EPA 460/3-82-009
A Study of Emissions from Light Duty
Vehicles in San Antonio, Texas
EPA Contract No. 68-03-3024, Year 2
prepared by:
Maurice Forshee
Mark Dalen
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
Oohn Shelton
EPA Project Officer
DATE: Duly 30, 1982
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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, contrac-
tors, grantees and non-profit organizations currently doing
business with the Government from the EPA Library,
2565 Plymouth Road, Ann Arbor, Michigan 48105. Copies are
also available 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, Year 2. The con-
tents of this report are reproduced herein as 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 1979 through 1982 in-use light duty vehicles
were obtained from the public, in the San Antonio metropoli-
tan area. These vehicles were tested, as received, for ex-
haust 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 com-
ponent 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-, Year 2
PAGE
ABSTRACT i
TABLE OF CONTENTS ii
LIST OF FIGURES AND TABLES iv
SECTION I - BACKGROUND 1
SECTION II - INTRODUCTION 3
SECTION III - PROCUREMENT OF VEHICLES 5
A - PROCUREMENT METHODS 5
SECTION IV - VEHICLE PREPARATION, INSPECTION,
AND MAINTENANCE 16
A - INITIAL MECHANICAL INSPECTION 16
B - POST TEST INSPECTION 16
C - RESTORATIVE MAINTENANCES 17
SECTION V - VEHICLE EMISSION TESTING 29
A - TEST LABORATORY 29
B - TEST PROCEDURES 31
C - CALIBRATIONS 33
SECTION VI - TEST RESULTS 37
SECTION VII - DATA HANDLING 38
i i
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TABLE OF CONTENTS
(Continued)
PAGE
- EMISSIONS TEST AUDITING AND VALIDATION . . 38
- TEST DATA TRANSMITTAL 38
- CALIBRATION TRANSMITTAL 38
APPENDIX A - SAMPLE PROCUREMENT PACKET 39
APPENDIX B - EPA VEHICLE DATA PACKET 52
APPENDIX C - LAB QUALIFICATION WORKSHEETS 64
APPENDIX D - CALIBRATION FORMS 77
APPENDIX E - AUDIT FORMS 93
i i
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LIST OF TABLES AND FIGURES
PAGE
TABLE III-1 ORIGINAL VEHICLE REQUIREMENTS ....... 7
TABLE III-2 VEHICLES OBTAINED BY ALTERNATE
PROCUREMENT METHODS ............ 13
FIGURE III-1 VEHICLE PROCUREMENT FLOW CHART
1981 MODEL YEAR EXAMPLE .......... U
FIGURE III-2 VEHICLE SUBSTITUTIONS ........... 15
TABLE IV-1 RESTORATIVE MAINTENANCES ......... 19
FIGURE V-1 EG&G AUTOMOTIVE RESEARCH, INC.
CHASSIS DYNAMOMETER TESTING LABORATORY. . . 30
i v
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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 administer proqrams designed to
quantify and reduce the pollution of the nations's resources
Authority in part for this objective is assigned to EPA's
Emission Control Technology Division (ECTD). ECTD is re-
sponsible 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. Subsequent Programs were conductd in FY's 1972, 1973,
197if, 1975, 1977, 1979, and 1980. The programs conducted in
FY's 1975, 1977 and 1980 were extended to include the follo-
wing years. These EF Programs were specifically designed to
obtain exhaust emissions data from in-use vehicles operated
in a wide range of topographical and climatological con-
ditions. 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 percentages by
manufacturer for each model year, changes in emissions stan-
dards, advancements in emission control technoloqy and re-
visions in Federal Testing Procedures.
In the recent EF Programs special short mode testing pro-
cedures 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 main-
tenance programs.
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The option year 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 metro-
politan area.
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SECTION II
INTRODUCTION
In April of 1981, Contract Modification Number 2 to EPA
Contract Number 68-03-3024- was issued. This modification
added a second group of 300 vehicles for procurement and
testing from the San Antonio, Texas metropolitan area.
Model years 1979 through 1982 vehicles were reguired.
Vehicles were procured in a random fashion from vehicle
registration listings through February of 1982. In accord-
ance with the contract terms, a limited number of 1982 vehi-
cles were obtained through local car rental agencies during
the period. A total of 249 vehicles had been procured using
these methods. In March 1982, Contract Modification Number
b was executed. This Modification reguired that the remain-
ing 51 vehicles be 1980 and 1981 models meeting certain high
mileage reguirements. Section III, Procurement of Vehicles
explains how these vehicles were located and procured.
At the reguest of EPA, two vehicles from the previous year
project (FY 1980 Emissions Factor Study) were re-procured
and tested and inspection and maintenance procedures were
performed. For the purposes of this report, these two
vehicles are included in with the 24-9 vehicles tested prior
to the execution of amendment four. Only light duty,
gasoline powered vehicles were included in the program with
a contract period from Ouly 1981 through Duly 1982.
This program is detailed in Section III through Section VII
o Section III contains a brief narrative of the
procurement methods utilized.
o Section IV outlines the methods and procedures used
in vehicle preparation, inspection and maintenance.
o Section V describes the emission testing equipment
that was used. It also explains calibration proced-
ures. 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.
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o Section VII explains the process that was used in
auditing and transmitting test results and equipment
calibration data.
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SECTION III
PROCUREMENT OF VEHICLES
A.
PROCUREMENT METHODS
The EPA supplied a list of three hundred vehicles to be
procured and tested. This list is found in Table III-1,
Substitutions were made by the EPA for some models that
unavailable. Table III-2 lists these substitutions and
reasons why they were made.
Total vehicle procurement requirements were as follows:
were
the
MODEL YEAR
NUMBER OF VEHICLES
1979
1980
1981
1982
*1980
*1981
25
25
100
99
34
17
*High mileage vehicles
TOTAL
300
Each of the model year lists specified the vehicle number,
number of units required, make, model, and in some cases,
engine size. 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 metroplitan area. All lists were randomized prior
to printing by the Wilson Publishing Company.
Procurement mailings were then made from these randomized
lists. The mailing consisted of an EPA supplied letter
briefly describing the project, a
questions and answers and a reply
response cards were followed with
Appendix A contains copies of all
list of normally asked
card. Receipt of positive
telephone interviews.
of the forms and documents
that were utilized in the procurement process.
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Each of the procurement mailings was 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. Figure III-1 is
a Vehicle Procurement Flow Chart which shows the procurement
method that was utilized prior to March 1982. This flow
chart reflects the 1982 year model requirements for
percentage of high mileages, number of rental vehicles,
etc. The same sequence of events applies for all year
models.
Amendment Number 4 specified 1980 and 1981 high mileage
vehicles. High mileage was defined as 40,000 miles for 1980
vehicles and 25,000 miles for 1981 vehicles. Trucks and
General Motors X body vehicles were not required. Other
than these exclusions, there were no specific make/model
requirements for the high mileage units.
According to the amendment terms, there were no limitations
on procurement methods, geographical location or number of
rental vehicles. In order to meet the requirements for the
high mileage vehicles, procurement methods were modified.
These methods included newspaper advertisements,(Appendix A)
posting of notices on bulletin board in high traffic areas,
making employees and their family and friends aware of the
program and contacting individuals and companies that used
passenger cars in their business.
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Veh. No,
ORIGINAL VEHICLE REQUIREMENTS
FV '81 EMISSION FACTORS PROGRAM
SECOND YEAR OPTION
1982 Model Years
Quantity
Make
Model
401-407
408-412
413-417
418-423
424-428
429-434
435-439
440-441
442
443-445
4.46-4.4.7
448-452
453-454
455-456
457-458
459-460
461-463
464-465
466-471
472-474
475-478
479-480
481-483
484-485
486
487-490
491-493
494-496
497-499
500-503
504-506
507-509
510-512
513-514
515-517
518-520
521-522
7
5
5
6
5
6
5
2
1
3
2
5
2
2
2
2
3
2
6
3
4
2
3
2
1
4
3
3
3
4
3
3
3
2
3
3
2
CHEV
CHEV
CHEV
CHEV
CHEV
OLDS
OLDS
OLDS
OLDS
OLDS
BUICK
BUICK
BUICK
PONTIAC
PONTIAC
PONTIAC
PONTIAC
PONTIAC
FORD
FORD
FORD
FORD
MERCURY
MERCURY
MERCURY
PLYMOUTH
PLYMOUTH
DODGE
DODGE
VW of A
AMC
TOYOTA
TOYOTA
TOYOTA
DATSUN
DATSUN
DATSUN
Chevet te
Citation
Camaro /Mali bu
Impala /Capri ce /Monte Carlo
Cavalier
Cutlass Supreme
88/98/Toronado
Omega
Ciera
Skylark
Le Sabre/Electra
Regal /Century
Skyhawk 3
6000
Phoeni x
Bonneville/Grand Pr i x /Fi rebi r d
3-2000
T-1000
Escort
Fairmont/Thunderbird/LTD
Mustang /Granada
EXP
Lynx
LN-7
Capri /Cougar /Monarch
Reliant
Hori zon
Omni
Ari es
Rabbit
Concord
Corolla
Tercel
Celica
210
310
Nissan St anza
TABLE III-1
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1982 Model Year (Cont'd)
Veh. No,
Quantity
Make
Model
523
528-530
531-533
534-535
536-540
541-545
546-547
548
549-550
1
3
3
2
5
5
2
1
2
DATSUN
HONDA
MAZDA
MITSUBUSHI
CHEV/GMC
FORD
DODGE
DATSUN
TOYOTA
200 SX/280SX/280Z
Civic Accord
GLC/626/RX-7
Colt/Champ/Challen
L.D. Truck
L.D. Truck
L.D. Truck
L.D. Truck
L.D. Truck
ger
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ORIGINAL VEHICLE REQUIREMENTS
FY '81 EMISSION FACTORS PROGRAM
SECOND YEAR OPTION
Veh. No,
Quantity
Make
Model
551-557
556-561
562-564
562-564
565
566-567
569-573
574-575
576-577
578-580
581-584
585
586-587
588
589-590
591
592
593
594-597
598-600
601-603
604
605-606
607
608
609-610
611-612
613-614
615-616
617-618
619-620
621-622
623-624
625
626-627
628-629
5
6
3
3
1
2
5
2
2
3
4
1
2
1
2
1
1
1
4
3
3
1
2
1
1
2
2
2
2
2
2
2
2
1
2
2
CHEV
CHEV
CHEV
CHEV
CHEV
CHEV
OLDS
OLDS
OLDS
BUICK
BUICK
BUICK
PONTIAC
PONTIAC
PONTIAC
PONTIAC
PONTIAC
CADILLAC
FORD
FORD
FORD
FORO
MERCURY
MERCURY
MERCURY
PLYMOUTH
PLYMOUTH
DODGE
DODGE
VW of A
AMC
TOYOTA
TOYOTA
TOYOTA
DATSUN
DATSUN
Chevett e
Citation-Three 4-Cyl, Three V-6
Malibu-Two V-6, One V-8
Camaro
Impala /Capri ce
Monte Carlo
Cut lass /Supreme-Th ree V-6, Two V-8
88/98
Omega-One 4-Cyl, One V-6
Skylark-Two 4-Cyl, One V-6
Century/Regal-Three V-6, One V-8
Le Sabre/El ectra
Phoenix-One 4-Cyl, One V-6
Firebird
Grand Prix
Catalina/Bonneville
Catalina/Bonnevi He
de Ville/Fleetwood
Escort
Fai rmon t
Mustang
Thunderbi rd
Lynx
Zephyr
Capri
Reliant
Hor i zon
Ar ies
Omni
Rabbit
Concord /Spir i t
Corolla
Tercel
Ce lica
210
310
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1981 Model Year (con'td)
Veh. No.
Quantity
Make
Model
630
631
632-633
634-635
636-637
638
639
640
641-643
644-646
647-648
649
650
1
1
2
2
2
1
1
1
3
3
2
1
1
DATSUN
DATSUN
HONDA
HONDA
MAZDA
MITSUBISHI
SUBARU
VW of A
CHEV/GMC
FORD
DODGE
DATSUN
TOYOTA
510
200SX/280Z
Civic
Accord
GLC/626/RX-7
Co It /Ar row/Champ
Any model except "BRAT"
Dasher
P.U.
P.U.
P.U.
P.U.
P.U.
10
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ORIGINAL VEHICLE REQUIREMENTS
FY '81 EMISSION FACTORS PROGRAM
SECOND YEAR OPTION
1980 Model Year
Veh. No. Quantity Make Model
651-652
653-654
655
656-657
658
659
660
661-662
663-664
665-666
667
668
669
670
671
672
673
674
675
2
2
1
2
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
CHEV
CHEV
CHEV
OLDS
OLDS
BUICK
BUICK
FORD
FORD
PLY/DODGE
VW of A
AMC
TOYOTA
TOYOTA
DATSUN
HONDA
HONDA
CHEV/GMC
FORD
Chevet t e
Citation-One 4-Cyl, One V-6
Malibu
Cutlass/Supreme-One V-6, One V-8
88/98
Skyl ark
Ce nt ur y /Reqal
Mustang
Fai rmont
H o r i z o n / 0 m n i
Rabbit
Concord /Spi r i t
Corolla
Tercel
210
Civic
Accord
P.U.
P.U.
11
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ORIGINAL VEHICLE REQUIREMENTS
FY '81 EMISSIONS FACTORS PROGRAM
SECOND YEAR OPTION
1979 Model Year
Veh. No. Quantity Make Model
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
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
OLDS
OLDS
BUICK
PONTIAC
PONTIAC
FORD
FORD
FORD
MERCURY
DODGE
PLYMOUTH
DATSUN
DATSUN
TOYOTA
TOYOTA
VW of A
HONDA
MAZDA
CHEV
FORD
DODGE
Chevet te
Mo nza
Malibu
Camaro
Cutlass/ Supreme
88/98
Century/Regal
Sunbi rd /Phoeni x
Firebird/Grand Prix
Mustang
Fai rmont
LTD/Thunderbird
Monarch
Omni
Horizon
B210
510/280Z
Corona/Corol la
Celica/Cressida
Rabbit
Ci vie /Accord
GLC/626 RX7
P.U.
P.U.
P.U.
12
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VEHICLES OBTAINED BY ALTERNATE
PROCUREMENT METHODS
p- Veh. No. Year Make/Model
Alternate Method Reason
582
401
474
481
487
488
504
516
1981
1982
1982
1982
1982
1982
1982
1982
Buick/Ce ntury
Chev /Che vette
Ford /Fai rmont
Mercury /Lynx
Plymouth/Reliant
Plymouth/Reliant
AMC/Concord
Datsun/210
Rental
Rental
Rental
Rental
Rental
Rental
Rental
Rental
EPA Project Officer re
quested reprocurement
of this vehicle.
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 III-2
13
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WCHIClt PROCUMMIMT flow CMAUT
t
Obtain Vehicle
list fro- Local
Car Rental
Agencies (1982
Models Only)
1)82 MOOCL r(AR tIAMPLE
Obtain Local Vehicle
Registration List
*
{
Screen 1979/80
Model rear
Vehicles
* •' ,-,
(Cent inuc Sim lar
to 1962 M.r. Strategy)
Climlante res
Candi date
Screen Candidate
Vehicle
J t L
Screen 1962 Model
Vear Vehicles 1
*
Is Vehicle Odometer
> 4,000 mi les)7
4 NO
Is the • of 1982
M.r. Hon-"Kigh
Mi leage" Vehicles
Selected to Date
> 1207
4 HO
Mo
*es
1 1 immate 1 *
1 US
Is Candidate
Vehicle Source
a Lease or
Rental Agtncy7
4 r,s
Is the • of 1982
M r. Vehicles
Selected from
This Source > )0'
4 MO
Vertfy Hake. Model.
Type and Model Year
*
Is ' of Vehicles
Which are not an
(•act Match on
All Parameters
4 No
Is I of Vehic les
Which are not an
[•act Match on
Make, Model and
Cngine Displace-
ment > IJ7
4 MO
Is loan/lncen| i»e
Agreeable or lease
Obtainable/Accept-
able to Owner7
4 res
Schedule Vehic Ic for
Drop at lab and
Testing
*
It » Of 1)82 M 1
Vehicles Selected/
Tested > 'SO?
4 res
Vehicle Procure-
ment Complete for
1 J87 M r veh.c les
\
Randomise list
1 f not tfone by
List Supplier
*
Mai 1 Procure-
ment Packets
j
Place Phone
Calls for Posi-
t Ive Responses
4
was Vehicle
Yes Owner Contact
Wi thin Two
Phone Cal Is?
ed ""^ 1 1 ."Injte
*
'• Screen 1981
Model rear
Vehicles
(Co«t inue Slmi lar
1982 M.r. Strategy)
res Eliminate
Candidate
He t 1 iminate
Candidate
Ho
i I.
Figure 1II-1
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ORIGINAL VEHICLE REQUIREMENTS
VEHICLE SUBSTITUTIONS
ORIGINAL REQUIREMENTS
SUBSTITUTIONS
Veh.
No.
582
614
617
618
640
No. of
Veh. Year Make/Model Engine
1 1981 Buick/Century V 6
1 1981 Dodqe/Aries Any
1 1981 VW of A Any/
Gasoline
1 1981 VW of A Any/
Gasoline
1 1981 VW of A/Dasher Any/
Gasoline
Veh. No. of
No. Veh. Year Make /Model Engine Reason
582 1 1981 Buick/Century V 6 EPA Project Officer reguested
reprocurement of this vehicle.
614 1 1981 Dodge/Aries Any EPA Project Officer reguested
reprocurement of this vehicle.
617 1 1981 VW/Pickup Any All Registration lists of 1981
VW Rabbits were used. Only
positive responses received were
from ineligible vehicles
(diesel). Substitution approved
by Project Officer.
618 1 1981 VW/Pickup Any All registration lists of 1981
VW Rabbits were used. Only
positive responses received were
from ineligible vehicles
(diesel). Substitution approved
by Project Officer.
640 1 1981 VW/Van Any Registration list supplier and
local VW dealers stated that the
1981 Dasher is available with
diesel engines only. Substitute
was approved by Project Officer.
FIGURE III-2
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SECTION IV
VEHICLE, PREPARATION, INSPECTION AND MAINTENANCE
A. INITIAL MECHANICAL INSPECTION
After each vehicle owner was screened by telephone, the
owner was asked to deliver the vehicle to the laboratory for
testing. On arrival, the vehicle was inspected 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 the type 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
inspection information. The methods for inspection and
the specifications for operating parameters on each system
were obtained from Manufacturer's shop manuals or Chilton'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 inspection.
Representatives from General Motors and the Chyrsler Cor-
poration actively participated in the inspection and
16
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maintenance portions of this pro.ject. The EPA Project
Officer allowed these representatives to receive copies of
emissions test data and observe and/or assist in the inspec
tion and maintenance procedures for their companies
respective vehicles. On numerous occasions this
participation was beneficial in locating parts, and
supplying technical information for emission control
systems.
C. RESTORATIVE MAINTENANCE
All three hundred vehicles were tested as received.
The test seguence consisted of the FTP emissions test,
Highway Fuel Economy Test and a four mode short cycle
test. After the test seguence, each vehicle received
an extensive inspection of emission-related components
and systems.
The first fifty vehicles that failed the exhaust
emissions test received a restorative maintenance
procedure, followed by an additional test seguence.
Pass/Fail criteria for the various model years were
established by the EPA as follows:
Emission results which were within two times the
standard for that model year were considered a pass
with the following exception: if during the inspec-
tion procedure a problem was found that could account
for excessive emissions, a maintenance procedure and
retest was recommended. Maintenance procedures and
retests were authorized by the EPA in some instances
when the results did not exceed the two times limit.
In order to simplify the complexity of 1982 standards
(due to the various waivers that were granted), the
following standards are used as a guideline for all
1982 vehicles:
HC gm/mi CO gm/mi *NOxgm/mi
.^1 7.0 1.0
A 2.0 NOX gm/mi standard applied to all 1982 American
Motors Corporation vehicles.
17
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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's recommended maintenance intervals. Each item
listed for the last interval was inspected and a determina-
tion was made as to whether or not the required maintenance
had been performed. Any part replacements, adjustments or
checks reguired at the last interval that had not been
performed were accomplished during the restorative main-
tenances .
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 as the contract excluded these repairs. 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 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.
18
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f 5 f I I I f
I 1
Vehicle
Number
1*1
203
15*
181
213
169
Ye»r
1981
1981
1981
1981
1981
190*
Odometer
7,S5«i
6.556
7,937
'7,059
2,828
«5,925
Make /Model
Chev/Chevette
Ford/Mustang
Chev/Chevette
Bulck/Hegal
Dodge/Aires
Olds/Cutlass
As Rec'd Test Resul tl
Test
Type
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Fal led Standards)
HC gm/ml .538
CO gm/ml 6.66
NOX gm/ml .617
Hexane ppm 215-5
CO* 1.67
HC gm/ml 3-76
CO gm/ml 83.14
Hexane ppm 1)06.9
cot 9.51
HC gm/ml 1.02
CO gm/ml 10.6
HC gm/ml 1 ,03
CO gm/ml 20.0
HC gm/ml .775
CO gm/ml 22.5
HC gm/ml .581
CO gm/ml 8.5
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
172
299
182
289
Year
1981
1979
1981
1979
Odometer
H.175
••6,125
9,173
25,182
Make/*ode1
Olds/Cutlass
Ford/Pickup
lutck/Century
)odge/0mnl
At Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Emissions Results
(Failed Standards)
NOx gm/ml 3.35
HC gm/ml
-------
* f f
Vehicle
Number
252
282
291
276
300
Year
1980
1979
1979
1979
1979
f *
Odometer
J2,»07
*l.59*
22,516
*5.966
31,230
f if -' *
Make/Model
Chev/Chevette
Bulck/Regal
Datsun/6210
Chev/Chevette
Dodge/Pickup
A*
Test
Type
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
CVS-CH
' * r " f 1 f * » i f t t
RESTO"RAT(VE MAINTENANCE'S
R»e'd T»«t R»«iil|«
Emissions Results
(fal led Standards)
NOx gm/ml l|.9t
- BOX
- 99. 7X
- 68X
- 27X
- 28X
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
267
690
67*
617
661
536
685
Te«r
1980
1979
1980
1981
1980
1982
1979
Odometer
12,M>9
**,750
29,133
6.1*5
26,6«i9
9.732
37.671
Hake/Model
W/Plckup
Plymouth/Horizon
Chev/Plckup
VW/Plckup
Ford/Mustang
Chev/Plckup
Ford/Mustang
As Rec'd Test Results
Test
Type
Idle
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
Idle
Idle
CVS-CH
Emissions Results
(Failed Standards)
CO* 2.60
HC gm/ml 2.75
CO gm/ml 45.61
Hexane ppm 253. 3
CO* 2.36
HC gm/ml 3.96
CO gm/ml 71.0
NOx gm/ml 1) . 1 1
Hexane ppm 321 .7
CO* 2.1*5
NOx gm/ml 3-28
HC gm/ml 1.70
CO gm/ml 29-0
Hexane ppm 256.8
CO* 7- "12
Hexane ppm 296.5
HC gm/ml 3- '5
Corrective Actions
Spark plugs were worn and fouled.
Idle mixture set rich (special tool
Is required to set mixture). Re-
placed spark plugs and reset Idle
mixture to manufacturer's specifi-
cations.
Idle limiting device was removed and
Idle mixture had been reset. Screws
were loose In carburetor causing fuel
leakage. Spark plugs were fouled and
not properly torqued.
Replaced spark plugs. Tightened car-
buretor screws and reset Idle mixture
to manufacturer's specifications.
Idle limiting device had been removed
and Idle mixture reset. Spark plugs
were fouled, air filter dirty and the
EGR valve was Inoperative.
Replaced spark plugs, air filter and
EGR valve. Reset Idle mixture to
manufacturer's specifications.
EGR vacuum supply line was damaged
and leaking. Replaced EGR vacuum
s upp 1 y 1 1 ne .
Idle limiting device had been removed
and Idle mixture reset. Spark plugs
were fouled, one spark plugs wire was
In poor condition and the air and
fuel filters were dirty.
Replaced spark plugs, one plug wire,
air filter and fuel filter. Reset
Idle mixture to manufacturer's
spec) f 1 cations .
Spark plugs were fouled and air
f 1 Iter was dirty.
Replaced spark plugs and air filter.
Idle limiting device had been removed
and idle mixture reset. Spark plugs
fouled.
Replaced spark plugs. Reset Idle
mixture to manufacturer's specifi-
c.it ions .
After Malnt. Test Results
Test
Type
Idle
CVS-CH
Idle
,
CVS-CH
Idle
CVS-CH
CVS-CH
Idle
Idle
CVS-CH
Emissions Results
COt .832
HC gm/ml 1.55
CO gm/ml 3>.6
Hexane ppm 11.3
COX .006
HC gm/ml 2.85
CO gm/ml *9.8
NOx gm/ml 1.M
Hexane ppm 20.*
cot .007
NOx gm/ml 2.*5
HC gm/ml .*70
CO gm/ml 11 .8
Hexane ppm 19.2
CO* .00
-------
* * f 1 f
RESTORATIVE MAINTENANCES
r i f i
Vehicle
Number
6*0
659
»08
"3
lilt
»57
Tear
1981
1980
1981
1980
1980
1980
Odopeter
6,766
33,«i66
25,»39
*0,*liO
••5.730
*»,322
Hake/.lodel
W/Vanagon
Bui ck/Sky lark
Chev/Nonte Carlo
Ford/Fairmont
Pontlac/Sunblrd
Plymouth/Horizon
As
Test
Type
Idle
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
Rec'd Test Results
Emissions Results
(Tal led Standards)
CO* 1.85
NOx gm/ml 6.01
HC gm/ml 2
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
*57
(continue
•ill
M6
»55
*15
««56
Year
J)
1980
1981
1980
1981
1980
Odometer
27>36
*2,995
70,397
50,33*
*0.650
Make/Model
PI ymouth/Horl ion
Mercury/Lynx
Plymouth/Horizon
Subaru/GL
Oatsun/210
As Rec'd Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
Idle
Emissions Results
(Tal led Standards)
HC gm/ml 1 .33
CO gm/ml 0.23
NOx gm/ml 1.57
HC gm/ml 13-9
CO gm/ml 16.8
NOx gm/ml 2.1(0
Hexane ppm 3^.5
HC gm/ml 2.63
CO gm/ml 71.2
CO* 2.23
Hexane pom 235-5
CO* 1.1i2
Corrective Actions
Problem was diagnosed as malfunction-
ing catalyst and/or carburetor
problem In the off Idle circuit.
Curb Idle speed was high. Spark plugs
were worn and Incorrect part number
for this engine. The air filter was
dirty.
Replaced spark plugs and air filter.
Reset curb Idle speed to manufac-
turer's specifications.
Basic timing was advanced 5°, curb
Idle speed high, spark plugs worn.
air filter dirty and the EGR vacuum
supply line was disconnected.
Replaced spark plugs and air filter;
connected EGR vacuum supply line. Re-
set basic timing and curb Idle speed
to manufacturer's specifications.
Air filter dirty, one spark plug Mire
was melted, another spark plug wire
was disconnected, curb Idle speed was
low and the Idle mixture was set rich
although the limiting device was In
place.
Replaced air filter and one spark
plug wire. Connected spark plug wire
and reset curb Idle speed and Idle
mixture to manufacturer's specifi-
cations.
Plug connector to the duty cycle
control solenoid valves was discon-
nected and the alternator belt was
loose.
Reconnected duty cycle control sole-
noid valves and tightened alternator
belt.
Idle mixture limiting device had been
removed and Idle mixture was reset.
The air cleaner was dirty and wrong
part number spark plugs were In the
engine .
Replaced air cleaner and spark plugs.
Reset idle mixture to manufacturer's
specl f ical Ions .
After Malnt. Test Results
Test
Type
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
Idle
Idle
Emissions Results
HC gm/ml .635
5. "17
NOx gm/ml .477
HC gm/ml .8*1
CO gm/ml 9.85
NOx gm/ml 1.53
Hexane ppm 11.2
HC gm/ml .191
CO gm/ml 3-H
C0» .009
Hexane ppm 3' • '
CO .008
1
* A
- 52*
- 31**
- 70*
- 9U
- *l*
- 36*
- 97*
- 93*
- 96*
- 99.6*
- 87*
- 99."«*
-------
I i f I f i
R£STo
uivl
Vehicle
Number
M6
*»5
*58
«>93
Tear
1980
1980
I960
1980
Odometer
76,563
53,579
59.888
73.586
Make/Node!
Datsun/B-210
Ford/Pinto
He reory /Monarch
Chev/Mallbu
As
Test
Type
Idle
CVS-CH
CVS-CH
Idle
CVS-CH
Rec'd Test Results
Emissions Results
(Tat led Standards)
Hexane ppm 259.3
CO* 1.21
NOx gm/ml 3.35
HC gm/ml 3.23
CO gm/ml 88.9
Hexane ppm 325-7
cot 10.5
HC gm/ml .752
Corrective Actions
Idle mixture limiting device had beer
removed and Idle mixture reset. Spark
plugs were worn, air filter dirty anc
curb Idle speed was fast.
Replaced spark plugi and air filter.
Reset curb Idle speed and Idle mix*
ture to manufacturer's specifica-
tions. Although the maintenance re-
sulted In emissions reduction, the
vehicle still did not pass the Idle
HC standards. The problem was diag-
nosed as malfunctioning carburetor.
Idle limiting device had been re-
moved and Idle mixture reset. Spark
plugs were worn, air filter was dirty
and the EGR valve was not working.
Further Inspection showed that the
carburetor spacer plate EGR ports
were completely plugged with carbon
deposl ts.
Replaced spark plugs, air filter and
EGR spacer plate. Reset Idle mixture
to manufacturer's specifications.
Idle limiting device was missing.
Further diagnosis Indicated • mal-
functioning carburetor. Spark plugs
worn and air filter dirty. Replaced
carburetor, spark plugs, and air
cleaner. Set Idle mixture and Idle
speed to manufacturer's specifica-
tions.
Spark plugs, distributor cap and
rotor were worn. Timing was advanced
fc0 and Idle speed was fast. Replaced
spark plugs, distributor cap and
rotor. Reset timing and Idle speeds
to manufacturer's specifications.
Although the maintenance procedure
was effective In reducing HC emls-''
slons. the vehicle still did not
meet the standard. Compression and
leakdown checks were performed. Re-
sults Indicated excessive piston
rinq wear on four cylinders and
valve guide wear on three cylinders.
After Halnt. Test Results
Test
Type
Idle
CVS-CH
CVS-CH
Idle
CVS-CH
Emissions Results
Hexane ppm 218.6
CO* . 389
NOx gm/ml 1.27
HC gm/ml .3*8
CO gm/ml 2.5
-------
RESTORATIVE MAINTENANCES
Vehicle
1.95
6«i3
662
587
1980
1981
t980
1981
Odoretcr
W.038
22.993
28,315
15,56*
Hake/*>del
Ford/Mustang
Chev/Plckup
Ford/Mus tang
Pont lac /Phoenix
ATI *
Test
TYP«
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
ec'd Test Results
Emissions Result!
(Fal led Standards)
HC gm/ml .809
CO gm/ml 11-952
<0x gm/ml 3-88
HC gm/ml 2.1?
CO gm/ml 38.2
llexane ppm 38 ' -8
CO* 5.55
HC gm/ml 1 .10
CO gm/ml 9-01
Corrective Actions
Idle mixture limiting device had beer
removed and Idle mixture reset. Spark
plugs were fouled, air filter dirty
and the distributor cap and rotor
were worn. Curb Idle speed was fast.
Replaced spark plugs, air filter and
the distributor cap and rotor. Reset
Idle mixture and curb Idle speed to
manufacturer's specifications. Al-
though the maintenance procedure was
effective In reducing emissions, the
vehicle still did not pass the
standards. A wet and dry cylinder
compression check was performed. The
results Indicated excessive ring and
valve guide wear on two cylinders.
EGR vacuum supply line was discon-
nected and plugged. Spark plugs
fouled and air filter dirty. Replacei
EGR vacuum supply line, spark plugs.
and air filter. Although the main-
tenance procedure was effective In
reducing NOX emissions, HC and CO
Increased substantially. Further
diagnosis Indicated a major carbure-
tor malfunction. Carburetor replace-
ment would have exceeded the con-
tractural limits. No further action
was taken.
Idle limiting device had been re-
moved and the Idle mixture was reset
Spark plugs were worn and fouled.
Replaced spark plugs. Reset Idle mix-
ture to manufacturer's specifica-
tions.
Preliminary diagnosis Indicated a
mixture control solenoid malfunction
and fouled spark plugs. A new car-
buretor assembly was supplied by
G.M. When the old carburetor assembl
was removed, It was discovered that
the ceramic grid portion of the Earl
fuel Evaporation (EFE) system had
been damaged by an electrical short.
Replaced spark plugs, EFE grid and
gasket and carburetor assembly.
After H«
Test
Type
CVS-CH
CVS-CH
CVS-CH
Idle
CVS-CH
lint, esi nesu is
Emissions Results
HC gm/ml .718
CO gm/ml -7.192
t
NOX gm/ml -979
HC gm/ml .515
CO gm/ml 6.2
-------
* ' f * f
RESTORATIVE MAINTENANCES
fill
f 1 f !
Vehicle
Number
66J
5*8
»65
«>99
501
Year
1980
19B2
1900
1980
1980
Odometer
27,t50
',989
7*. 2*5
*0.37I
••5,851
Mike/Model
Ford/Granada
Datsun/Plckup
Ford/Fairmont
Pon i 1 ac/Bonnev tile
Ford/Pinto
As Rec'd Test Results
Test
Type
CVS-CH
Idle
CVS-CH
Idle
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
CO gm/ml 34.0
/
Hexane ppm ft83.2
CO* 5.2
-------
RESTORATIVE MAINTENANCES
Vehicle
Number
501
[continue
505
506
503
519
Year
)
1980
1980
1980
1980
Odometer
39,10k
59.339
*0.671
"•5.121
Make/Model
Olds/Cutlass
Chev/Caprlce
Old* /Cutlass
Chev/Chevette
As Rec'd Test Resul ts
Test
Type
CVS-CH
CVS-CH
CVS-CH
CVS-CH
Emissions Results
(Failed Standards)
NOx gm/ml 5.39
HC gm/ml .970
CO gm/ml 8. 19
1C gm/ml 1 . 3*1
CO gm/ml 10.8
CO gm/ml 9.32
NOx gm/ml 5.1*6
Corrective Actions
Replaced spark plugs and air filter.
Cleaned carbon deposits from the ECR
passages In the spacer plate. Reset
Idle mixture to manufacturer's speci-
fications .
Spark plugs were worn and the air
filter was dirty. The EGR valve was
malfunctioning and the carburetor
vent line to the evaporative emission
cannlster was disconnected.
Replaced spark plugs, air fitter and
EGR valve. Reconnected cannlster vent
1 Inc.
Spark plugs were worn and the air
filter was dirty. Idle speeds were
fast.
Replaced spark plugs and air filter.
Reset Idle speeds to manufacturer 's
spec! f (cations.
Spark plugs were worn and the air
filter was dirty. Replaced spark
plugs and air f 1 Iter.
The maintenance procedure was not
effective In reducing vehicle emis-
sions. Further diagnosis Indicated
a malfunctioning carburetor and/or
catalyst. Replacement of these Items
would have exceeded contractual
limits.
Spark plugs were worn, air filter was
dirty and the EGR valve was not
funct loni ng.
Replaced spark plugs, air filter and
EGR valve.
After Malnt. Test Results
Test
Type
CVS-CH
•
CVS-CH
CVS-CH
CVS-CH
Emissions Results
NOx gm/ml 1.3».
HC gm/ml .bU
CO gm/ml 7-71
HC gm/ml 1.72
CO gm/ml 10.1
CO gm/ml 8.72
NOx gm/ml 2.1*7
X A
- 75X
- 32*
- 6X
+ 28t
- 6X
- 6t
- 55X
co
-------
SECTION V
VEHICLE EMISSION TESTING
A. TEST LABORATORY
EG&G-AR Chassis Dynamometer Testing Laboratory Is located at
54-04 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 and chassis dynamometers, one
motorcycle chassis dynamometer test cell, emissions ana-
lytical eguipment, soak area and support equipment. Details
on most equipment are available in Appendix C, EPA
Laboratory Qualification Worksheets.
Test Cell Number One was used for the data generated in the
Emission Factor Program. This cell contains a Clayton
ECE-50 chassis dynamometer with an inertia range of 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 con-
tract. 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 12 to 14 vehicles, dependent
upon vehicle size. Soak area temperature is controlled
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
-------
EGSG AUTOMOTIVE RESEARCH, INC.,
CHASSIS DYNAMOMETER TESTING LABORATORY
FIGURE V-t
CMAf •!• OVNO TtSTM* IA«
» «M
-------
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. TEST PROCEDURES
1. Precondition Procedures
On all vehicles the "as received" fuel was drained and
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 preconditioning and the cold
transient phase of the FTP, a vehicle driveability
evaluation form was completed. The preconditioning en
sured that the test fuel had purged the vehicle's fuel
system and the engine had achieved a normal operating
termperature. Test vehicles were then placed in the
soak area. The reguired ambient temperature 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 Procedure for exhaust emissions as
described in Federal Register Vol. 42, No. 125 -
Tuesday, Dune 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.
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 comple-
tion 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
31
-------
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 procedures reguired for FTP tests.
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 accomplished with
instruments described in Section V - A. Test Laborato-
ry. The entire seguence was conducted with the hood
open and the auxiliary cooling fan on. For the final
test (two speed idle test), the inertia was reduced to
the lowest available setting (1,000 Ibs.). Each of the
short cycle tests began after a six (± one) minute idle
period with the transmission 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 thefirst 505 seconds of the FTP Driving
Schedule. The test seguence 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, eguilibrium 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
below.
The 50 Cruise Test was a high speed loaded test that
takes advantage of the three minute preconditioning
run before the HFET. Tailpipe emission concentra-
tions 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.
32
-------
The Four-Speed Idle Test involved four steady state
idle conditions with the transmission in neutral.
Emissions concentrations 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.
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 and 1,000 Ibs inertia
weight. Immediately following sampling in this
mode, the vehicle was returned to the idle mode, the
transmission placed in neutral and the emissions
samp led again.
The Bagged Idle Test followed the FTP and preceded
the HFET . The Bagged Idle Test reguired the use of
the same instrumentation as the FTP to measure
dilute 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 transmission 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 three minute period,
the exhaust sample was gathered through the CVS.
C. CALIBRATIONS
The following calibrations were performed routinely during
the contract period. No changes in usual lab operations
were reguired to meet the requirments of the subject
contract.
33
-------
1. Chassis Dynamometer
The chassis dynamometer received the following calibra-
tions: A complete calibration was performed prior to
initiation of testing. The calibration included speed,
load cell deadweight, deadband adjustment and dynamome-
ter coastdowns. This calibration was repeated after
maintenance was performed that could affect the cali-
bration 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 dynamo-
meters 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 guidelines 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 exceed-
ded 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 perform-
ed 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%
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 full scale). The gases used to calibrate the CO,
C0£ and NOX analyzers are all single blend gases with
nitrogren as the diluent. The gases used for the FID
were single blend gases using propane with air as the
diluent. All of the above gases were purchased from
Scott Speciality Gases and were gravimetric blends with
certified analysis (± 1%) and are traceable to NBS
standards. An Aadco Model 737-13 pure air generator
was verified weekly by cross-checks with compressed
zero air with certified levels of impurities. A com-
plete calibration was performed following maintenance
or when curve checks were out of limits.
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 ± 1% of the concentration for gases,
above 50% of meter, the instrument received a complete
calibration. On alternating weeks, 75, 45, and 15%
gravimetrics were substituted in the procedure.
The entire analytical system was leak checked daily.
Zero and span drift on all analyzer 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 recoveries were performed, span gas
cylinder pressures recorded, HC hangup was checked and
ambient HC and CO analysis was performed.
Soak Area Temperature Recorder and Wet Bulb/Dry
The temperature recorders were calibrated monthly by
referencing the temperature sensors to a certified
thermometer. They were checked at ambient, cool
(approximately 60^ F) and warm (approximately 90° F)
temperatures. Response time was recorded. The
recorder was checked daily at ambient temperatures.
35
-------
5. Strip Chart Recorders
The chart speed and linearity of all emissions
recorders and the driver's aide 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.
6. Quality Audit
In order to ensure that all calibrations were completed
in a consistent manner and that no procedural or opera-
tional errors had occurred during the calibrations,
each completed data sheet was audited by the EG&G-AR
Quality Control Group.
36
-------
SECTION VI
TESTS 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.
37
-------
SECTION VII
DATA HANDLING
A. EMISSIONS TEST AUDITING AND VALIDATION
Upon completion of each vehicle test sequence, test data
packets were reviewed by the Department Quality Control
Auditor. This group is independent of testing operations.
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 equipment.
A-. 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 Systex Inc., via United Parcel Services.
C. CALIBRATION 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. The monthly analytical instrument
calibration curves were sent to Systex, Inc. as directed by
the EPA. The remainder of the packets were sent to the
Environmental Protection Agency.
33
-------
APPENDIX A
Sample Procurement Packet
1) Letter of Introduction
2) Emission Factor Testing Program - Question and Answers
3) Telephone Questionnaire
*0 Incoming Vehicles Inspection Sheet
5) Test Agreement
6) Standard Vehicle Loan Agreement
7) Savings Bond Information Sheet
8) Test Agreement Addendum
9) EG&G-AR Letter of Appreciation
10) EG&G-AR Letter of Acknowledgement for Response
11) Vehicle Owner Questionnaire Data Sheet
12) Newspaper advertisement for high mileage vehicles
-------
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
ANN ARBOR MICHIGAN 46105
EMISSION FACTOR TLSTIN& PROGRAMS
Quest torus and Answers
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 from
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 vehicles. 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 for
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 EG 4 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 4 C 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. Bejrna, Project Officer
Emission Control Technology Division
1. Must I participate In this program?
No, your cooperation in this research program is completely voluntary. If, f.-r
any reason, you decide not to participate, p lease 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, VOLT
participation will benefit you indirectly by helping EPA understand 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 mus t be
comp letely cooled off before the exatolnat ion can begin. This requires that the
vehicle not be started for 12 to 36 hours to simulate overnight parking.
Therefore, we will need to have your vehicle at the laboratory for two or three
days. You wll 1 be contacted once the evaluation Is complete so that
arrangements can be made to pick up your vehicle. In general, we suggest that
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 every da \
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
wh ich would normal ly be encountered on the road. A hose is connected I*- t^o
exhaust pipe to collect the exhaust. A specially trained driver then starts tho
vehicle and "drives" it through a "driving cycle" which represents rvpi^al
operation In urban, suburban, and rural areas. Throughout this tin*-, a portion
of the exhaus t gases are collected for subsequent analvsis. This anal\sis
al lows us to calculate the quantity of exhaust emissions emi t tod b1- \oar
vehicle. Values for the city and highway fuel economy are also c.ilcula t ed . \
complete inspect ion of the emission control components is conducted at tor the
examlnation.
Enclosures
-------
I 1
I !
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. 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.
8. What determines whether or not my vehicle will be ultimately selected?
Your vehicle has been initially identified by a statistically random sampling
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 met.
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.
9. 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 ln-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.
10. How can I obtain the results from your examination of my vehicle?
After the completion of the examination you will be provided with a form 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
aoon as all the data have been processed.
TELEPHONE fjULSTIONHAIRE
Cor, trol .'.c,
uATA FGF-'I :,:
t-acje 1 Of )
of contact:
If owner was not contacted, list the number of attempts that have been made
(eliminate after three attempts).
Individual Contacted:
If you were instructed to call back later, obtain convenient date
and time
VEHICLE CONTROL NO.
TELEPHONE NO.
you have been randomly selected from a list of
• Mr./Mrs.
19 vehicle owners living in the San Antonio Metropolitan area. As tne letter
you recently received explains, a study of vehicle exhaust emissions is currently
being conducted in this area by the UniteJ States Environmental Protection Agency
and EG&G Automotive Research.
your participation in this program is strictly voluntary. EPA is autnorized by
law to conduct this study and to offer incentives to you for your cooperation
should you decide to participate.
your cooperations will aid EPA's efforts to control air pollution due to vehicle
exhaust.
The conditions for participation in this program are:
1) We ask you to bring your vehicle into our testing facility, which is
located at 5404 Bandera Road. You will receive a late model loaner vehicle
which will have a full tank of gas. This vehicle is yours to use for the
duration of the testing program which will take approximately 3 to 4
working days. During this time we will be conducting a series of exhaust
emissions test on your vehicle.
2) At the completion of our testing, if a full program has been performed,
your vehicle will be returned to you with a tune-up and oil change (if
required) and a full tank of gas. You will also receive a $100.00 L.S.
Savings Bond for your cooperation in this study.
* If individual listed on the reply card was not contacted, enter name of perso;.
you talked with and indicate relationship i.e. husband, wife, son, dauqhtei ,
friend, etc.
-------
Telephone Questionnaire
DATA FORM NU . 3_024 2
Page 2 of J
Prior to releasing your vehicle into our possession you will be given some
documents to sign. These documents, which will also be signed by an authorized
EG&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 be given and assign full liability responsibilities to EG&G
Automotive Research for your vehicle while in our possession.
3) Leaner Car Agreement explains the terms and liability responsibilities
for both parties in relation to the leaner vehicle.
4) Savings Bond information sheets. This form when completed will contain
all the information necessary for a Savings Bond to be issued in your
name.
Do you think you would be willing to participate in this program?
IF RESPONSE IS POSITIVE
Yes
For the purpose of identifying your vehicle as a possible candidate for this study,
I am going to ask you a few question. None of this information can be used against
you in any way and you should answer these questions to the best of your knowledge.
Please indicate when you are not sure of something.
1) What is the made, model, year, transmission type, vehicle identification
number and engine size?
MAKE
MODEL
YEAR
TRANS: AUTO_
ENGINE
2) What is the approximate odometer reading:_
3) Has your vehicle ever been involved in an accident?
Yes
If the answer is yes, indicate the type and extent of damage, i.e. frame,
engine, drive train, cooling system, exhaust system, etc.
Telephone Questionnaire
DATA FORM NO. 30i4 2
Page 3 of 3
4) Because this is an exhaust emissions test, it is critical that the
exhaust systems on the vehicle tested be in good condition. To your
knowledge, are the exhaust pipes, muffler and catalyst on your vehicle
in good condition with no leaks or holes. Yes No
Would you consider making the necessary repairs or replacements to your
exhaust system at your own expense in order to participate in this
program? Yes No
IF NO ELIMINATE
If Yes 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 information will have to be reviewed by the Project Manager and a decision
should be made within the next few days. We will notify you as soon as possible.
Is it convenient for you if we contact you at this same number and time when the
decision is made. Yes No
IF NO, obtain number and tune
Thank you very much for your cooperation.
-------
INCOMING VEHICLE INSPECTION SHEET
PART II
TIRES:
RADIAL OR
BIAS
ENGINE SIZE:_
BODY STYLE:_
YEAR:
MAKE/MODEL:
A/C OR NONE A/C_
VEHICLE NUMBER:
•PLEASE GIVE JOHN R. INFORMATION
Fuel Tank Cap:
Trans.
Oil
Date_
Time
AUTOMOTIVE RESEARCH,,.
Control *jo.
Fora No. 302..1
5404 BANOEHA HOAO. SAN ANTONIO TEXAS 782M . TELI5I2|6S4-J310 TWX 91O8M-1075
TEST AGREEMENT
Your vehicle Is being loaned to EG4C 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 EC&C AUTOMOTIVE RESEARCH,
INC., or its designed representatives.
EG4G AUTOMOTIVE RESEARCH, INC., agrees to be fully responsible for 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 haraless
the vehicle owner of any repairs, damage, loss, or liability sustained b>
the vehicle owner by reason of accident or damage to the vehicle while in
its possession.
EG&C AUTOMOTIVE RESEARCH, INC., agrees to provide primary automobile
insurance on the vehicle while in Its possession.
EGiC 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 non&al wear and tear,
as when the vehicle was received by EC4C AUTOMOTIVE RESEARCH, INC.
EG&G AUTOMOTIVE RESEARCH, INC., reserves the right to perfonr. anv repairs
and maintenance upon the vehicle, at its sole discretion, provided all such
repairs and maintenance are performed according to the manufacturers specifica-
tions .
I,
described as a __ __
registered In the State of
(Year)
agree to loan my vehicle,
(Make and Model),
under License Plate No.
to EC4G AUTOMOTIVE RESEARCH, IN:'., for a
period of approximately
days for a series of tests.
I further agree that, should testing not be completed 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 ECiC AUTOMOTIVE
RESEARCH, INC., at any time and that I am under no obligation
whatsoever.
AGREED TO this
day of
. 198
VEHICLE OWNER:
By:
ECiC AUTOMOTIVE RESEARCH
By:
-------
Control No.
Data Form No.3024 4
STANDARD VEHICLE LOAN AGREEMENT
THIS STANDARD VEHICLE LOAN AGREEMENT (the "Agree
Into by and between Mr./Mrs./Miss/Ms.
ent") is
ade and entered
of
, County, State of Texas
(referred to in this Agreement as the "Participant"), and EG&C Automotive
Research, Inc., a Texas corporation having a usual place of business at 5404
bandera Road, City of San Antonio, Bexar County, State of Texas (referred to
in this Agreement as "Automotive Research").
H1 I 2 £ 1 iI1i IMA!
WHEREAS: Automotive Research has entered into a contract with the
United States 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
WHEREAS: The Participant has agreed to let Automotive Research test
the Participant's car on the condition that Automotive Research lend the
Participant a car to use during the period of such tests; and
WHEREAS: 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 forth in this Agreement, Participant and Automotive Research
do hereby contract, covenant 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 they 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 vehicle or trailer. The Car will be operated onlv
by Participant and permitted members of his immediate faniH, 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 otr.er legal violations assessed against the Car,
Participant, or Automotive Research, except wnere caased through fault of
Automotive Research; (b) Automotive Research's costs including reasonable
attorney'* 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 ml icon-
duct of the operator; provided, however, that Participant's liability for
such damage will not exceed $100.00.
5. Participant and any au
insured in benefits of an
which is available from Au
other insurance carried b>
bodily injury or death lia
accident and Is subject to
all persons in each accid^
for eacn accident. Partic
limitations, and restrictl
policy is a standard Texas
thonzed operator agree to participate as an
automobile liability Insurance policy, a copy of
tomotlve Research. Said policy cones before any
Participant or authorized operator and contains
bility Units of $250,000 for each person in each
the following limitations: A $500,000 limit for
nt and a property damage liability limit of $50,000
ipant is bound by and agrees to the terms, conditions,
ons of said policy; it being understood that the
tor 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 ten 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 the Agreement to be executed by its authornea
representative, all under seal, as of the day of , 196
in the city of San Antonio, Texas.
PARTICIPANT:
By:
EC4C AUTOMOTIVE RESEARCH, INC.
Driver's License »_
Expiration Date
By:
JATE:
Loan Car License No:
Loan Car Condition: OL'T_
DATE IN
_OK/Initial
OK/Initial
Defects noted when Car was received bv Participant
-------
f 1 I
I -.
Control No.
DATA FORM NO. 3024
Contrc.1 No.
DATA FORM NO. 30243
EGIG AUTOMOTIVE RESEARCH, INC.
5404 Banders Road
San Antonio, Texas 78238
Ul
SAVINGS BOND INFORMATION
NAME SOCIAL SEC. NO.
STREET ADDRESS
CITY STATE
ZIP
HOME TELEPHONE NO. BUSINESS TELEPHONE NO.
THE FOLLOWING PERSON, IF ANY, IS TO BE
OWNER
CO- OWNER
BENEFICIARY
NAME {SOCIAL SEC. NO.
MAILING ADDRESS (IF DIFFERENT THAN ABOVE)
CITX STATE
ZIP
CLASS/SERIAL NO.
CODE NO.
YEAR/MAKE OF VEHICLE
MODEL OF VEHICLE
ACCEPTED
BOND NO.
REMARKS
REJECTED
ISSUE DATE
TEST AGREEMEHT ADDENDUM
I,
owner! ) and/or joint-
owner! ) and/or principal driver! ) of the vehicle described as a
(year) (Make and Model)_
registered in the State of
original testing agreement dated_
period of days.
, agree to extend
, 19 for a
VEHICLE OWNER
By:
Date:
-------
AUTOMOTIVE RESEARCH,^
W04 BANDERA ROAO. SAN ANTONIO TEXAS 78238 • TEL(M2|68«-23ia TWX »lO-6n-1075
AUTOMOTIVE RESEARCH,.*
M04 BANDCflA ROAD SAN ANTONIO TEXAS 78238 • TtLlblJltM-2310 TWX »\0-e7l-1075
CTl
Dear Participant:
This letter is to express my thanks to you for your recent participation
in the exhaust emissions testing program which EGSG 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 specifications. Attached for your records is a detailed
summary of any maintenance performed on your car while in our laboratory.
Again, thank you very
effort.
Sincerely,
ich for your kind cooperation in this important
Dear Vehicle Owner:
Thank you for your response to our recent inquiry on your venicle.
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 in
the actual testing phase at this time.
Again, we would like to express our appreciation for your timely
response.
Sincerely,
Mark D. Dalen
Project Manager
MDD/bh
Attachment
Mark D. Dalen
Project Manager
MDD/bh
-------
! 1 f
I t
VDIIICLC OWNEK QUEbTlONNAIRt
DATA SllttT
VUJJC'J.L DWf
% (don't hi>ow)
4 Urvqurnt ly|
) Iftui.'t know)
1 lnrw«r u'C.I qt^ohol)
*> (i^n't know)
) Inevni usi rt t).i»ohr>))
i (fuel cconuwy better)
1 (fuel econtxiy wor*«)
5 (don't know)
I (1-1? MUltthS)
) (1-? years]
DATA EMTHIES FOR QUESTIOH II
ENTEJ*
AMOC
AACO
BOHA
BP
CHEV
CITC
BRAND NAHE
AMOCO
AACO
BONAf IDE
BP
CHEVRON
CITCO
ENTEA
CLAA
cono
DERB
ENCO
ESSO
rxxo
BRAND NAME
CLARK
CONOCO
DERBY
EWCO
ESSO
CKXON
EOTER
TINA
C£MC
HESS
MUDS
HAA5
HART
BRAND NAME
CCHCO
HESS
HUDSON
HARS
CMTTR
HOftI
MOTO
PHIL
SCOT
SEAR
SHAH
BRAND NAHT
HOB 1 1.
MOTOR
PHILLIPS
tCOTT
SCARS
ttrrt:*
KTL
INC
K£L
UNO
BRAND NAHE
SHELL
SINCLAIR
SKI.LLV
SUTOTO
ENTER
UNIO
VICK
ZtPH
UNKN
BRAND f*AHE
UNION
VZCXTfti
OTMift
IF BRAIJD l-i 'OTHCR'. THEN EOTES THE FULL BRAND IU.1C VEHICLE OWNER USES.
61 On i y«*rly tMBli, ho** i
cl Ccncr furil io*d*
C\ I .tin*** Inot to «nn ti. i
-------
VKIIICLK UHNEK
DATA SHEET
VUIH.LI:
UAT/\
03
101 Ho- it ihi« vehicle us*d? •) Drlv« only
•oeti 15-41%
little or non*t<20t b> Driver end on* p*«een?er
c) Driver end 2 or More peeiervjer*
d) Driver only with heevy ctryo
e) Driver. p*e*eno,er end c*tqo
f| Towing e treiler
some dutence end ecoppinq the engine)
perfontence probleiu with thi« vehicle?
b) St«llift9
c| ftooqh idla
d| tnqlne •leflrinq
•) Poor ecceleretion
II ttu«,U»,
,1 w..t*t.on
hi Eoqine knock ot plnq
1 («lmo»t ell)
2 (eoet)
J leoMl
4 (little or none)
1 (el«o«t ell)
2 (enet)
4 (little or none)
) (COM)
4 (little ot none!
1 (AlMoat ell)
1 IftOM)
4 (little at none!
1 (*L»oit elll
2 (eott)
4 (little or none)
1 Ulecet ell)
2 iBoetl
> learn)
4 Illttleor none)
m
2 (once ot twice)
3 li-t ci*eh)
4 (every dey)
1 (y*t)
2 (not
1 (yes)
2 (no)
1 (yet)
2 (not
1 (ye»
2 (no)
1 (yes)
2 ino)
1 (y**J
2 inoi
1 (yet)
2 (no)
1 ire*>
2 lr>a)
2 Ino) ,
l»i M4-, /ou h*j eny r.,4ir, to your v.r,tl. f«« the
* P
i,j Wh4t rn-ir. ,ere f.«'<°n~cr«)
S idon'c kftowj
1 ino ntr*l
4 tdv*r 4 fwrtnt)
& idon't iincj-i
1 Lfta r«p*it»i
I .T«»l
J mol
1 ir'»'
1 idon't know!
-------
VEHICLE OWNEK Uu
DATA SHEET
VLIUCLE OWN EH QUi-S'J' 1QNNAI (U.
DATA SHEET
«ny of Ui« following .»•*•?
t>) Cooling •y«t«*
cl r-. .y.c«
d. U»u.t.,.t..
• t Ho d«Mo,«
f) Don't know
Jol ,<*» any Mint«n*nc« p«rtonMd •inc. eh« U*t t««?
"•O^no i»ini!ft*nc« OOI don't know COS. not t«t«d
„, *o ^.,— «. -nt-nc.,
1 ly«l
1 (no)
1 (yu)
3 (no)
1 .r[«ncy)
1 (none)
4 (not t«ft>al
LTD
1 no Mi.ntcn.inc*>
t> not i«tl*J)
)OI fto you *ccur«t«iy k«*p ricnrda o< th« fiMl •con»y on thtt vehicle?
«J MoACJt
— i don v knrw -- i not r*quir*a -^ i iwv«r int^cccto
*** b» »««r
14)
t>) If '"i, t»J«ci(y «|>|-rOHt«t«L* total ni*O*.r of •tl«* thi» w*hirl« lot
ttucn drlucn
1 (y«*l
3 IIM>)
1 (r«»t
2 (no
1 pl«»)
1 f«Ul
1 rtOft't kfKMt)
4 not r*quli«U)
•> n«w*r lnBi<«<.t«di
»)
I no)
I
-------
VEHICLE OWE* QUESTIONNAIRE
DATA SHEET
VEHICLE owni goisriomuiu
DATA tart
o
A) Bow often It the etr we are teatlng tun«d up?
B) How long ago wea toe lot tun* up?
C) Who did th« lest tun* up?
D) Ut art interested In the «) in the city?
*"*' »C<""~T ptopl* «<-f"«lly , ., ._
get with th«Ir c»r». How b) on the highway
you get with this car? c) combined city
t highway
(Ent«r "98" If Don't Know)
(Enter "99" If Not Applicable)
1 («t least every six)
months)
2 (7 to 12 months)
3 (Lets often than once
per year)
* (According to owner i
nanual)
5 (Too new to be tuned)
6 ("When Needed")
7 (Other)
8 (Don't Know)
9 (Not Applicable)
1 (6 monthi or let*)
2 (7 to 12 month.)
3 (longer than 12 nontha;
8 (Don't Know)
9 (Not Applicable)
1 (car dealer)
2 (service atatlon)
3 (independent garage)
4 (self or other family
•caber)
7 (Other)
8 (Don't Know)
9 (Not Applicable)
L_LJ
LJJ
cm
(D
(2)
3)
4-5)
6-7)
8-9)
F)
C)
Has unleaded
been used In
gaaollne usually
this car?
Unleaded' ea> la more a) Have you ever ueed
expensive than leaded leaded gasoline in
and at tlmsa has been this car?
hard to find.
Is regular or
b) If yes.
how often?
premium used?
2 (No)
8 (Don't Know)
9 (Not Applicable)
1 (yea)
2 (no)
8 (don't know)
9 (Not Applicable)
50 (50 or mere)
51 (Never)
52 (Seldom)
53 (Occaalonally)
54 (Frequently)
99 (Don't Know or
not Applicable)
1 (Regular)
2 (Premium)
7 (Other)
8 (Don't Know)
9 (Not Applicable)
(10)
(11)
(12-13)
to
-------
EBcQ AUTOMOTIVE RESEARCH,*
MO4 lAMOtftA MOAO. IAN ANTONIO. 1UA« IWK • mitllXtt-ni* tw» (I»4ll
VEHICLES NEEDED FOR RESEARCH PROGRAM
1981 CARS WITH OVER 25,000 MILES
1980 CARS WITH OVER 40,000 MILES
HE HUD THESE HIGH MILEAGE VEHICLES FOR AN IMPORTANT RESEARCH PROJECT FOR THE
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY.
If YOU OUN ONE OF THESE VEHICLES AND MOULD LIKE TO IE A PART OF THIS COUNTRY'S
EFFORT TO CONTROL AIR POLLUTION. YOU MILL BE PROVIDED WITH:
1. A LATE MODEL LOANER CAR FOR YOUR USE WHILE YOUR CAR IS BEING TESTED.
2. BOTH YOUR VEHICLE AND THE ONE BEING LOANED TO YOU MILL BE FULLY INSURED.
3. YOUR CAR HILL BE RETURNED TO YOU HUH A FULL TANK Of CAS.
4. YOU HILL RECEIVE A $ 1 00 SAVINGS BONO.
CALL US TODAY 684*231 OsXT.317 r« ADDITIONAL INFORMATION.
-------
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
II) Drlveability Evaluation Data Sheet
12) Emission Component Data Sheet
-------
f i f
VEHICLE INFORMATION DATA SHEET
ENGINE PARAMETER DATA SHEET
-------
VEHICLE INFORMATION DATA SHEET
EMISSION STICKER P»R1 NUMBER
(LEFT JUSTIFY,
Cont.ro; sc
DXTA FJkl S0~:
MtCMAKICS INSPECTION TORM
VEHICLE NO.
Fuel Fllltr Heck 0*>a9<
AXLE RATIO_
TIRE SIZE
TIRE MANUFACTURER
ECR VALVE PART NUMBER
CARBURETOR PART NUMBER
DISTRIBUTOR PART NUMBER
MECHANIC
INSPECTION DATE
1 - Y««, Unleaded full v.nicl.
2 - No, Un;«*d«d fu«; v.hicl«
3 - N/A, Lttdid fuel »cc«pt«t;«
_(Includt« all , etc.J
-------
I I
FTP AND EVAP TEST DATA SHEET
FTP TEST DATA
Page (1 of 2)
FTP AND EVAP TEST DATA SHEET
FTP TEST DATA (continued)
Page (2 of 2)
BAROU
-HO
•I I
INLET
PRESS
•HO
I
H
CVS
nuf
26 30
- CONCENTRATION OF Ou/TON AM
MC
PO"
CO
ppm
50 IS 10
CONCENTRATION OF OILUTf EXHAUST (AMPLE •
NOX
ppilt
Cm
ppm
EVAP TEST DATA
-------
HIGHWAY FUEL ECONOMY TEST DATA SHEET
WET
BULB
f
JO M 30
CONCENTRATION OF DILUTION AIR -
DISTANCE
MILES
fi
80 Si «0
• CONCENTRATION OF DILUTE EXHAUST SAMFI
NOX
PP"
CO
14CO2
I I U*l I I I I I 1*1 I M I I I I I I 1*1 NTT
H| 2
80
BAG IDLE AND 50 MPH CRUISE TESTS DATA SHEET
BAG IDLE TEST DATA
ao a 10
CONCENTRATION OF MJSnOH AM -
so u
• CONCENTRATION OF DILUTE EXHAUST (AMPLE -
J»L
Cm
PC"!
CH4
ppm
SO MPH CRUISE DATA
-------
I 1
f *
FOUR MODE IDLE AND LOADED TWO MODE TESTS DATA SHEET
FOUR MODE IDLE TEST DATA
PROPANE GAIN DATA SHEET
Page (1 &t 2)
50 55 M
LOADED TWO MODE TEST DATA
»WAY CLOSED LOOP
6TEP1
STEP 2
STEP 3
STEP 4
PRESET FLOW RATE
RECORD: •) FLOW RATE
b) RPM
C) IDLE%CO
INDUCE PROPANE, OBSERVE VEHICLE BEHAVIOR
RECORD ONE: •) RPM RISES SMOOTHLY TO
b) RPM FALLS SMOOTHLY TO
O ENGINE RUNS ROUGH AND THEN
STABILIZES d-YES)
d) ENGINE DIES (1-YES)
*) RPM STAYS THE SAME n-VES)
WHEN ENGINE STABILIZES, RECORD:
•) RPM
b) IDLE%CO
(ConllnuM on N»»t Pig«)
IN
NEUTRAL
g
ILLJ
4
H 1
IS
1 1 1 •
IN
DRIVE
P
Ull
10
II- 1
10
• III
1 1 1 • 1 1 1
» 30
Trnr^^
D
4)
D
4i
D
4)
• Ml
40
D
44
D
D
41
TTTMTII
u 1 » .
•I 1
60
!• 1
ei
-------
PROPANE GAIN DATA SHEET
Page (2 of 2)
S-WAY CLOSED LOOP (Continued)
un
O>
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:
I) RPM
b) IDLE%CO
IN
NEUTRAL
— | — | — I — •
IN
DRIVE
tm — i — i — r-
IN •MM
5
10
TTTwnr
IS
D'
21
D
23
g
20
D
22
D
24
D
21
1 1 1 • 1 1 1
30
•
40
HBBBE
35
I-
45
•• •• 1.
INN MM HI
I I I I M I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I UUi
VEHICLES OTHER THAN 3-WAY CLOSED LOOP
IN
-------
KM I bL, JON COUPONLNTS DATA bill.I.
IIKI UI.AIi I I.ITV r.V/U.U.YI'lOM HATA MILI.T
.ONTKACT]
AMBIENT TEMPERATURE °F
ROAD CONDITION (1-DRY 2-WET 3-ICY 4-$NOW)
CONSTANT SPEED PHASE
RESTART PHASE
CRANKING TIMt TO START AFTLH 10 MIN (IN SECONDS)
IDLE QUALITY AFTER RESTART
COLD START AND IDLE PHASE (DYNAMOMETER)
NUMBER OF STALLS, PASS-OUTS UPON
ACCELERATION TO ROAD SPEED
PART THROTTLE
ACCELERATION QUALITY
CRUISE QUALITY
SI.lt.IIT ACCELERATION RESPONSE
IDLE QUALITY AT STOP WITH A/C
ini.i: QUALITY AT STOP WITH A/C
(PASSING)
'ON
'
'OFF1
D
1 2
1 2
1 2
1 2
1 2
3
1
i
3
1
4
4
4
4
4
5
b
5
5 9
*>
ACCELERATION FROM STOP PHASE
QUALITY OF ACCELERATION UNDER
OUAI.ITY OP ACCELERATION UNDKR
QUALITY OF ACCELERATION UNDEK
QUALITY OF ACCtLKRATION UNDER
1/4
1/2
2/3
3/4
THROTTLE
THROTTLE
THROTTLE
THROTTLE
I 2
1 2
1 2
1 2
3
3
3
J
4
4
4
4
5
5
b
S
11 2 3 4
INITIAL CRANKING TIME (IN SECONDS)
NUMBER OF ENGINE IDLE-OUTS AFTER START
NUMBER OF ENGINE STALLS AFTER GEAR SELECTION
HESITATION, IM, UPON SLIGHT ACCELERATION (1-YES 2-NO)
IDLE QUALITY
DRIVE AWAY PHASE (DYNAMOMETER)
NUMBER OF STALLS, PASS-OUTS UPON SLIGHT
ACCELERATION TO ROAD SPEED
ACCELERATION Q1IAI 1TY
IDLE QUALITY AfTER 0.5 MILE FM« STOP
NUMUER OF STALLS, PASS-OUTS UPON SLIGHT
ACCELERATION TO ROAD SPEED
ACCELF.RAT10N \*JALITY
IDLL QUALITY AFTER 0.4 M1I.FS FROM STOP
Ej
1 2
1 2 3 1 ">
D
12345
1 2 3 •) 5
D
123-1'-
UALITY CODE f H
CARBURETOR AND FUEL SYSTEM - FUEL SUBSYSTEM
b) IDLE MIXTURE ADJUSTMENT LIMITING DEVICE
9-iF NOT I:QPD, S-^EXCF.LLENT, 4-0000, J-FAIK, 2»POOR, I-FAIL
-------
:< I UN rOMPONL'MVii DATA MII.I.T
IHI.'iMON I OtU'ONl.N'l:; DATA :.lll.l I
CTi
O
CARBURETOR AND FUEL SYSTEM - CHOKE SUBSYSTEM
») CHOKE ADJUSTMENT (NOTCHES)
b) CHOKE ADJUSTMENT (VACUUM BREJJC)
c> CHOKE ADJUSTMENT LIMITING DEVICE
d) FAST IDLE SPEED
e) VACUUM DIAPHRAGMS
f| ELECTRICAL CONTROLS
q) EXHAUST HEAT CONTROL VALVE ASSEMBLY
h) HOSES, LINES, WIRES
j) OTHER
TTTT
IGNITION SYSTEM
a) DISTRIBUTOR ASSEMBLY
INITIAL TIMING
c) INITIAL TIMING LIMITING DEVICE
d) SPARK PLUGS AND HIRES
c) VACUUM ADVANCE ASSEMBLY
f) SPARK DELAY DEVICES
9) SPARK KNOCK DETECTOR
h) ELECTRONIC TIMING NODULE
i) COOLANT TEMPERATURE SENSORS (TVS)
3) HOSES, LINES, WIRES
Kl OTHER
TTTB
nai
-------
I.MI:,:;IUM ruMPoNi.NT:; DATA .MII./.I
KMIb.MI.iN L-OMI'UNI.NT.', l.i/1'IA ftllli.i
CT>
EGR SYSTEM
a) EGR VALVE ASSEMBLY
c) DELAY SOLENOID
d) VACUUM AMPLIFIER
e) VACUUM RESERVOIR
f) COOLANT TEMPERATURE SENSOR (TVS)
q) HOSES. LINES. WIRES
JU OTHER ..
nn
AIR INJECTION SYSTEM
AIR IHJEirlON ASSEMBLY
b) AIR BYPASS VALVE
c) AIR DlVERTEX VALVE
dl CHECK VALVE
c) DRIVE BELT
f) HOSES, LINES, MIRES
q) OTHER
PCV SYSTEM
•I PCV VALVE
b) PCV FILTER
cl HOSES
dl OTHER
TTTM|
TiUS
-------
rMl:...liifl fUMPONTHT:! HATA Mil.1.1
I Ml.SMI IN I llHIMINI.NT.'i DATA Mil.I T
EXHAUST SYSTEM
») MANIFOLD, TAILPIPE. MUFFLERS
b) CATALYST
c) OTHER
EVAPORATIVE rflNTBfir. SYSTEM
a) CANISTER
b| CANISTER FILTER
c) CANISTER PURGE SOLENOID/VALVE
d) HOSES. LINES, WIRES
•) OTHER
ENGINE ASSEMBLY
a) ENGINE ASSEMBLY
b) COOLING SYSTEM
cl VALVE ADJUSTMENT
dl BELT TENSIONS
c) IIOSUS, LINES, WIRES
•) ELECTRONIC CONTROL UNIT
b) OXYGEN SENSOR
c) BAROMETRIC PRESSURE SENSOR
d) LOAD SENSOR (THROTTLE POSITION, MANIFOLD VACUUM, ETC.I
c) ENGINE SPEED SENSOR
O COOLANT TEMPERATURE SENSOR
9> CRANKSHAFT POSITION SENSOR
ECR POSITION SENSOR
i) ECR CONTROL SOLENOID(SI
j) AIR/FUEL CONTROL ACTUATOR (SOLENOID, .STEPPER MOTOR)
k) AIR BYPASS SOLENOID/VALVE
TTTB^
Trraq
naa
1) AIR DIVERTOR SOLENOID/VALVE
ii.aa
THROTTLE KICKER ACTUATOR
li) 101.1 STFt-'O fnNTBQI.
-------
i.Mi:>MiiM t'linrtim.N'i:; IIATA MII.I T
r) DIAGNOSTIC SYSTEM CODE (61
-------
APPENDIX C
Lab Qualification Worksheets
1) Facility 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
CTi
*» 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 - Aux!I Mary Devices
19) Record Keeping System Check
20) List of Documents to be included in the Lab Qualification
Packet
21) General Comments
-------
i i
f I
LABORATORY QUALIFICATION WORKSHEETS
Facility Inspection
I. Test Site San Antonio, Texas
2. Contractor
Yes/
Pass
No/
Foil
Corrected
EGCG Automotive Research, Inc.
3- Date of Inspection December II, I960
<(. Inspector Butch Naegel in
5. Contractor personnel
a. H. Dalen d. J. Rivenburgh g. C. Jackel j. L. Hernandez
b. H. Forshee e. R. Martinez h. R. Gilmore k. S. Gearhart
c. B. Naegelin
f. B. Martinez
i. C. Van Tassel
6. Test area of adequate size?
7- Soak area of adequate size? Number of vehicles I2-|I«
8. Soak area temperature between 68°F and 86°F? 72 °F
9. Distance from soak area to dynamometer 0+ ft. (same building)
10. Soak area free of precipitation? X
II. Laboratory floor area? A,W,
X
X
,5^7 sq. ft.
12. Laboratory air conditioned? 73 + 5 °F
a. Air conditioning capacity 56 tons
TC-2 only
13- Laboratory humidity controlled? 72+5 Grains
H. Laboratory elevation 830 ft.
15. Office space 723 ft2
16. Test Fuel
a. Does leaded fuel meet all specs? (Attach analysis) X
b. Does unleaded fuel meet all specs? (Attach analysis) X
c. Are fuel containers clearly identified?
d. Are separate systems used for leaded and unleaded
fuels?
e. Is the fuel dispensing system accurate within 2{?
f. Storage area and temperature SS * S F
17- Gas Cylinders
a. Storage area of adequate size?
b. Temperature of area (60°F-86°F) 63 ? IO°F
c. Are cylinders secured?
d. Is each cylinder equipped with a regulator?
Only cylinders in-use
e. Are cylinders considered empty at 100 psi7
18. Lead Analysis
a. Make and model Scientic Class i. Instruments/33060
b. Work area adequate to perform analysis?
c. Good laboratory techniques utilized?
Comments:
Yes/
Pass
t of 21,
No/
Fdl I
Gas cylinder storage reaches low at 55 F at low ambient temperatures.
Corrected
Contractor EGEG Automotive Research, Inc.
Site San ^tomo, Texas
Prepared by Butch Naegelin
Date
12/u/En
Submitted by Mark Dalen
Date 12/11/30
-------
Page 3 of
Page
Dynamometer Inpsection
I. Make and model Clayton ECF.-50
Pass
X
2. Is dynamometer equipped with direct drive inertia
assembly? X
3. Is dynamometer equipped with 125 Ib. increment
inertia weights? X
A. Is dynamometer equipped with 50 Hp power absorber unit? X
5. Are dynamometer rolls 8.65" dia., 78" long, and on
17-25" centers and not damaged? X_
6. Is dynamometer calibration kit used? X
7. Is dynamometer horsepower calibrated in accordance with
the requirements of the contract? X
8. Horsepower meter accurate and readable to 0.25 hp
or less? X
9. Check speedometer-actual vs. indicated using a
Strobotach. For ECE 50, <|6.3 mph=l800 rpm,
I|5 mph - 1750 rpm, 55 mph- 2\><0 rpm. X
10. Tach. generator located on rear roll? X_
II. Vehicle restraint cable available? X
12. Is dynamometer equipped to measure actual distance
traveled. X
13. Capacity of fixed speed cooling fan should be 3300 CFH
(Hartzell Model N2ADUW or equiv.) and positioned 6-12"
in front of vehicle with hood open during testing? X_
Comments:
No/
Fa i I
Corrected
Driver's Aid Inspection
I. Make and model Hewlett Packard 7133 (A)
Ye-./
Pass
2. Check elapsed time for complete LA-'t test with accurate
stop watch. (Tolerance I 0 sec or less) Cell II
Serial » 1060A00302
a. Stopwatch time
b. Chart time
1873.63 sec.
I87<< sec
3. Zero and span driver's aid, check after test (t I mph)I.Omph X_
k. Zero and span driver's aid, check after test (t I ihp) .5ihp X
5. Are drivers aid strip charts within t I mph and * 1.0 sec.
for all driving cycles?
6. Chart width
7. Chart speed
mph
8. Scale 12 in.
cm
min
i n.
i n/min
mi les/inch
Comments:
n Drivers aid Serial I I606A0030I
Cell 12
A Stopwatch time: 1873.06
B Chart time:
I871I.OO
So/
FaiI Corrected
Contractor:
EG&G Automotive Research, Inc.
Prepared by: Butch Naegelin
Submitted by: Mark Oalen
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
Contractor: EG6G Automotive Research. Inc
Prepared by: Butch Naege I i n
Submitted by: Hark Oalen
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
-------
Page 5 of
Pane 6 of 2*.
Analytical System Checks Pass
I. Check for leaks in the system using daily procedure. X
2. Is the system plumbing ei ther stainless steel or teflon? X
3- Is system leak check done before and after each test? X
k. Are bags purged, evacuated, and leak checked before
each use? X
5- Are sample filters changed before each test? _
6. Are zero and span gas traces identified before and
after each analysis? X
7- Is NOX analyzer spanned through converter? X
8. Are all samples analyzed on the lowest available range? X
9. Are analyzer flows the same for calibration and sample
analysis? X
10. Are samples analyzed within 20 minutes of end of test? X
II. Do the analyzers stay in calibration throughout the
test? (± It FS) X
12. Is dilution air less than 30 ppm Carbon (less than 10
ppm C for 1975 and later model year vehicles): .
9. Fuel source pressure
10. Air pressure
II. Air source pressure
12. Sample pressure
13. Response time (zero gas to 901 span point)
(less than 3 sec) 2 sec.
14. Zero gas 5t scale return time from span point
(less than 5 sec) 1.7 sec.
15. Analyzer range(s) 0- 100 ,0-500 .0-1000 .0-5000
16. Sample bypass flow rate 6 cfh
17. Stability check p zero and span point. Enter max.
variation after 10 mins.
(t\_% FS Range 0-100 Zero 0 * FS Span _U FS)
Comments:
Contractor-
EG6G Automotive Research, Inc.
Prepared by: Butch Naege 11 n
Submitted by. Mark Oalen
No/
Fdi 1 Cor reeled
N/A
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
-------
Page 7 of
Page 8 of 2"i
Hydrocarbon Analyzer B (high range;,)
I. Make and model Horiba FIA-23A with OPE-AI5
1, Use prepurified air for zero gas-Carbon less than I
ppm, CO less than I ppm, C<>2less than *tOO ppm, NOX
less than I ppmj Mfr. AADCO Clean air O.I ppm C.
generator
3. Prepurified air used for combustion?
Mfr. Liquid Carbonics
k. Calibration gases cover all ranges?
5. Analyzed span gas available for each range?
(80% FS) min.
6. Check curve at three (3) points across each range.
Calibration shall be within t!3 of full scale or
±5$ of measured value, whichever is smaller
7. Approved peaking procedure used?
8. Fuel pressure (H2-N2)
9. Fuel source pressure
CO 10. Air pressure
II. Air source pressure
12. Sample pressure
1.0 - 1.5 kg/cm
20
psi
1 .0 - 1.5 kg/cm
Ifr Psi
6.0 psi
13. Response time (zero gas to 30% span point)
(less than 3, sec) 2 sec.
14. Zero gas 51 scale return time from span point
(less than 5 sec) I.7 sec.
IS. Analyzer range(s) 0-100 ,0-500 ,0-1000, 0-5000
16. Sample bypass flow rate 6 cfh
17- Stability check $ zero and span point. Enter max.
variation after 10 rains.
(±1* FS) Range 0-100 Zero 0 % FS Span .1 *FS
Comments:
PdbS
Contractor:
Prepared by:
Submitted by:
Butch Naegelin
No/
Fa i I
Corrected
N/A
Site San Antonio. Texas
Date 12/11/80
Mark Da I en
Date 12/11/80
Carbon Hunuxide Andly/ers A (Low
Make and model
Horiba AIA-23-AS
2. Flow rates bypass
cfh, Sample S cfh
3. Check for C02 and H20 interference using wet 3-C C02
cal. gas (less than 3 ppm on 100 ppm CO range) 0 ppm
-------
Puge 9 of 2>f
CTi
Carbon Monoxide Analyzer 6 (High Ranges)
I. Make and mode I See Carbon Monoxide Analyzer A
2. Flow rates Bypass cfh, Sample cfh
3. Check for C02 and h^O interference using wet 3$ C02
cal. gas (less than 1$ FS on 3000 ppm CO range) ppm
l|. Do calibration gases cover all ranges?
5. Analyzed span gas available for each range?
(80* FS)
6. Use prepurified air or Nj for zero gas. Concentration
CO less than I ppm, C02 less than kOO ppm, carbon less
than I ppm, NOX less than O.I ppm. Mfr.
ppm CO.
7. Check curve at seven (7) points across each range.
Calibration shall be within ill of full scale or
±5$ of measured value, whichever is smaller.
8. Response time (zero gas to 90$ span point)
(less than 5 sec.) sec.
9. Zero gas 5$ scale return time from span point
(less than 5 sec.) sec.
10. Analyzer range(s) 0- ,0-
, 0-
II. Stability check £ zero and span point. Enter max.
variation after 10 mins.
(tU FS) Range 0; Zero I FS Span *FS
Comments:
Yes/
Pass
No/
Fai I
Corrected
Carbon Dioxide Andly/er
I. Make and model Horibd AIA-23A
2. Flow rates Bypass_6_ cfh. Sample 6 cfh
3. Calibration gases cover all ranges?
k. Analyzed span gas available for each range?
(80$ FS)
5. Use prepurified air or Nj for zero gas. Concentration
CO less than I ppm, C02 less than 400 ppm, carbon less
than I ppm, NOX less than O.I ppm.
Mfr. Liquid Carbonic < AOO ppm COj.
6. Check curve at seven (7) points across each range.
Calibration shall be within tl% of full scale or
±5& of measured value, whichever is smaller.
7. Response time (zero gas to 90$ of span point)
(less than l| sec.) 7.3 sec.
8. Zero gas 5$ scale return time from span point
(less than 5 sec.) 9.23 sec.
9. Analyzer range(s) 0-1.SI, C-fr.0% .
10. Stability check P zero and span point. Enter max.
variation after 10 mins.
(JU FS) (Range 0- 1.51) Zero .1 % FS Span 0 FS
Comments:
Page 10 of 2^
Yes/ Hi,/
Pass F
-------
Page i I of 2It
Pdye 12 of 2>
Constant Volume Sampling System Inspection
I. Hake and model Horiba CVS 20B
No/
FdiI Corrected
1. Submit all pertinent data obtained during laminar
flow element calibration.
3. Where is the source of the CVS dilution air? Cel1 I
k. What is the total flow capacity of the CVS? (Hin
325 cfm) 328 cfm
5. What is CVS sample bag flow rate? (Hin 10 cfh)I5.75cfh
6. What is CVS background bag flow rate (Hin 10 cfh)
15.75 cfh
7. Check static pressure at mixing point of dilution air
and exhaust sample. Pressure should be less than 1"
H20 below ambient when the CVS is operating at its
maximum flow rate. 0.5
H,0
8. Check static pressure at the vehicle tailpipe.
Pressure shall be less than +5" H20 as referenced
in 39 Federal Register 101, Section 85.075-20(b) (2).
O £ "2°
9. Propane Recovery Test
a. Recovery shall be within +2.0% of injected volume
-0.87 % -0.86 I
b. Instrument grade propane used: Hfr. Liquid Carbonic
c. Hake and model of balance used (Accuracy within
±0.1 grams) Hettler P12IO
d. Is upper third of 0-500 ppm carbon range used?
90.3 def 83.11 def
e. Submit all pertinent data.
10. Stainless steel convoluted tubing between vehicle and
CVS as short as possible?
II. Are CVS sample bags made of tedlar and of sufficient
size not to restrict sample flow?
Comments:
Oxides of Nitrotjen Andl//er
I Mdke and model Horcbd CLA-22
Y«:s/
Pu.s
2. Flow rates 02 N/A psi Internal Bypass N/A cfh
External Bypass (if used) 6 cfh
3. Sample pressure/reactor vacuum N/A ps i N/A torr/im
It. Use prepunfied nitrogen or air for zero gas.
Concentration NOX (less than O.I ppm) <.I ppm NOX
5- Calibration gases cover all ranges?
6. Are NOX cylinder regulators corrosion resistant?
7. Analyzed span gas available for each range? (80t FS)
8. Check curve at three (3) points across each range.
Calibration shall be within tU of full scale or
±5% of measured value, whichever is smaller.
9. Spanned through the converter?
10. Response times (zero gas to 30% of span point)(5 sec max)
a. Through Converter 2.2 sec.
b. Bypass Converter 1.8 sec.
II. Zero gas 5% scale return time for span point.
(must be 5 sec. or less) it.Q sec.
12. Analyzer range(s) 0- 100, 0- 300, 0- 1000, 0;
13. Check converter efficiency (95* t 5*)? 98 I \_%
I't. Is NOX converter efficiency detector used?
15. Is converter efficiency check performed daily?
16. Stability Check (j> zero and span point. Enter max.
variation after 10 minutes - (±U FS) Range 0- 100
Zero . I I FS Span _J *FS
Comments.
140 /
Fai I
N/A
Corrected
Contractor: EG6C Automotive Research, Inc.
Prepared by: Butch NaegeIi n
Submitted by: Hark Da I en
Si te San Antonio, Texas
Date 12/11/80
Date 12/11/80
Contractor:
Prepared by:
EC&C Automotive Research, Inc.
Butch Naege 1 i n
Submitted by: Hark Oalen
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
-------
Page I 3 of
Page 11) of
Methane Analyzer
I. Hake and model
Pass
No/
Fdi I
Corrected
2. Use prepurified air for zero gas - Carbon less than I
ppm, CO less Chan I ppm, C02 less than 400 ppm, NOX
less than 0.1 ppm. Mfg. ppm
3. Prepurified air used for combustion? Mfg.
b. Calibration gases cover all ranges?
5. Analyzed span gas available for each range? (80S FS)
6. Check curve at three (3) points across each range.
Calibration shall be within i\% of full scale or
±5% of measured value, whichever is smaller.
7. Approved peaking procedure used:
8. Fuel Pressure (H2-Hg)
9. Fuel source pressure
. 10. Air pressure
II. Air source pressure
12. Sample pressure
13- Analyzer range 0- ,0- ,0-
ftdK Exh^q^L IU.-x.JfK.- Andly/er
1. Make and model Honba Hexa 32 IE
Ye-,/ Hi,/
Pd', '> Fd i 1 Cor rec ted
2. Flow rates Sample 6 cfh
3. Calibration gases cover all ranges?
V Analyzed span gas available for each range? (803 FS)
5- Use prepurified nitrogen or air for zero gas 0.I ppm C
6. Check curve at 6 points across each range.
Calibration shall be within i21 of full scale or
t\0t of measured value, whichever is smaller
7. Response time (zero gas to 90$ of span point) (less
than 5 sec) } sec.
8. Zero gas 5% scale return time from span point (less
than 5 sec). 2 sec.
9. Analyzer range(s) 0- 500, 0- 2000
Convnen t s:
N/A
\k. Method of reading output of analyzer
Comments:
N/A
Contractor:
Prepared by:
Submitted by:
EG6G Automotive Research, Inc.
Butch Naegelin
Mark Dalen
Si te San Antonio, Texas
Date 12/11/80
Date 12/11/80
Contractor: EGfcG Automotive Research, Inc
Prepared by: Butch NaegeI in
Submitted by: Mark Dalen
Site San Antonior Texas
Date 12/11/80
Date 12/11/80
-------
Pjge 15 of
Puyu 16 of 2".
Raw Exhaust CO Analyzer
) . Make and model
2. Flow rates
Horiba AIA-23-A
sample 5 cfh
Yes/
PJiS
X
X
No/
Fai 1
Cor rec ted
Corrected
3. Check for CO, 4nd r^O interference using wet 8%
CO, cal. gas (less than 1% FS on .5$ CO range)
0 ppm % FS X
k. Calibration gases cover all ranges? X
5. Analyzed span gas available for each range? (80% FS) X
6. Use prepurified air or N2 for zero gas (Concentration
CO less than I ppm) Hfr. AADCO < . I ppm X
7- Check curve at 7 points across each range.
Calibration shall be within t2% of full scale or
Hot of measured value, whichever is smaller. X
8. Response time (zero gas to 90% span point) (less
than 5 sec.) 6.2 sec. 'N/A
9. Zero gas 5$ scale return time from span point (less
than 5 sec.) 6.9 sec. *N/A
10. Analyzer range(s) 0- 2.0%. 0- 10.0%
Comments:
The times shown reflect the response times through the entire sampling system.
There is no practical method for isolating the individual analyzers to deter-
mine their response times.
I Hake and model
2. Flow rates
3. Calibration ga<
Honbd AIA-23A
Sample 5_
rail ranges?
cfh
ppm
A. Analyzed span gas available for each range?
5. Use prepurified nitrogen or air for zero gas 1
6. Check curve at 7 points across each range. Calibration
shall be within +2'{ of full scale or 110^ of measured
value, whichever is smaller.
7. Response time (zero gas to 90't of span point) (less than
5 sec.) 5.7 sec.
8. Zero gas 5* scale return time from span point (less than
5 sec.) 59 sec. _ _ __
9. Analyzer range(s) 0 -T .0% . 0-15.03
Comments :
The times shown reflect the response times through the entire sampling system.
There is no practical method for isolating the individual analyzers to deter-
mine their response times.
'N/A
Contractor:
Prepared by:
Submi tted by:
EGEG Automotive Research, Inc.
Butch Naegelin
Hark Da ten
Si te San Antonio, Texas
Date 12/11/80
Date 12/11/80
Contractor: EGtG Automotive Research. Inc.
Prepared by: Butch Naegel in
Submit ted by .
Hark Oalen
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
-------
iff!
Page I? of 21)
Page 18 of
Raw Exhaust NO Analyzer
1. Make and model Same as NOx Analyzer
2. Flow rates 02 ps i Internal Bypass chf
External bypass (if used) cfh
3. Sample pressure/reactor vacuum ps i / torr/mm
4. Calibration gases cover all ranges?
5. Analyzed span gas available? (80% FS)
6. Use prepurified nitrogen or air for zero gas.
(NOX concentration less than O.I ppm) ppm NOX
7. Check curve at points across each range.
Calibration shall be within +21 of full scale or
i!02 of measured value, whichever is smaller.
8. Response time (zero gas to 90% of span point)
(10 sec. max.)
9- Zero gas 5t scale return time from span point.
(10 sec. max.) sec.
No/
Fal I
Correc tud
10. Analyzer range(s) 0- ,0-
Comments:
,0-
0,
Contractor:
Prepared by:
Submitted by:
EG&G Automotive Research, Inc.
Butch Naegelin
Site
Date 12/11/80
ed Housing for Evaporative Detfcrmi ridl ion
Hydrocarbon analyzer
a. Make and mode)
b. Use prepurified air for zero gas - Carbon less than
I ppm, CO less than I ppm, C02 less than **00 ppm,
NOX less than .1 ppm. Mfr. __
pm C.
c. Prepurified air used for combustion? Mfr.
d. Calibration gases cover all ranges?
e. Analyzed span gas available for each range? (80t FS)
f. Check curve at three (3) points across each range.
Calibration shall be within ±1% of full scale or
-&'•£ of measured value, whichever is smaller.
g Approved peaking procedure used?
h. Fuel pressure (H2~He)
i. fuel source pressure
j. Air pressure
k. Air source pressure
I. Sample pressure
m. Response time (zero gas to 90t
span point) (less than 1.5 sec.)
Hark Da I en
Date 12/11/80
n. Zero gas 5$ scale return time from span
point (less than 5 sec) sec.
o. Analyzer range(s) 0- , 0- , 0-
p. Sample bypass flow rate cfh
2. Test Fuel
a. Does fuel meet specifications?
b. Was sample of fuel analyzed by other than manu-
facturer? (attach analysis)
c. Refrigerated fuel handling system adequate?
re-,/
Pas-,
Hu/
fa, \
Corrected
-------
Page 19 of
P
-------
Page 21 of
Paqe 22 of
Record Keeping System Check
1. Complete analytical system check made weekly?
2. Dynamometer calibration check made bi-weekly?
3. HC hang-up check using zero grade air results
recorded daily? '
Sample bag and line O.S ppm/C (less than I ppm C)
b. Are prepurified air and N2 checks suitably recorded?
A copy of manufacturer's analysis is required for
each cyIinder.
5. HC, CO, C02, NOX analytical system leak check
performed and recorded daily?
6. CVS calibration check using propane injection on
0-300C range done daily before testing begins?
7. CVS sample and background bags purged, leak checked
before each test and results recorded daily?
8. Check log of daily, weekly, bi-weekly, monthly cali-
brations and checks. Does each entry contain date,
•-J results, and signatures?
Ui
9. Check maintenance log for all laboratory equipment?
10. Check for proper test fuel as required by Federal
Register and/or contract.
I). Daily log of instrument settings.
12. Master log of all tests performed.
13. Proper storage for all instruments and driver's
trace and temperature recorder charts?
1*1. Check master log of gas cylinders (including lab
standards and span gases) to insure record of dates,
cylinder numbers, pressures, types of gases, concen-
trations, and ranges of use?
Yes/
Pel SS
No/
Fai 1
Corrected
feW No/
Pass Fai I Correc ted
15. Check i nf oriiuj 11 on on test data sheets
d Test lab location, date and time of test
b. Type of test (CVS, etc.)
c. Personnel involved.
d. Vehicle data - make, model, year, transmission
type, odometer, engine family, carb. information,
displacement, cylinders, type of emission controls,
fuel tank capacity, inertia loading, actual road load
HP i> 50 mph, indicated HP setting P 50 mph, tire
pressure, air conditioning.
e. Test conditions - Are barometric pressure and
ambient temperature (dry bulb and wet bulb) in
front of vehicle recorded continuously on strip
charts during the tests (dry bulb tolerances
68°F - 86°F).
f. Temperature and pressure of the exhaust and
dilution air mixture entering the positive
displacement pump. Temperature of the mixture
shall be recorded continuously during the test.
Set point °F max. Variation during test F.
16. Do records include vehicle inspection parameters such
as idle rpm, spark advance, idle mixture, exhaust
HC, CO, etc?
17- Check for records of all pertinent information on
recorder charts, such as: location, car and run no ,
date, time, person in charge; identify zero and span
gas traces before and after test, gas analyzed and
range(s) used?
Comments:
N/A
Contractor: EG&G Automotive Research, Inc.
Prepared by: Butch Naetje 1 i n
Submi tted by:
Hark Dalen
Site San Antonio, Texas
Date 12/11/80
Date 12/11/80
-------
Pjge 23 of
P,I
-------
APPENDIX D
Calibrat 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) Dally 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
-------
f-irr HO
DAILY WORK SUMMARY LOG
-J
00
Shift:
LNTEft TI.'IT OP COMPLETION ANU INITIALS IN LACII ACTIVITY SI'ACI
PERFORM DAILY
Analytical Bench Start Up:_
Equipment Qiecks:
PERFORM WEEKLY
Chassis Dyno Verification: Dyno 111
A/ialyzer Calibrations.
Dyno »2_
NOx Converter Efficiency:
Propane Injection Verification:
Span/Cas/Pressure Locj:
Maintenance Performed:
PERFORMED PERIODICALLY
Chassis Dyno Calibration: Dyno Vl_
CVS Flow Calibration:
Uyno «2_
Dynamometer Warm Up: Dyno »1_
Dyno *2_
Test
Number
Vehicle
Number
Vehicle
Make t
Model
Received
Main-
tenance
Precon-
ditioning
Dyno n
Dyno ft
Dyno »
Dyno *
Dyno II
pyno tt
Dyno 4
Dyno II
FTP
Dyno II
3yno *
5yno I
byno I
t>yno II
Dyno D
Dyno H
Dyno tt
Data
Reduc-
tion
Data
Valida-
tion
FTP Sequence 4
Result
(Good/Abort)
Technician's Siqnature:_
Quality Control Signature:^
SUBSCRIBED AND SWOHN TO BtrOR£ ME
THIS DAY OF , 19
NOTARY PUBLIC
MY COMMISSION EXPIRES:
-------
DAILY I'..HI I'M! NT illll'K Mttl-T
l' 1 1
I.:
1
TT
:xite
L' 1 1 • '
i 1 [ UfK t 1
(1- 1 )0 I'!
.'(TO
Dl
»ria 1 v. hcc k
t (PI -I >
iff
CO .'unct Hi
o- rnv rf
..„„
, (TO
—
Dr
Znro
Dr it l
t
No 1 si-
1.1 1 Check
1 (Rl-J)
ft
Drift
: i l -• *- ch^i-ks
u,
1
1
!
, t
F
FT
1
1
No ISO
COJ Functional Check
0-1. St (RL-l)
flat n
Zero
Drift
Zero
Drift
Noise
CO^ Functional Check
0-41 (Rl-2)
'~'A l n
Zero
Span
Drift
Zero
Jnft
System Leak Checks
Anal .
System
Bl
B2
B3
B4
R5
B6
Noise
NO*
Conv .
Eff .
HC Functional Check
0-100 PPM (R-l-1)
r.a in
Zora
L.pan
Drift
Zero
Drift
Mnise
0-500 PPM (Rl-2)
''•am
Zrro
Span
Drift
Propane
Verification
% Frror
Zero
Drift
\
Noise
NO* rupee IT jl rh.-_k
0-101" PP" {vi-i }
Oain
Zero
Span ^ei.i i t
Dr if t Pr i r t ' *Vj i *
i
I
1
NO, Functional Check
0-300 PPM (Rl-2)
<~,a i n
Zero
Span
Drift
Zero %
Drift '4oii
HC Hang-up In Ambient
Deflection Units Data
Somplu
Line
4
Bag
5
Bag
6 CO II' '
DAILY FOl'TPMrNT CHl-rK =;HEET
Daf.
Date
D.ite
CO Functional Check
0-1000 PPM (Rl-3)
Gain
Tero
Span
Drift
Zero
Drift
t
Noise
CO Functional Check
0-5000 PPM (Rl-4)
Gain
Zero
Span
Drift
Zero
Drift
Noise
NOX Functional Check
0-30 PPM (Rl-0)
Ga in
Zero
span
Drift
Drift
Noise
CO Functional Check
0-2.01 (Rl-5)
Gain
Zero
Span
Drift
Zero
Drift
Noise
CO Functional Check
0-10* (Rl-6)
Gain
Zero
Span
Drift
Zero
Drift
t
Noise
NOX Functional Check
0-1000 PPM (Rl-3)
Gain
Zero
bpan
Drift
Zero
Drift
t
Noise
C02 Functional Check
0-7. 0» (Rl-3)
Gain
Zero
Span
Drift
Zero
Drift
t
Noise
CO2 Functional Check
0-151 (Rl-4)
Gain
Zero
Span
Drift
HC Functional
0- ^"OC PPM
Gain
Zero
Span
Drift
Zero
Drift
\
Noise
Check
H£x -Too
Zero
Drift
*
Noise
HC Functional Check
0-1000 PPM (Fl-3:
Gain
Zero
Span
Drift
Zero
Drift
HC Functional Check
0-5000 PPM (Rl-4)
Gain
Zero
He. F**"
O - 3e»o f
Gain
Zero
Span
Drift
~4
WH
Span
Drift
Zero
Drift
NoliJ/
N01S
<- CHUM.
Hfjr 3.000
Zero
Drift
t
No is i?
79
-------
DATA FOKM HO.
Paqe of
DATA FORM NO.
Supplemental
SPAN I.AS I NI I illMA T I ON
STAJI CAS IIIIURltATlOH
OD
O
co2
°2
HC
TOTAL
CARBON
HEXANE
IIEXANC
NO
X
RAiiqe
11
12
11
14
15
16
11
12
U
14
11
11
12
11
14
N/A
N/A
10
11
12
11
Full
100 ppm
SOO ppm
l.OOO p|«ii
S.OOO ppw
2.0\
10. 0\
1.5»
4.0%
7.0»
IS. 01
2S.U»
100 ppm
SOO ffm
1 . OOO pp«
S.OOO |ipm
SOO f'p"
2,000 p|m>
JO M»
100 |>p«
JOG |>|H>
1,000 p|«i
S()an Gas
S|ion Fnint
Effective
Date
Lf f < ct ive Run
Numbers
CO
roa
°2
HC
TOT At,
CARBON
HEKANC
HCXANC
%
Mnqe
11
12
1J
14
IS
16
11
12
1)
14
11
11
12
1)
14
N/A
N/A
10
11
12
11
Full
10O p[K«
SOO (•!«
1.000 ppm
5. OOO ppn
2.0%
10. 0»
l.S%
4.0<
7.0t
IS.Ot
2S.O%
100 pp»
SOO ppn
1.000 (>pm
5.0OO ppK
SOO pp-
2.OOO ppn
30 pp»
100 ppo
3OO pp*
l.OOO pf*>
S|>«n C*s
Span Point
DvfKctloni
Ef frctlv*
Datt
effective Run
Nunhert
Dat«t
Dat«:
Date
Dat*:
Datei
Date
Date:
Technician:
Technician:
Technician:
Technician:
Technician!
Technician:
Technician:
Duality Audit:
Quality Auditi
Quality Audit:
Duality Audit:
Quality Aoditt .
Prepared By:
Quality Audit:
Date
Date
Quality Audit:
-------
WEEKLY ANALYZER CALIBRATION CURVE SHEET
Gas Analyzed:
Analyzer MaJcc/Model:_
Serial Number:
Zero Setting:
Range:
C«U Length:_
Recorder:
Gain:
Tim* «t Start!
an/pi
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.
Operator's Signature:
Quality Control Signature:
Vw Observer:
Completion Time:
am/pa Date:
MO.vrHLY ANALVZti? CALIbRATlON CURVE SHEET
Gas Analyzed:
Analyzer Make/Model:_
Serial Number: ^
Zero Setting:
Range:
Cell Length:_
Recorder:
Gain:
Time At Start:
Nonunal
Meter
(*l
0
90
75
60
45
30
15
bpan
90
Nominal
Concentrat.
(PPM)
0
Cylinder
Serial
Number
Cylinder
Pressure
(To Reg)
Cylinder
Pressure
(Out Reg)
Analyzer
Outlet
Flow (SCFH)
Cylinder
Concentrat.
(PPM)
Meter
Deflectioi
Operator's Signature:
Quality Control Signature:
Completion Time:
am/pro Date:
81
-------
DATA FORM 18 PACE 1 OF J
03
KJ
WEEKLY COVH20 INTERFERENCE CIUXK
DATE:
ANALYZER MODEL:
SERIAL
1. ZERO LCO ANALYZER RANGE 1 (LCO2 ANALYZER MUST BE ON RANGE 2)
2. SET RECORDER PEN ON THE 10.0 LINE OF CHART PAPER AND USE THIS AS ZERO SET
POINT.
3. INTRODUCE INTERFERENCE GAS. BUTTON SELECTION:
LCO - Master
UX>2 " SPAN
MASTER - Idle
INTF CHK - in
4. WET CO2 DEFLECTION (Bubblei should be seen in Bubbler)
S. ZERO LCO ANALYZER. WtT COj DEFLECTION MUST BE LESS THAN 3.0 PPM.
BUTTON SELECTION FOB ZERO:
LCO • Zero
LCO2 • Zero
MASTER - Idle
INTF CHK • out
OPERATORS SIGNATURE
QUALITY CONTROL SIGNATURE
DATA FOk-1 18 PACE 2 Or 2
7.LRO COMPENSATION ADJUST'irUT tOR CO; 1111 FRi ERLT.C.F
NOTE: IF ANY ADJUSTMENT ARE REQUIia.D, ALL STEPS MUST BE DONE
AFTER COMPLETION OF ADJUSTMENTS A MONTHLY ANALYZER CALIBRATION HIST
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 AND E (COM) ON MOTHERBOARD 2E
5. ZERO AND SPAN LCO ANALYZER AND RETURN TO ZERO. ( DO NOT TOUCH SPAN K.'OB AGAIN
AFTER ANALYZER IS SPANNED)
6. INTRODUCE INTERFERENCE CAS. BUTTON SELECTION:
LCO - MASTER
LC02 - SPAN
MASTER - IDLE
INTF CHK • in
7. ON MOTHERBOARD 2E, ADJUST THE CS 1 POTEHTIOMETER FOR A 0.000 *_ Inv INDICATION
ON THE VOLTMETER
8. INTRODUCE ZERO GAS AND CHECK ANALYZER FOR ZERO READING. BUTTON SELECTION:
LCO " ZERO
LCO2 - ZERO
MASTER - IDLE
INTF CHK - out
9. REPEAT STEPS »6 - 8. IF NO ADJUSTMENTS ARE REOURIEO CONTIN'.'E TO STEP * 10
10. LCO ANALYZER TO RANGE 3. CHECK ZERO. IF ZERO IS NOT CORRECT. ADJUST HI 3
POTENTlOIETER ON MOTHERBOARD 2E UNTIL VOLTMETER INDICATES 0.000 *_ Imv.
11. INTRODUCE INTERFERENCE GAS. (BUTTON SELECTION IS SAME AS STEP 16)
12. ADJUST THE CG 3 POTENTIOMETER ON MOTHERBOARD 2E FOR A 0.000 ^ Imv INDICATION
ON THE VOLTMETER. ~
13. INTRODUCE ZERO GAS AND CHECK ANALYZER FOR ZERO READING. (BUTTON SELECTION
IS THE SAME AS STEP IS)
14. REPEAT STEPS »10 - 13. IF NO FURTHER ADJUSTMETS ARE REQUIRED, THIS CC'lt 1/rrES
INTERTEItENCC ZERO COMPENSATION ADJUSTMENTS. THE ANALYZER REQUIRES A MONTHLY
CALIBRATION ON ALL RANGES.
DATE
ANALYZER MODEL/M A "3 SERIAL NO tytrt 1J0/J
WERE THE FOLLOWING POTENTIOMETERS ADJUSTED?
HZ 1 YES NO
CS 1 YES NO
HZ 3 YES NO
CG 3 YES 'NO
OPERATORS SIGNATURE
-------
00
Data Form ;g
Page 1 of J
DAILY NOX COHVERTlft EFFICIENCY TFST
DATE OF TEST:
OPERATOR
TIME:
(NO) CYLINDER II
AIR CYLINDER *
ANALYZER MAKE AND MODEL
CONCENTRATION PPM VENDOR
VENDOR POT SET
BAROMETRIC PRESSURE
HG BAROMETER TEMPERATURE
2. VERIFY THAT OZONE GENERATOR IS ON
3. FLOW CONTROL VALVES ON DRY AIR, OZONE BYPASS, AtlD NITRIC OXIDE ARE OFF
4. POWER SWITCH "OFF" AND OZONE AMD AIR SHUT OFF VALVE "CLOSED"
5. ADJUST NITRIC OXIDE FLOW CONTROL VALVE FOR 6 TO 10 SCFH
i. NOX ANALYZER TO "NO" MODE, AND SPAN TO BO.O. RECORD THIS ON CHART.
7. POWER SWITCH TO "ON".
8. OPEN OZONE t AIR SHUTOFF VALVE AND ADJUST OZONE BYPASS FLOW CONTROL VALVE TO
1 SCFH
9. ADJUST OZONE FLOW NEEDLE VALVE UNTIL THE NOX ANALYZER INDICATES APPROX. 16.0
RECORD READING
10. POWER SWITCH TO "OFF". HOTE:
DVM MUST RETURN TO 75.0 OR HIGHER. If IT DOES NOT,
REPEAT STEPS 6-9 WITH OZONE B1FASS FLOW SET AT A
LOHER RATE. ( LESS THAN 1.0 SCFH)
11. ADJUST FLOW CONTROL ON DRY AIR FLOWMETER FOR A READING OF 72.0 " 1.0
RECORD READING
12. POWER SWITCH TO "ON".
13. READJUST OZONE FLOW NEEDLE VALVE FOR A READING OF 14.4 - 1.0 RECORD R£ADING_
14. POWER SWITCH TO "OFF".
15. VERIFY THAT THE READING IS STILL APPROX. 72.0 RECORD READING
16. POWER SWITCH TO "ON" t RECORD READING
17. NOX ANALYZER TO "NOX" MODE ALLOW TO STABILIZE AMD RECORD READING
IB. POWER SWITCH TO "OFF" AND ALLOW TO STABILIZE AND RECORD READING
19. CLOSE OZONE AND AIR SHUTOFF VALVE AND RECORD STABLE KEADIIJG_
NOTE THIS READING WILL NOT BE MORE THAN 4.0 OF STEP »G
DAILY NOX CONVERTFF- FFFICM'.C/ TE:T
( IIORIBA NOW GLNEPATOR IIOLLL H2irJi
f-a-jf
20. NOX ANALYZER TO ZERO.
21. PRESS NOX GEN. BUTTON ON CONTROL PANEL TO RELEASE BUTTON TO THE OUT " OFT •
POSITION.
22. PERFORM THE FOLLOWING CALCULATION FOR PERCENT CONVERSION
(l+(a-b)/(c-d))• 100 NOTE This is how it is entered in the H/P CalcuJatcr.
a - step « 17
b - step « 18
c - step I 15
d * step I 16
Percent efficiency -
OPERATOR'S SIGNATURE
( must be over 90% )
DUALITY CONTROL SIGNATURE
-------
Data Form No. 20
a'-je i cf 1
MONTHLY
L
1
C
DYNAMOMETER CALIBRATION DATA SHEET
feouwntt troa Electrical Adjuetne
•
ntx:
Dyno I
Techni
.D. :
cian:
00
Inertia
Tim
Run 1 _
e (Secon
Run 2
is)
Run 3
Average
K
Actual RHP
DATE: DYNO I.D. No.
TECHNICIAN:
DATE OF LAST ELECTRONIC CALIBRATION:
DATE OF LAST MECHANICAL CALIBRATION:
Inertia F.F. [ R.R. Time (Seconds) Calc-»ated Oiff.
Wt. Ubs) T.W. l.H.P. Run 1 Run 2 Run 3 Averaje me ise")
Speed at
1800 R.P.M. 46.3 + .2
Thi« ri-,«errtr>un la tn ho iiturt fnr FA r , . 11^ 1
Actual Horsepower * , K Factor -
Actual RHP - Avec.ge T1B
Technician'• Signature:_
Technician's Signature:
Duality Control Signature:
am/pm Date:_
Quality Control Signature:_
Af BcB AUTOMOTIVE RESEARCH
-------
OPERATOR:
BAROMETER TEMP.
HAIL* C. F. V. PROPANE VERIFICATION
DATE:
°F
BOTTLE WEIGHT BEFOR£_
BOTTLE WEIGHT AFTER_
Vimx (SCF)
EXHAUST BAG I
HC RANGE METER DEFLECTIONS
CD
BACKGROUND BAG I _
HC RANGE METER DEFLECTIONS
OPERATOR'S SIGNATURE
QUALITY CONTROL SIGNATURE
BAROMETRIC PRESSURE
21
PFM
PPII
TIME:
DATE
DM.'._t •/,• WO
~
Pd,"
CVS-CFV FLOW CALCULATION CHECK
TIME
AH / PM TECHNICIAN
CVS MASS CALCULATION TAPE, PROGRAM ,<',
TEST 1
TEST 2
TEST 3
AVERAGE
TA (UF)
AMBIENT
TEMP
B(IN. HQ)
BARO PRESS
BT (°C)
BARO TEMP
TIME
SECONDS
A P
(IN H20)
INDICATED
\. OLUME
CALCULATEO
VOLi-i't
: iFfCPt-.
TECHNICIAN'S SIGNATURE
TIME
DATE
AM / Pn
Q. C. ENGINEER'S
SIGNATURE
TIME
DATE
AM / PM
-------
H.OW CCKi-urCH
Cat a Fn«n (V
UATA LULL I SlifL-t 1 of
CVS NUMULH
CVS NUMBER
DATE
AM/PM TECHNICIAN
NOTKl USE CVS MAii CALCULATION TAPC, PROGRAM
CO
Phase
Average
This Phase
Obs.
(In. Itg)
Avg .
Avq .
Avq .
Avq .
Avg .
Avq .
Avq .
Avg.
Avg .
(Seconds)
AP
en uri
(In. M20)
Counter
(FL.3 )
(Ft 3I
Count r
(1 t 3I
For
Fhasu
Average
Before
This Phdbu
OLis
Pressure
(Jn. lly)
Avg .
^vq .
Avq .
Tcmji
(°C)
Avq .
Avq .
Avg .
Trmp
(°f )
Avq .
Avq.
Avg .
Ti me
1 Seconds. I
6 P
Inlet DCJ
(If, H5G
Co jr.te
Inrt
Vol
.'ft 3
c* ic
v-i
;F t -
t ' ' • '
! / - ' 1
-------
Sheet
3 of 3
Applicable Speci t ic.jt ions :
Elopsrci Timo
(Seconds)
500
1000
M-ix jmum
Al lowed Error
For Single Counter
(ft.3)
10.00
15.00
Maximum Allowed
Average Error For
(Ft. 3)
6.00
9.00
Jlox j/num Al JO-H ,1
Difference lip t ^ i i. n
Any Two of the Three
Counter Kr roi s
(It.3)
B.OO
10 00
TECHNICIAN'S SIGNATURE
00
DATE
TIME
AM / FM
THIS DATA HAS BCEN REVIEWED AND APPROVED
BY ECfcGAP QUALITY CONTROL DEPARTMENT:
Thermocouples
Three bcukcrb, each of which has a capacity of at least bu
Ice (needed only if 50 water cannot DC obtained from, tj^,
Precision thermometer having NBS tracealiility
Instrument repair tool kit
Inclement for stirring water baths
CALIBRATION AMD FUNCTIONAL cncciC:
/. Use the pertinent sections of the instrument manual to maXe aj.y mocha .1 ai aaj--i-
ments which are deemed necessary after observing the recorder in op ur a LI or.
i. Allow the recorder and its servo-mechanism to warm up for at least 10 r.. ,utej
•? Osiny the beakers, tap water and the precision thermometer, rr.axe Lnrec water ^ju.i.
having different temperatures, as follows:
Cool Water bath - 50° to 60°K
o o
Room Temperature Water BaUi - 70 to dO F
Warm Water Bath - 85° to 66°F
When this is complete, check each tnermocouple aj.d its associated recorder c".- el
against the precision thermometer in each water bath in the following se^jer.cc
Room Temperature Water Bath
Cool Water Bath
Hoom Temperature Water Bath
Warm Water Bath
Koom Temperature Water Bath
When performing these checks, the water bath in use should be stirred constaj^tl^
and readings should be taken only after both the thermometer and tne recorder rea.2i:-;
have been stabilized. When changing water, baths, visually observe the transient re-
sponse of the recorder to see whether or not overshoot occurs and to see whet-ner or
not th« overshoot is less than two percent (2\} of full scale.
Usually, no overshoot will occur and a rough estimate of the instru.-ae.it dead£o.:id ex.
be obtained from the diffcrcnco between the first and second and the second a,.j Uiiru
readings of the room tenu>crature water bath. DeaJband, as indicated b> t_he ar^vc
mentioned differences, should not exceed t0.2\ of full scale. If tuc indicated j^-a^-
band does exceed ^0.2% of full scale, the readings discussed above should bo tikei
again to ensure that the high indicated deadband was not a result of temperat-re
changes in the room temperature water bath.
The temperature readings on the recorder should aqree with the corrected Lhermoretcr
readings within +l°f. If only one of the thermocouples shows A response wnich is c_i
-------
T l"np>; r.tluio J]iow a re ^.'^jj.
o
ouLslclu Ulu ^i F tolerance, the recorder gain and zero potentiometers may need ad
jubtjncat. before adjustlliij Lhc 9aln or zero potentiometers, each thermocouple s'.
t>e rucheckud against. Uie thermometer in eacli water bath to cnburc Uiat ai, out-ul-
culeraiicu uondition indeed exists.
t-SULTS Or CALIUKAT10N AND TUNCTIUNAL CHLCK:
1. Mecuon.ical Adju^uncntb Performed:
1. Electrical Adjustments Performed:
CO APPLICATION SPECIFICATIONS i KOM C1H: Accuracy to wiUun »1.8 F
oo
OTHER SPLClriCATlONS: Overshoot <2\ of full scale
Ocadiiand <0. 2\ of full scale
CALIBRATION AND FUNCTIONAL CHCCK PtwoKMED BY:
JATE: TIML: am/pm
Observer:
SUBSCRIBED TO AND SWORN TO BEFORE M
THIS DAY OF , 197
NOTARY PUBLIC
«V COMMISSION EXPIM-S:
-1 O
F i
H °
o
"n
OVERSh
FULL ?
o g
o
T
T1IEPJ
*OCOUP
n
n
n
r1
H
n
0
b
5
n
r*
5
~
H
"
H
i
r
n
IANNKL
n
z
r
1
r
l
INDIC;
'i n
a ?)
r". m
•S
INDTC
H -n
"3 3>
n
fi
n
T3
!i O
H T3
H
S3
CJ
0
'"1
u
H
*:
s
2
o
J?
a
1
15
I,'
-------
Page 1 of 7
-ATA FSRM t.Z
Page 2 of 7
DYNAMOMETER/RLPC CALIBRATION CHECX LIST
* (Dyno * ONLY, Serial »A-32206-3-578)
DVNAMOMETER NUMBER;_
TECHNICIAN:
SERIAL NUMBER:
DATE:
CO
IT)
WARM UP:
I. 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 terminal 211:_
8. REAR ROLL CALIBRATION; (Reference Figure 2)
1. Speed/power switch to: REAR ROLL
2. Positive lead of DVM to test point 2 board 8.
3. Adjust pot 3 board 8 to DVM reading of 0.000+
.002 VDC (ROLLS STOPPED).
4. Ad]ust pot 4 board 8 to DVM reading of 4.63±
.002 VDC (REAR ROLL at 1800 rpm) Time:
AM/PM
S. Hecheck pot 3 board 8 reading at O.OOCH
.002 VDC (ROLLS STOPPED) .
C. FRONT ROLL CALIBRATION: (Reference Figure 2)
1. Speed/power switch to: FRONT ROLL
2. Positive lead of DVM to test point 5 board 7.
3. 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. Recheck pot 6 board 7 reading at O.OOCH
.002 VDC (ROLLS STOPPED).
OYNAMOMETER/RLPC CALIBRATION CHECK LIST
D. DIGITAL SPEED READ-OUT CALIBRATION:
1. Positive lead 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 DVM reading of
5.000 +, .002 VDC.
4. Adjust span pot under logo on instrument box to:
50.0 mph ON DIGITAL SPEEDMETER.
E. TORQUE CELL CALIBRATION:
1. Remove vehicle - RELEASE DYNO BRAKES.
2. Switches 1 and 2 board 8 and switch 1 board 7 to:
RUM (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 SPEES'gTER.
6. Positive lead of DVM to test point 1 board 8.
7. Remove load cell hysteresis (LIGHTLY TAP LOAD CELL
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 JUST
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.
AUTOMOTIVE RESEARCH ~
AUTOMOTIVE RESEARCH
-------
Page 3 of 7
DATA FCP.1
DYNAMOMETER/RLPC CALIBRATION CHECK LIST
E. TORQUE CELL CALIBRATION; (continued)
_ 14. Adju«t pot 2 board 8 to DVM reading of 4.07;* .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 B to
proper setting - - THEN REPEAT STEPS 12 through 16.
F. DIGITAL POWER READOUT CALIBRATION:
1. Adjust power meter reading to: 00.0 HP (ADJUST SCREW
LOCATED AT LOWER RIGHT HAND CORNER^ oF^METER DVM) .
G.
2. Switches 1 and 2 board B to: CAL (AWAY FROM BOARD) .
3. Adjust pot 5 board B to: 50.0 mph (ON DITITAL SPEEDMETER>_
4. Positive lead of DVM to test point 1 board 8.
5. Adjust pot 6 board B to DVM reading of 4.070 +_ .002 VDC.
6. Adjust power span pot for reading of 40.7 (LOCATED UNDER
CLAYTON LOGO).
HORSEPOWER SCALING VERIFICATION:
1. Switch 1 board B to: RUN (TOWARD BOARD)
2. Adjust pot 5 board 8 to: SQ.O mph (ON DIGITAL SPEEDMETER)_
3. Install arbor and weights and verify reading (REMOVE
HYSTERESIS AFTER EACH WEIGHT) .
None 00.0 ±0.1
Arbor 1.9 + 0.1
Arbor + 70» 27.8 + 0.1
Arbor + 35* 14.8 + 0.1_
Arbor + 110» 40.7 +0.1
4. If not within tjolerance, STEPS "E" AND "F" REPEATED
TO CORRECT.
DYNAMOMETER/RLPC CALIBRATION CHECK LIST
H. HORSEPOWER "CAL CHECK" CALIBRATION:
1. Warm up dynamometer for minimum 15 minutes.
2. Set mode selector switch to: PEKDENT
3. Switch 1 board 8 to: RUN (TOWARD BOARD).
4. Switch 1 board 7 to: RUN (TOWARD BOARD).
5. Switch 2 board 8 to: CAL (AWAY FROM BOARL).
6. Adjust pot 5 board 8 to: 50.0 mph (ON DIGITAL SPEESMETER)
7. Remove vehicle - RELEASE DYNO BRAKES.
8. Remove load cell HYSTERESIS.
HP
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: FRONT ROLL
4. Set thumbwheel to: 30.0 ir.ph
5. Set mode selector to: THUMBWHEEL
6. Set vehicle factor to: 0.00
7. Switches 1 and 2 board 8 and switch 1 board 7 to:
CAL (AWAY FROM BOARD).
8. Adjust pot 5 board 8 to: 50.0 mph (ON DIGITAL SPEEDMETER)
9. Adjust pot 6 board 8 to: 30.0 mph (ON DIGITAL SPEEDMETER)
10. Adjust pot 6 board 8 to START LOW RATE UNLOAD
LIGHT PULSE - RECORD HP READING HP.
AUTOMOTIVE RESEARCH.~
AUTOMOTIVE RESEARCH
-------
DATA FORM NO. 301.2
Page 5 of 7
f-a-je 6 of 7
DYNAMOMETER/RLPC CALIBRATION CHECK LIST
I. DEADBAND ADJUSTMENT: (continued)
11. Adjust pot 6 board 8 to START LOW RATE UNLOAD
LIGHT PULSE - RECORD HP READING HP.
K.
12. Difference between 11 and 12 HP
(THIS IS THE DEADBAND).
13. Adjust pot 3 board 2 and 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
4. Switches 1 and 2 board 8 and switch 1 board 7 to:
CAL (AWAV 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.
8. 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.
THUMBWHEEL "SPAN" ADJUSTMENT:
1. Set thumbwheel to: 39.0 HP
2. Set mode selector to: THUMBWHEEL
_^B_ ^ •
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 SPEEDMETER.
DYNAMOMETER/RUC CALIBRATION CHECK LIST
K. THUHBWH££L "SPAN" ADJUSTMENT. (continued)
6. Adjust pot 6 board 8 to: 39.0 HP ON DIGITAL POWER METER.
7. Adjust pot 1 board 1 until LOW AMD HIGH RATE LOAD/UNLOAD
LIGHTS GO OUT.
8. 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 LOAO
LIGHT PULSE. RECORD HP READING: HP
10. Adjust pot 1 board 1 for LOAD LIGHT PULSE AND UNLOAD
LIGHT PULSE. TO BE CENTERED AROUND 39.0 HP.
(DIFFERENCE BETWEEN 8 and 9).
L. HIGH RATE DEADBAND ADJUSTMENT:
1. Set thumbwheel to: 39.0 HP.
2. Set node 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 SPEEPf-ETER.
6. Adjust pot 6 board 8 to: 40.5 mph ON DIGITAL POWER METER.
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 METER.
9. Adjust pot 1 board 2 to START HIGH RATE LOAD LIGHT.
M. DRIVER CUT-OFF ADJUSTMENT:
1. Set thumbwheel to: 00.0 HP
2. Switches 1 and 2 board 8 and switch 1 board 7 to.
RUN (TOWARD THE BOARD)
3. Positive lead of DVM to TEST POINT 1 board 8.
4. Adjust pot 1 board 8 to DVM READING OF +0.060 ^ .005 VDC.
AUTOMOTIVE RESEARCH
AUTOMOTIVE RESEARCH -
-------
DATA FORM NU. 301.2
Page 7 of 7
DYNAMOMETER/RLPC 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 B to SAME READING AS RECORDED IN
E-ll - READING (INCLUDE + OR - SIGN).
N. 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 HATER SUPPLY ON. (RECORD WATER PRESSURE).
SIGNATURE OF TECHNICIAN:
DATE: TIME:
THESE DATA SHEETS HAVE BEEN REVIEWED AND APPROVED BY EGSG-AR QUALITY CONTROL DEPARTMENT.
DATE:
AUTOMOTIVE RESEARCH -
-------
APPENDIX E
Audit Forms
LJ
1) Comments to be resolved
2) Quality Control Audit of:
Check List
3) Quality Control Audit of:
4) Qua I Ity Control Audit of:
5) Quality Control Audit of:
6) Quality Control Audit of:
7) Quality Control Audit of:
8) Quality Control Audit of:
9) Qua I Ity Control Audit of:
10) Quality Control Audit of:
11) Quality Control Audit of:
12) Quality Control Audit of:
13) Qua Iity Control Audit of:
Economy)
14) Quality Control Audit of:
Economy)
15) Quality Control Audit of:
16) Quality Control Audit of:
17) Quality Control Audit of:
18) Quality Control Audit of:
19) Qua Iity Control Audit of:
20) Quality Control Audit of:
21) Quality Control Audit of:
22) Quality Control Audit of:
23) QuaIity Control Audit of:
Non-Evaporative Hot LA-4 Precondition
Precondition Trace
Dynamometer Warm-up Check List
Driver's FTP Check List
WB/DB Chart (EPA sequence)
FTP Driver's Trace
CO/C02 Instrument Traces
CO/CC-2 Instrument Traces (Bagged Idle Test)
HC/NOx Instrument Traces
NO Instrument Traces (50 Cruise Test)
HC/NOx Instrument Traces (Bagged Idle Test)
HC/NOx Instrument Traces (Highway Fuel
CO/C02 Instrument Traces (Highway Fuel
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
-------
APPENDIX E
Audit Forms
(continued)
24) Qua Iity Control Audit of: Bagged Idle Test
25) Qua Iity Control Audit of;
26) Quality Control Audit of;
27) Qua 11ty ControI Aud J t of;
28) Quality Control Audit of;
50 Cruise Test Data Sheet
Highway Fuel Economy Data Sheet
4 Speed Idle Test (Data Sheet)
Loaded Two Mode (Data Sheet)
29) Quality Control Audit of: Computer Input and Output
30) Data Packet Enclosure Test
-------
COMMENTS TO BE RESOLVED
S. Geartvart
B. Martinez
C. Jacket
B. GILHORE
L. HERNANDEZ
R. Martinez
C. Vantassel
R. Bellows
R. Schneberger
Comments
Comments
Resolved
QC
Review
OK
01
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 Item 1-6
Completed Properly?
13) Correct Time Entered for
Last Dyno Use?
14) Are Items 9-16
Completed Properly?
IS) 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 IS.O.S.)
19) Items 21 - 28
Completed Properly?
20) Is Soak Area Temp
Between 68 F and B6°F?
21) Driver's Signature
Entered?
22) QC Signature Entered?
Yes No
Contact
Comments
Conments
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.H. Correct?
8) I.H.P. Correct?
,£, 9) SO MPH Entered
-------
i 1 f
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) Driver's Name Entered'
6) I.H. 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 Item 1-7
Properly Completed?
15) Were Vehicle Tires at
Approx. 45 PSI for Test?
16) Are Items 8-16 Properly
Completed'
17) Do Sling and Strip Chart
Agree Within 1.8°F?
18) Are Items 17-2f>
Properly Completed?
19) Starting Conditions
Pro[>erly Noted?
20) Are Items 27-41
Properly Completed?
21) Driver's Signature
Entered?
22) (JL Signature Entered?
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 Marked?
7) SOP 2 Harked?
8) Hot Soak Harked?
9) SOP 3 Marked?
10) EOT Harked?
11) DB Temp. 68°F to B6°F?
3 HIM. BAGGED IDLE
12) SOT Harked'
13) EOT Harked?
14) DB Temp 60°F to 86°F?
Yes
NO
Contac t
Comments
Comments
Resolved
50 CRUISE TEST
15) SOT Harked?
16) EOT Harked'
17) DB Temp. 68°F to 86°F'
HFET
18) SOT Harked'
19) EOT Harked?
201 DB Temp 68°F to 86°F'
4 SPEED IDLE
21) SOT Harked?
22) SOT Harked?
23) DB Temp 68°F to 86°F'
LOADED 2 MODE
24) SOT Marked?
25) EOT Harked?
26) DB Temp. 68°F to 86°F?'
Q.C. SIGNATURE ENTERED?
-------
QUALITY COtlTHOL AUDIT Of
CO/COj INSTRUMENT TRACES
QUALITY CONTROL AUDIT OF:
FTP DRIVER'S TRACE
00
1) Vehicle Number
2) Test Number
3) Dyno Number
4) Date
5) Time
6) Driver's Signature on
Trace
7) I.H. Correct?
8) I.H. P. Correct?
9) 50 HPH Entered
Adjacent to I.H. P.?
Beginning of Trace?
11) Trace OK?
12) Driving Abnormalities
Noted?
13) SO MPH Speed Check at
End of Trace?
14) Is I.H. P. Within + O.S
HP of Original Setting?
IS) QC Signature Entered?
Yes
No
Contact
Comments
Comments
Resolved
1) Vehicle Number
2) Test Number
3) Dace
4) Time Entered?
5} Signature Entered?
6) Chart Speed Entered?
7) CO Span OK? (Low Range)
8) COj Span OK? (Low Range)
9) Zero OK?
10) CO Span OK?
11) COj Span OK?
12) Zero OK?
13) CO Sample OK?
14) CO Range?
15) CO Deflection?
16) CO2 Sample OK?
17) C02 Range?
18) CO2 Deflection?
19) Ambient CO Trace OK?
20) Ambient CO Deflection?
21) Ambient CO OK?
22) Ambient CO2 Trace OK?
23) Ambient COj Deflection?
24) Zero OK?
25) CO Span OK?
26) CO, Span OK?
27) Zero OK?
28) Repeat Steps 9-27
29) All Operator Errors
Harked?
30) QC Signature Entered?
Phase 1
Yes No
Phase 2
Yes Ho
Phase 3
Ves No
Contact
Comnents
Cooaents
R*sol wed
-------
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
CO/CO2 INSTRUMENT TRACES
(Baqged Idle Test)
QUALITY CONTROL AUDIT OF:
HC/NOX INSTRUMENT TRACES
1 I Zero OK'
2) CO Span OK'
3) CO; Span OK"
4) Zero OK?
5) CO Sample OK"
6) CO Ranqe "
7) CO Deflection"
8) COj sample OK >
91 CO; Range?
10) CO? Deflection'
11) Ambient CO OK'
12) Ambient CO Deflection'
13) Ambient CO; OK?
14) Ambient CO; Deflection;
15) Zem OK?
16) CO Span OK"
1^1 CO 2 Span OK?
18) Zero Of
19) ALL OPERATOR ERRORS
HARKED'
20)Q.C. SICiNATUKE 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 CDC (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?
1 7 ) NOx Range
18) NOx Deflection
19) Ambient HC Trace OK?
20) Ambient HC Deflection
21) Ambient HC OK?
221 Ambient NOx Trace OK?
23) Ambient NOX 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
hase 2
es No
hase 3
es No
Contact
Comment s
Comments
Resolved
-------
DATA FORM NO.
QUALITY CONTROL AUDIT OF:
NO INSTRUMENT TRACES-
(50 Cruise Test)
'.•iALITY CONThOL AUDIT ',1
HT'Ilt^ lO^THIMltlT TfALti
(Ba'i'jeJ WJe lest I
o
O
1) Zero?
2) NO Sjian 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
Harked?
11) g.C. Signature Entered?
30 Second
Sample
Contact
Comments
Contnents
Resolved
11 Zero'
2) HC Span OK?
3) HOX Span OK?
4) Zero OK?
5) HC Sample OK?
6) HC Range'
7) HC Deflection?
8) NOX Sample OK'
9) NO,, Range?
10) NOX Deflection?
11) Ambient HC OK?
12) Ambient HC Deflection'
13) Ambient NOx OK?
14) Ambient NOX Del let ion?
15) Zero OK'
16) HC Span OK?
17) NOX Span OK?
18) Zero OK?
19) All Operator Errors
Marked?
20) O.C. Signature Entered"
Yes
Ho
Cont AC t
Comments
_ orane MS
Pesol /ed
-------
DATA FORM NO.
DATA FOP.'I tin
DUALITY CONTROL AUDIT OF-
HC/NOx INSTRUMFNT TRACES
(Highway Fuel Economy)
QUALITY CONTROL AUDIT OF
CO/(.02 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 R^nqe?
10) NOX Deflection'
11) Ambient HC OK?
12) Ambient HC Deflection?
13) Ambient NO, OK?
14) Ambient NOX Defletion?
15) Zero OK?
16) HC Span OK?
17) NOX Span OK?
18) Zero OK?
19) All Operator Errors
Marked'
Yea
No
20) Q.C. Signature Entered?
Contact
Comments
Comments
Resolved
1) Zero OK7
2) CO Span OK7
3) CO2 Span OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range ?
7) CO Deflection?
8) COj Sample OK?
9) CO 2 Range?
10) C02 Deflection?
11) Ambient CO OK?
12) Ambient CO Deflection?
13) Ambient CO2 OK?
14) Ambient €03 Deflection;
15) Zero OK?
16) CO Span OK?
17) C02 Span OK?
18) Zero OK?
19) ALL OPERATOR ERRORS
MARKED'
20IQ.C. SIGNATURE ENTERED'
Ye 9
No
Contact
Comments
Comments
Resolved
-------
DATA FORM HO
IUAL1TY CONTROL AUDIT Ot' •
NO INSTRUMENT TKACE;
LOADED TWO MODE
L't J^yj^jMLNT i PA: L
14 b|.pprl Idle Test)
1) Zeici OK°
2) NO Span OK?
3) Zero OK?
4) WO Sample OK?
5} No :
-------
1111
I 1 I 1 I 1
r f
DATA FOPJ1 HO
DATA FORM HO.
O
U)
QUALITY CONTROL AUDIT OF:
CO/CO; INSTRUMENT TRACES:
(4 Speed Idle Test)
11 Zero?
2) CO Span OK?
3) CO.; S|>an OK?
4) Zero OK?
5) CO Sample OK?
6) CO Range'
7) CO Deflection'
8) C02 Sample OK?
9) COn Range'
101 CO2 Deflection"1
11) Zero OK?
12) CO Span OK"
13) CO2 Span OK'
14) Zero OK'
IS) Repeat Steps 6-10
16) All Operator Errors
Marked?
17) Q.C. Signature Entered?
Basic Idle
In Neutral
Yes 1 No
Idle
2500
Yes
At
rpm
No
Basic Idle
In Neutral
Yes 1 No
Basic Idle
In Driva
Yes 1 No
1
1
Contacts/
Conn en ts
Coiranents
Resolved
QUALITY COIfTROL AUDIT OF
CO/CO;. INSTRUMENT TP-ACES
(5n Cruise Test)
1) Zero'
2) CO Span OK?
3) C02 Span OK'
41 Zero OK?
5) CO Sample OK?
6) CO Range
1) CO Deflection
8) C02 Sample OK?
9) CO? 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
Sample
Contact
Comments
TonntM t s
Pesol.'ed
• Does not apply with manual transmission.
-------
Ddt-> Form No.
DUALITY CONTROL AUDIT Ol
HEXANF 1NSTKUMLNT TRACE
(50 Cruise TesTl
; ) Zero OK?
2) Hcxane Span OK?
3) Zero OK.'
4) Hexane Sample OK?
S) Hexane Ranqe (ppm)
6) Hexane Deflection
7 ) Zero OK'
8) Hexane Span OK?
9) Zero OK?
10) All Operator Errors
Harked?
11) O.C. Signature Entered?
JO 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 (pp.mj
r. I Hexane Deflection
7) Zero OK?
8) Hexane Span OK?
9) Zero OK?
10) Repeat Steps
11) All Operator Errors
Harked?
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
~T~
Contacts/
Comments
Comments
Resolved
,' -^ IUS.TFI nun
LOADED TWO MODE
1 ) Zero OK'
2) CO Span OK?
31 CO2 Span OK'
4) Zero OK'
5) CO Sample OK'
6) CO Ranqe
7) CO Deflection
8) COj Sample OK?
9) C02 Range
10) CO2 Deflection
11) Zero OK?
12) CO Span OK?
13) CO2 Spal. OK?
14) Zero OK?
IS) Repeat Steps 1-14
marked'
30 m|
19.0
jh
\HP
Basic
Trans
Mle
In Neu
Contact
Comment: *>
omr.e r. r =
f*eS'- i "e'l
_J
;
* Does not apply with manual transmission
-------
fill!
r i
DATA FORM NO.
Page 1 of 2
QUALITY CONTROL AUDIT OF:
HEXANE INSTRUMENT TRACE;
LOADED TWO MODE
DUALITY CONTROL AUDIT OF:
CVS-CTV TEST DATA SHEET
1) Zero OK?
2) Hexane Span OK?
3) Zero OK?
4) Hexane Sample OK?
5) Hexane Range (PpfTi)
6) Hexane Deflection
7) Zero OK?
8) Hexane Span OK?
9) Zero OK?
10) Repeat Steps
11) All Operator Errors
Marked?
12) O.C. Signature Entered?
30 nph
19.0 APH
Basic Idle
Trans. In Neut
Contact
Comment!
Comment!
Resolved
o
en
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. Hq.)
8) Barometric Temp. Reasonable?
9) Dry Bulb Temp. Correct?
10) Met Bulb Temp. Correct?
11) Roll Revs. Entered
Correctly?
12)
13) VHIX 1 Reasonable?
14) VMIX 2 Reasonable?
IS) VMIX 3 Reasonable?
16) Time at SOP 1?
17) Is SOP 1 Within Two
Hours of Warm Up?
18) Time at EOF 1?
19) EOP 1 - SOP 27
20) SOP 2 - SOP 1 - +8.5 + 0.5
Minutes?
21) EOP 2 - SOP 2 - +14.5 + 0.5
Minutes?
22) SOP 3 - EOP 2 - 10 t_ 1 Min. ?
23) EOP 3 - SOP 3 - +8.5 + 0.5
Minutes?
24) ET 1 - 505 t_ 4 sec. t Stall
Seconds?
25) ET 2 - 867 + 4 Seconds?
26) ET 1 - 505 + 4 Seconds
+ Stall?
Yes
No
Contact
Comments
Coiments
Resolved
-------
Page 2 of 2
ClATA FORM NO.
QUALITY COIfTROL AUU1T Of
BAGGED WLL TEST
QUALITY CONTROL AUDIT OF:
CVS-CFV TEST DATA SHEET (CONTINUED)
27) flanges 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 O>2?
33) Ranges Correct for HC?
35) Deflections for HC
Read Correctly?
!_,
O 36) Deflections for NO*
^ Read Correctly?
37) Concentrations Correct
for HC?
38) Concentrations Correct
for NOx?
39) EOA Less Than or Equal
To EOF 1 t 20 Minutes?
40) EOA 2 Less Than or Equal
to EOP 2 t 20 Minutes?
41) EOA 3 Less Than or Equal
to EOP 3+20 Minutes?
42) Does Constant Imply last
Is OK?
43) Operator's Signature
Entered?
44) QC Signature Entered?
Yes
NO
Contact
Comments
Comments
Resolved
2) Time at START OF TEST?
3) Tune at EM) OF TEST?
4) Elapsed Tune?
5) I« Total Test TUie
3 mm. * (30 sec. )
(28.S to 30 in.hq. )
7) Barometric Temp, reasonable?
B) (VIHX) reasonable?
91 Dry bulb correct?
10) Wet bulb correct?
12) Ranges correct for CO}?
13) Deflections for CO read
correctly?
14) Deflection* for CO} read
correctly?
15) Concentrations correct
for CO?
16) Concentrations correct
for CO2?
IB) Ranges correct for NO*?
19) Deflections for 1C read
correctly?
20) Deflections for NOX read
correctly?
21) Concentrations correct
for HC?
22) Concentrations correct
for NOg?
23) EOA Less Than 20 sun. Frost
End Of Sample?
~>4) Does Cooraent Imply Test
is OK?
25) Operator's Signature Entered)
26) o.c. Signature Entered?
Yes
No
Contact
Comments
Cowmen ts
Resolved
-------
f 1
DATA FORM HO
DATA FORM NO.
QUALITY CONTROL AUDIT OFt
SO CRUISE TEST DATA SHEET
I-1
O
1) Test Start Time:
2) Test End TIM:
3) End of Sample Equal
3O Seconds:
28.5 to 30 In.Hg.?
5) Barometric Temp, reasonable?
6) Dry Bulb Temp, correct?
7) Het Bulb Temp, correct?
8) Ranges correct for CO?
9) Ranges correct for CO2?
10) Deflections for CO read
correctly?
11) Deflections for COj read
correctly?
12) Concentration* correct
for CO?
13) Concentrations correct
for CO2?
14) Ranges correct for HC?
IS) 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 NO ?
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
QUALITY CONTROL AUDIT OF:
HIGHWAY FUEL ECONOMY DATA SHEET
1) TEST START TIME!
2) TEST END TIME:
3) I« ELAPSED TIME
12.45 min. (* .5 Bin.)?
(28. 5 to 30 in.hg.)?
S) Barometric Temp. reasonable?
6) Dry bulb Temp, correct?
7) Het bulb Temp, correct?
8) VMIX reasonable?
9) Roll Revs, correct?
11) Ranges correct for CO2?
12) Deflections for CO read
correctly?
13) Deflections for CO2 read
correctly?
14) Concentrations correct
for CO?
15) Concentrations correct
for CO2?
16) Ranges correct for HC?
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.?
23) Does comment imply test
is OK?
24) Operator's signature
entered?
25) Q.C. Signature entered?
Yes
No
Contact
Comments
Cottment s
Resolved
-------
DATA FORM NO.
DATA tORM HO
QUALITY CONTROL AUDIT OF-
4 SPEED IDLE TEST (Data Sheet)
QUALITY COIITHOL AUDIT OF
LGADtU TWO HCJUi (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?
7) Ranges correct for CO?
8) Ranges correct for COj?
9) Deflections for CO read
correctly?
10) Deflections for CO 2 read
correctly?
11) Concentrations correct
for CO?
12) Concentrations correct
for C02?
13) Ranges correct for HC?
14) Ranges correct for NO ?
IS) Deflections for HC read
correctly?
16) Deflections for NO read
correctly?
17) Concentrations correct
for HC?
LS) 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
11 TEST START TIME:
2) TEST END TIME:
3) ELAPSED TIME:
28.5 to 30 in.hg.?
5) Barometric Temp, reasonable?
6) Dry bulb Temp, correct?
7) Wet bulb Temp, correct?
8) Is the I.M. 1000 lbs.7
9) Is the I.H.P. correct?
12) Deflections for CO read
correctly?
13) Deflections for CO} read
correctly?
14) Concentrations correct
for CO?
15) Concentrations correct
for CO2?
., . up?
' Kan9«s correct lor n
18) Deflections for HC read
correctly?
19) Deflections for NO* read
correctly?
20) Concentrations correct
for HC?
21) Concentrations correct
for NO,?
22) Does content unply test
is OK?
23) Operator'* Signature
entered?
24) Is R.P.H. reasonable?
?5) Q.C. Signature Entered?
Yes
No
Contact
Comments
torment s
Resolved
-------
DATA PACKET ENCLOSURE LIST
EPA Contract No. 68-03-3021)
QUALITY CONTROL AUDIT OF:
COMPUTER INPUT AND OUTPUT
VD
To be submitted with etch Oat* Packet.
I. Emissions Testing Data
1)
2)
3)
5)
6)
7)
8)
Date
Vehicle Number
Test Number
Roll Revs. Entered
Correctly
f 1977 Year Model, Were
STD Rol 1 Revs. Used
BO Entered Correctly?
BT Entered Correctly?
DB Temp Correct?
9) WB Temp Correct?
10)
VMIX Correct?
H)
12)
17)
U)
Meter Reading Correct?
Concentration Values
Correc t?
QC Signature Entered?
.es
No
Contac
Comments
Comment s
Resolved
Precondition Check List
Precondition Trace
Test Drivers Check List Pages I through 7
FTP Trace
Vehicle Refueling Records
Bench Operator Data forms Pages 1 through 7
WB/OB Trace
Soak Area Trace
Analytical Traces
CVS Print-Out
Quality Audit Work Sheets
Vehicle Drlveabillty Report
Highway Fuel Economy Print-Out
Bagged Idle Print-Out
Test Validity Statement
II. Procurement Data
Telephone Survey (302^.2)
Incoming Inspection Form, ( 302^.6)
Test Agreement (3021*.I)
Test Agreement Addendum (302"<.3)
Standard Vehicle Loan Agreement (302'<.'<)
Savings Bond Information Sheet (302'<.6)
Vehicle Owner Questionnaire Data Sheet
Supplemental Owners Survey
Loaner Vehicle Log (302^.7)
Mechanics Inspection Form (302l<.9)
Vehicle Maintenance Log (302<«.IO)
EPA Data Pack
Vehicle Information Sheet (30214.12)
Post Test Inspection Form (302
-------
TECHNICAL REPORT DATA
(Please rttd Inuructiora on the reverse before completing)
1 FUPORT NO. 2.
4 TITLE AND SUBTITLE
A Study Of Emissions From Light Duty Vehic es In
San Antonio, Texas
7 AUTHORIS)
Mark Dalen, Maurice Forshee
9 PERFORMING ORGANIZATION NAME AND ADDRESS
EG&G Automotive Research, Inc.
5404 Bandera Road
San Antonio, Texas 78238
12 SPONSORING AGENCY NAME AND ADDRESS
Environmental Protection Agency
2565 Plymouth Road
Ann Arbor, Michigan 48015
15 SUPPLEMENTARY NOTES
3. RECIPIENT'S ACCESSION NO.
6. REPORT DATE
September 1982
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
EPA 460/3-82-009
10. PROGRAM ELEMENT NO.
\ 1. C6NTRACT/GRANT NO.
68-03-3024, year 2
13 TYPE OF REPORT AND PERIOD COVERED
Final : 7/29/81 to 7/29/82
14. SPONSORING AGENCY CODE
16 ABSTRACT
Three hundred 1978 through 1982 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 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.
17. KEY WORDS AND DOCUMENT
a. DESCRIPTORS b.lDENTI
Emissions-Exhaust Gases
Gas Ana I ys i s
Air Pol I ut ion
18. DISTRIBUTION STATEMENT 18.SECU
Un
20.SECU
Un
ANALYSIS
FIERS/OPEN ENDED TERMS C. COSATI Field/Group
RITY CLASS (This Report) 21. NO. OF PAGES
class f ed 109
RITY CLASS (Thilpatt) 22. PRICE
classi f ied
EPA Form 2J20-1 (»-73)
------- |