MIXTURE
d) IDLE SPEED
e) IDLE SPEED SOLENOID
f) FUEL INJECTION COMPONENTS
q) HOSES, LINES. HIRES
h) OTHER
o
i
-------
roMPONiiurs DATA
(.MISSION C'l' IMINLN'IS HA'I'A Sill.I I
CARBURETOR AND FUEL SYSTEM - CHOKE SUBSYSTEM
a) CHOKE ADJUSTMENT (NOTCHES)
b) CHOICE ADJUSTMENT (VACUUM BRE1.K)
c) CHOKE ADJUSTMENT LIMITING DEVICE
d) FAST IDLE SPEED
e) VACUUM DIAPHRAGMS
q) EXHAUST HEAT CONTROL VALVE ASSEMBLY
h) HOSES, LINES, WIRES
1) OTHER
n
na
a) DISTRIBUTOR ASSEMBLY
b) INITIAL TIMING
C) INITIAL TIMING LIMITING DEVICE
e) VACUUM ADVANCE ASSEMBLY
f) SPARK DELAY DEVICES
g) SPARK KNOCK DETECTOR
h) ELECTRONIC TIMING MODULE
il COOLANT TEMPERATURE SENSORS (TVS!
j) HOSES, LINES, WIRES
n
CTi
I
-------
i.MI;;:; M if I CDMCHNCNT:; IIATA
KMISiilON I'OMI'UNCNTS nn'IA SHI.1.1
EGR SYSTEM
a) EGR VALVE ASSEMBLY
I
C^
KJ
b) BACK PRESSURE TRANSDUCER
DELAY SOLENOID
d) VACUUM AMPLIFIER
e) VACUUM RESERVOIR
f) COOLANT TEMPERATURE SENSOR (TVS)
q) HOSES, LINES, KIRES
h) OTHER
a) AIR INJECTION ASSEMBLY
b) AIR BYPASS VALVE
cl AIR DIVERTER VALVE
dl CHECK VALVE
e) DRIVE BELT
f) HOSES, LIMES, WIRES
q) OTHER
PCV SYSTEM
a) PCV VALVE
b) PCV FILTER
-------
HM1 :.:.M XI flJMI'ONr.HT!; DATA :.MI.I.I
I:HI:.:;IHM I'IIMCOUKNT;; DATA (;III:I:T
a) MANIFOLD. TAILPIPE, MUFFLERS
EVAPORATIVE rONTROT. SYSTEM
a) ELECTRONIC CONTROL UNIT
b) OXVGEN SENSOR
d) LOAD SENSOR (THROTTLE POSITION, MANIFOLD VACUUM, ETC.)
e) ENGINE SPEED SENSOR
f) COOLANT TEMPERATURE SENSOR
h) EGR POSITION SENSOR
CONTROL SOLENOID(C)
j) AIR/FUEL CONTROL ACTUATOR (SOLENOID. STEPPER MOTOR)
K) AIR BYPASS SOLENOID/VALVE
1) AIR DIVERTOR SOLENOID/VALVE
«l) THROTTLE KICKER ACTUATOR
I
ON
-------
CMISSIHN CDMI'DNLNTS DATA Slll:i:T
r.nic; I" "i ID
o) HOSES, LINES, HIRES
p) DIAGNOSTIC BUI.R CHECK
q) DIAGNOSTIC WARNING
r| DIAGNOSTIC SYSTEM CODE(61
B19B
n
-pi
I
-------
APPENDIX C
Lab Qualification Worksheets
1) Fac iIity Inspection
2) Dynamometer Inspection
3) Driver's Aide Inspection
4) Analytical System Checks
5) Hydrocarbon Analyzer A (Low Ranges)
6) Hydrocarbon Analyzer B (High Ranges)
7) Carbon Monoxide Analyzers A (Low Ranges)
8) Carbon Monoxide Analyzers B (High Ranges)
9) Carbon Dioxide Analyzer
10) Constant Volume Sampling System Inspection
11) Oxides of Nitrogen Analyzer
12) Methane Analyzer
13) Raw Exhaust Hexane Analyzer
14) Raw Exhaust CO Analyzer
15) Raw Exhaust C02 Analyzer
16) Raw Exhaust NO Analyzer
17) Sealed Housing for Evaporative Determination
18) Temperature Recording - Auxilliary Devices
19) Record Keeping System Check
20) List of Documents to be included in the Lab Qualification
Packet
21) General Comments
-65-
-------
tgtATOItT
POM5TOTS
Facility Inspeition
Yes/ No/
Fill Correetec
. Test Site
San Antonio, Texas
C. toe fuel containers clearly loentlfleo?
o. Ar« sepirtt* syitms useo for leaded ano
fuslf?
2 Contractor ECtC Automotive Research, Inc.
J. Olte Of inspection December 11, 1980
4. Inspector Butch Naegelin
J. Contractor personnel
1. H. Dalen
b. H. Forshee
0. J. Rivenburqh 0. C. Jacket
• . R. Martinez h. R. Gilmore
L. Hernandez
f. B. Martin
lez
1. C. VanTassel
k. S. Gear hart
C.
7.
•.
10.
11.
12.
13.
J*.
IS.
C. B. Haeqelin _
Te*t area of eoequeu tlie? x
So* we* of aoequau ilxe? Mutter of vthleles_d^2^.4 _ g.
Soak arcs Ufflperaturt b*t»ten M°F ana 8*°F7 72 °F _ x.
OUt»Ct ftO« tO«k «T*» to Oyna«0«et«r _0_*__ft same building.
Soak area fx*« of precipitation? "
U*bor«tory floor Mtt?
»Q ft
73
Jtons
TC-2 only
s Grain*
Laboratory air eondltloneo?
•. All conditioning capacity _ 56
Uboratory ruatelty controlleo? 72
Laboratory elevation BW ft
Office space 7" n'
Test fuel
a. Does laaoea fuel eeet aU «pecs7 (Attach analysis) —2
b. DOM irlaaOM full a««t aU specs? (Attach analysis)—
t. Is the fuel olspenslng system accurate within 21?
f. Storage arei and temperature 55 ± 5 Hr
17. Cas Cyllnoers.
a. Storage area of aoequate site?
b. Temperature of area (4W-Bfi°r) 65 ±10 OF
c. toe cyllnoer« secured?
a. Is each cylinder equipped with a regulator?
Only cylinders in-use.
a. to* cylinder considered empty 'at 100 Psl?
33060
Scientic Glass t, Instruments/
IB. Leao Analysis
a. Make ana «ooel
b. Mirk area adequate to per for* analysis?
c. Good laboratory techniques utilized?
Comment*:
F«ti 2 of 14
vei/
Fill Correct??
Gas cylinder storage reaches low o! 55°F at low ambient temperatures.
Contractor
BGSG Automotive Research, Inc.
51t* San Antonio, Texas
«r*o by
Butch Naegelin
.. ./ f.
SutMlttM by Mark Dalen
data: ' J- -/
cn
l
-------
Clayton ECE-50
t. M*e tnd eDdel _
;. ' Is dynarowter equipped with direct Crlvt
Inertia essenoly?
3. Is dynvomter •quipped wltti 129 la. Incranent
Inertia wti?
i. Is dynamometer equipped with SO H>. power absorber
,. *r« dynamsneter roll* «.«3" dls., 78" long, and on 17.23"
centers and not damaged?
«. Is dynuenatat calibration kit used?
7. Is dynaaometer hor»epo»er calibrated In accordance with the
nqulrenentj of the contract?
0. Horsepower eeUr accurate and rsadaale to
0.25 hp or less?
/ Check apeeooneter-actual vs. Indicated using a
^ StroboUcti. fct ECE SO, 4«.3 •?>• 18CD rp»,
43 aph. 1730 rpm, S3 aph> 21*0 rpn
ec
Zero ano apan or Ivor's aio, efteck after test U 1 «pn) i.o •&
Zero ana apan Driver's aio, check after test (* 1 Ihp) .5 Ihp
toe orlvers aid strip charts ultMn *1 •pn ano »1.0 sec. for
all driving cycles? ~ ~
Chart cloth 11 in
cm
Chert apeeo __i_min_ln/«ln
mph
Scale
Detents:
12
mph
in
•Ues/lnch
12 Drivers aid Serial * 16O6A003O1
Cell 12
* Stopwatch Time: 1B73.06
B Chart Time: 1874.OO
.94 sec.
Yes/ ND/
Pass fail Cornet?:
•factor: ECUS Automotive Research, Inc.
Submitted by:
Butch Naegelin
Mark Dalen
Site! San Antonio, Texas
p aate; / ? ''•>'-
date; ' z //'5'-
'-anti actor:
EGtG Automotive Research, Inc.
'''•oaieu by:
~Uj*ltteo by:
Butch Naeqelln
Mark Dalen
lite: San Antonio, Texas
date:
Data:
-------
•t'.v.
s ff s*
Yes/ HJ/
Piss Ft 11 Certectgo
1.
a.
J.
7.
I.
ff.
10.
U
12.
13.
U.
17.
Chech fbr lews In V* iyiu» utlng oally procecfcre.
It the iy«e* eli/iftlng either tUlnletss tteel or ttflon?
It tytt«« latk ene<* corn before mo ifur each U«t7
He
p-:;-3, evtrutteo, «no letk
before each use?
S. Are tanple fUtert etiangeo before «ech test?
C. Are sero tnc tp*n CM titcei loentlfleo before
ano afttr «*ci tntlysit?
If entlytlctl iyrtrn t*tuit properly v«ntea
outslae tne liborstary?
N/A
Is ND» analyzer aptmeo through converter? —i.
Are aU tablet antlyica on the lo«ett evtiltble range? __x_
Are arnlyttr flows the tt«e for calibration
arc cample anelytlt? _JL
Arc tangles aralyrea •Itriln 20 "Inut** of eno of test? _j_
Do the tntlynts ttty In eallbrttlon
throughout the test? (*U FS) __i
Is oUutlon tlr less than 30 pp« Ctrbon (less than 10
pp« C for U75 ano later «coel yetr vehicles):^_io_ppn _jc^
It oUutlon tlr ID pp* CO for I»TT sx) laur
eooel yetr tests? < 5 PP" __1
For 3—ty caulytt vehicle testing U oUutlon
air concentmion of tC tn CO less than or eooal
to the appUctcle tanple? __Jt
ahtt are typical OUutlon air levels (pg») 7
9.0Carbon 1.3 CO 3.1 CD? 0.2 K?«
It tytte* purges contlnously with tlr or nitrogen
between emission tests to reouce •—'
• -TOCaibon truly If: A (L0»
1.
2.
Mske eno eooel
Horiba FIA-23A with OPE-415
Use prepurlfleo »li for tero o»5 - cerbon less than ,
CO less then 1 ppn, CC^ less tnin *00 ppn>, MD, l«u tMn
C
•1 ppn, Kfr». AADCO clean air generator 0.1
3. Frepurlfleo air usea for'conoustlon? Mfr. Liquid ca
a. CallbrsUon gases cover all ranges?
3. Antlyreo span gts tvtUtMc for etch range?
(801 FS)*ln
<. Check curve tt three (3) points across etch rtnce.
Calibration trail be vltMn «1S of full scale or
«3S of •etsurtc value, ^lenever Is smaller.
7. Approveo petxlng procedure ucecr?
•. Fuel pressure (HJ-^)
9. Fuel source pressure
Air pressure
U. Air source pressure
12. Stnple pressure
13. Response tine (nro gu to 90S span ptl/.t)
(less than 3 tec)
1*. tero gu J* scale return tine fro* span
point (less than 3 «ec)
tec
1.7 tec
13. Analyser tange(t) 0- 100 .0- soo .0- looo. o-sooo
16. Staple bypass flo» rat* s efh
17. Stability ehech • nro ana tptn point
Cnur e«x. vtrlttlcn tfter 10 «lns.
(.»!» TS Range 0-iooIero o «TS Span .1 « FS
Comentt:
• •*
Ves MI/
Fill Cerre:t*e
N/A
Automotive Research, Inc.
hv:
Naegelln
Murk Dal en
.. San Antonio, Texas
Ottt! /^ :l ' -'-
te:
Contractor:
EG&G Automotive Research. Inc.
•tepareo by:
Butch Naeqelin
•lie:
, San Antonio, Texas
otte:
-------
f- 9 fhf». r-.r-7-s)
»»I. 7 of I*
V«S/ NO/
toss Fill Correctcc
1. . -,
2 use pre^tlfleo .lr for zero gas - Cjrton le» U*n 1 pp.,
£ 'ess 1.-.3.1 I P-*. tCi —» tn*n "-" FP ' - r
£« "*?! 4% "»• »»•*•" "•--•• ^' a-u»- . c
3. Piepurifieo air useo for
H*£ • *-** ^^I^LJL^L-Mp^^w*^^""™^
4. Calibration gases cover aU. ranges?
5. Analyzes span gas available for each range?
(BCi. FS) «in
7. Approveo peaking proceoure usetf?
8. Fuel pressure (H2-N1)
9. Fuel source pressure
jQ. Air pressure
11. Au source pressure
-12. Sample pressure
13. Response time (zero gas to ft» span pomO
( less than 3 see)
U Zero gas 5* scale return U« fro* apan point
( less tnan 3 sec) • —
0- 1000, o-
15. Analyzer range(s) O-ioo .0-50Q_
16. Sa«ple bypass flow rate
17 Stability check • zero anc span point
Erter Max, variation after 10 -ins.
(»jjl FS) Range 0-i°° I*ro o » FS V" .
Contents:
cTh
N/A
on »tonci«loe analyzers » (Lox Ranges)
Make ano tcosl
Horlba AIA-23-AS
!. Flo* rates 6yp*ss_5_cfh, Sangle 5 cfh
i. Chech for 007 ano H;0 Irsterfersnce using »et
3k COj cai. gas (less man 3 ppm on ICO pom
CO range) o ppro
\. Oo caiitratlon gases cover all ranges?
•>. Analyzed span gas available for aaeti 'range? '
(BOX FS)
Use prepurlfleO air on No for zero gas. Concentration
CO less tnan 1 pern, COj less tnin AOC ppn,
carbon less tnan 1 ppm, MDX less than 0.1 ppm.
Nfr. AAPCO .01 PP"
Check curve at seven (7) points across eacn range.
Calibration anall be within *1X of full scale or *!X
of aieasurea value, whichever Is s*aller. ~
. Response tin; (Zero.gas to 90S span point)
( less tnan 5 fee) B.T> sec
Zero gas 5X scale return ti«e fro» span point
( less than 5 tec) 11.26 tec
0.' Analyzer range(s) O-ioo . 0- 500, o-)aoo. o-sooo
1. StaOlllty checks • Zero ana span point
Enter aax. variation after 10 alns.
<»1* FS) Range 0- IQU Zero j> I FS Span. .1 V.S.
omencs:
ra<< I of 24
ves/ tto/
Pass Fail Corrected
N/A
N/A
The times shown reflect fhe response times through the entire bdinpling
There is no practical method for isolating the individual anal yzei.5 ro
determine there response times.
IJte San Antonio. Texas
EGI.G Automotive Hesearch, lnc
Tctm:
epareo by:
toalttM by:
EG&G Automotive Research, ' Inc.
Butch Naegelin
Mark Dalen
Site: s
date: '
date: '
an Antonio, Texas
~l // gV"
, 1,-^
VD
I
-------
f ot 24
i.-oon Monoxide Analyier 6 (Klji Ranges)
Yes/ No/
Pass Fail Ccr
1
2.
3.
4.
5.
6.
7.
f
9.
101"
ll.
anO BOdel Sue Cdiboii Monoxide Analyzer A
Fi~« rstes Bypass _ cfh. Sifols _ cfti
Cr.e=< fcr 003 and H^ Interference using »et JS C02
cal. gas (less than IX FS on 30CO ppra CO range)
Do cs-liaratian gases cover ill rang:*
Analyzed span gas availaale for t»cfi range?
(8Ci FS)
Use prspurifled air or ^2 for zero gas. Concentration
CD less tnan 1 ppm.COj less than *00 ppm. carion less than 1 ppm,
NCK less than 0.1 ppm
Mfr. __ __PP» CC _
cfc curve tt teven (7) points across tach rar^e.
Calibration shall be •itnln »1X of full tcale or
•}'* of aeasuttd vtlue, »hlcn«ver Is utaller.
Response time (Zero gas to 90S span point)
( less trian 5 tec)
MC
Zero Jis 5S scale return tine from span point
( less trtan 3 sec)
«n«lyier range(s) p-
.0-
.0-
Stability cneck • uro nd (pan point.
Enter ux. variation after 10 tins.
yx FS) Range 0-_ Zero « FS Span
XFS
Coooents:
a-actor:
Prepared by:
ij Automotive
San Antonio, Texas
dtte:
Submitted by:
Oate:
c'; Aralyrer
E«(t 10 of 2*
Yes/ >:: •
Pass Fall Corrected
1. :-C'-'.S »r.S ICdtl Horlba A1A-23A _
2. Flo» rates Bypass e. cfh. S*^is__6__cfn
3. Calibration gases cover all ranges:
A. Ar.ilyiec »pan gis avallaole foe each range?
(!=* FS)
5. t'ss prspvrifiec air cr M^ for Zsro SES ecncentratlon
CO less tnan 1 ppr., CC2 less th»n
-------
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-------
13 of 2*
fa* ExTnust Co Analyzer
Horiba AIA-23-A
sample
No/ •
Pass Fill
1. ttake and «cisl_
2. Flo* raUs
3. Check for CO2 and M^ Interference it:
•et 8X C02 cil. gas (lass tnan IX FS on .5*
CO range) ' n ppm X FS
A. Callbritlon gases cover all ttfiflesT
3. Analyzed span gas available for Men range? (SOX FS)
f. Usf prspurlflea air or Nj fox zero gas (Concentration
CO l*ss tnan 1 ppn)
Kfr. AAHCQ <.1 ppffl
7. Cnecfe curve at
_polnts across e»cn
range. Calibration shall be «itninc, ^21. of full acala or
^10* of oeasursd value, i^daiever 1* imaller x_
Hespoase tiro (Zero flis to KSX tpan point)
than 5 *ec ) 6.2 aec
N/A
9. Zero gas SX scale return time from tpan point
(less tnan } »ec ) 69
N/A
I he tinieb ^hown lefltsel 1tiu rubpunbu tlinob Ihrongh the entire Sdinp I I ny system.
lher~e ib no pi CK Meal iiiethud for ibulotirig the individual arialy^ersto
deleiinine theie respoiibe 1lmcb.
Contractor:
Prepand by:_
Sutnltted by:.
EGt.G Automotive Kebearcti, Inc.
alta:
. San Antonio, Texas
Butch Naegelin
Hark Udlen
Otta: • 1-
1. Mske ana looel
2. Flo» rates
Horiba AIA-23A
cfh
3. Calitratlon g
-------
s
H
S
Housing ror Evaporative Determination
1
I
si
•I
lyoTocarbon tnalym
l. Make ana •oael N/A
\i
1^ ?
5S S
•l "*
1 -4 w
-i j>
Si i
2? ' •
S-fi^ S
3^ c
e
»l«.
i. Calibration gases cover all ranges?
u AnalyZM span gas available for tadi range?
. Chech curve at three (9) points tcrott tacn
Calibration shall be »ltMn «1X or rull seal
•9k or •easureo value, •hlcfirver Is analler
*l *l *l *l *I * ^
1 1 1 1 1
4J
s
I J
» i
i J J
s * i
s s ;
|?j .. J.I
[ffihij8*
i ! § S 1 1 if »
h s 33 ! !i i
UMS man 3 aeej
. Analyzer ranged) 0- .0- .0-
u.
1
. Sa^le bypass flow nu
ttt Fuel
. DOM rutl tMt apeciricatloni?
t
^
. wu staple of fuel analyno by other than at/
(atucri analysis)
S
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-74-
-------
•at* It •( I*
i*
'V.
t.
7.
I.
Enclosure Calibration
a. Bacfccrouna eolsslons (.» o»s/» hrs. «*«.)
B. verify enclosure calibration (« kS of injecteo
value) I
a. Enclosure vcluw (frn> caii^rttlon)
c. Enclosure retention checx (less than at leak rate
in t hours) t
Temperature Aecoroers
at. Capable of resolving time to 15 s«c?
b. Capable of resolving tewp. to * .7S°F (.*7°C)?
c. Te«p. accuracy of * 2°F (1.1°C)?
e. Tl«e accuracy over one (1) hour per too («• 13 sec
•*«.) " sec
I. Temp, sensor correctly locateo (3 * .3 ft. from
floor, appro*. * incnes from •ail,*"approx. at vertical
cenurline of •all)?
Purge blo»er accquate?
Internal •ixing blo*ers aoequace?
Evaporative aystew pressure check e~..ip*»nt.
•. Hble to acasure fifteen (15) ''•^es of MjO pressure?
b. Capable of resolving pressure to ^1.0 in. H^
Enclosure eooling ayste*.
•. Cooling surfaces aonltoreo to «alntaln temp, betveen
te° F (ZJOC) anfl MD f (JOQC) 7
N/A
t. Device useo to oontinucusly aetsure «et ano ory
bulb tc«peratures curIn; tests.
res/ NO/
Pass fall Correcteo
Make era eooel
Thermocouples
b. Hecoroer eake ana icael Easteriine Anges MS 42-e
Mange 0- 50-100 OF x
Soak ana temperature continuously •onltoreo ano
rewrote on a strip chart?
Distance fro* VeMcles Man 15
o to
loo
Chart Speed,
Chart "loth
0.5
in/hr
n Inches
fOI Step Change in lass than 10 sec? 4
•nts:
ace.
' Contractor i
EGfiG Automotive Research, Inc.
•ite* San Antonio, Texas
by* Butch Naegelin
Bate: /2 il ?
' SubMltteO by; Mark Dal en
Oate
te^itzactar: EGKG Automotive Research, Inc.
by; Butch Naegelin
San Antonio, Texas
aater rl ri ?<-
by
Mark Dalen
Bate:
-------
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-------
*•<• 24 of 24
"f 24
General CD"»"ents;
ppo->ig-its to be jjxluoo is Mrt of this p»d<»gg
1. Latest copy of all analyzer curves.
2. Copy of certlfieo calibration foe the laminar flo« clemsnt
in tr«; cvS Mlioraticn.
3. Litest copy of the oynanometer curves.
4. Copy of dally, xekly , (oncMy logs.
3. Copy of preventive maintenance «no nlltritlon acf^eoule
for laboratory equipment otrxr than oyno, CvS ana analytical
t. Copy of fuel analysis.
7. Copy of analysis of zero air ana/or nitrogen cylinders.
6. Copy of calibrations of flo. «etrrj.
9. Copy of calibrations of temperature recorders.
omnenu:
NO/
Pass Fill Cot-rec tea
N/A
Preventive maintenance and calibrations are performed on a monthly
basis or sooner if deemed necessary by the lab supervisor or lab technician.
Contractor:
LGS.G Automotive Research, Inc.
; San Antonio, Texas
I have rwleved til the data contained In this report and hive discussed its
contents «lth the EPA Inspector.
Prepareo by:
Butch Mac-cjelii
Submitted by:
M-uk [talen
_oate:_
Date:
Signature
Date
-------
APPENDIX D
Ca I i brat ion Forms
1) Daily Work Summary Log
2) Daily Equipment Check Sheet
3) Span Gas Information
4) Weekly Analyzer Calibration Curve Sheet
5) Monthly Analyzer Calibration Curve Sheet
6) Weekly C02/H20 Interference Check
7) Zero Compensation Adjustment for C02 Interference
8) Daily NOx Converter Efficiency Test
9) Weekly Chassis Dyno Calibration Verification Data Sheet
10) Monthly Dynamometer Calibration Data Sheet
11) Daily CFV Propane Verification
12) CVS-CFV Flow Calculation Check
13) CVS-CFV Flow Computer Calibration Data Sheet
14) Monthly Temperature Recorder Calibration and Functional Check
15) Dynamometer/RLPC Calibration Check List
16) CVS-CFV Calibration Data Sheet
-79-
-------
Data Form No. 13
Anal-, ticaj. Ber.cr. Start Up
E=-i.--=r.t Cnec^.s . _
Prcjanc Ir.^eclior. '.eriricatiop.
S.^a: Gss/Pressurc- Log
.laintenancc Pc-rfornc-
Lvno =:
PE."J~DP.". KEEKLY
Cnassi£ Dyno Verif icatxor.. D-yno =1
Ar.aivzcr Calibratior.s •
Cr.ascis D/no Calibration. Dyne =1_
CVS "low Calibration-
Test j Venicle
1 "jncer . Nurjacr
i j
venicie
lla>;e £.
:ioucl
Main- Precon-
Rcccived tenance ! ditioninc
i jLr/no =
1
FTP
D-yno ~
uata | C-ata
Reduc- I Valida-
tion tier
1
FT? Sequence- &
Result
jDyno
ID-yno =
pyno =
pyno
lA-no s
Tecr.ni-iar. ' s Signature .
aiiry Control Signature ;_
Os so r vc r . _
SU3SCKIBEC A;;D SI:OR:: T: EuroHE :
THIS DAY or , 197
NOTARY TbaLIC
MY CO."j:lSSION EX?I?£S.
-80-
-------
SHI
CONSOLE NUMBER 1
,'JOl
Page
1 of 3
Date
Date
Date
CO Functional Check
0-100 PPM (Rl-1)
Gain
Zero
Span
Drift
Zero
Drift
«
Noise
CO Functional Check
0-500 PPM (Rl-2)
Cain
Zero
Span
Drift
Filter Checks
CFV
Fl
F2
F3
Z*ro
Drift
%
Noise
CO: Functional Check
0-1.5% (Rl-1)
Gain
Zero
Span
Drift
Zero
Drif
%
Noise
COj Functional Check
0-4» (Rl-2)
Gain
Zero
Span
Drift
Zero
Drift
System Leak Checks
Anal.
System
Bl
B2
83
B4
B5
B6
t
Noise
HC Functional
0-100 PPM tP-
Gain
Zero
Span
Drift
rheck
(•~M
Zero
Drift
%
Noise
HC Functional Check
0-500 PPM (Rl-2)
Gain
Zero
Span
Drift
NOx Propane
Conv. Verification
Eff. » Error
Zero
Drift
%
Noise
HO, Functional Check
0-100 PPM (R - 1
Gain
NC
.
Zero
Span
Drift
Zero
Drift
I
Moi
>x Functional Check
1-3 00 PPM (Rl-2)
Zero
HC Hang-up In
Deflection Units
Sample
Bag
Bag
5
Bag
Span
Drift
Zero
Drift
%
NO1S'
Ambient
Data
•
Dat«
Date
Date
'
CO Functional Check
0-1000 PPM (Rl-3)
Gain
Zero
Drift
Drift
Noise
0-5000 PPM (Rl-4)
Gain
Zero
Drift
Drift
Neise
0-30 PPM (Rl-0)
Gain
Zero
Drift
Drift
Noise
DATr.y t\ :r'«nT rurc*. SIIEVT oat-i i
CONSOLE NUMBER 1 p.?v 2 ut J
0-2. OX (Rl-5)
Gain
Zero
0-10*
Gain
Zero
Drift
Drift
(Rl-6) '
Drift
Zero
Drift
Noise
0-1000 PPM (Rl-3)
Gain
span
Drift
Drift
0-7.0* (Rl-3)
Zero
Span
Zero
Noise
Gain
Zero
Span
Drift
HC Functional
Drift
Zero
Drift
*
Noise
Check
Drift
HC Functional Check
Span |Zero
\
HC Functional Check
o - 3t»° f
Span
^Tr«*r«
n* ,
Span
Zero ^
|
t/fj IOK
Zero
'•
-------
DATA FORM NO.
Page of
SPAN GAS INIOKMATION
DATA FOKI1 MO.
SujiplcTiK'n tal Page?
Si'Afl GAS llirORHATION
Component
CO
C°2
°2
HC
TOTAL
CARBON
HEXANE
IIEXANE
X
Range
Code
11
12
13
14
15
16
11
12
13
14
13
11
12
13
14
N/A
M/A
10
11
12
13
Full
Cone.
100 ppm
500 ppm
1 , 000 ppm
5 , 000 ppm
2.0%
10.0'i
1.51
4.0%
7.0%
15.0%
25.0%
100 ppm
500 ppm
1 , 000 ppm
5,000 ppm
500 ppm
2,000 ppm
30 ppm
100 ppm
300 ppm
1 , 000 ppm
Span Gas
Concentration
Span Point
De flections
Effective
Date
Effective Run
Numbers
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Technician :
Technician:
Technician:
Technician :
Technician:
Technician :
Technician :
1
CO
r\j
Quality
Quality
Quality
Quality
Quality
Quality
Quality
Audit:
Audit :
Aud i t :
Audit.
Audit:
Audit-
Audit-
Component
CO
CO
2
°2
HC
TOTAL
CARBON
HEXANE
HEXANE
NO
X
Range
Code
11
12
13
14
15
16
11
12
13
14
13
11
12
13
14
N/A
N/A
10
11
12
13
Full
Cone.
100 ppin
500 ppm
1,000 ppm
5,000 ppm
2.0%
10.0%
1.5%
4.0%
7.0%
15.0%
25.0%
100 ppm
500 ppn
1 , 000 ppm
5,000 ppm
500 ppm
2,000 ppm
30 ppm
100 ppm
300 ppm
1,000 ppm
Span Gas
Concentration
Span Point
Deflections
Effective
Date
Effective Run
Numbers
Prepared By:
Quality Audit:
-------
WEEKLY ANALYZER CALIBRATION CURVE SHEET
Gas Analyzed:
Analyzer Make/Model:_
Serial Number:
Zero Setting:
Range:
Cell Length:_
Recorder:
Gain:
Time at Start:
am/pm
Nominal
(»>
0
90
75
60
45
30
15
Span
90
Nominal
(PPM)
0
Cylinder
Number
Cylinder
(To Reg)
Cylinder
(Out Reg)
Analyzer
Flow (SCFH)
Cylinder
(PPM)
Deflect.
Lower
Deflect.
Upper
Deflect.
I
!
Operator's Signature:
Quality Control Signature:
VW Observer:
Completion Time:
am/pm Date:
MOr.THL- ANA^i'ZL.v CALIBRATION CURVc. 5HEET
Gas Analyzed
Analyzer MaX
Serial Mumbe
2ero Setting
Moral rial
:ietsr
;%>
0
90
75
: Range :
5/Modei. Cell Length:
tr: Recorder:
: Gain: Tine At Start: am/;
Nominal
Concentrat.
(PPM)
0
Cylinder Cylinder C/linder Analyzer C/linder j
Serial Pressure Pressure Outlat Concentrat Meter
Nuncer (To Sec;) (Out Real Flow (SCFH) (PPM.) Deflsctic
I |
1 ' ]
60
45
>
\ \ ' '
30
15
11 1
Operator's Signature _
Duality Contro- Sigr-.at
am/-.~, Jacs
-83-
-------
DATA roRii 18 PAGE i OF ?
WLt KLY_ COj/H2O INTERFERENCE CHECK
DATE:
ANALYZER MODF1.:
1. ZERO LCO ANALYZER HANGE 1
(I.CO2 AtlALYZCR MUST BE ON RANGE 2)
2. SET RECORDER PEN ON HIE 10.0 LINE OF CHART PAPER AND USE THIS AS ZERO SET
POINT.
3. INTRODUCE INTERFERENCE GAS. BUTTON SELECTION:
LCO = Master
LCO 2 = SPAN
MASTER = Idle
INTF C1IK = in
4. WET C02 DEFLECTION (Bubbles should be seen in Bubbler)
5. ZERO LCO ANALYZER. WLT CO2 DEFLECTION I1UST BE LESS THAN 3.0 PPM.
BUTTON SELECTION FOR ZERO:
LCO - Z'*ro
LCO2 = Znio
MASTER - Idle
INTF CHK = out
OPERATORS SIGNATURE
QUALITY CONTROL SIGNATURE
I
CD
Ji.
I
I'ATA [ OI'M 18 PAGE 2 Ol 2
ZERO COMPENSATION MM US 1 MINT I OR CO^ IN'l EFJ LKI NLP
NOTE: IF ANY^ ADJIJSTMI.Nr ARE RFOUIRLD, AIJ, STI PS 111)=. I1 HI, DONE
AITER COI1PL1TION OF ADJU.SI'tlLN rs A MONTHLY ANALYZER CALIBRATION MUSI
BE DONE ON ALL RANGES.
1. LCO ANALYZER TO RANGE 1
2. LCO2 ANALYZER TO RANGE 2
3. DVM SELECTOR TO LCO
4. CONNECT A VOLTMETER BETWEEN TP2 AMD E (COM) ON MOTII1 PIIOAIU) 21
5. ZERO AND SPAN LCO ANALYZER AND RETURN TO 7I.RO. ( IK) HOT TOUCH SPAN Hl'lR AGAIN
AFTER ANALYZER IS SPANNED)
6. INTRODUCE INTERIFRENCE GAS. BUTTON SELECTION:
LCO = MASTER
LCOj - SPAN
MASTER = IDLE
INTF CHK = in
7. ON MOTHERBOARD 2E, ADJUST THE CS ] POT I III lOIII TER I OR A 0.000 t Imv INDICATION
ON THE VOLTMETER ~~
8. INTRODUCE ZERO GAS AND CHECK ANALYZt R FOR ZERO READ ING. BUI ION SILK I ION •
LCO = ZERO
LCO2 = Zl RO
MASTER = IDLE
INTF CHK = out
9. RF:PEAT STEPS 86 - 0. IF NO ADJUSTMENTS ARE RLOURIID CONTIHIT TO SUP » lo
10. LCO ANALYZER TO RANGE 3 CHECK ZERO. IF 7.1 RO IS NOT ( ORRI ( 1 , ADJUST 117. 1
POTLNTIOMLTIR ON MOTHERBOARD 2E UNTIL VOI/IMI.TIR INDKA11S 0 000 + lnw.
11. INTRODUCE INTEW ERENCE GAS. (BUTTON SELECTION IS SAME AS STEP DC)
12. ADJUST THE CG 3 POTENTIOMETER ON MOTHERBOARD 2E FOR A 0 000 I Imv INDICATION
ON THE VOLTMETER.
13. INTRODUCE ZERO GAS AND CHECK ANALYZER K>R ZERO PI AD IMG. (BUT'ION SFITlTlntl
IS THE SAME AS SIT P 08)
!
-------
D.lt.i form 19
Pn./e 1 of 7
DATE OF TEST:
OPERATOR
(NO) CYLINDER II
AIR CYLINDER 8
BAROMETRIC PRESSURE
DAILY NOX CONVERT! '< llriCIHHY '1 I S I1
( HORIBA (JO GEN! KATOR MODI I, H 2 1 0)
X
TIMI.
ANALYZER I1AKL AND MODEL
COIICEHTRATION [Til VENDOR
POT SLT
VLNDOR
" IIG BAROMETLR TEMPERATURE
2. VERIFY THAT OZONE GLNLRATOR IS ON
3. FLOW CONTROL VALVES ON DRY AIR, OZONE BYPASS, AND NITRIC OXIDE ARE OIF
4. POWER SWITCH "OIF" ADD OZONE AND AIR SHUT OFF VALVE. "CLOSED"
5. ADJUST MITH1C OXIKF. PLOW CONTROL VALVE FOR 6 TO 10 SCEVI
£. IIOX ANALYSER TO "HO" MODE, AND SPAN TO UO.O. RECORD THIS ON CHART.
7. 1'OUER SWITCH If) "ON"
B. OPLII O'/.OUE i. AIR SIIUTOl'F VALVE AND ADJUST OZONE BYPASS 1 LOW CONTROL VALVE TO
1 SCTH
RECORD READING
10. 1'OWl R SWITCH TO "Oil"'. NOTE:
DVM MUST RETURN TO 75.0 OR HIGHER IE IT DOES NOT,
RFPEAT STEPS 6-9 WITH OZONE BYPASS FLOW SET AT A
LOWER RATE. ( LFSS JUAN 1.0 SCI II)
11. ADJUST 1 LOU CONTROL ON DRY AIR F1/)WMLTER FOR A R1ADING Ol 72 .0 * 1.0
RECORD READING _
12. POWER SWITCH TO "ON".
13. READJUST OZOtlE Fl/DW Hl.EDLE VALVE FOR A READING OF 14.4 - 1.0 RF.CORD READING
14 POWER SWI'ICII TO "OTF".
15. VERIFY THAT Till; RIADINfi IS STILL APPROX. 72.0 KE.COKD Rl ADJNG
16. POWF.R SUVTOI TO "Oil" S. Rl CORi) READING
17. NOX ANALYZER TO "NOX" MODE ALLOW TO STABILIZE AND RECORD REAPING
10. POWfR SWITCH TO "OFF" AND ALLOW TO STABILIZE AND RECORD READING
19. CLOSE O20W, Atll) AIR SllU'lorr VALVE AND RECORD STAHLE READING
NOTE THIS RiADING WILL NOT BE MORE: THAU 4 0 OF STEP IIG
I
CO
U1
I
DAILY NOX C01IVITUT R IfriCIENCY TEST
21. PRESS NO GEN. BUTTON ON CONTROL PANEL TO RELEASE BUTTON TO THE OUT " OFF"
POSITION.
22. PERFORM THE FOLIOWING CALCULATIOU FOR PERCENT CONVERSION.
(l+(a-l))/(c-d» * 100 NOTE- This is, how it is entered in I he H/P C.iU-u l.iLor.
a = step » 17
I) = step » 18
c = slcp tt 15
tl = stop » 16
Percent efficiency =
OPERATOR'S SIGNATURE.
( must be over 90* )
QUALITY CONTROL SIGNATURE
-------
Data I orin No. 21). 1
(Rpvisrd A. 11-25-80)
I'aye 1 of 1
MEEKLY CHASSIS DYNO_ CALIBRATION
VERiriCATION DATA SHEET
DATE:
TIME: AH - PM
DATE OF LAST ELECTRONIC CALIBRATION:
DATE OP 1.AST MECHANICAL CALIBRATION:
DYNO I.D. NO.
TECHNICIAN:
Inertia
Wt. (Ibs)
T . W .
F.R. 1 R.R.
1. 11 P.
Time (Seconds)
Run 1
Run 2
Run 3
Average
Calculated
Time
Dlff .
(SQC)
_ rTront Roll T~ Hoar_toU__T___Must__Be
Jcd"It [ I
OO R.P.M.J_ [__ ^__ I.46' J - '2
F.R. \ Diff. / R.R.
Tins coastdown is to be used for Car(£.) If ^__—.
| Actual Hgrbg|Xj_wer^= _[__K Factor =
Technician ' s Siqnature : __ _
Quality Control Signature:_
fi()N Ull.Y
IJYNAMOHKTliR CAl.IBitATlON DATA SHLDT
Date :
llyiio 1 .D. •
Time: am/pm Technician:
Comments from Electrical Adjustments:
Inertl a
Weight (LBS)
Indicated 11. P.
Time (Seconds)
Run 1
Run 2
Run 3
Aver.itjc
K
Actual Rill1
-- -
K
Average Time
Technician's Signature:
Quality Control Signature:
.im/pni IM Lo
I
CO
-------
U,n .i lii 111 21
BAROMETER TEMP.
DAILY C F. V. PHOPAML VERIFICATION
DATE:
°F
BOTTLE WEIGHT BLFORE_
BOTTLE WEIGHT AFTER
Vmix (SCF)
EXHAUST BAG It
HC RANGE METER ~DEH.LCTIONS
BACKGROUND BAG
HC RANGE
MET! R DEFLECTIONS
OPERATOR'S SIGNATURE
QUALITY CONTROL SIGNATURE
BAROMETRIC PR£SSUR£
CVS-LfJ I LOW f.ALCULAI I Oil UIUK
DATE
CVS MASS CALCULATION lAI't , PROC.KAII l,(>
TEST 1
TEST 2
TEST 3
AVERAGE
TA (D|r)
AMBIENT
TEHP
B(lll IIG)
BARO PRESS
Bj (°C)
UARO TEIIP
I IMF
SECONDS
A P
(III H^U)
llinifATEl)
VOL Wll
CAI { IILAIEP
VOLUML
(HIM 111 '1
I
CD
-J
I
TECHNICIAN'S SIGNATURE
TIME
OA1E
All / PM
Q C. EtlGIHEER'S
SIGNATURE
TIME
DATE
-------
'i.-( I V I LOW lUHI'UlLIt LAI.UIHATlOll LlAIA Mil 1.1' Sheet 1 of _J
CVS NUMlirH
AH/I'M TECHNICIAN
NOTE; USE CVS MASS CAI.CUI.AnoN TAPC, PROGRAM N5
Couti ter
For
Phase
Aver aye
""ot 'I nrns
fief oro
Ilns 1'liasc
Ohs.
Raro.
'icssiirt-
(In. My)
Avt(
Avy .
Avg .
Bnro
Tc>in[>
t°a
Avq .
Avg .
Avg .
Ainb lent
Tem[)
<°F>
Avg .
Avg.
Avg .
Elapsed
Time
(Seconds 1
Ap
Vcn tur i
Inlet Di-p
(In. M20)
CoufiLer
I n-3 .
Vol.
(ft.3 )
Calc.
Vol.
(I t.3)
Count <•!
Lr ror
(1 t 3)
CO
oo
I
n.it.i
("Li
Avg.
AvtJ .
Avu .
Anilil <>ML
•l.:m|,
(°l )
AviJ
Avg .
Avcj .
[;],I]I;,CH|
T i me
(Second:,)
A P
Vi-nl in 1
Inlet Ilc|.
(In 11.0]
( uunl «' i
In.l
Vol
(It.3 )
r.i Ic
Vol
(1 l 1)
< Mlllll
III'
II 1 -
-------
Appl icable Spt-c i 1 i cat i on:; •
E lops nl Turn;
(.Second:,)
'jOO
1000
M.ix i mtiin
Alluwfil K, ctu
1 or .r, i n'j 1 c C(jurit.or
(I L. 1)
10 00
15.00
Mcixiniinn Allowed
Avoraqe r.rror For
Th« 'Ihrco Conn tors
(1 L. ')
6.00
9 00
lUMinum Al lo.r.l
1)1 f Inreiico IH'lv • i n
J\ny IVo of tin- HIUM-
Coun tot Ti i 01 s
(It. 1I
a. oo
10.00
TECHNICIAN'S SlGtlAUJW.
DA'lL
TIME
AM / I'M
THIS DATA HAS 111 1 N HLVILl-JLD AND API'HOVKD
BY EG&GA1* QUALITY CON I ROL DEPARTMENT:
I
CO
Thermocouples
111 100 beakers, eat h of "Inch has a tap,
Ite, (needed only if Si) witt-r cannot h<
Precision thermoiiK't or ha\M uOl) nil I 1 i 1 i I.- rs
obt .11 nod from tap)
b i I i I y
_ATJD _FLHCJ'J ONAI, C11
Use t ho pertinent- sect ions of Lin- i nst i ument ni imiri 1 L<> nuke any mo< ham ( .il ad j ust -
men ts which are. deemed necossa ry after obsf j v i nq rhe r ei.orde r 1 11 ope ra I i on ,
A] low the recorder ami i ts scrvo-im -r hnii i sm to wn mi up foj a I 1 eas t 10 nil nu t < ". .
IKiny Uie beakors, tap water 0°P
Room Toinpei ,it lire W.iier Rath - /o'' to H0°f
Warm Water Hatli - Hr>° to HH°P
Wlion this i > complete , < I KM k ea< h thci nun oupLu and j ( -j as:-oci at ^d i >>, < -t dcr < naiin. • 1
ae,ai UH L tlio precis ion I lieiiuoioe te r in eac h wa) n r hath in the t o I lovi nn porformiiMj tliesc- clu.'ck^, tlie water bath in uso should be s M i i ed i - MIS t ,111 1 ! y
and rfjfiduiijs sitould lie taken only aft et both the 1 hei moniet^r and t li»> > ei ordei rnatli IHJS
liave been s tdbil i^cd. Wlien < lian?. of full scale, the leading- tHstusst^! above should be taken
acjain to ensure that the liltjh indicated deadb.and was not a result of tempe ra t ur'1
chancjos in the loom temporal ure wa1 er bath.
'1'hc tenn^era t ure roadi ncjs on I IIG r et o n ]•* t shou 1 d acj t ee wi t h the cor -j ee t ed ! he rinoini1 1 er
readuiqs WL tJiln +L f. If on ly one of t lu t hot mocoupK-s hhov^r, a t esucmso whi ch I ^ out
-------
Data Form No. 27
WATER BATH
ROOT- Tenoera:ure
Cool
KOO^ Te^Derature
warr
3oo^ Tenperature
THERMOMETER
INDICATED TEMPERATURE
THERMOCOUPLE CHANNEL
RECORDER
INDICATED TEMPERATURE
THERMOCOUPLE CHANNEL
CORRECTED
THERMOMETER READING
THERMOCOUPLE CHANNEL
Overshoot (« of
ruil Scale)
Deadband (±3 of
Full Scale)
THERMOCOUPLE CHANNEL
THERMOCOUPLE CHANNEL
Technician:
•w Observer:
•C 0 r2 tfi U-
a a o
O v- 'O
-------
DA'fL 1'OHM NO. 301.2
Page 1 of 7
DYHAHOMETEK/RLPC CALIBRATION CHECK LIST
* (Dyno » I ONLY, Serial ItA-32206-3-578)
DYNAMOMETER NUMBER
TECHNICIAN.
SERIAL NUMBER._
DATE.
A. WARM UP:
1. Unless the dynamometer has been used within the last half hour,
obtain a copy of DATA FORM 107.1 and perform a dynamometer warm
up, as per the procedure on that form.
Warm up performed:
Warm up not necessary since
dynamometer last ust at:
A.M./P.M.
2- Negative lead of DVM connected to ITB COMMON ternnal 211:
B. Kl.AR ROLL CALIBRATION; (Reference Figure 2)
1- Speod/power switch to: REAR ROLL
2. Positive lead of DVM to test point 2 board 8.
3. Ail just pot 3 board 8 to DVM reading of 0.000+
002 VDC (HOLI.S STOPPED) . ~~
4. Adjust pot 4 board 8 to DVM reading of 4.63+
.002 VDC (REAR ROLL at 1800 rpm) Time ;
_____ 5. Ki-( hock pot 3 board 8 reading at 0.000+
.002 VDC (ROLLS STOPPED).
C. EkONT ROLL CALIBRATION: (Reference Figure_2)
__ 1. Speed/power switch to: FRONT ROLL
__ 2. Positive lead of DVM to test point 5 board 7.
___ i. Adjust pot 6 board 7 to DVM reading of 0.000+
.002 VDC (ROLLS STOPPED). ~
___ 4. Adjust pot 7 board 7 to DVM reading of 4.63+
.002 VDC (FRONT ROLL at 1800 rpm) ~
____ 5. Re-check pot 6 board 7 reading at 0.000+
002 VDC (ROLLS STOPPED) . ~
AM/PM
AUTOMOTIVE RESEARCH
IMqo 2 of 7
DYNAJIOMETER/RLPC CALIBRATION CHECK LIST
D. DIGITAL SPEED READ-OUT CALIBRATION
1. Positive ]ead of DVM to test point 2 board 8.
2. Switch 2 board 8 to: CAL (Away from board)
3. Adjust pot 5 board 8 to DVt! reading of
5.000 + .002 VDC.
Adjust span pot under logo on instrument box to:
50.0 mph ON DIGITAL SPLEIVUTI.R.
E. TORQUE CELL CALIBRATION:
1. Remove vehicle - RELEASE DYNO BRAK1S.
2. Switches 1 and 2 board 8 and switch 1 board 7 to:
RUN (TOWARD BOARD).
3. Positive lead of DVM to test point 4 board 8
reading (INCLUDING + or - SIGN).
4. Switch 2 board 8 to: CAL (AWAY FROM BOARD).
5. Adjust pot 5 board 8 to:
50 mph READING ON DIGITAL SPLEDMETER.
6. Positive lead of DVM to test point 1 board 8.
7. Remove load cell hysteresis (LIGHTLY TAP LOAD CfLI,
MOUNTING CHANNEL WITH MALLET).
8. Adjust pot 1 board 8 to DVM reading of 0.05 + 0 005 VDC
9. Positive lead of DVM to test point 4 board 8.
10. Adjust pot 1 board 8 clockwise until DVM reading JUbT
equals reading at 3 (TURN POT SLOWLY SO AS
NOT TO OVERSHOOT READING).
11. Positive lead of DVM to test point 1 board 8 (RECORD
READING).
12. Install arbor D33102 and TIGHTEN - retaining screw to
snug.
13. Gently install three D33112 Weights - REMOVE HYSTERESIS.
, EGnG AU TOMO TIVE RE SEA RCH „
-------
DATA FORM HO. 301.2
Page 3 of 7
DYNAMOMI.TLR/RJ.PC^'AL IHRATIOH CHECK LIST
E. TURQUC CLLL CALIBRATION: (continued)
14. Adjust pot 2 board 8 to DVM reading of 4 .07jt .002 VDC.
15. Remove weight and arbor - REMOVE HYSTERESIS.
16. Compare DVM reading with reading in 11 within + 0.002
VDC if not within tolerance, adjust pot 1 board 8 to
proper setting - - THEN REPEAT STEPS 12 through 16.
F. DIGITAL POWER READOUT CALIBRATION:
I. Adju-it power meter reading to: 00.0 HP (ADJUST SCREW
LOCATED AT LOWER RIGHT HAND CORNER OF METER DVM) .
2. Switches 1 and 2 board 8 to. CAL (AWAY FROM BOARD).
3. Adjust pot 5 board 8 to: 50.0 mph (ON DITITAL SPEEDMETER)_
4. Positive lead of DVM to test point 1 board 8.
5. Adjust pot 6 board 8 to DVM reading of 4.070 +_ .002 VDC.
6. Adjust power span pot for reading of 40.7 (LOCATED UNDER
CIA1TON LOGO).
HUKSH'OWLK SCALING VERIFICATION:
]. Switch 1 board 8 to: RUN (TOWARD BOARD)
.'.. Adjust pot 5 board 8 to: 50.0 mph (ON DIGITAL SPEEDMETER)_
3. Install arbor and weights and verify reading (REMOVE
HYSTERESIS AFTER EACH WEIGHT).
None 00.0 l_ 0.1
Arbor 1.9 +_ 0.1
Arbor ^ 70S 27.8 + 0.1
Arbor + 35H 14 . 8 + 0 . 1_
Arbor + HOtt 40.7 + 0.1
If not within tolerance, STEPS "E" AMU "K" REPEATED
TO CORRECT.
AUTOMOTIVE RESEARCH •
DYNAMOHETER/RiPC CALIBRATION CIILCK LIST
^OkM no. JO] .
Page 4 of 7
H. HORSEPOWER "CAL CHECK" CALIBRATION:
1. Warm up dynamometer for minimum 15 minutes.
2. Set mode selector switch to: PENDEtIT
3. Switch 1 board 8 to: RUN (TOWARD BOARD).
4. Switch 1 board 7 to: RUM (TOWARD BOARD).
5. Switch 2 board 8 to: CAL (7iWAY FROM BOARD).
6. Adjust pot 5 board 8 to: 50.0 mph (ON DIGITAL KPi f l<;in I r)_
7. Remove vehicle - RLLEASE DYNO BRAKES.
8. Remove load cell HYSTERESIS.
Ill'
9. Press CAL check button and record HP reading
on digital HP meter.
DEADBAND ADJUSTMENT:
1. Turn water supply to dynamometer OFF.
2. Press pendant load or unload button to RELEASE pressure
in the lines.
3. Speed/power switch to: iROUT ROLL
4. Set thumbwheel to: 30.0 mph
5. Set mode selector to: THUMBWHEEL
6. Set vehicle factor to: 0.00
7. Switches 1 and 2 board B and switch 1 board 7 to.
CAL (AWAY FROM BOARD).
8. Adjust pot 5 board 8 to: 5U.O mph (ON DIGITAL SPCKUMITI R)
9. Adjust pot 6 board 8 to: 30.0 mph (ON DIGITAL, M'l.llDNiTI l()
10. Adjust pot 6 board 8 to START LOW RATE UNLOAD
LIGHT PULSh - RECORD IIP READING HI'.
AUTOMOTIVE RESEARCH •
-------
DYNAMOMETER/RLPC _CAL1 BRATION CHECK LIST
I. DEAUBAMD AUMUSTHLHT. (continued)
11. Adjust- pot 6 board 8 to START LOW RATE UNLOAD
LIGHT PULSE - RECORD HP READING HP.
12. Difference between 11 and 12
(THIS IS THE DEADBAND).
DATA tORM NO. 301.2
Page 5 of 7
1J. Adjust i»t 3 board 2 ajid REPEAT 8 and 9 UNTIL DEADBAND
IS 0.4 HP.
THUMBWHEEL "LOW RANGE" ADJUSTMENT:
1. Set thumbwheel to: 3.0 HP
2. Set mode selector to: THUMBWHEEL
3. Set vehicle factor switch to: 0.00
1- .Switches 1 and 2 board 8 and switch 1 board 7 to.
CAL (AWAY FROM BOARD) .
5. Adjust pot 5 board 8 to: 50.0 mph (ON DIGITAL SPEEDMETER)
6- Adjust pot 6 board 8 to: 3.0 HP (ON DIGITAL POWER METER)_
7- Adjust pot 1 board 7 until LOW AND HIGH RATE LOAD AND
UNLOAD LIGHTS GO OUT.
"• Adjust pot 6 board 8 counter - CLOCKWISE TO START LOW
RATE UNLOAD LIGHT PULSE - RECORD HP READING: HP.
9- Adjust pot 6 board 8 CLOCKWISE TO START LOW RATE LOAD
LIGHT PULSE - RECORD HP READING: HP.
_____ 10. Adjust pot 1 board 7 for LOAD LIGHT PULSE AND UNLOAD
LIGHT PULSE - TO BE CENTERED AROUND 3.0.
K . THUMBWHI LL "SPAN" ADJUSTMENT:
_ 1. Set thumbwheel to: 39.0 HP
2. Set mode selector to: THUMBWHEEL
3. Set vehicle factor to: 0.00
4. Switches 1 and 2 board 8 and 1 board 7 to:
CAL (AWAY FROM BOARD).
5. Adjust pot 5 board 8 to: 50.0
ON DIGITAL SPEEDMETLR.
AUTOMOTIVE RESEARCH ,
D/Y1 AJ ul Jl I10_.__3U1
Page 6 of 7
DYNAMOMETER/RLPC CALIBRATION CHECK LIST
K. THUMBWHEEL "SPAN" ADJUSTMENT (continued)
6. Adjust pot 6 board 8 to: 39.0 IIP ON DIGITAL POH1.R METL.R.
7. Adjust pot 1 board 1 until LOW AMD HIGH RATE LOAD/UNLOAD
LIGHTS GO OUT.
8. Adjust pot 6 board 8 connter-CLOCKWISE TO START LOW RATL
UNLOAD LIGHT PULSE. RECORD HP READING- 111'
9. Adjust pot 6 board 8 CLOCKWISE TO START LOW RATE LOAD
LIGHT PULSE. RECORD HP READING : HP
10. Adjust pot 1 board 1 for LOAD LIGHT PULSr AND UIII/JAD
LIGHT PULSE. TO BE CENTERED AROUND 39.0 HP.
(DIFFERENCE BETWEEN 8 and 9).
L. HIGH RATE DEAJ3BAND ADJUSTMENT:
1. Set thumbwheel to: 39.0 IIP.
2. Set mode selector to: THUMBWHEEL
3. Set vehicle factor to 0.00
4. Switches 1 and 2 board 8 and switch 1 board 7 to:
CAL (AWAY FROM BOARD).
5. Adjust pot 5 board 8 to. 50.0 mph ON DIGITAL SPEEDMETCIi.
6. Adjust pot 6 board 8 to: 40.5 mph ON DIGITAL POWER Hl/lLH
7. Adjust pot 1 board 3 to START HIGH RATE UNLOAD LIGHT
8. Adjust pot 6 board 8 to 37.5 HP ON DIGITAL POWER HE I'll'.
9. Adjust pot 1 board 2 to START HIGH RATE LOAD LIGHT.
DRIVER CUT-OFF ADJUSTMENT:
1. Set thumbwheel to: 00.0 HP
2. Switches 1 and 2 board 8 and switch 1 board 1 to:
RUN (TOWARD THE BOARD)
3. Positive lead of DVM to TEST POINT 1 board 8.
4. Adjust pot 1 board 8 to DVM R£ADING OF +0.060 +_ 005 VDC.
AUTOMOTIVE RESEARCH.,
-------
DATA FOFm HO. 301.2
Page 7 of 7
DYHAflOMLTt.R/RLf'C CALIBRATION CHECK LIST
M. DRIVER CUT-OUT ADJUSTMENT: (continued)
5. Adjust pot 2 board 3 CLOCKWISE UNTIL BOTH LOW AND
HIGH RATE UNLOAD LIGHT GO OUT.
6. REMOVE HYSTERESIS.
7. Adjust pot 1 board 8 to SAME READING AS RECORDED IN
E-ll - READING (INCLUDE + OR - SIGN).
FINAL SYSTEM PREPARATION:
1. Switches 1 and 2 board 8 and switch 1 board 7 to:
RUN (TOWARD THE BOARD).
2. Remove DVM leads.
3. Reinstall COVER ON CONTROL BOX.
4. Return LOGO ON INSTRUMENT BOX TO HORIZONTAL.
5. Turn WATER SUPPLY ON. (RECORD WATER PRESSURE)
SIGNATURE OF TECHNICIAN:
DATE TIME:
THESE DATA SIILLTS HAVE BEEN REVIEWED AND APPROVED BY EGSG-AR QUALITY CONTROL DEPARTMENT.
DATE:
I
VD
AUTOMOTIVE RESEARCH,•
- 3: c- —
-------
APPENDIX E
Audit Forms
1 ) Comments to be
2) Qua!ity Control
Check List
3) Qua Iity Control
4) Qua I ity Control
5) Qua I ity Control
6) Qua Iity Control
7) Quat ity Control
8) Qua!ity Control
9) Qua Iity Control
10) Qua Iity Control
11) Qua I ity Control
12) Qua I ity Control
13) Qua! ity Control
Economy)
14) Qua Iity Control
Economy)
15) Qua I ity Control
16) Qua Iity Control
17) Qua I ity Control
18) Qual ity Control
19) Qual ity Control
20) Quality Control
21) Qual ity Control
22) Quality Control
23) Qual ity Control
resolved
Audit of: Non-Evaporative Hot LA-4 Precondition
Audit of Precondition Trace
Audit of Dynamometer Warm-up Check List
Audit of Driver's FTP Check List
Audit of WB/DB Chart (EPA sequence)
Audit of FTP Driver's Trace
Audit of CO/C02 Instrument Traces
Audit of CO/C02 Instrument Traces (Bagged Idle Test)
Audit of HC/NOx Instrument Traces
Audit of NO Instrument Traces (50 Cruise Test)
Audit of HC/NOx Instrument Traces (Bagged Idle Test)
Audit of HC/NOx Instrument Traces (Highway Fuel
Audit of: CO/C02 Instrument Traces (Highway Fuel
Audit of
Audit of
Aud it of
Aud it of
Aud it of
Audit of
Audit of
Audit of
Audit of
NO Instrument Trace - Loaded Two Mode
NO Instrument Trace (4 Speed Idle Test)
CO/C02 Instrument Traces (4 Speed Idle Test)
CO/C02 Instrument Traces (50 Cruise Test)
Hexane Instrument Trace (50 Cruise Test)
Hexane Instrument Trace (4 Speed Idle Test)
CO/C02 Instrument Traces - Loaded Two Mode
Hexane Instrument Trace - Loaded Two Mode
CVS-CFV Test Data Sheet
-95-
-------
APPENDIX E
Audit Forms
(conti nued)
24) Quality Control Audit of
25) Quality Control Audit of
26) Qua Iity Control Audit of
27) Quality Control Audit of
28) Quality Control Audit of
29) Qua Iity Control Audit of
30) Data Packet Enclosure Test
Bagged Idle Test
50 Cruise Test Data Sheet
Highway Fuel Economy Data Sheet
4 Speed Idle Test (Data Sheet)
Loaded Two Mode (Data Sheet)
Computer Input and Output
-96-
-------
COMMENTS TO BE RESOLVED
S. Gearhart
B. Martinez
C. Jackal
B. GILMORE
L.HERNANDEZ
R. Martinez
C. Vantassel
R. Bellows
R. Schneberger
Comments
Comments
Resolved
QC
Review
OK
QUALITY CONTROL AUDIT OF:
NON-EVAPORATIVE HOT LA-4 PRECONDITION CHECK LIST
1) Test Number
2) Vehicle Number
3) Date
4 ) Dyno Code
5) Time
6) I.W. Correct?
7) I.H.P. Correct?
8) Correct Fuel Type Used?
9) Correct Fuel Tank
Capacity Entered?
10) Correct Amount of Fuel
Put In Tank?
11) Fuel Temp Less Than 86°F
12) Are Items 1-8
Completed Properly?
13) Correct Time Entered for
Last Dyno Use?
14) Are Items 9-16
Completed Properly?
15) Is Test Area Temp
Between 68°F and 86°F?
16) Are Items 17 - 20
Completed Properly?
17) Is IHP From Digital Dis-
play within + .2 of the
Value Determined During
Calibration?
18) Time at End of Precon-
dition (S.O.S.)
19) Items 21 - 28
Completed Properly?
20) Is Soak Area Temp
Between 68 F and 86 F?
21) Driver's Signature
Entered?
22) QC Signature Entered?
Yes No
Contact
Comments
Comments
Resolved
-------
QUALITY CONTROL AUDIT OF:
DYNAMOMETER WARM-UP CHECK LIST
QUALITY CONTROL AUDIT OF:
PRECONDITION TRACE
1) Vehicle Number
2) Test Number
3) Dyno Number
4) Date
5 ) Time
6) Time Less than 2 Hours
After Dyno Warm Up?
7) I.W. Correct?
8) I.H.P. Correct?
9) 50 MPH Entered
Adjacent to I.H.P.
10) 50 MPH Cal. Check
on Trace?
11) Driver's Signature
on Trace?
12) Trace OK?
13) Q.C. Signature Entered?
Yes
NO
Contact
Comments
Comments
Resolved
Part "A"
1) Date
2) Dyno Code
3) Test Number
4) Car Number
5) Start Time
6) Vehicle Make Entered?
7) Vehicle Model Entered?
8) I.H.P. Correct?
9) I.W. Correct?
10) Tech. Name Entered?
11) Items 1-14 Properly Completed?
Part "B"
12) Item 1 Completed?
13) Is applied Inertia Weight
correct?
14) Items 3-6 Completed Properly?
15) Stop Time from Item 6
16) Items 7-11 Completed Properly?
17) Driver's Signature Entered?
18) Date Entered?
19) Time Entered?
20) QC Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
CO
I
-------
DATA K)RI1 MO.
QUALITY CONTROL AUDIT OF
DRIVER'S FTP CHECK LIST
QUALITY CONTROL AUDIT OF
WB/DB CHART (EPA Sequence)
1) Date
2) Test Number
3} Vehicle Number
4) Dyno Number
5 ) Dn ver ' s Name Entered?
6) I W Correct?
7) I.H.P. Correct?
8) Time at Beginning of
12 Hour Soak (SOS)
9) Is Above Time Same as
End of Precondl tion ?
10) Time at Start of Test?
11) Is SOT 12-24 Hours
Later Than SOS?
12 ) Is Calculated Soak
Time Correct?
13) Time at Which Dyno
Was Last Used?
14) Are Items 1-7
Properly Completed?
IS) Were Vehicle Tires at
Approx. 45 PSI for Test?
16) Are Items fl~16 Properly
Completed ?
17) Do Sling and Strip Chart
Agree Within 1.8°F?
18) Are Items 17-26
Properly Completed?
19) Starting Conditions
Properly Noted?
20) Are Items 27-41
Properly Completed?
2 1 ) Driver ' s Signature
Entered?
22) QC Signature Entered7
Yes
No
Contact
Comments
Comments
Resolved
1) Vehicle Number
2) Test Number
3) Jate
4} Time Entered?
5) Driver's Name or
Initial's Entered?
6) SOP 1 Harked?
7) SOP 2 Marked?
8) Hot Soak Marked?
9) SOP 3 Marked?
10) EOT Marked?
11) DB Temp. 68°F to 86°F?
3 MIN. BAGGED IDLE
12) SOT Marked?
13) EOT Marked?
14) DB Temp 6C°F to 86°F?
50 CRUISE TEST
15) SOT Marked?
16) EOT Marked?
17) DB Temp. 68°F to 86°F->
HFET
18) SOT Marked?
19) EOT Marked?
20) DB Temp 68°F to 86°F?
4 SPEED IDLE
21) SOT Marked?
22) SOT Marked?
23) DB Temp 68°F to 86°F?
LOADED 2 MODE
24) SOT Marked?
25) EOT Marked?
26) DB Temp. 68°F to 86°F?
Q.C. SIGNATURE ENTERED?
Yes
No
Contact
Comments
Comments
Resolved
-------
QUALITY CONTROL AUDIT OF:
CO/C02 INSTRUMENT TRACES
QUALITY CONTROL AUDIT OF:
FTP DRIVER'S TRACE
1) Vehicle Number
2) Test Number
3) Dyno Number
4) Date
5 ) Time
6) Driver's signature on
Trace
7) I.W. Correct?
8) I.H.P. Correct?
9) 50 MPH Entered
Adjacent to I.H.P.?
10) 50 MPH Calibration at
Beginning of Trace?
11) Trace OK?
12) Driving Abnormalities
Noted?
13) 50 MPH Speed Check at
End of Trace?
14) Is I.H.P. Within +0.5
HP of Original Setting?
15) QC Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
1) Vehicle Number
2) Test Number
3) Date
4) Time Entered?
5) Signature Entered?
6) Chart Speed Entered?
7) CO Span OK? (Low Range)
8) CO2 Span OK? (Low Range)
9) Zero OK?
10) CO Span OK?
11) CO2 Span OK?
12) Zero OK?
13) CO Sample OK?
14) CO Range?
15) CO Deflection?
16) C02 Sample OK?
17) CO2 Range?
18) CO2 Deflection?
19) Ambient CO Trace OK?
20) Ambient CO Deflection?
21) Ambient CO OK?
22) Ambient CO2 Trace OK?
23) Ambient CO2 Deflection?
24) Zero OK?
25) CO Span OK?
26) CO? Span OK?
27) Zero OK?
28) Repeat Steps 9-27
29) All Operator Errors
Marked?
30) QC Signature Entered?
Phase 1
Yes No
1
Phase 2
Yes No
Phase 3
Yes No
Contact
Comments
Comments
Resolved
o
o
I
-------
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
CO/CO2 INSTRUMENT TRACES-
(Bagged Idle Test)
QUALITY CONTROL AUDIT OF
HC/NOx INSTRUMENT TRACES
1) Zero OK?
2) CO Span OK'
3) CO2 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range '
7) CO Deflection?
8) CO2 Sample OK'
9) CO2 Range?
10) CO2 Deflection?
11) Ambient CO OK?
12) Ambient CO Deflection?
13) Ambient CO2 OK?
14) Ambient CO2 Deflection;
15) Zero OK?
16) CO Span OK?
17) CO2 Span OK?
18) Zero OK'
19 (ALL OPERATOR ERRORS
MARKED'
20IQ.C. SIGNATURE ENTERED'
Yes
No
Contact
Comments
Comments
Resolved
1) Vehicle Number
2) Test Number
3) Date
4) Time Entered?
5) Signature Entered?
6) Chart Speed Entered?
7) HC Span OK (Low Range)?
8) NOx Span OK (Low Range)?
9) Zero OK?
10) HC Span OK?
11) NOX Span OK?
12) Zero OK?
13) HC Sample OK?
14) HC Range
15) HC Deflection
16) NOX Sample OK?
17) NOX Range
18) NOx Deflection
19) Ambient HC Trace OK?
20) Ambient HC Deflection
21) Ambient HC OK?
22) Ambient NOx Trace OK?
23) Ambient NO* Deflection
24) Zero OK?
25) HC Span OK?
26) NOX Span OK?
27) Zero OK?
28) Repeat Steps 9-27
29) All Operator
Errors Marked?
30) QC Signature Entered?
Phase 1
Yes No
Phase 2
Yes No
i
Phase 3
Yes No
1
I
Contact
1 Comments
Comments | Resolved
i_
I
o
I
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DATA FORM NO.
DATA FORM NO-
QUALITY CONTROL AUDIT OF:
NO INSTRUMENT TRACES:
(50 Cruise Test)
QUALITY CONTROL AUDIT OF:
HC/NOx INSTRUMENT TRACES
(Bagged Idle Test)
1) Zero?
2) NO Span OK?
3) Zero OK'
4) NO Sample OK?
5) NO Range
6) NO Deflection
7) Zero OK'
8) NO Span OK?
9) Zero OK'
10) All Operator Errors
Marked?
11) Q.C. Signature Entered?
30 Second
Sample
Contact
Comments
Comments
Resolved
1) Zero?
2) HC Span OK'
3) NOX Span OK?
4) Zero OK?
5) HC Sample OK?
6) HC Range?
7) HC Deflection?
8) NOX Sample OK?
9) NOx Range?
10) NOX Deflection?
11) Ambient HC OK?
12) Ambient HC Deflection?
13) Ambient NOx OK?
14) Ambient NOX Deflation?
15) Zero OK?
16) HC Span OK?
17) NOX Span OK?
18) Zero OK?
19) All Operator Errors
Marked?
20) Q.C. Signature Entered
Yes
No
Contact
Comments
Comments
Resolved
I
o
I
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DATA FORM NO.
DATA FORM »0.
QUALITY CONTROL AUDIT OF:
HC/NOX INSTRUMENT TRACES
(Highway Fuel Economy)
QUALITY CONTROL AUDIT OF
CO/C02 INSTRUMENT TRACES
(Highway Fuel Economy)
1) Zero?
2) HC Span OK?
3) NOX Span OK?
4 ) Zero OK?
5) HC Sample OK?
6) HC Range?
7) HC Deflection?
8) NOx Sample OK?
9) NOx Range?
10) NOX Deflection?
11) Ambient HC OK?
12) Ambient HC Deflection?
13) Ambient NOx OK?
14) Ambient HOX Defletion?
15) Zero OK?
16) HC Span OK?
17) NOX Span OK?
18) Zero OK'
19) All Operator Errors
Marked?
Yes
No
20) Q.C. Signature Entered?
Contact
Comments
Comments
Resolved
1) Zero OK?
2) CO Span OK?
3) CO2 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range ?
7) CO Deflection?
8) CO2 Sample OK?
91 CO2 Range?
10) C02 Deflection?
11) Ambient CO OK?
12) Ambient CO Deflection?
13) Ambient C02 OK?
14) Ambient C02 Deflection:
15) Zero OK?
16) CO Span OK?
17) CO2 Span OK?
18) Zero OK?
19) ALL OPERATOR ERRORS
HARKED?
201Q.C. SIGNATURE ENTERED?
Yes
NO
Contact
Comments
Comments
Resolved
I
o
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DATA FORM NO.
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
NO INSTRUMENT TRACE:
LOADED TWO MODE
QUALITY CONTROL AUDIT OF
NO INSTRUMENT TRACE-
(4 Speed Idle Test)
1) Zero OK?
2) NO Span OK?
3) Zero OK?.
4) NO Sample OK?
5) No Range
6) NOdEf lection
7) Zero OK?
8) NO Span OK?
9) Zero OK'
10) Repeat Steps
11) All Operator Errors
Marked?
12) Q.C. Signature Entered:
30
19.0
mph
APH
Basic
Trans.
Idle
In Neut
Contact
Comments
Comments
Resolved
D Zero'
2) NO Span OK?
3) Zero OK?
4) NO Sample OK'
5) NO Range
6) NO Deflection
7) Zero OK'
8) NO Span OK'
9) Zero OK?
10) Repeat Steps
11) All Operator Errors
Marked?
12) Q.c. Signature Entered?
Basic Idle
In Neutral
Yes
No
Idle At
2500 rpra
Yes
No
Basic Idle
In Neutral
Yes
No
Basic Idle
In Drive
Yes |No
Contacts/
Comments
Comments
Resolved
Does not apply with manual transmission
I
o
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DATA FOPJ-1 NO
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
CO/C02 INSTRUMENT TRACES:
(4 Speed Idle Test)
1) Zero?
2) CO Span OK?
3) C02 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range'
7) CO Deflection?
8) CO2 Sample OK?
9) C02 Range?
10) CO2 Deflection?
11) Zero OK?
12) CO Span OK?
13) C02 Span OK?
14) Zero OK?
15} Repeat Steps 6-10
16} All Operator Errors
Marked'
17) Q.C. Signature Entered?
Basic Idle
In Neutral
Yes
No
Idle At
2500 rpm
Yes No
Basic Idle
In Neutral
Yes No
Basic Idle
In Drive
Yes
No
Contacts/
Comments
Comments
Resolved
QUALITY CONTROL AUDIT OF-
CO/CO? INSTRUMENT TRACES.
(50 Cruise Test)
1) Zero?
2) CO Span OK?
3) C02 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range
7) CO Deflection
8) C02 Sample OK?
9) CO2 Range
10) CO2 Deflection
11) Zero OK?
12) CO Span OK?
13) CO2 Span OK?
14) Zero OK?
15) All Operator
Errors Marked?
16) Q.C. Signature Entered?
30 Second
Samp 1 e
Contact
Comments
Comments
Resolved
Does not apply with manual transmission.
o
U1
-------
QUALITY CONTROL AUDIT OF:
HEXANE INSTRUMENT TRACE:
(50 Cruise Test)
Datp Form No.
DATA FORM NO.
1) Zero OK?
2) Hexane Span OK?
3) Zero OK?
4) Hexane Sample OK?
5 ) Hexane Range (ppm)
6 ) Hexane Deflection
7) Zero OK?
8) Hexane Span OK?
9) Zero OK?
10) All Operator Errors
Marked?
11) Q.C. Signature Entered?
30 Second
Sample
Contact
Comments
Comments
Resolved
QUALITY CONTROL AUDIT OF:
HEXANE INSTRUMENT TRACE-
(4 Speed Idle Test)
1) Zero?
2) Hexane Span OK?
3) Zero OK^
4 ) Hexane Sample OK?
5 ) Hexane Ranqe CpP- m )
G) Hexane Deflection
7) Zero OK^
8) Hexane Span OK1
9) Zero OK^
10) Repeat Steps
11 ) All Operator Errors
Marked?
12) Q.C . Signature Entered?
Basic Idle
In Neutral
Yes
No
Idle At
2500 rpm
Yes
No
Basic Idle
In Neutral
Yes
No
Basic Idle
In Drive
Yes |No
Contacts/
Comments
Comments
Resolved
QUALITY CONTROL AUDIT OF
CO/C02 INSTRUMENT TRACES
LOADED TWO MODE
1) Zero OK?
2) CO Span OK?
3) C02 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range
7) CO Deflection
8) CO2 Sample OK?
9) C02 Range
10) CO2 Deflection
11) Zero OK?
12) CO Span OK?
13) C02 Spar, OK?
14) Zero OK?
15) Repeat Steps 1-14
11
marked?
17) Q.C. Signature entered'
30 mi
19.0 /
>h
\HP
Basic
Trans .
Idle
In Neut
Contact
Comments
Comments
Resolved
* Does not apply with manual transmission
I
o
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DATA FORM NO.
Page 1 of 2
QUALITY CONTROL AUDIT OF;
HEXANE INSTRUMENT TRACE:
LOADED TWO MODE
QUALITY CONTROL AUDIT OF:
CVS-CFV TEST DATA SHEET
1) Zero OK?
2) Hexane Span OK?
3) Zero OK?
4 ) Hexane Sample OK?
5) Hexane Range (PprW)
6) Hexane Deflection
7) Zero OK?
8) Hexane Span OK?
9) Zero OK?
10) Repeat Steps
11) All Operator Errors
Marked?
12) Q.C. Signature Entered?
30 mph
19.0 APH
Basic Idle
Trans. In Neut
Contact
Comments
Comments
Resolved
1) Date
2) Test Number
3) Vehicle Number
4) Odometer
5) I.W. Correct?
6) Thumb Wheel Correct?
7) Barometric Pressure Reason-
able (28.5 to 30 in. Hg. )
8) Barometric Temp. Reasonable?
9) Dry Bulb Temp. Correct?
10) Wet Bulb Temp. Correct?
11) Roll Revs. Entered
Correctly?
12)
13) VMIX 1 Reasonable?
14) VMIX 2 Reasonable?
15) VMIX 3 Reasonable?
16) Time at SOP 1?
17) Is SOP 1 Within Two
Hours of Harm Up?
18) Time at EOF 1?
19) EOF 1 = SOP 2?
20) SOP 2 - SOP 1 = +8.5 + 0.5
Minutes?
21) EOF 2 - SOP 2 = +14.5 + 0.5
Minutes ?
22) SOP 3 - EOF 2 = 10 +_ 1 Kin.?
23) EOF 3 - SOP 3 = +8.5 + 0.5
Minutes?
24) ET 1 = 505 + 4 sec. + Stall
Seconds?
25) ET 2 - 867 + 4 Seconds?
26) ET 3 = 505 + 4 Seconds
+ Stall?
Yes
No
Contact
Comments
Conments
Resolved
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Page 2 of 2
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
BAGGED IDLE TEST
QUALITY CONTROL AUDIT OF:
CVS- CFV TEST DATA SHEET (CONTINUED)
27) Ranges Correct for CO?
28) Ranges Correct for CO2?
29) Deflections for CO
Read Correctly?
30) Deflections for CO2
Read Correctly?
31) Concentrations Correct
for CO?
32) Concentrations Correct
for CO2?
33) Ranges Correct for HC?
34) Ranges Correct for NOx?
35) Deflections for HC
Read Correctly?
36) Deflections for NOX
Read Correctly?
37) Concentrations Correct
for HC?
38) Concentrations Correct
for NOx?
39) EOA Less Than or Equal
To EOF 1+20 Minutes?
40) EOA 2 Less Than or Equal
to EOF 2 + 2O Minutes?
41) EOA 3 Less Than or Equal
to EOP 3+20 Minutes?
42) Does Comment Imply Test
Is OK?
43) Operator's Signature
Entered?
44) QC Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
1) Transmission in proper gear?
2) Time at START OF TEST?
3) Time at END OF TEST?
4) Elapsed Time?
5) Is Total Test Time
3 mm. + (30 sec. )
{28.5 to 30 in.hg.)
7 ) Barometric Temp, reasonable?
8) (VIMX) reasonable?
9} Dry bulb correct?
10) Wet bulb correct?
11) Ranges correct for CO?
12) Ranges correct for CO2?
13) Deflections for CO read
correctly?
14) Deflections for CO2 read
correctly?
15) Concentrations correct
for CO?
16) Concentrations correct
for CO2?
17) Ranges correct for HC?
18) Ranges correct for NQx?
19) Deflections for HC read
correctly?
20) Deflections for NOX read
correctly?
21) Concentrations correct
for HC?
22) Concentrations correct
for NOx?
23) EOA Less Than 20 mm. From
End Of Sample?
°4) Does Comment Imply Test
is OK?
E25) Operator's Signature Entered?
26) Q.C. Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
-------
DATA FORM NO.
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
HIGHWAY FUEL ECONOMY DATA SHEET
QUALITY CONTROL AUDIT OF:
50 CRUISE TEST DATA SHEET
1) Test Start Time.
2) Test End Time:
3 ) End of Sample Equal
30 Seconds:
4 ) Barometric Press, reasonable
28.5 to 30 In.Hg.?
5) Barometric Temp, reasonable?
6) Dry Bulb Temp, correct?
7) Wet Bulb Temp, correct?
8) Ranges correct for CO?
9) Ranges correct for CO2?
10) Deflections for CO read
correctly?
11) Deflections for CO2 read
correctly?
, _ . .,
for CO?
13) Concentrations correct
for CO2?
14) Ranges correct for HC?
15) Ranges correct for NO ?
16) Deflections for HC read
correctly?
17) Deflections for NO read
correctly?
18) Concentrations correct
for HC?
19) Concentrations correct
for HO ?
20) Does comment imply test
is OK?
21) Operator's Signature Entered?
22) is R.P.M. reasonable?
23) Q.C. Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
1) TEST START TIME:
2) TEST END TIME:
3) Is ELAPSED TIME
12.45 mm. (^ .5 nun.)?
4) Barometric Press, reasonable
(28.5 to 30 in.hg. )?
5) Barometric Temp. reasonable?
6) Dry bulb Temp, correct?
7) Wet bulb Temp, correct?
8) VMIX reasonable?
11) Ranges correct for CC>2?
12) Deflections for CO read
correctly?
13) Deflections for COj read
correctly?
Idle t-
for CO?
15) Concentrations correct
for CO2?
_
18) Deflections for HC read
correctly?
19) Deflections for NOX read
correctly?
20) Concentrations correct
for HC?
21) Concentrations correct
for NOX?
22) EOA less than or equal
to 20 min.7
23) Does comment imply test
is OK?
24) Operator's signature
entered?
25) Q.C. signature entered?
Yes
No
Contact
Comments
Comments
Resolved
I
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DATA FORM NO.
QUALITY CONTROL AUDIT OF:
4 SPEED IDLE TEST (Data Sheet)
DATA FORM NO-
QUALITY CONTROL AUDIT OF:
LOADED TWO MODE (Data Sheet)
1) TEST START TIME:
2) TEST END TIME:
3) ELAPSED TIME.
. , .
(28.5 to 30 in.hg.)?
5) Dry bulb Temp> correct?
6) Wet Bulb Temp, correct?
8) Ranges correct for CO2?
9) Deflections for CO read
correctly?
10) Deflections for CO2 read
correctly?
. ,
for CO?
for COj?
13) Ranges correct for HC?
14) Ranges correct for NO ?
15) Deflections for HC read
correctly?
16) Deflections for NO read
correctly?
17) Concentrations correct
for HC?
181 Concentrations correct
for NO ?
19) Is R.P.M. reasonable?
20) Does comment imply test
is OK?
21) Operator's Signature entered?
22) Q.C . Signature entered?
Yes
No
Contact
Comments
Comments
Resolved
1) TEST START TIME:
2) TEST END TIME:
3) ELAPSED TIME:
4 ) Barometric Press . reasonabl e
28.5 to 30 in.hg.?
5) Barometric Temp, reasonable?
6) Dry bulb Temp, correct?
7) Wet bulb Temp, correct?
8) Is the I.W. 1000 Ibs.?
9) Is the I.H.P. correct?
10) Ranges correct for CO?
12) Deflections for CO read
correctly?
13) Deflections for CO2 read
correctly?
14) Concentrations correct
for CO?
15) Concentrations correct
for C02?
17) Ranges correct for NO*?
18) Deflections for HC read
correctly?
19) Deflections for NO* read
correctly?
20) Concentrations correct
for HC?
21 ) Concentrations correct
for NOx?
22) Does comment imply test
is OK?
23 ) Operator * s Signature
entered?
24) Is R.P.M. reasonable?
25) Q.C. Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
I
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DATA PACKET ENCLOSURE LIST
EPA Contract No. 68-03-302^
QUALITY CONTROL AUDIT OF:
COMPUTER INPUT AND OUTPUT
To be submitted with each Data Packet.
I. Emissions Testing Data
1) Date
2) Vehicle Number
3) Test Number
Correct 1 y
5) If 1977 Year Mode ^Were
STD Rol 1 Revs. Used
6) BO Entered Correctly?
7) BT Entered Correctly?
8) DB Temp Correct?
3) WB Temp Correct?
10) VMIX Correct?
11)
12) Meter Reading Correct?
Cor rec t?
IM QC Signature Entered?
Yes
No
Contac
Comments
Comments
Resolved
Precondition Check List
Precondition Trace
Test Drivers Check List Pages 1 through 7
FTP Trace
Vehicle Refueling Records
Bench Operator Data Forms Pages 1 through 7
WB/DB Trace
Soak Area Trace
Analytical Traces
CVS Print-Out
Quality Audit Work Sheets
Vehicle Driveability Report
Highway Fuel Economy Print-Out
Bagged Idle Print-Out
Test Validity Statement
II. Procurement Data
Telephone Survey (302^.2)
Incoming Inspection Forin. (302^.8)
Test Agreement (302^.1)
Test Agreement Addendum (302^.3)
Standard Vehicle Loan Agreement (302^.M
Savings Bond Information Sheet (302'<.6)
Vehicle Owner Questionnaire Data Sheet
Supplemental Owners Survey
Leaner Vehicle Log (30214.7)
Mechanics Inspection Form (302<<.9)
Vehicle Maintenance Log (302<).10)
EPA Data Pack
Vehicle Information Sheet (302^.12)
Post Test Inspection Form (302^.11)
Vehicle Release and Savings Bond Receipt (302').5)
Procurement Check List (302^.13)
III. Supplied To Owner
Fuel Economy Kit
Contractor Information Filled In
Vehicle Fuel Fill In Information Recorded
letter Of Appreciation
EPA Follow-up Letter »nd Envelope
Contractor Portion Fill In
Savings Bond
Vehicle Maintenance Log (302't.lO)
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
A Study Of Emissions From Light Duty Vehicles In
San Antonio, Texas
5. REPORT DATE
September 1981
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Mark Dalen, Maurice Forshee, L. Kevin Kott
8. PERFORMING ORGANIZATION REPORT NO.
EPA 460/3-81-019
9. PERFORMING ORGANIZATION NAME AND ADDRESS
EG&G Automotive Research, Inc.
5404 Bandera Road
San Antonio, Texas 78238
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-03-3024
12. SPONSORING AGENCY NAME AND ADDRESS
Environmental Protection Agency
2565 Plymouth Road
Ann Arbor, Michigan 48015
13. TYPE OF REPORT AND PERIOD COVERED
Final: 9/29/80 to 7/29/81
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
6. ABSTRACT —
Three hundred 1978 through 1981 in-use light duty vehicles were obtained from
the public, in the San Antonio Metropolitan Area. These vehicles were tested
as received, for exhaust emissions utilizing the Federal Test Procedure, the
Highway Fuel Economy Test, and four short mode tests. All vehicles were subjected
to a thorough emissions control component inspection. Fifty vehicles which failed
to meet applicable standards, received maintenance and a retest.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Emissions-Exhaust Gases
Gas Analysis
Air Pollution
'EMEN1
19. SECURITY CLASS (This Report;
Unclassified
21. NO. OF PAGES
114
20. SECURITY CLASS (This page I
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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