United States
Environmental Protection
Agency
Motor Vehicle Emission Lab
2565 Plymouth Rd.
Ann Arbor, Michigan 48105
EPA-460/3-80-026
November 1980
oEPA
Air
Operation of a Pilot
Motor Vehicle Inspection
Station in Houston, Texas
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EPA-460/3-80-026
OPERATION OF A PILOT
MOTOR VEHICLE INSPECTION STATION
IN HOUSTON, TEXAS
By
HAMILTON TEST SYSTEMS, INC.
2303 East Thomas Road
Phoenix, Arizona 85016
Contract No. 68-03-2894
EPA Project Officer: David J. Brzezinski
Prepared for:
ENVIRONMENTAL PROTECTION AGENCY
Office of Air, Noise and Radiation
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
Characterization and Applications Branch
Ann Arbor, Michigan 48105
NOVEMBER, 1980
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This report is issued by the Environmental Protection Agency to
disseminate technical data of interest to a limited number of readers.
Copies are available free of charge to Federal employees, current
contractors and grantees, and nonprofit organizations - in limited
quantities from the Library, Motor Vehicle Emission Laboratory, Ann
Arbor, Michigan 48105, or, for a fee, from the National Technical
Information Service, 5285 Port Royal Road, Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
Hamilton Test Systems, Inc., 2303 East Thomas Road, Phoenix, AZ
85016, in fulfillment of Contract No. 68-03-2894. The contents of this
report are reproduced herein as received from Hamilton Test Systems,
Inc. The opinions, findings, and conclusions expressed are those of the
author and not necessarily those of the Environmental Protection
Agency. Mention of company or product names is not to be considered
as an endorsement by the Environmental Protection Agency.
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ABSTRACT
In conjunction with an EPA project to assess methods, costs, projected effectiveness
and acceptability of various motor vehicle exhaust emissions inspection and
maintenance (I/M) alternatives, and to support the State of Texas in complying with
its implementation plan, the Office of Mobile Source Air Pollution Control of the U.
S. Environmental Protection Agency assisted the Texas Air Control Board in
establishing a pilot motor vehicle emissions inspection and maintenance program in
Houston, Texas. A portion of the program involved the operation of a centralized
vehicle emissions inspection station which performed idle tests, underhood
inspections of emission control systems and components, and physical/functional I/M
tests to simulate the operation of the various alternative configurations for the
legislatively mandated I/M program. The contract for the centralized concept was
conducted by Hamilton Test Systems, Inc. of Phoenix, Arizona.
The purpose of the contract was to assist the Texas Air Control Board in evaluating
the cost and technical details of operating a centralized vehicle emissions inspection
station using an underhood inspection of emission control systems and components
with either an idle mode tail pipe emission test or a "physical/functional" test
procedure. A total of ^,647 vehicles was tested using one or both procedures during
the span of the contract. Each vehicle was to be determined to have "passed" or
"failed" using criteria established by the EPA. Specific instructions regarding test
procedures, cutpoints, data handling and reporting was also provided by EPA.
Hamilton Test Systems (HTS) was responsible only for the set up and operation of the
inspection station. HTS was not responsible for soliciting vehicles for participation
in the pilot I/M program, or for evaluation and analysis of test data.
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11
TABLE OF CONTENTS
SECTION PAGE
1.0 INTRODUCTION 1
2.0 FACILITY 4
2.1 FACILITY SELECTION 4
2.2 FACILITY AS SELECTED 4
2.3 FACILITY MODIFICATIONS 5
3.0 EQUIPMENT 9
3.1 LIST OF EQUIPMENT 9
3.2 EQUIPMENT SPECIFICATION 12
3.3 EQUIPMENT DESCRIPTION 18
4.0 INSPECTION PROCEDURES 26
4.1 TEST DESCRIPTION - AUTOMATIC MODE 26
/
4.2 SPECIAL OPERATION MODES 34
4.3 EXPERIMENTAL TESTS 37
5.0 DATA HANDLING 40
5.1 DATA TRANSMITTAL PROCEDURES 40
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Ill
TABLE OF CONTENTS
SECTION PAGE
5.2 DATA FORMAT , 41
5.3 VIR PRINTOUT LOGIC 49
6.0 PROGRAM RELATED ACTIVITIES 63
6.1 INSPECTOR RECRUITMENT AND TRAINING 63
6.2 MAINTENANCE AND CALIBRATION 64
6.3 VEHICLE RECRUITMENT 67
6.4 PROGRESS REPORTING 69
7.0 INSPECTION SUMMARY 71
7.1 PATTERN OF INSPECTION 71
7.2 DIFFICULTIES ENCOUNTERED AND RESOLUTIONS 78
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IV
TABLE OF CONTENTS - ILLUSTRATIONS
FIGURE PAGE
2.3-1 FACILITY EXTERIOR 6
2.3-2 FACILITY LAYOUT 7
2.3-3 FACILITY POSITIONS AND EQUIPMENT LAYOUT 8
3.1-1 EQUIPMENT INTERCONNECT AND DATA FLOW 11
5.3-1A FRONT OF VIR FORM 50
5.3-1B BACK OF VIR FORM 51
7.1-1 WEEKLY TEST VOLUME GRAPH 73
7.1-2 WEEKLY VOLUME AS PERCENT OF CAPACITY GRAPH 76
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TABLE OF CONTENTS - TABLES
NUMBER PAGE
5.2-1 VTR FORMAT *2
5.3-1 VIR PRINTOUT 52
7.1-1 TOTAL INSPECTION PER OPERATION WEEK 72
7.1-2 PERCENTAGE CAPACITY USED ... 75
7.1-3 TEST VOLUME PER DAY OF THE WEEK 77
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VI
TABLE OF CONTENTS - APPENDICES
A. INSPECTOR TRAINING MANUAL
B. PERIODIC MAINTENANCE MANUAL
C. REPORTING GUIDELINE
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1.0 INTRODUCTION
This document represents the final report in fulfillment of the
requirements of Contract 68-03-2894 and summarizes the work performed
under the subject contract by Hamilton Test Systems, Inc. for the U. S.
Environmental Protection Agency (EPA).
The Clean Air Act Amendments of 1970 made each State responsible for
assuring air quality within its boundaries. The State was to do this by
preparing and following an Implementation Plan specifying the manner in
which national air quality standards would be achieved by 1975 and
maintained thereafter. The State's Plan for each air quality control
region was made subject to the approval of the EPA Administrator.
In conjunction with an EPA project to assess methods, costs, projected
effectiveness and acceptability of various motor vehicle exhaust
emissions inspection and maintenance (I/M) alternatives, and to support
the State of Texas in complying with its implementation plan, the Office
of Mobile Source Air Pollution Control of the U. S. Environmental
Protection Agency assisted the Texas Air Control Board in establishing a
pilot motor vehicle emissions inspection and maintenance program in
Houston, Texas. A portion of this program involved the operation of a
centralized vehicle emissions inspection station which performed idle
tests, underhood inspections of emission control systems and components,
and physical/functional I/M tests to simulate the operation of the various
alternative configurations for the legislatively mandated I/M program.
The contract for the centralized concept was of twelve (12) months'
duration, and was conducted by Hamilton Test Systems, Inc. of Phoenix,
Arizona. The twelve-month period was divided into a Start-Up Phase and
an Operational Phase. The Start-Up Phase commenced September 29,
1979, and the Operational Phase March 3, 1980.
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The purpose of the contract was to assist the Texas Air Control Board in
evaluating the cost and technical details of operating a centralized
vehicle emissions inspection station using an underhood inspection of
emission control systems and components with either an idle mode tail-
pipe emission test or a "physical/functional" test procedure. A total of
25,000 vehicles was to be tested using one or both procedures during the
span of the contract. Each vehicle was to be determined to have "passed"
or "failed using criteria established by the EPA." Specific instructions
regarding test procedures, cutpoints, data handling and reporting was also
provided by EPA. Hamilton Test Systems (HTS) was responsible only for
the set up and operation of the inspection station. HTS was not
responsible for soliciting vehicles for participation in the pilot I/M
program, or for evaluation and analysis of test data.
The details of the implementation and operation of the Houston pilot
inspection program are contained in Sections 2 through 8. The following
paragraphs briefly summarize the vehicle testing.
The Operational Phase for vehicle testing commenced on March 3, 1980
and ended on August 30, 1980. During this time 4674 vehicles were
inspected. On each vehicle the following inspections were performed:
1. vehicle identification/registration data entry
2. test suitability inspection
3. tire inflation
4. emission inspection - HC, CO, CO2> and rpm measured at idle,
2500 rpm and again at idle
5. steering alignment (toe-in, toe-out)
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6. visual inspection of ECS equipment
a) PCV
b) air injection
c) EGR
d) fuel evaporative system
e) catalytic converter
f) leaded fuel restrictor
7. propane enrichment check
8 ignition timing check
9. inspection report generation and presentation to motorist.
All test data were recorded on floppy disks and then transcribed to a
magnetic tape for transmittal to the EPA for analysis.
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2.0 FACILITY
2.1 FACILITY SELECTION
Facility selection criteria consisted mainly of location, availability, cost
of lease and ease of refurbishment and modification. Specific site location
in Houston was highly important due to the vast sprawl of the city and
heavy traffic congestion in many areas. The short period allotted for the
start-up phase required a site that could be leased and occupied rapidly
without extensive and costly modification. Other items considered were
queue line capacity, test lane configuration and participant waiting and
information areas.
2.2 FACILITY AS SELECTED
The scarcity of leasable commercial property was evident from the
beginning. Fortunately, HTS located a building at 4303 San Felipe Street
that was well suited for the Houston Pilot Emissions Test Program.
Fronting on San Felipe Street, a major heavily travelled arterial close to
the Galeria Mall and the Interstate 610 Loop, the area site was easily
identified and accessible. The original construction was for an auto
dealership, providing HTS with a spacious testing and office area.
The office complex consisted of a reception and waiting room, manager's
office, conference room, employees' lounge, computer room and
restrooms. The eventual testing area was comprised of a large workshop,
a parts department, and the paint shop. This large building was selected
because of the initial requirement to design a high technology emissions
test lane with capability of adding safety inspection. However, safety
inspection was never implemented.
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2.3 FACILITY MODIFICATIONS
To prepare the building for proper test lane operation several
modifications were required.
A. Due to test lane area configuration, four test positions were
established for optimum thruput. Exhaust removal systems were
installed in three of the test positions including excavating a pit
at Position 2 for the underground exhaust system louvers. Large
holes were cut in two walls to allow vehicles to enter and exit
Position 3. Electrical wiring was added to service the test
equipment and interconnect the computers with their respective
terminals. Existing auto service equipment such as lifts were
removed. After all major modifications were completed the
entire shop interior was steam cleaned and painted, and traffic
lane stripes added.
B. Modifications to the office complex included enlarging the
participant waiting room by removing an office wall, painting the
remaining walls, and installing new carpeting. The employees
lounge and conference room were cleaned and painted. New
carpeting was installed in the lounge and computer room.
Reducting of the air conditioning system was also required for
adequate cooling of the computer room.
C. To facilitate employee parking and traffic ingress to the test
lane, a portion of the adjacent vacant lot was also leased, and a
small asphalt parking lot and queue lane area was added to the
exterior of the facility.
D. Solar sunscreen sheeting was applied to the showroom windows
and the roof was patched to stop several water leaks.
Figure 2.3-1 shows the facility exterior. Figure 2.3-2 shows the final
layout of the facility, and Figure 2.3-3 shows the facility positions and
equipment layout.
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DRIVE IN FOR AUTO
POLLUTION CHECK
FIGURE 2.3-1 FACILITY EXTERIOR
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COUNSELING AREA
CRT
COS. 4
PRINTER
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WAITING AREA
OFFICE CORE
///////////////////
7 -
EXH.
LOUVER
EMS
TEST CUE
PANEL
SCUFF
GAUGE
POS. 1
POS. 3
FIGURE 2.3-3 FACILITY POSITIONS AND EQUIPMENT LAYOUT
oe
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3.0
EQUIPMENT
3.1
This section describes the various equipment used in the Houston pilot
emission program. It concentrates on technical aspects since the use of
this equipment is described in the Inspection Procedure section of this
report, and the Inspector Training Manual attached.
LIST OF EQUIPMENT
The following lists the equipment used in the program by type,
manufacturer, model or part number, and quantity.
Type
Manufacturer
1. Emission Computer
2. Auxiliary Computer
3. Emission CRT
*. Auxiliary CRT
5. Emission Measure-
ment System (EMS)
6. Test Cue Panel
7. Exhaust Louvers
8. VIR Printer
9. Scuff Gauge
10. Timing Light
11. Tire Pressure
Gauge
12. CO Monitor
(Ambient)
Digital Equipment Corp.(DEC)
Alpha Micro
Applied Digital Data
Systems (ADDS)
ADDS
Hamilton Test Systems (HTS)
HTS
Clayton Manufacturing Co.
DEC
Applied Power
Mac Tools
Sears Roebuck
Scientific Engineering
Model
or P/N
Quantity
11/3* 1
AM-100 1
Regent 100 2
Regent 100 1
HT200600-1 1
HT2008*0-1
3-DES/O
LA-35
BEAR 2*0
TL-86
1
1
1
1
3
3
Ecolizer
*000
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10
Model
Type Manufacturer or P/N Quantity
13. Digital Engine Heathkit CM-1550
Analyzer
14. Stand-Alone HTS CEA-610
Analyzer
Figure 3.1-1 shows the equipment interconnect and the data flow.
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C 0
MONITOR
EMS
EMISSIONS CRT
{(REGISTRATIONS
' AND TEST SUITIABILITY
LDAIAI
EMISSIONS
COMPUTER
TEMfSSIONS"1
TEST DATA)
AUXILIARY CRT
[(FUEL ECONOMY DATA)!
11
TCP
LOUVERS
EMISSIONS CRT
i (ECS DATA)
U«.*.4
VIR PRINTER
j(TEST PRINTOUT)!
"
AUXILIARY
COMPUTER
(ODMPLETE
TEST DATA) j
BULK STORAGE
!( COMPLETE 1
L.IEST..RECOR.DJJ
1
|(MANUALY ENTERED)
;
TIRE PRESSURE
GAUGE
i
SCUFF
GAUGE
'
. TIMING
LIGHT
PROPANE
INJECTION
FIGURE 3.3-1 EQUIPMENT INTERCONNECT AND DATA FLOW
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12
3.2 EQUIPMENT SPECIFICATION
3.2.1 Emission Computer
The emission computer used was Digital Equipment Corporation PDF
11/34 configured as follows:
A. CPU & Memory
. 16-bit word direct addressing of 32K word memory
. hardware implemented multiply and divide instruction
. parity detection on each 8-bit byte
B. Peripherals Interface
. 20 MA current loop multiplexer
C. Mass Storage
. dual RK05, random access data storage of 1.2 million words
each
. dual RX01 floppy disk, random access data storage of 256K
words each.
D. System Console
. DEC LA-36 printer
3.2.2 Auxiliary Computer
The auxiliary computer used was Alpha Micro AM-100 configured as
follows:
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A. CPU & Memory
. general purpose micro-programmed
. 8-bit word of 64K RAM byte
B. Peripheral Interface
. 6 RS-232 compatible I/O ports
. 1 parallel and 2 serial I/O ports
C. System Console
standard CRT
3.2.3 Emission CRT & Auxiliary CRT
The emission and auxiliary CRT used were Applied Digital Data System
model Regent 100 with the following features:
A. Display Characteristics
. 64 displayable characters
. character size of 0.20" high and 0.11" wide
. 5X7 dot matrix
. nondestructive cursor
. 80 characters per line
. 24 lines on a full screen
. 2400 baud transmission speed
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B. Operating Functions (Software Control)
. field protection (to prevent operator keyboard data entry to
protected fields)
. tab to unprotected fields
. overstrike editing
. cursor wraparound
3.2.4 Emission Measurement System
The Emission Measurement System used was Hamilton Test Systems part
number HT200600-1 containing:
A. Emission Processor (PN HT200830-1)
. 8K word of random access memory
. data for operation (emission limit and analyzer curves were
stored and loaded via magnetic tape cassette)
B. Sample System
. sample probes
. water separator
. air dryer
. sample pumps
. filter
. solenoid valve
. interconnect tubing
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15
C. Gas Analyzers (PN HT200850-1 and HT200067-1)
. NDIR temperature control optical benches
. analyzer ranges:
HC: 0-2000 ppm n-hexane
CO: 0-10% CO
CO2: 0-20% CO2
D. Maintenance/Relay Panel (PN HT200810-1)
. status lights
. control switches
E. Filter Panel (PN HT200820-1)
. flow control valve
. analyzer flow meters
F. Emission Data Entry Panel (PN HT200835-1)
. keyboard entry
. innunciation lights
. display windows
3.2.5 Test Cue Panel
The Test Cue Panel used was Hamilton Test Systems unit part number
HT200840-1 with the following features:
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test status lights
display windows
special message display lights
3.2.6 Louvers
The louvers used were Clayton model 3-DES/O with the following
features:
pneumatic-hydraulic driven actuators
2 independently operated louver panels for accommodation of
various length vehicles
adjustable louver opening/closing time
3.2.7 VIR Printer
The VIR printer used was DEC LA-35, Receive only, with the following
device characteristics:
RS-232 interface
64 ASCII printable characters
30 characters per second print speed
80 characters per line
3.2.8. Scuff Gauge
The scuff gauge used was Applied Power model Bear 240 with the
following features:
surface mounted
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17
up to 16,000 Ibs. per axle capability
mechanically operated
automatic reset
3.2.9 Timing Light
The timing light used was Mac Tools model TL-86 with the following
features:
timing advance
adjustable flash from 0-60 degrees
linear Xeon flash tube
3.2.10 Tire Pressure Gauge
The tire pressure gauge used was Sears Roebuck with following features:
pencil type
10- 60 Ib. scale
3.2.11 CO Monitor
The CO monitor used was Scientific Engineering model Ecolizer 4000 with
the following features:
calibration meter
visual alarm
0-500 ppm range
adjustable set point
explosion proof housing
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18
3.2.12 Digital Engine Analyzer
The digital engine analyzer used was Heathkit model CM-1500 with the
following features:
4-digit liquid crystal display
inductive pickup rpm probe
2 rpm ranges
additional engine analyzing capability (dwell, volts, amp, ohms)
3.2.13 Stand-Alone Emissions Analyzer
The stand-alone analyzer used was Hamilton Test Systems computerized
emission analyzer model CEA-610 with the following features:
microprocessor logic
digital readout of HC, CO and rpm
auxiliary hand-held digital display panel
paper tape printer
flow fault indicator
3.3 EQUIPMENT DESCRIPTION
The concept used for the equipment in this program was based on a proven
approach to the operation of an automated vehicle inspection station.
The following is a brief description of the equipment used.
3.3.1 Computer Equipment
The computer equipment was required to control the automated
inspection test process and to ensure proper real-time validation of the
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19
inspection data accumulated for subsequent storage. The responsibility
for these tasks was divided between three levels of system computer
control: the emissions computer, the auxiliary computer and the lane
Emissions Measurement System (EMS) processor.
The emissions computer was responsible for orchestrating the automated
emissions inspection process. It had the primary responsibility for
performing the real-time data acquisition and performance monitoring
aspects of all automated emissions inspection. The emissions computer
had the capacity for simultaneous handling of all real-time system
interrupt requests and for performing data transfers from and to its
associated lane peripherals located in all positions of the lane.
The auxiliary computer had the responsibility of receiving the real-time
inspection data from the emissions computer and the manually-entered
test data for the fuel economy tests performed. The auxiliary computer
had the capacity of performing the logic required for the VIR printout and
the storage of the completed inspection data.
The EMS processor was fully self-sufficient, being capable of executing an
emissions test cycle as an independent, stand-alone piece of emissions
test equipment, or in conjunction with the emissions computer.
3.3.2 CRTs
All CRTs used in the program had the capability of supporting a full-
screen format that was generated by the appropriate computer as a
"background form" for which the operator had to "fill in the blanks." The
data acquired in this manner was transferred to the appropriate computer
when the test operator was satisfied that the data entries were correct
and signalled the terminal to transmit the data.
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3.3.3 Emissions Measurement System
The Emissions Measurement System used in the program was an HTS
designed, fully developed, production vehicle emissions test system. This
was the same system that has proven itself in the high-volume vehicle
emissions testing facilities operated by HTS in California and Arizona.
Operated by an inspector, the EMS measured vehicle emissions for
compliance with the advisory emissions standards established for this
program. The EMS passed samples of the vehicle exhaust through gas
analyzers to measure the HC and CO concentrations. The results were
automatically compared with permissible levels for the type and model
year of vehicle under test. In addition, results were stored and
transmitted to the emissions computer from which they were ultimately
transferred to the auxiliary computer. C©2 emissions were also measured
to establish sample validity and became part of the vehicle's test record.
In addition to the gas analysis, the EMS also measured the vehicle's engine
rpm for conformance to the idle rpm limits.
The Emissions Measurement System included two main subsystems: the
emissions processor and the emissions analysis subsystem. The emissions
analysis subsystem was comprised of various subsystems which included:
sample system, gas analyzers, maintenance/relay panel and filter panel.
In addition to the above, the Emissions Data Entry Panel and the Test Cue
Panel were connected and interfaced to the EMS system.
3.3.3.1 Emissions Processor Subsystem
The Emission Processor, a small digital computer, performed the
following functions:
A. Controlled the emissions analysis subsystem.
B. Prompted and cued inspector during measurement.
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21
C. Converted raw analog measurement and status data to digital
information.
D. Performed necessary calculations.
E. Compared results to the established emissions standards.
F. Displayed emissions values and compared results.
H. Transmitted data to the emissions computer.
3.3.3.2 Emissions Analysis Subsystem
A. Sample System
The Sample System drew a sample of exhaust via a probe(s). The
sample was dried, filtered and a portion was pumped via a special
pump through the NDIR gas analyzers which detected
hydrocarbons, carbon monoxide, and carbon dioxide
concentrations in the exhaust gas sample.
B. Gas Analyzers
The emissions analyzers were a nondispersive infrared (NDIR)
device specifically developed for interfacing with digital control
electronics. As a result of this digital implementation, several
factors were incorporated which were unique to this approach.
. The use of digital techniques enabled automatic analyzer zero
compensation.
. Enabled precise compensation for the non-linearities
associated with the gas absorption properties.
. enabled ambient pressure and gas temperature compensation.
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22
A digital display for backup mode operation eliminated operator
interpretation errors, as compared to an analog meter display.
The basic analyzers had a range of 0-2000 ppm HC and 0 to 10% CO which
adequately covered the ranges required for this application for all four-
stroke gasoline vehicles.
C. Maintenance/Relay Panel
The Maintenance/Relay Panel was a subsystem which provided
the interface between the emissions processor and controlled
devices that operated on 110 VAC. It also provided the system
fault indicators, manual control switches and fuses.
D. Filter Panel
The filter panel contained the ambient air and fine analyzer
filters. It also provided selection of various gases during
calibration and for adjustment of correct individual analyzer
flow.
3.3.3.3 Emissions Data Entry Panel
The Emissions Data Entry Panel was the interface between the inspector
and the emissions processor. This panel provided inputs and displays. A
computer type keyboard with sixteen keys and an ENTER key enabled the
inspector to feed data into the processor and provided the inspector with
certain operating options for the EMS.
A series of lights were used by the processor to: prompt and inform the
inspector to ENTER QUEUE NUMBER, ENTER VEHICLE CLASS, and
ENTER INSPECTION NO./CODE. Other lights (HC and CO LIMIT)
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23
indicated when these gas concentrations had exceeded permissible
limits. SAMPLE ERROR, KEYBOARD ERROR, and SYSTEM ERROR
lights indicated when a mistake or malfunction existed.
Four-digit displays were used to display readings of gas concentrations
during testing.
3.3.3.* Test Cue Panel
The function of the Test Cue Panel was to provide test status and
sequencing information to the test operator. The message displays on the
panel were the primary means for giving instructions to the inspector.
The messages were labeled to conform to test lane operation. Three
message indicators were provided to inform the inspector of the overall
test status. Other prompts indicated: (1) the vehicle/test mode
condition ; (2) a diluted sample condition (low CO2 reading) ; (3) the
Emissions Measurement System is in the backup mode (not communicating
with the emission computer); and (4) there is an ambient CO message on
the emission computer console.
3.3.4 Exhaust Removal Louvers
Behind the emissions inspection position in the test lane, a set of exhaust
removal louvers were installed. Each louver extended across the test lane
and covered a pit that was vented to the exterior of the facility by an
exhaust system capable of maintaining safe lane ambient air levels. The
louvers were lowered as the vehicle under test moved into the test
position. Then at the start of the test the inspector selected one of the
louvers to be opened by the EMS. This selection was based on the
vehicle's exhaust system configuration in order to achieve maximum
exhaust removal from the facility. The actuators that raised and lowered
the louvers were only powerful enough to raise the louvers, thus
eliminating any danger of personnel injury or vehicle damage.
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3.3.5. Vehicle Inspection Report (VIR) Printer
The VIR printer, which was a "receive only" device, was used to print the
double continuous VIR. It was connected to the auxiliary computer and,
therefore, all inspection related data on the VIR was computer generated.
3.3.6 Scuff Gauge
The scuff gauge used was Applied Power Bear-240. This was a floor-
mounted wheel alignment tester capable of measuring side slip or drag.
The check was performed by driving the vehicle over the floor-mounted
plate. Vehicles were driven at a slow speed of 1-3 mph.
As each tire rolled across the platform, it came into contact with a
sensitive blade that moved freely in a lateral direction. If the wheel was
out of alignment and thus had a side drag or scuff action, it moved the
blade in the direction of the scuff.
The amount of lateral movement of the blade was instantly recorded on
the dial. The reading remained on the dial until reset. The trip
mechanism reset the pointer to zero as the next pair of wheels moved
across the trip plate.
3.3.7 Timing Lights
The timing light used was the gun type light with the light trigger
mounted at the handle. The ignition timing was picked up by the
inductive pickup arm attached to the plug wire. The amount of timing
advance was determined by reading a round adjustable dial at the back
end of the timing light.
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25
3.3.8 Ambient CO Monitors
The ambient CO monitor was installed on the side of the EMS, 5 feet
above the floor, with the pickup pointed toward the vehicle's line of
travel. The output of the CO monitor was an electrical signal indicative
of the concentration of ambient CO in the test lane at that point. That
signal was used by the emissions processor in the EMS to compute: (1)
the current concentration level, (2) the accumulative level (ppm-hrs), and
(3) the rate of accumulation.
This data was transmitted to the emissions computer which monitored the
readings to ensure ambient CO levels were within established safety
levels.
3.3.9 Propane Injection
The equipment used for the propane injection test consisted of: (1) a
propane cylinder connected to a hose and a middle valve, and (2) a
digital rpm meter. The propane cylinders were 3-lb. cylinders used by
recreational type vehicles.
The digital rpm meter was connected to any engine spark plug wire using
the inductive pickup. By setting the digital analyzer to the 0-2000 rpm
scale, the change in engine rpm, due to the propane injection, was
detected.
3.3.10 Stand-Alone Analyzer
The stand-alone analyzer was available whenever the EMS could not be
used for emissions testing. Accuracy of measurement was not
compromised since the CEA-610 was a micro-processor control analyzer.
Before any vehicle exhaust measurements were taken, an automatic zero
and electrical span was performed by the micro-processor. The HC range
of 0-2000 ppmh and 0-10% CO, plus the rpm measurement, were
comparable to the EMS.
All measurements were recorded on the built-in paper tape.
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26
INSPECTION PROCEDURES
TEST DESCRIPTION - AUTOMATIC MODE
Position 9 1 Test Description
When a vehicle arrived at the test facility for inspection, it entered the
station and was directed to stop at Position// 1.
A. The inspector detached a queue card from the queue card pad and
entered the queue card number into the CRT. This entry, which
was the "Log-On" function, allocated the vehicle test file in the
emissions computer memory and enabled the emissions computer
to track the vehicle data sent to it through the various test
positions. The inspector then gathered and entered vehicle
information data which identified the vehicle and determined how
the vehicle was to be tested. This function was called
"Registration Information Entry."
The data entered was:
. vehicle model year
. vehicle make
. retest counter number
. vehicle plate number
. vehicle identification number (VIN)
. vehicle odometer readings
. number of engine cylinders
. air inject!on/catalytic converter (AIC) code for the vehicle.
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27
In addition to the above, if the vehicle was tested previously and the
current inspection was a retest, the inspector entered the following
data (related to the previous test) from the original test VIR:
. Previous test station code and lane number (were always: DB1,
the Houston program station code and lane - 1).
. The station operation mode at the time the previous test was
performed.
. The test number for the previous test.
. The date and time when the previous test was conducted.
. Repair information (if available) as it was presented on a
repair order form such as parts and labor costs, vehicle rpm
and rpm gain.
B. Once all the above information was entered into the CRT, the
inspector visually checked the vehicle for conditions which would
have made it unsafe or unsuitable for testing. The conditions under
which vehicles were deemed unsafe or unsuitable for testing were:
. fuel leaks
. excessive oil leaks
. excessive coolant leaks
. severely damaged or deteriorated exhaust system
. inaccessible exhaust system
. symptoms which would indicate possible imminent
mechanical failure.
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28
If any of the above conditions were found, the inspector informed
the vehicle owner about them and then entered an appropriate
code identifying the unsafe condition in the vehicle test file.
Since those vehicles were precluded from further testing, the
driver was instructed to walk to the consulting area where he
received the vehicle and the VIR specifying the unsafe or
unsuitable test conditions found on the vehicle.
C. Once the inspector finished all his entries into the CRT, he then
"logged off" signalling the emissions computer that all Position # 1
entries for the vehicle were completed. The inspector then
requested the driver's permission for checking and inflating (if
needed) the vehicle tires.
For those vehicles where the driver granted permission for the
tire pressure inspection, the inspector checked and recorded the
individual tire pressure on the queue card and inflated the tires if
he found them to be below the tire pressure criteria.
Where driver permission was not granted for the tire pressure
check, this was marked as "not tested" on the queue card.
D. Once all functions were performed on the vehicle, the queue card
was placed on the vehicle's windshield or dashboard, and the
driver was requested to leave the vehicle and walk to the
designated waiting area. The Position ft 2 inspector then entered
the vehicle and drove it to Position # 2 for the emissions portion
of the test.
. 1.2 Position # 2 Test Description
A. Once the vehicle was driven to Position # 2, the inspector exited
the vehicle, chocked it, raised the hood and connected the EMS
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29
rpm pickup to a spark plug wire. The inspector then selected the
appropriate probe(s) and inserted it into the vehicle's tailpipe.
The inspector then entered the queue number into the EMS via
the Emission Data Entry Panel (EDEP). The EDEP then displayed
the weight class (year, weight, number of cylinders and AIC code)
that the EMS received from the emissions computer.
Once the inspector verified and accepted the weight class, he
observed the vehicle and selected the correct louver opening
according to the vehicle's length.
B. At this point the EMS started the first idle portion of the test.
Exhaust and rpm were sampled, HC, CO and CO2 were analyzed
and stored by the EMS while the Test Cue Panel (TCP) displayed
the engine's rpm.
C. At the end of the first idle mode the TCP enunciated to the
inspector to accelerate the vehicle to 2500 rpm. The inspector
accelerated the vehicle until the TCP display of actual engine
rpm was between 2300-2700 rpm. Once the vehicle's rpm had
reached this band, HC, CO and CO2 were again automatically
sampled by the EMS.
D. At the end of the 2500 rpm mode the TCP instructed the
inspector to bring the vehicle to a second idle. After a built-in
delay (to allow the vehicle to reach stable idle conditon) the EMS
again measured the HC, CO, CO2 and rpm of the vehicle. The
inspector then observed the vehicle for tail pipe smoke and
entered a Smoke Failure into the EMS if excessive smoke was
observed.
E. At this point the EMS automatically compared the measurement
taken at each mode to the limits (where applicable) and
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30
transmitted this data to the emissions computer. The inspector
meanwhile exited the vehicle, disconnected the rpm pickup,
lowered the hood, and removed the exhaust probe(s). The Position
# 3 inspector entered the vehicle and proceeded to Position # 3.
1.3 Position ft 3 Test Description
A. The Position # 3 inspector drove the vehicle at a speed of about 1-
3 mph over the scuff gauge ensuring that only the front wheels
cleared the floor plate (in order not to reset the meter readout).
B. He then exited the vehicle, recorded the scuff gauge reading on
the queue card and proceeded to check the Emission Control
System (ECS) devices.
The ECS check results were entered into the emissions computer
via the CRT located at this position by entering the queue number
followed by the letter "E." The CRT then displayed the ECS
devices to be checked and a device condition code, as follows:
ECS Devices
. positive crankcase ventilation
. air injection
. exhaust gas recirculation
. fuel evaporative
. exhaust converter
. leaded fuel restrictor
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31
Device Condition Code
. modified
. disconnected or bypassed
. missing
. not inspected
C. When the inspector finished the ECS check and his entries (if all
devices passed, inspector only entered his inspector number), he
"logged-off" the CRT, entered the vehicle and drove it to Position
it 4. The "log-off" function at this position initiated the transfer
of all the data stored at the emissions computer memory into the
auxiliary computer memory for further data processing.
Position # * Test Description
A. When the vehicle arrived at Position # 4 it was placed in one of
the two inspection bays located at this position. The vehicle was
placed in "park" or "neutral" with the parking brakes applied and
the exhaust removal hose connected over the tail pipe. The
engine was shut off in preparation for verification and connection
of test equipment for the subsequent tests.
B. The inspector then performed the following in preparation for
the propane injection and timing tests.
. If the intake port of the air cleaner was accessible without
the use of tools, the rpm pickup from the digital engine
analyzer was connected to a spark plug wire and the propane
cylinder hose with the middle valve shut off was inserted
into the intake port of the air cleaner.
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32
. If timing marks were clean and visible and vehicle emissions
label present, the timing light was connected to the vehicle
battery terminals and the inductive pickup was connected to
a spark plug wire.
. If the intake port of the air cleaner was not accessible or
timing marks and emissions label were not present, the
queue card was marked as "no test performed" in the
appropriate place.
C. Once all connections were in place the vehicle was started and
allowed to reach stable idle condition. The rpm value was
recorded on the queue card as "propane gain initial rpm." The
inspector then opened the needle valve on the propane cylinder
hose and recorded the vehicle rpm changes as "final rpm" as
follows:
. Rpm increased to a peak and then decreased, inspector
recorded peak value.
. Rpm increased to a steady value - inspector recorded steady
value.
. Rpm decreased until vehicle stalled - inspector recorded the
same rpm as initial rpm value.
D. The inspector then performed timing checks by recording on the
queue card the degrees of advance or retard as was determined by
aiming and adjusting the timing light to the top dead center mark.
The vehicle timing specifications as appeared on the emissions
label were also recorded on the queue card.
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33
E. Following the propane and timing tests, the inspector would
determine if the EGR vacuum hose was accessible to accomplish
the EGR test. If so, he would clamp off the hose and hold it.
From inside the vehicle another inspector would increase the
engine RPM to the specified test value while observing the digital
analyzer (2500 rpm for GM-L4 engines, 2000 rpm for all others).
When the specified rpm was reached and allowed to stabilize, the
under-hood inspector was signalled to immediately release the
hose. The inspector observing the digital analyzer, while holding
a steady throttle position for at least 5 seconds, and then noted
the drop, if any, in engine rpm. Later this was recorded on the
EGR test form.
When the above testing was completed, the vehicle was shut off
and all equipment disconnected.
F. The inspector then "logged-on" on the auxiliary CRT located at
Position # k by entering the queue number from the queue card.
The auxiliary CRT then provided the inspector with a screen
format to enter all the test information recorded on the queue
card, as follows:
. tire pressure
. alignment
. propane gain
. ignition timing
Once all the information was entered and verified by the
inspector as being correct, the auxiliary computer generated the
VIR on a double N.C.R. IV X 8 1/2" paper. The inspector then
separated the second copy of the VIR, attached the queue card to
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it and placed it for storage. The vehicle, with the top copy of the
VIR, was then moved by the counselor to the counseling area.
4.1.5 Counseling Area Procedure Description
Once the vehicle arrived at the counseling area the counselor located the
vehicle owner, presented the VIR and informed him/her of the test
results. The different sections of the form were described noting the
vehicle test limits and readings. Limited diagnostic information was
provided from the back of the VIR and any questions were answered.
After completing the counseling conversation, the vehicle and owner
departed from the station.
4.2. SPECIAL OPERATION MODES
In order to ensure vehicle testing at all times, special operation modes
were designed to allow vehicle testing without the use of one of the major
pieces of equipment due to failure. A brief description of these special
operating modes follows:
4.2.1 Backup Mode
Vehicle tests were performed in this mode whenever the emissions
computer was not operational.
A. The emissions computer console (LA-36 printer) was placed at
Position # 3 and connected directly to the EMS through a special
data link. The "temporary VIR" was placed in the printer.
B. The Position # 1 inspector performed only test suitability checks
and tire pressure checks. If vehicle was unsuitable for testing,
the appropriate code(s) was hand-written on the queue card
instead of being entered into the CRT. Vehicle was then driven
into Position^ 4.
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35
C. The emissions test was performed as normal except the weight
class (year, weight, number of cylinders, AIC code) which the
EMS was to receive from the emissions computer was entered
into EMS by the inspector. When the emissions test was over the
EMS generated the "temporary VIR" which contained the
emissions readings and limits.
D. The vehicles then were processed at Position # 3 as normal, with
the exception that ECS failure codes (if applicable) were hand-
written on the queue card. Position # *f testing was performed as
normal.
E. At the end of all testing the inspector at Position # 4 entered the
registration data (that was not entered at Position//1) and all the
data from the "temporary VIR" into the auxiliary computer via a
special screen format on the auxiliary CRT. Those entries
allowed the auxiliary computer to have the same data that
normally was transmitted from the emissions computer. Once
this process was completed and the data from the queue card
entered, printing of the VIR and data storage on the data file
were performed as normal by the auxiliary computer.
4.2.2 Semiautomatic Mode
Vehicle tests were performed in this mode whenever the EMS was non-
operational. The stand-alone computerized emissions analyzer, model
CEA-610 was used to perform the emissions tests.
A. The Position it 1 inspector performed all test functions as
normal. At the end of the test the vehicle was moved to Position
# 2 and the stand-alone analyzer was used to perform the first,
2500 rpm and 2nd idle emissions test. Measured values for HC,
CO, CO2 and rPm *°r each section of the test were printed on the
paper tape of the CEA-610.
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36
B. At the end of the emissions test the Position # 3 functions were
performed as normal. The ECS failure code (if applicable) and
the measured values for the emissions test (printed on the CEA-
610 paper tape) were entered into the emissions computer via a
special screen format on the CRT at Position// 3.
C. The Position # 4 test, queue card data entry, VIR generation and
data storage were performed as normal.
4.2.3 Deferred Mode
Vehicle tests were performed in this mode whenever the auxiliary
computer was non-operational. The VIR printer (LA-35) was connected
directly to the emissions computer via a special data link located at
Position// 4. The "temporary VIR" was placed in the printer.
A. All testing and entries at Position # 1 through Position # 3 were
performed normally. At the end of Position # 3 test, the
emissions computer generated the "temporary VIR". All data that
normally was to be transmitted from the emissions computer to
the auxiliary computer was printed on the "temporary VIR".
B. Position # 4 testing was performed as normal, however, since a
VIR could not be generated due to the non-availability of the
auxiliary computer and, in order to eliminate erroneous
information on the VIR if it were to be hand-filled, the mailing
address of the vehicle owner was recorded.
C. The vehicle driver was informed of the station equipment
malfunction and that the VIR would be mailed to him as soon as
possible. Once the auxiliary computer became operational the
data from the "temporary VIR" and the queue card was entered
into it, a VIR was generated and mailed to the vehicle owner.
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37
4.3 EXPERIMENTAL TESTS
4.3.1 Propane Injection
The test was easily performed on almost any vehicle. Access to any plug
wire and the engine air intake opening was all that was required. The
most significant step in performing the test was to slowly inject propane
into the air intake, while observing the digital analyzer. This would allow
detection of even the smallest increase in rpm. A small needle valve with
an .080 inch diameter orifice was used for this purpose to finely meter the
propane.
Engines with an unstable idle RPM were difficult to test. It was
necessary to mentally average both the initial and final RPM readings
before these values could be recorded.
It was noted by Hamilton Test Systems that many vehicles with catalytic
converters passed the tail pipe emissions test and were out of limits on
the propane test. This may suggest that the vehicles curburetor was set
too rich, with the exhaust being "cleaned" as it passed through the
converter. The test could have future diagnostic use in fuel economy
testing by easily detecting this over-rich condition.
4.3.2 Basic Timing
This test was difficult to perform as well as time consuming. It required
knowledge of the location of a great many timing marks that were both
difficult to see and interpret. Many marks were so dirty or rusted that
even cleaning could not render them identifiable. To clean the marks on
some engines the crankshaft first had to be rotated so that the marks
were accessible.
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38
In accordance with manufacturer's procedures, the distributor vacuum
advance hose is disconnected on most engines while the basic timing was
checked. This was not integrated into the testing procedure in order to
shorten test time and avoid broken hoses. However, this made the test
invalid as a measure of basic timing for the many vehicles that had
vacuum advance at idle.
Checking basic timing seemed to be an impractical test to incorporate in
a high throughput test lane operation.
4.3.3 Alignment Checks
The Bear model 240 scuff gauge was an efficient unit for measuring toe-in
or front wheel side drag. Calibration was simple and it required little
maintenance. Approaching and crossing the unit in a direct straight line
was the most important factor in the test. The manufacturer
recommended the vehicle be driven forward a minimum of 20 feet with no
steering wheel movement before crossing the floor plate. This allowed
the tire tread to conform to its normal shape. HTS found this to be more
critical with radial tires than conventional ones. The only problem
encountered was a general misunderstanding of the test by the public,
i
which perceived it as a complete front end alignment check. People were
confused when their front tire tread wear was uneven but the vehicle
passed the test. A more detailed explanation was required which
extended counseling time and slowed thruput.
Tire Pressure Measurement and Inflation
Participants were pleased to have their tire air pressure checked and
adjusted if it was found to be low. HTS found many tires with incorrect
air pressure. Most were underinflated due to neglect, but some were
deliberately overinflated to an unsafe level by people trying for better gas
mileage. The qualification of not testing any vehicle with an unaccessible
valve stem made the test run smoothly and no problems were
encountered.
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39
4.3.5 EGR Test
An EGR functional check was added to the inspection procedure, per EPA
request, in mid-3uly. The test involved clamping the EGR vacuum hose,
raising and holding the engine rpm, then releasing the hose and noting the
effect on the rpm. To keep test time to a minimum and avoid
complications, the air cleaner was not removed. This made the EGR hose
inaccessible on many engines, especially Ford and American Motors
products. Access to the throttle from under the hood was also made
impossible on most engines ; therefore, the test required two inspectors:
one inside the vehicle to control the throttle and observe engine rpm and
one under the hood to operate the clamp on the EGR vacuum hose.
The test as performed showed a high rate of EGR system failures. HTS
conducted several experimental tests to determine if the EGR system or
the operational procedure was at fault. A visual check of the valve and
vacuum supply operation was first tested by the "goose" acceleration
method. In this method, the inspector momentarily snapped the vehicle
throttle to the wide open position while observing the EGR stem for
movement. As a second check manifold vacuum was applied to the valve
with the engine at the required rpm and the rpm drop noted. Only a small
random sample of vehicles (10-15) were tested in this manner but they
showed the test procedure to be at fault in all cases. The 2000 rpm test
speed was too low for most ^-cylinder models since it required only a
slight throttle opening. Many valves were made to open on acceleration,
while under sustained light throttle operation they did not function.
These findings suggest that the test method be reviewed for procedural
changes.
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5.0 DATA HANDLING
This section describes the test data collection and submission to the
vehicle owner, and the EPA.
5.1 DATA TRANSMITTAL PROCEDURES
At the test facility, for each vehicle that was tested, a Vehicle
Information Report (VIR) was generated on a double NCR paper. The top
copy of the VIR was handed to the vehicle owner, the bottom copy was
retained by HTS for the duration of the program, at which time they were
submitted to the EPA. In addition, for each vehicle tested the complete
set of test data items was recorded on floppy disks.
At the end of each day the data floppy disk used that day contained a
record of all tests performed during that day's testing. A copy of this
floppy disk was made each day and the copy was maintained at the test
facility for a minimum of 31 days, as a backup of the primary data source.
On a weekly basis the original test floppies were accumulated and
converted to one IBM compatible floppy.
At the end of each reporting period the IBM compatible floppies were sent
to HTS Headquarters in Phoenix, Arizona, where the data was merged
onto a 9-track magnetic tape. This merging was performed by a service
bureau under contract to HTS. Three copies of this IBM magnetic tape
were made ; two were delivered to the EPA via Federal express, and one
was retained by HTS as the final test data backup medium. Once the IBM
magnetic tapes had been generated and verified to contain all the data,
the original floppy disks retained at the station were reused.
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5.2 DATA FORMAT
All test data was delivered to EPA on magnetic tapes with the following
specifications:
IBM compatible
1600 BPI
vehicle test record encoded in EBCDIC character format in
unpacket form.
tapes were unlabeled and blocked 10 VTR's (Vehicle Test
Record) per block with interblock gap.
each VTR record was 256 bytes in length with the last 58 bytes
blanks.
Table 5.2-1 defines the content of the VTR as it appeared on the
magnetic tapes.
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TABLE 5.2-1 - VTR FORMAT
ITEM NO.OF
NO. BYTES DESCRIPTION
EXPLANATION
Termst
A) "character" = any keyboard character
B) "alpha character" = "A" to "Z", "-", blank
C) "numeric character" - "0" TO "9"
D) "alpha-numeric character" = "A" TO "Z", "-", blank, "0"
to "9"
1 3 Queue No.
1 Mode
Date
4 5 Time
5 3 Station
6 1 Lane
7 8 Plate
Three numeric characters. Number as appears on queue card
assigned to each vehicle for the duration of the inspection.
One alpha character. Mode under which the vehicle was
inspected.
Possible values:
"A" = automatic
"S" = backup mode
"M" = semiautomatic mode
Six numeric characters. Date on which the vehicle was
inspected. Stored in the form MMDDYY. Date must be less
than or equal to current date.
Where:
MM= month
DD= day
YY= year
Five characters. Time of test expressed as HH:MM
Three characters. Station identification name (always DB1).
One numeric character. Lane number on which the vehicle
was inspected (always 1).
One to eight characters. License plate number, left justified,
with no spaces between character license plates with two
characters in a vertical column shall be stored with the upper
character first. Out of state license plates shall be stored as
"*OS*".
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43
ITEM
NO.
NO.OF
BYTES
DESCRIPTION EXPLANATION
10
11
12
16
5
1
Vehicle
I.D. No.
(VIN)
Make
Retest No.
13
15
16
17
3
2
1
Test No. Three numeric characters. Number assigned by the computer
for the inspection. Test numbers are assigned sequentially
starting at "001". The queue number is the test number for
semiautomatic or backup testing.
Model Year One alpha character ("M") followed by two numeric
characters. The numeric characters are the model year. The
maximum model year shall be the current year plus one.
One to sixteen alpha numeric characters.
Number is left justified with no spaces
between characters.
One to five alpha-numeric characters. Vehicle make, left
justified, with no spaces between characters.
One numeric character. A zero value signifies the first test
performed on the vehicle. A value of one to nine indicates
the nth retest. The retest number will be the retest number
appearing on the old vehicle report (VIR) plus one.
Three numeric characters. Odometer reading in thousands of
miles ("000" TO "999").
Odometer
Cylinders
Air
Injection
Code
(AIC)
Customer
Reject
Reason
Codes '
Two numeric characters.
inspected vehicle.
Number of cylinders for the
One numeric character.
Possible values:
"0"= No air injection, no catalytic converter
"1"= air injection, no catalytic converter
"2"= no air injection, normal catalytic converter
"3"= air injection, normal catalytic converter.
One to three alpha numeric characters.
Normal test will have a customer value of"". Tests
conducted for equipment checks will have a value of "HTS".
4 groups of 2 character numeric codes possible.
Values for each group:
"00"= No code entered
"01-13"= reject reason
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44
ITEM
NO.
18
19
20
21
22
23
24
25
26
27
28
29
30
NO.OF
BYTES
1
12
4
5
5
6
5
5
6
5
5
6
5
DESCRIPTION
Smoke
ECS
Failure Code
HC Limit
(Idle)
CO Limit
(Idle)
i
1st Idle HC
reading
1st Idle CO
reading
1st Idle
CO2 reading
2500 rpm
HC reading
2500 rpm
CO reading
2500 rpm
CO2 reading
2nd Idle
HC reading
2nd Idle
CO reading
2nd Idle
CO2 reading
EXPLANATION
One alpha character. Smoke failure indicator.
Possible values:
"N"= Passed smoke test
"Y"= Failed smoke test
Six groups of two alpha numeric characters. If no code
entered, then group will contain "blank"
Four numeric characters that define the HC
diagnostic value used for this vehicle's test.
Form = XXXX
Five numeric characters that define the CO
diagnostic value used for this vehicle's test.
Form = XX.XX
The HC reading expressed as XXXXI
Where: XXXX= HC reading in ppm
1= "blank" when reading limit
I_ "*" when reading limit
The CO reading expressed as XX.XXI
Where:
XX.XX= CO reading in %
1= "blank" when reading _ limit
1= "*" when reading limit
The CO2 reading expressed as
XX.XX in % CO2
same as item 22
same as item 23
same as item 24
same as item 22
same as item 23
same as item 24
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NO.
BYTES DESCRIPTION EXPLANATION
31
Idle speed
32
33
34
35
36
37
38
39
3
2
2
2
Propane gain
Results
(P/F)
Initial rpm
Propane Gain
Final rpm
Propane
Rpm Gain
Propane
Propane rpm
gain limit
Tire Pres.
Right Front
Tire Pres.
Right Rear
Tire Pres.
Left Rear
Tire Pres.
Left Front
The idle speed as measured during the 2nd idle emission
test. Expressed as XXXXI
Where:
XXXX= rpm
1= "blank" when reading _ limit
1= "*" when reading limit
The result of the Propane gain test. Valid Values are:
"P"= gain _ limit
"F"= gain limit
"blank"= no test (see item 33)
The rpm at the outset of the Propane gain test.
Four numerics (XXXX) define the rpm. An alpha entry of
"NT" signifies no test, an entry of "AB" signifies an
aborted test.
The rpm at the completion of injection of
Propane. Four numerics (XXXX) define the rpm.
"blank"= no test (see item 33).
Three numerics plus sign (SXXX).
Where: XXX = final rpm - initial rpm
S = sign.
Three numerics that define the limit used to
determine Propane gain Pass/Fail.
Two characters that define the "as received"
Right front tire pressure. Possible values are:
XX= pressure in psig
TR= inflation refused by owner
NT= no measurement made for all other
reasons
Two characters that define the "as received"
pressure for the referenced tire. Possible values are:
XX= pressure in psig
"blank"= no test (see item 37)
same as item 38
same as item 38
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46
ITEM NO.OF
NO. BYTES DESCRIPTION
EXPLANATION
Tire Pres.
ResultR.F.
42
43
44
45
1
1
1
3
46
47
48
49
Tire Pres.
Result R.R.
Tire Pres.
Result L.R.
Tire Pres.
Result L.F.
Scuff test
data
Scuff test
Spec.
Scuff test
result
Timing data
3 Timing
specifi-
cation
Single character tire pressure Pass/Fail
Indicator for referenced tire. Possible values
are:
"P"= Pass
"F"= Fail
"Blank" = no test
same as item 41
same as item 41
same as item 41
Three numeric characters (XXX) define the
amount of scuff. An alpha entry of "NT"
signifies no test.
Three characters that define the
specification that the scuff data is compared to
for Pass/Fail determination. Possible entries are:
"XXX"= Spec.
"blank"= no test (see item 44)
This character defines the scuff test result.
Possible values are:
"P"= Pass (data _ spec.)
"F"= Fail (data spec.)
"blank" = no test (see item 44)
Ignition timing in crankshaft degrees.
Possible entries are:
"SXX= Timing data
Where: S = (+) for BTDC, (-) for ATDC
XX= data in degrees
"NT"= no test
"NA"= specification not available
"AB"= aborted test
Ignition timing specification obtained from
vehicle emission label. The form is SXX.
Where: S= (+) for BTDC, (-) for ATDC
XX= numerical value of spec.
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NO. BYTES DESCRIPTION EXPLANATION
50 3 Timing limit The limit on the difference between the timing data and
the timing spec.
Pass if: spec. - data _ limit
Fail if: spec. - data limit
51 3 ECS ID One to three characters. Inspector identification required
with ECS entry/exit.
52 3 EMS ID One to three characters. Inspector identification required
for weight class override and abort. If less than three
characters, then dashes ("-") will fill out the remaining
characters.
Total 198 bytes of 256 used (last 58 bytes blanks)
C. The values used for the various limits were:
Reject Reason Codes (Item 17)
01 oil system leak
02 oil system light on
03 oil system transmission leak
04 coolant system leak
05 coolant system light on
06 exhaust system excessive leak/noise
07 exhaust system loose/dragging
08 exhaust system inaccessible
09 fuel system leak - engine
10 fuel system leak - underbody
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Emission Limits (Items 20 & 21)
Year HC - PPM CO - %
Prior to '68
'68 - '69
70 - 74
75 - 77
78 - 79
'80
RPM Limits (Item 31)
1200
700
500
400
300
200
7.5
5.0
4.0
3.5
3.0
2.0
Year RPM Limits
Prior to '68 1000
'68 - '80 1200
Propane RPM Gain Limits (Item 36)
Year RPM Gain
Prior to 74 0
75 - '80 10
Tire Pressure Limit (Items 41-43)
"Pass" if tire pressure were equal to or greater than 20 psi
"Fail" if tire pressure were less than 20 psi
-------
"Pass" if reading were equal to or less than 10 ft/mile
"Fail" if reading were greater than 10 ft/mile
Timing Limits (Item 49)
"Pass" if reading were advanced, or less then or equal to 5°
retarded. "Fail" if reading were greater than 5° retarded.
5.3 VIR PRINTOUT LOGIC
Figure 5.3-1 A. presents field numbers (e.g., 1, 2, 3, etc.) referred
to in Table 5.3-1 which lists the information and the explanation or
logic for the data printed on the VIR.
-------
Figure 5.3-1 A
(front of VIR form)
50
VEHICLE INFORMATION REPORT
0035063
TEXAS MOTOR VEHICLE EMISSION CONTROL PILOT TESTING PROGRAM
Than* you tor puticlpitlng In tne Texas Motor Vehicle Emission Control Pilot Testing Program. Dili pro-
gram l< p«rt ol i State study of ways to Increase tht effectiveness ot motor vehicle pollution controls and
depend! on voluntary public ptrtlelpMlon. The test readings tram your vehicle and other vehicles will be
uod to prapara wcommandattona to the Texas Laglalatura.
The tot readings from your vehicle ara typed in the block labeled "Emlaaiom Teat Data*. For companion.
diagnostic values nave been typed above your readings, in the shaded areas. These values ara experimental
and raffed values which vehicles the same age as yours can usually meet If they ara operating property. If
your vehicle is not meeting one or more of the diagnostic values, i" * " will have been typed next to the
corresponding tact readlng(s).
SEE REVERSE SIDE FOR FURTHER INFORMATION
omumo-
STMicemo.
own
e
8
VCHICLB INFORMATION
VMCLC nemncATiON NO. TIM
10 11 12
4.000
16
TMT SUMMARY
ID
No operating probten
Your vehicle may have an operating problem. See block labeled Emissions Test Data" and
other tide for further Information.
BCD See-bottom block for fuel economy lips.
Your vehicle was not tested for the following reason(s):
EMISSIONS TEST DATA
A. Excessive Smoke Observed
B. Catalytic Converter
C. Fuel Intel Restrtetor
t 20
(21
[22
E. Second Idle
TIC
»mt
i
HC(ppm)
23
27
C0<*|
24
28
HC(ppm)
28
29
C0(%|
28
80
F. Idle Speed (MM)
81
88
DUONOfTIC
V*1.U« (LOWCT)
82
84
run ICONOMY TIPS
I Teal)
Not Checked
., n| I This Check Indicates Possible Front End Misalignment.
| Proper Alignment Improves Mileage.
Proper Tire Inflation Improves Mileage. Check Regularly and Inflate to the Proper Pressure for
Your Vehicle.
These Tires Were Very Underlnflated When Checked:
Left
Front
Not Checked
48
FIGURE 5.3-1A FRONT OF VIR FORM
-------
51
Figure 5.3-1B
(back of VIR form)
CONTINUED FROM FRONT OF REPORT
Texas currently has no laws which place emission limits on vehicles after sale. Therefore,
your car Is not required to meet any specific legal limits on the test preformed on it as part of
the Pilot Testing Program. The readings from your vehicle and the diagnostic values In the
shaded areas are for your information only.
If a "*" appears next to one of your vehicle's readings there Is a good chance that your
vehicle is not operating properly. Below you can find some advice which may assist you In
improving the operation of your vehicle. Repair of your vehicle as a result of this test la strictly
voluntary. Repair also may lower trie-emissions from your vehicle.
If you decide to have your vehicle repaired In order to correct problems which may be keeping
it from meeting the diagnostic values, you are welcome to bring the vehicle back for a second
test. By doing so. you can check whether the repairs have resulted In lower emissions. You
will also be contributing useful data to the study.
As a service to participants like yourself, and to collect Information on the condition of vehi-
cles in Texas, some checks related to fuel economy are being performed on marry vehicles In
addition to the emission tests. The bottom section of the front of this form shows the results
from these checks, along with some tips for better mileage.
TEST PROCEDURE
Tailpipe emissions of Carbon Monoxide (CO) and Hydrocarbons (HC) from your vehicle
measured twice during the test. First, the emissions were measured while your vehicle w
were
. vehicle was at
idle. The readings from this first step are shown on the front of the form under the heading "0.
First Idle."
Next, your vehicle's engine was accelerated to about 2500 RPM while parked. This evacuated
any excess emissions that may have accumulated in the exhaust system while you were
waiting in the test line. The vehicle was then returned to idle and the emissions were
measured again. The readings are shown under the heading "E. Second Idle". This second
idle measurement may represent more accurately the operation of your vehicle. Therefore
the "Test Summary" block Is based on the second Idle measurement only.
The idle speed (RPM) of your vehicle was checked during the second idle measurement. The
inspector also watched for the presence of excessive smoke In your vehicle's. exhaust
A visual check was made for the presence of a catalytic converter and an appropriate reside-
tor in the fuel filler neck for those vehicles on which these are standard equipment.
Where appropriate, a propane gas enrichment procedure has been carried out to evaluate the
air/fuel mixture provided by your carburetor. If the mixture is set properly, the engine speed
should show an increase (Propane Gain) when the propane gas is injected Into the car-
buretor. The results of this propane enrichment procedure will be used at the end of the
study to determine how much of an increase Is typical with a properly set carburetor.
Meanwhile, diagnostic values for the increase have been chosen for use during the study.
Following are diagnostic values which vehicles can usually meet If they are operating
properly. If the readings from your vehicle are higher than the HC, CO, or RPM diagnostic
values or lower than the propane gain diagnostic value shown in the table for your vehicle's
model year, this indicates that your vehicle may not be operating properly. You can find in the
block labeled "DIAGNOSTIC INFORMATION" some advice concerning steps you may want
to consider to Improve operation of your vehicle.
Model Year
MC(ppm|
RPM
Propane O4n
pre-1966
1968-1969
1970-1974
1975-1977
1976-1979
1980-later
1200
700
500
400
300
200
7.5
5.0
4.0
3.5
3.0
2.0
1000
1200
1200
1200
1200
1200
0
0
0
10
10
10
DIAGNOSTIC INFORMATION
Hydrocarbon (HC) readings which are higher than the HC diagnostic value generally are
caused by one or more of the following problems:
1) Faulty Ignition or Misfire
2) Air/Fuel Mixture Set Too Rich, Too Lean, or Unbalanced
3) Improper Ignition Timing
4) Vacuum Leaks
5) Worn Piston Rings or Valves
Carbon Monoxide (CO) readings which are higher than the CO diagnostic value are generally
caused by one or more of the following problems:
1) Air/Fuel Mixture Set Rich
2) Dirty Air Filter
3) Choke Stuck
4) PCV System Plugged
5) Air Pump or Control Valve Inoperative
Propane gain readings which are lower than the propane gam diagnostic value are generally
caused by one or more of the following problems.
1) Air/Fuel Mixture Set Rich
2) Idle Speed Set Too High
3) Dirty Air Cleaner
4) Choke Stuck
5) PCV System Rugged
Excessive smoke generally Is caused by worn piston rings or valves.
Usually a simple tuneup In which defective parts are replaced and settings are put to
manufacturer specifications will correct the pollution problem.
G
FIGURE 5.3-1B BACK OF VIR FORM
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52
TABLE 5.3-1
VIR PRINTOUT
Figure 5.3-1
Ref.tf
VIR Field
Name
Explanation or Logic
Queue No.
Three numeric characters. Number
as appeared on queue card assigned
to each vehicle for the duration of
the test.
Station No.
Three characters. Station iden-
tification name always DB1.
Lane No.
One numeric character. Lane
number on which the vehicle was
inspected - always 1.
Test Mode
One alpha character. Mode under
which the vehicle was inspected.
"A"= Automatic (normal)
"S"= Backup
"M"= Semiautomatic
Test No.
Three numeric characters.
Numbers were assigned by the
computer for the inspection. Test
numbers were assigned sequentially
starting at 001. For backup and
semiautomatic mode Test Number
= Queue Number.
-------
53
Figure 5.3-1
Ref.tf
VIR Field
Name
Explanation or Logic
Date
Six numeric characters. Date on
which the vehicle was inspected.
Date printed in the form of
MMDDYY.
Where: MM = Month
DD = Day
YY = Year
Time
License
Plate
Time of test expressed in
hr.clock. Time printed in the form
HH:MM.
Where: HH = Hours
MM = Minutes
The vehicle license plate number.
Out-of-State license plates were
denoted by "*OS*".
Vehicle
Identification
No.
1-16 alpha numeric characters with
no Identification spaces between
characters.
10
Year
The letter "M" followed by the last
two numeric characters of the
vehicle model year
11
Make
1-5 alpha numeric characters with
no space in between characters.
-------
Figure 5.3-1
Ref.#
VIR Field
Name
Explanation or Logic
12
Cyl.
Two numeric characters. Number
of cylinders for the inspected
vehicle.
13
Vehicle weight code always = 0
Mileage
Three numeric characters.
Vehicle odometer readings in
thousands of miles.
15
Air injection code as follows:
"0" = no air injection, no catalytic
converter.
"1" = Air injection, no catalytic
converter.
"2" = no air injection, normal
catalytic converter.
"3" = air injection, normal catalytic
converter.
16
Test Summary:
"No Operating
problem
detected"
"X" was printed in this
block if:
a) vehicle was not
rejected, and
b) Excessive smoke was not
observed, and
c) catalytic converter was not
missing, and
d) fuel restrictor was not
modified or missing, and
-------
55
Figure 5.3-1
Ref.tf
VIR Field
Name
Explanation or Logic
e) vehicle passed emission
measurement (2nd idle) and
f) propane injection test was
"pass" or "not tested."
17
Test Summary:
"Your vehicle
may have an
operating
problem."
"X" was printed in this
block if:
a) catalytic converter was
missing, or
b) excessive smoke was observed,
or
c) fuel restrictor was modified or
missing, or
d) vehicle failed emission
measurement (2nd idle), or
e) vehicle failed propane injection
test.
18
19
Test Summary:
"See bottom
block for fuel
economy tips."
Test Summary:
"Your vehicle
was not tested
for the follow-
ing reasons."
"X" was printed if:
a) vehicle failed alignment
test, or
b) any tire pressure was below 20
psi
"X" was placed in the block if:
vehicle was not tested due to
unsafe conditions. Up to 4
reasons for reject were printed,
as applicable in the space
below it (Ref.# 19 a.).
-------
56
Figure 5.3-1
Ref.#
19 a.
VIR Field
Name
Explanation or Logic
Oil system leak
Oil system light on
Oil system transmission leak
Coolant system leak
Coolant system light on
Exhaust system excessive
leak/noise
Exhaust system loose/dragging
Exhaust system inaccessible -
Fuel system leak - engine
Fuel system leak - under body
Others
20
"Excessive a) The word "YES" was printed in
Smoke Observed" the blue shaded area if
excessive smoke was observed
during the emissions test.
b) The work "NO" was printed in
the blue shaded area if
excessive smoke was not
observed during the emission
test.
21
"Catalytic
Converter"
a) The word "MISSING" was
printed in the blue shaded area
if it was determined as part of
the ECS check that the
catalytic convertor was
missing.
-------
57
Figure 5.3-1
Ref.tf
VIR Field
Name
22
"Fuel Inlet
Restrictor"
Explanation or Logic
b) In all other cases the message
"PRESENT OR NOT RE-
QUIRED ON YOUR VEHICLE"
was printed.
a) The words "MODIFIED"
or "MISSING" were printed in
the blue shaded area according
to the determination during the
ECS checks.
b) The words "NOT INSPECTED"
were printed in the blue shaded
area if it was entered as part
of the ECS checks as not
inspected.
c) In all other cases the message
"PRESENT OR NOT RE-
QUIRED ON YOUR VEHICLE"
was printed in the shaded area.
23
1st idle, HC
diagnostic value
This field was left blank.
1st idle, CO
diagnostic value
This field was left blank.
-------
58
Figure 5.3-1
Ref.#
25
VIR Field
Name
2nd Idle, HC
Diagnostic
Value
Explanation or Logic
4 numeric characters that
defined the HC diagnostic
value (limit) used for the vehicle
test. Printout was in the form
xxxx.
26
2nd Idle, CO
Diagnostic
Value
5 numeric characters that
defined the CO diagnostic value
(limit) used for the vehicle test.
Printout was in the form XX.XX.
27
28
1st Idle, HC
Emission
Reading
1st Idle, CO
Emission
Reading
The 1st idle HC readings as
measured. Printout was in the
form XXXXI.
Where: XXXX-HC readings in ppm
1= "blank" if reading below or
equal to the diagnostic value
1= "*" if reading above the
diagnostic value
The 1st idle CO reading as
measured. Printout was in the
form XX.XXI.
Where: XX.XX CO reading in %
1= "blank" if reading below or
equal to the diagnostic value.
1= "*" if reading above the
diagnostic value.
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59
Figure 5.3-1
Ref.#
VIR Field
Name
Explanation or Logic
29
2nd Idle, HC
Emission Reading
Same as Item 27.
30
2nd Idle, CO
Emission Reading
Same as Item 28.
31
Idle Speed
(rpm)
Diagnostic Value
4 numeric characters that
defined the 2nd idle rpm
diagnostic value for the vehicle.
Printout was in the form XXXX.
32
Propane Gain
Diagnostic
Value
2 numeric characters that
defined the diagnostic value for
rpm gain during the fuel injection
test. Printout was in the form of
XX.
33
Idle Speed (rpm)
Readings
The idle rpm as measured
during the 2nd idle emission test
printout was in the form of
XXXXI.
Where: XXXX= rpm
1= "blank" if reading below or
equal to diagnostic value
1= "*" if readings above the
diagnostic value.
-------
60
Figure 5.3-1
Ref.#
VIR Field
Name
Explanation or Logic
35
Propane Gain
Readings
Fuel Economy
Tips - Wheel
Alignment
5 numeric characters that
are the value readings of "final
rpm" - "initial rpm" as recorded
during the propane injection
test. Printout was in the form of
SXXXI.
Where: S = sign (+) or (-)
XXX rpm value
1= "blank" if rpm gain equal or
greater to diagnostic value
1= "*" if rpm gain less than
diagnostic value.
a) "X" was printed in the
box if wheel alignment test
was not performed (equip-
ment malfunction)
b) In all other cases this block
was left blank.
36
Fuel Economy
Tips - Wheel
Alignment
a) "X" was printed in the
box if wheel alignment
test "fail", (readings greater
than limit).
b) In all other cases this
block was left blank.
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61
Figure 5.3-1
Ref.#
VIR Field
Name
Explanation or Logic
37-40 Fuel Economy
Tips - Tire
Inflation
a) "X" was printed for each tire
checked that had less than
20 psi pressure
b) In all other cases these
blocks were left blank.
Fuel Economy
Tips - Tire
Inflation
a) "X" was printed in this
this block whenever tire
pressure checks were
refused or could not be
performed.
42
Customer
b) In all other cases this block
was left blank.
One to three alpha numeric
characters as follows:
All normal tests were printed as
"~_"
Tests conducted for equipment
checks were printed as "HTS".
ECS I.D.
3 numeric characters which
specified the I.D. number of the
inspector who performed the ECS
checks on the vehicle.
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62
Figure 5.3-1
Ref.#
VIR Field
Name
Explanation or Logic
EMS I.D.
3 numeric characters which
specified the I.D. number of the
inspector who performed the
emission test on the vehicle.
45
a) The code "TIP1 was printed
in this space whenever the
vehicle failed the timing
test.
b) In all other cases this space
was left blank.
46
Smoke
a) One alpha character spec-
ifying smoke observation as
follows:
"N" was printed if smoke OK
"Y" was printed if smoke
was excessive.
47
Retest
b) In all other cases "-"
was printed in this field.
One numeric character. A zero
value signified the first test
performed on the vehicle. A
value of one to nine indicated the
nth retest. The retest number
was the retest number which
appeared on the old vehicle report
(VIR) plus one.
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63
6.0 PROGRAM RELATED ACTIVITIES
6.1 INSPECTOR RECRUITMENT AND TRAINING
After a survey of the Houston labor market by the HTS Personnel
Manager, a Job Order was filed with the Texas Employment
Commission and an advertisement placed in the local newspaper. The
facility operations required a staff of nine: seven inspectors, one group
supervisor, and one manager. All employees except the manager were
hired from the local job market. The Inspector job qualifications
required individuals with a high school education and light automotive
background. Group Supervisor qualifications were a minimum of two
years electronic technical/college training plus some supervisory
experience. The Group Supervisor was advertised for in November,
1979, and filled in December of that year. There were no responses
from the Texas Employment Commission. The person hired was a
response to the newspaper advertisement. The Group Supervisor was
immediately placed on a temporary assignment to Hamilton Test
Systems, California, for training on the maintenance and repair of the
Emissions Measurement System. The individual hired for Group
Supervisor, when he returned to Houston, was utilized to assemble
instrumentation necessary in the performance of the inspection system.
In January, 1980, a Job Order was filed with the Texas Employment
Commission for Emission Control Systems (ECS) Inspectors. A
newspaper advertisement was also placed which resulted in approx-
imately twenty-five responses which ultimately filled the seven
requirements. During the course of the program, four of the original
seven remained on the payroll. To maintain a full operational staff
five additional inspectors (ECS) were subsequently hired as others
terminated their employment for various reasons.
-------
The inspector training period consisted of four weeks, two in the
classroom and two on the job. The first week in the classroom was
spent on orientation and inspection procedural training. The second
week covered emission control systems identification using a slide
presentation with a cassette recording and manual. The final two
weeks were spent with "hands-on" operations, testing employees'
vehicles.
Appendix "A" presents the detailed Inspector Operation Manual utilized
for the inspector training program.
6.2 MAINTENANCE AND CALIBRATION
6.2.1 Maintenance
Equipment maintenance was divided into two groups. Those items
which were serviceable by HTS and items serviced by the equipment
manufacturer only.
A. HTS-Serviced Equipment;
1. Emission Measurement System and related subsystems
2. Clayton exhaust louvers
3. Bear scuff gauge
4. Heathkit digital analyzer and timing light
5. Ecolizer ambient CO monitor
6. CEA-610 stand-alone analyzer
The Group Supervisor and Station Manager provided the
technical service for the equipment in this category. They were
also supported by the HTS California maintenance and repair
facility. A complete inventory of electronic parts was kept in
stock at the station for the repair or replacement of all .EMS
subassemblies and related components.
-------
General maintenance was performed in accordance with the HTS
Periodic Maintenance Manual (see Appendix "B"). Preventive
maintenance service was performed with daily, weekly and
monthly checklists.
B. Manufacturer-Serviced Equipment
1. ADDS CRT
2. Alpha Micro computer
3. DEC computer and printers
The ADDS CRTs and Alpha Micro computer were serviced
respectively by their local representatives on an "as-needed"
basis. HTS purchased a DEC Service Contract for the DEC
computer providing for a bimonthly periodic maintenance check
and immediate repair if necessary.
6.2.2 Calibration
All calibration was performed by the Group Supervisor. The items of
test equipment associated with test parameter measurement were:
1. tire pressure gauges
2. scuff tester
3. engine rpm tachometer
4. timing light
5. exhaust gas analyzers (HC, CO, CO2)
The tire pressure gauges were not calibrated per se, but were cross-
checked against each other as a check for improper operation. The
scuff tester, tachometer and timing light were periodically calibrated
per the manufacturers' procedures.
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66
The final and most important item was the exhaust analyzers. These
analyzers (HC, CO, CC^) were calibrated weekly in accordance with
the procedures defined by the Periodic Maintenance Manual. The
weekly calibration interval was established as adequate to maintain the
analyzers well within their accuracy specifications by extensive
experieince in the HTS programs in Arizona and California.
Calibration gases for this project have their named concentration
traceable to NBS standards. The procedure for naming these gases is
outlined below.
1. Certified gases, NBS traceable, were supplied to Hamilton test
Systems California, Inc. by the Air Resources Board, State of
California, from their laboratory in El Monte, California.
2. Monthly, the certified gases were used to run a curve check on
each of the three ranges of the Beckman 865 gas analyzer which
is used by Hamilton Test Systems California, Inc. for gas
naming.
3. Gases to be named for calibration purposes were initially 5%
named gases supplied by Liquid Carbonic. Based on the
manufacturer's concentration, a suitable range was selected on
the Beckman 865.
4. A certified gas is selected which will give approximately the
same meter deflection (digital meters used) as the gas to be
named, and the instrument is spanned at this point. In this way
the maximum measurement accuracy is assured for establishing
the concentration of the gas to be named.
5. The gas to be named is then introduced to the analyzer and the
concentration recorded.
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67
6. Steps 4. and 5. are repeated two more times and the average of
the three concentration readings is used as the bottle
concentration. The naming accuracy is within^ 1%.
Two other pieces of equipment not normally associated with vehicle
testing required calibration - the ambient CO monitor and the backup
HC, CO analyzer (CEA 610). These devices were calibrated at least
monthly per the Periodic Maintenance Manual.
Records of each calibration were maintained at the station and kept
available for EPA review.
6.3 VEHICLE RECRUITMENT
In the first month and a half of operations, the Texas Air Control Board
(TACB) their own advertising campaign. They contacted local
newspaper columnists, placed ads in different sections of the
newspaper, and ran public service announcements on the radio. The
Public Relations firm, Rasco & Co., was hired a month and a half
after test operations began, and TACB released all advertising
responsibility to them. Rasco started a basic "grass roots" campaign
contacting local business and industry through the Chamber of
Commerce and other organizations. High schools and social service
clubs were also contacted. As vehicle testing proceeded and the low
test volume did not significantly increase, TACB responded again with
more ads and media articles. During the final two months they ran an
effective direct mail campaign to local ZIP code areas using addresses
from the August and September registration renewals.
HTS conducted an informal poll on participant response for the last 19
weeks of testing. People who entered the station were asked the
question, "How did you hear about the program?" The poll represented
over half the test vehicle owners (2434 people). It was separated into
-------
68
two time frames because of the later addition of the direct mail
category. The breakdown on public response was as follows:
Week 8- 26 Week 19-26
(2130 vehicles) (1089 vehicles)
Newspaper 33%
Automotive Testing
Laboratories 22% 18%
Walk-ins 16% 12%
TV & Radio 12% 6%
Other 17% 12%
Mail - 28%
The high response from the newspaper was generated mainly by one
columnist (Harold Scarlett) writing four different articles. These
articles caused the three abnormally high peaks in test volume.
Automotive Testing Laboratories, the EPA subcontract CVS test
facility, provided a large number of vehicles for inspection.
Walk-ins were people who saw the facility or sign and came in for the
inspection.
TV and radio advertising consisted mostly of public service
announcements and news broadcasts.
The "other" category included government vehicles, word-of-mouth
advertising, and all other forms of solicitation.
The direct mail effort involved "Dear Citizen" letters and statement
stuffers mailed with local water bills. This method of vehicle
solicitation, though only used for a short period, proved to work very
well.
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69
PROGRESS REPORTING
In compliance with the contract, HTS submitted various reports during
the program as follows:
A. A Weekly Status Report listing the tests performed and
categorizing them for various Pass/Fail criteria was mailed to
EPA on a weekly basis.
B. A Monthly Progress Report which included:
. Statement of work accomplished prior to the start of the
current reporting period.
. A statement of the work performed during the reporting
period, including difficulties encountered and remedial
actions taken. Also reported were any technical problems
and scheduled changes.
. An Organization Chart indicating the personnel assigned to
the program.
. The Station Daily Operations Log which indicated
operating hours for each day, personnel at work, and
visitor information.
. Hourly Test Work Sheet which indicated, for the month
reported, the average inspection rate as a function of the
hour of the day, and for all of the months since the start of
the Operational Phase taken together, the average
inspection rate as a function of the hour of the day.
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70
. Hourly Queue Work Sheet which indicated for the month
reported, the average queue as a function of the hour of
the day and,
. for all of the months since the start of the Operational
Phase taken together, the average queue as a function of
the hour of the day.
Appendix "C" presents the Reporting Guidelines. This document
detailed the procedures for preparing and submitting the various
reports.
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71
7.0 INSPECTION SUMMARY
7.1 PATTERN OF INSPECTION
7.1.1 Total Inspection
The inspection program Operational Phase was operated for 26 weeks.
The program provided 125 days of testing due to a total of 5 holidays
when the station was closed.
A total of 4674 vehicles were tested in which 4501 tests were Initial
tests and 173 were Retests (3.84% of initial test volume).
Table 7.1.-1 lists the weekly testing volume for each operational
week. Figure 7.1-1 shows the weekly test volume for each testing
week.
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72
TABLE 7.1-1
Week#
1
2
3
4
5
6
7
8
9
10
11
12
13
1*
15
16
17
18
19
20
21
22
23
24
25
26
TOTAL INSPECTION PER OPERATION WEEK
Operating Dates
3/3/80 - 3/7/80
3/10/80- 3/14/80
3/17/80- 3/21/80
3/24/80 - 3/28/80
3/3/80 - 4/4/80
4/7/80- 4/11/80
4/14/80- 4/18/80
4/21/80 - 4/25/80
4/28/80 - 5/2/80
5/5/80 - 5/9/80
5/12/80-5/16/80
5/20/80 - 5/24/80
5/27/80 - 5/31/80
6/3/80 - 6/7/80
6/10/80-6/14/80
6/17/80 - 6/21/80
6/24/80 - 6/28/80
7/1/80-7/5/80
7/8/80 - 7/12/80
7/15/80-7/19/80
7/21/80 - 7/26/80
7/29/80 - 8/2/80
8/5/80 - 8/9/80
8/12/80- 8/16/80
8/19/80 - 8/23/80
8/26/80 - 8/30/80
Operating Days T<
5
5
5
5
5
5
5
4
5
5
5
5
4
5
5
5
5
3
5
5
5
5
5
5
5
4
Total Inspections
295
358
231
163
197
147
147
117
146
141
131
314
218
190
177
149
100
42
155
121
125
203
135
152
196
324
Total
3/3/80 - 8/30/80
125
4674
-------
360_.
HQ_.
}20_
J00_
2
-------
74
7.1.2 Capacity Evaluation
A. In compliance with the contract requirement, the station and
equipment were designed for a throughput capacity of 20 vehicles
per hour. Based on this design criteria the program's weekly
testing capacity was (45 hours/week) X (20 vehicles/hour) = 900
v/week. Table 7.1-2 shows the weekly percentage of actual
capacity usage for each of the testing weeks. Figure 7.1-2 shows
the above in graph form.
B. As can be seen from Table 7.1-2 and Figure 7.1-2, testing volume
ranged from as low as 7.0% of actual weekly capacity (Week# 18)
to a high of 45.0% of actual weekly capacity (Week #26). Testing
exceeded 25% of actual weekly capacity only 6 times (Weeks # 1, 2,
3, 12, 13, 26).
C. An examination of the Hourly Test report (submitted to EPA as
part of the Monthly Progress Report) reveals that out of 125 days
(1125 hours) of operation:
only 52 times (4.6%) did actual testing exceed 50% (11
vehicles/hour) of the hourly testing capacity of 20
vehicles/hour.
only 3 times actual testing exceeded 100% hourly design
capacity when in 3 consecutive hours the station processed
27, 28 and 22 vehicles/hour.
-------
TABLE 7.1.2-1
PERCENTAGE CAPACITY USED
75
Week#
% Capacity
Week*
1
2
3
*
5
6
7
8
9
10
11
12
13
32.8
39.8
25.7
18.1
21.9
16.*
16.*
16.3 (see Note 1.)
16.2
15.7
1*.5
3*.9
30.3 (see Note 2.)
1*
15
16
17
18
19
20
21
22
23
2*
25
26
% Capacity
21.1
19.7
16.5
11.1
7.0 (see Note 3.)
17.2
13.*
13.9
22.5
15.0
16.9
21.8 (see Note *.)
45.0
Notes; The following weeks' capacity was adjusted as follows:
1. Less 9 testing hours on Monday, capacity equal to 720
vehicles/week.
2. Less 9 testing hours on Monday, capacity equal to 720
V/Week.
3.
Less 9 testing hours on Friday and 6 testing hours on
Saturday, capacity equal to 600 vehicles/week.
Less 9 testing hours on Wednesday, capacity equal to
720 vehicles/week.
-------
_100_
_an-
WEEKLY VOLUME AS PERCENT OF CAPACITY
1234 56 78 9 10 11 12 13 14 IS 16 17 18 19 20 21 22 23 24 25 26
FIGURE 7.1-2 WEEKLY VOLUME AS PERCENT OF CAPACITY
ON
-------
77
7.1.3 Testing Hours Evaluation
At the start of the testing program commencing'Monday, March 3, 1980,
the facility was opened for testing Monday through Friday between the
hours of 8:00 A.M. and 5:00 P.M. (including lunch periods) for a total of 45
inspection hours per week.
At the request of the TACB the operating hours were changed on Tuesday,
May 20, 1980 as follows:
Tuesday 8:00 A.M. to 5:00 P.M.
Wednesday 8:00 A.M. to 5:00 P.M.
Thursday 8:00 A.M. to 8:00 P.M.
Friday 8:00 A.M. to 5:00 P.M.
Saturday 8:00 A.M. to 2:00 P.M.
Table 7.1-3 shows the overall inspections per day of the week. Total days
are adjusted for holidays and operation schedule changes.
Table 7.1.3-1 Test Volume per Day of the Week
Average
Inspection
Day of Week Vehicles Tested Test Days Per Week Day
Monday 358 10 35.8
Tuesday 854 25 34.2
Wednesday 827 25 33.1
Thursday 1171 26 45.0
Friday 986 25 39.5
Saturday 478 l± 34.1
Total 4674 125
-------
78
Further analysis shows that total volume during Thursday extended hours
(5:00 P.M. to 8:00 P.M.) was only 94 tests or 6.7 vehicles per each Thursday
extended hours, which tends to suggest that those extended hours were not
effective in drawing vehicles for inspection.
In addition, average inspections per weekdays between Monday and
Saturday showed that the Monday testing average was slightly higher than
Saturday's average. However, since Saturday testing hours were only 8:00
A.M. to 2:00 P.M. (6 hours of testing) vs Monday 8:00 A.M. to 5:00 P.M. (9
hours for testing), it appears that response for the testing was slightly
better on Saturday than on Monday.
7.2 DIFFICULTIES ENCOUNTERED AND RESOLUTIONS
7.2.1 Station Visibility
The initial signs gave the facility a very low profile for public recognition. A
blue and white rectangular V X 8' sign mounted high on a 25" pole was the only
identification available. The sign read "State Vehicle Emission Test Center"
and was difficult to make out from a distance while traveling either direction
on San Felipe Road. Several ideas were implemented by HTS and the PR firm
contracted by TACB to attract greater attention to the station. A large
portable sign was leased to display messages, at eye level, by the queue lane
entrance. Blue and white pennant flags were strung in front of the building.
Later, banners were hung on the building's sides, a large "Open" sign was placed
out front and the outlined word "State" on the high rectangular sign was colored
in.
7.2.2 Low Test Volume
The extremely low test volume caused several problems in the station. It
affected work quality and the general station atmosphere. The inspectors'
morale suffered when the work load was light over an extended period.
-------
79
Employee turnover stemming from job dissatisfaction consisted of 5
inspectors. The employees were kept busy as often as possible under the
circumstances. Team spirit was promoted, additional training classes given,
and work quality was frequently checked. Errors or bad habits were discussed
in meetings at appropriate times. Overall, the inspectors presented a
professionalism in their work, and the public seemed satisfied, as evidenced by
many compliments on the job performed.
7.2.3 Public Participation
There were many causes for lack of participation in the program. The following
are listed, and are based on comments expressed by participants as to why
others did not participate:
Apathy and disinterest in more Federal controls.
The fear of penalties for test failure, or being contacted
by the State later on.
Houston's traffic congestion; the test was not worth
competing in cross-town traffic.
Since there was no scientific poll taken by HTS, these comments, pro
and con, cannot be deemed to reflect public opinion as a whole.
It can be stated, however, that the majority of participants appeared
to be supportive of the program. A comment that was often heard
was, "More people need to be made aware of the testing program"
-------
APPENDIX "A"
EPA/HOUSTON
DEMONSTRATION PROGRAM
INSPECTOR OPERATION MANUAL
PREPARED BY!
APPROVED BY:
NAFTALI AMIR
RELEASE DATE: 2/8/80 A,"j, ARRIGO
-------
TABLE OF CONTENTS
PAGE
INTRODUCTION .... 1
GLOSSARY 2
SECTION A. - EQUIPMENT A-l
1.0 EMISSION CATHODE RAY TERMINAL (CRT) A-l
2.0 EMISSIONS DATA ENTRY PANEL (EDEP). A-8
3.0 TEST CUE PANEL (TCP) A-l2
4.0 SCUFF GAUGE A-15
5.0 DIGITAL ANALYZER A-16
6.0 TIMING LIGHT A-18
7.0 AUXILIARY CATHODE RAY TERMINAL (CRT) A-20
SECTION B. - INSPECTION TASKS ..... B-l
1.0 REGISTRATION INFORMATION AND TEST SUITABILITY ENTRY B-l
2.0 TIRE PRESSURE CHECKS B-10
3.0 EMISSIONS TESTING B-l2
3.1 Automatic Mode B-l2
3.2 Backup Mode B-16
4.0 ALIGNMENT CHECKS B-22
5.0 EMISSION CONTROL SYSTEM (ECS) CHECKS B-23
6.0 PROPANE INJECTION CHECKS B-25
7.0 BASIC TIMING CHECKS B-27
8.0 QUEUE CARD TEST INFORMATION ENTRY B-29
9.0 MANUALLY-ENTERED EMISSION DATA B-31
9.1 Emission Data Entries into Emission Computer . B-31
9.2 Emission Data Entries into Auxiliary Computer . B-33
10.0 EGR FUNCTIONAL CHECK ....... .......... . B-37
-------
TABLE OF CONTENTS (Cont'd)
PAGE
SECTION C - OPERATION PROCEDURES C-l
1.0 AUTOMATIC MODE C-2
2.0 BACK-UP MODE C-3
3.0 SEMI-AUTOMATIC MODE C-5
4.0 DEFERRED MODE C-6
11
-------
LIST OF FIGURES
FIGURE PAGE
A
1
2
3
4
5
6
7
8
9
10
n
12
13
14
15
16
17
18
QUEUE CARD
EMISSION CRT "PRE LOG-ON SCREEN FORMAT"
EMISSION CRT - REGISTRATION ENTRY SCREEN FORMAT ....
EMISSION CRT - SAFETY SCREEN DISPLAY ...
EMISSION CRT - VISUAL ECS SCREEN DISPLAY
EMISSION CRT - MANUALLY-ENTERED EMISSION DATA SCREEN DISPLAY
EMISSIONS DATA ENTRY PANEL
TEST CUE PANEL (TCP-FRONT VIEW)
SCUFF GAUGE
DIGITAL ANALYZER CONTROL UNIT AND METER
TIMING LIGHT - PARTS & HOOK-UP
AUXILIARY CRT - PRE LOG-ON SCREEN DISPLAY
AUXILIARY CRT - LOG-ON SCREEN DISPLAY (AUTOMATIC MODE) . .
AUXILIARY CRT - LOG-ON SCREEN DISPLAY (BACKUP MODE) . . .
AUXILIARY CRT - QUEUE CARD TEST INFO. ENTRY SCREEN DISPLAY .
AUXILIARY CRT - EMISSION INFORMATION ENTRY SCREEN DISPLAY .
VIR - TOP HALF
TEMPORARY VIR
EGR FUNCTIONAL CHECK DATA FORM
4
A-3
A-4
A- 5
A-6
A-7
A-9
A-13
A-15
A-17
A-19
A-21
A- 22
A-23
A-24
A-25
B-6
B-36
B-39
TABLES
TABLE B-l - VEHICLES EXEMPT FROM TIRE CHECKS B-ll
APPENDIX
VEHICLE-MAKE ABBREVIATION LIST D-l
111
-------
INTRODUCTION
This manual is intended to serve as a training and operation guide for
the lane operation of the EPA/Houston Demonstration Program.
The manual is divided into three (3) sections:
SECTION A. - EQUIPMENT. This section describes the inspector-
related functions on equipment associated with the vehicle
testing.
SECTION B. - INSPECTION TASKS. This describes the step-by-step
inspection procedures for all tasks to be performed by the
inspectors.
SECTION C. - OPERATION PROCEDURES. This lists the order of the
inspection tasks for various operational modes.
THIS MANUAL CONTAINS PROPRIETARY HTS INFORMATION AND SHOULD NOT
BE DUPLICATED OR MODIFIED WITHOUT PRIOR APPROVAL OF HAMILTON TEST
SYSTEMS., PHOENIX, ARIZONA,
-1-
-------
GLOSSARY
The following are some of the terms which will appear throughout this manual:
1, EQUIPMENT
Emission-CRT
Auxiliary CRT
EMS
TCP
Emission Computer
Auxiliary Computer
Scuff Gauge
RPM Gauge
Timing Gauge
2, GENERAL
VIR
Temporary VIR
Field
Queue Number
Cathode Ray Terminal - remote computer input
terminal and display screen connected to the
emission computer located at Positions T and 3.
Cathode Ray Terminal - remote computer input
terminal and display screen connected to the
auxiliary computer and located at Position 4.
Emissions Measurement System - the cabinet
housing all the emissions testing subassemblies.
Test Cue Panel - meter type device remotely
connected to the EMS for iadieating the actual
emissions test sequence; it prompts the driver
through the testing sequence.
The device (DEC 11/34) that receives, stores and
controls all the emission test data; it is
connected to the EMS computer.
The device (Alpha Micro) that receives, stores
and controls the printing of all test data
performed in the facility. It is connected to
the emission computer.
The device that checks front wheel alignment as
a drag in feet/mile.
The device that, when attached to the vehicle
ignition system will measure engine RPM.
The device that with the use of light, shows
measurement of engine timing.
Vehicle Information Report - the form with all the
inspection data printed thereon.
The temporary form used in the printer connected
to the EMS in backup mode.
Information block on the CRT - all fields have a
name and dashes to indicate the field length.
A 3-digit number which is used to "track" a test
between all the equipment, through each test position.
-2-
-------
2. GENERAL (cont'd)
Queue Card . The card with the queue number preprinted on it
and the fields for manual recording some of the
test data. (Figure A, page 4)
Special Timing . EPA supplied form to be given to all vehicles
Handout that failed basic timing checks. (Code "TTT"
appears on bottom line of VIR.)
Address Label . Pressed-on label to be filled-in by vehicle owner
with his mailing address (used in deferred mode
of operation).
-3-
-------
QUEUE CARD
DATE
PLATE
TIRE PRESSURE
RIGHT FRONT
RIGHT REAR
LEFT REAR
LEFT FRONT
ALIGNMENT
DATA
SPEC
PROPANE GAIN
INITIAL RPM
FINAL RPM
IGNITION TIMING
TIMING
SPEC
001
TEST REFUSED = TR
NO TEST = NT
NO TEST= NT
I NO TEST = NT
|_ABORT = AB
J~NO TEST= NT
(_A_BORT = AB
ATDC= -
FIGURE A
-4-
-------
SECTIQN-A, - EQUIPMENT
1 .,0 EMISSION CATHODE RAY TERMINAL (CRT)
The CRT (ADDS Regent 100) located at Positions 1 and 3, is the device
which allows the inspector to receive and send emission information to
the main computer (DEC 11/34).
The following is inspector-related information:
1.1 Keyboard
Keyboard characters, with a few exceptions noted below, are standard
upper-case-only characters associated with typewriters.
1.2 Cursor
The cursor is a blinking blo.ck which designates the location of the
next character to be entered in the CRT.
1.3 Cursor Wrap
If an incomplete or incorrect entry has been made in a data field and
the NEW LINE key has been depressed to advance the cursor, the cursor
will return to the first point of entry within the same data field.
This is termed a "cursor wrap."
1.4 Special Control Functions
1.4.1 Pressing the ESCAPE (ESC) key plus a predesignated numeric key (see below) will
provide the following:
CRT Key Function Name Description
ESC+1 PRE LOG-ON Prepare CRT to receive information (queue
number). (See Figure 1, page A-3)
Note: 1. In normal operation the CRT is
already in this state.
2. This function should be used only
if CRT is not in its normal stage at start
of operation.
ESC+2 LOG OFF Terminate entries to CRT, reverts CRT to
starting stage PRE LOG-ON.
A-l
-------
CRT Key Function Name Description
ESC+3 BACKFIELD Backs cursor up to previous data field.
ESC+4 HOME Returns cursor to the first data field
in the plate field (first entry on CRT).
ESC+5 PAGE To call up "Test Suitability" screen and "Manually
Entered Emission Data" screen.
ESC+6 EXIT Terminate emission computer entries.
Tasks - send information to auxiliary computer.
ESC+8 CANCEL Cancels all information currently displayed
on CRT - reverts CRT to-PRE LOG-ON state.
1.4.2 Pressing the following keys by themselves will provide for:
NEW LINE Causes cursor to be advanced to the next data field.
DELETE IT!I Causes cursor to move to the left within the data field.
BACKSPACE \**f | Causes cursor to move one space to the left to permit
re-entering the previous character.
1.5 Validation
Upon LOG-OFF the computer will check that all necessary entries are present
and correct; if a mistake is found the cursor will indicate the field with
the error.
Note: 1. If more than one field is in error the cursor will show the
first error field in the entry sequence.
2. Should the cursor "lock up" and not advance or move, it has
found an invalid entry and is waiting for a correction.
1.6 CRT Display
There are four applicable CRT displays:
a. basic registration entry display (Figure 2, pag'6 A-4)
b. safety code (test suitability) display (Figure 3, page A-5)
c. visual ECS display (Figure 4, page A-6)
d. manually-entered emission data (Figure 5, page A-7)
Note: If any other display appears on the CRT, call manager.
A-2
-------
QUEUE
CO
V
FIGURE 1
EMISSION CRT
"PRE LOG-ON SCREEN FORMAT"
-------
QUEUE oo i~-
DB1 LANF: i TIME DATE
HAKE RETEST - PLATE
DOOM CUST
WEIGHT 0 CYl. AIC - SS
QUALIFY - RRR - SMUKE
RE INSPECTIOM
STATION LANi: - - MOCiE - DATE
TE:ST ND TUMI: HC TUM: co
REP ID REP RPM.
$ PARTS $ LAPUR ~- RPM GA'tN
FIGURE 2
EMISSION CRT
REGISTRATION ENTRY SCREEN FORMAT
-------
QUEUE XXXXX
**MESSAGES**
VISUAL SAFETY
cn
OIL SYSTEM
01 leak
02 light on
03 transmission leak
EXHAUST SYSTEM
06 excessive leak noise
07 loose dragging
08 inaccessible
TIRES LOADED
11 bulging torn
12 under inflated
COOLANT SYSTEM
04 leak
05 1ight on
FUEL SYSTEM LEAK
09 engine
10 under body
OTHER
13 other
CODES
FIGURE 3
EMISSION CRT
SAFETY SCREEN DISPLAY
-------
QUEUE 001E- REFERENCE CARD 1234
YEAR E78 MAKE FORD- CYL 06 AIC 1
FIRST DIGIT
A PCV
B AI
C EGR
D FE
E CAT CON
F FUEL RES
SECOND DIGIT
> 1 MODIFIED
2 DISCONNECTED OR BYPASSED
3 MISSING
4 NOT INSPECTED
CODES ECSID
FIGURE 4
EMISSION CRT
VISUAL ECS SCREEN DISPLAY
-------
QUEUE 001RM
EMISSIONS ANALYSIS
MODE I
HC CO NO
HC
TYPE -
MODE II
CO NO
HC
IDLE SP
MODE III
CO NO
C02
RESULT
MESSAGE
C02
ECS ID -
C02
CERTIF -
EMS ID ---
FIGURE 5
EMISSION CRT
MANUALLY-ENTERED EMISSION DATA SCREEN DISPLAY
-------
2.0 EMISSIONS DATA ENTRY PANEL (EDEP)
2.1 The EDEP is the device by which the inspector receives and sends information
to the EMS (Figure 6, page A-9).
Note; Unlike the CRT, all information needed for the emissions test has
to be entered via the EDEP in special sequence. This sequence is controlled
by the EMS program and will be enunciated on the EDEP.
2.2 The main parts of the EPEP are:
10 numeric keys 0-9 (white)
5 special control keys (blue)
1 enter key (red)
1 tape load key (green)
8 instruction (enunciation) lights - LED
3 display windows
2.3 The following is inspector-related information:
2.3.1 Keys:
Button ID Color
0-9 whi te
A,B,N white
Functi on
RESTART
CLEAR
blue
blue
OVERRIDE
blue
ABORT
blue
Numerals 0 to 9 allows inspector to enter numeric
combinations.
Allows inspector to select louver opening when
the ENTER LOUVER LED is on, as follows:
A - closer louver opening
B - further louver opening
N - no louver opening
Allows inspector to restart emissions test after
the test sequence has started.
Allows operator to change certain information
received from the EMS by erasing the current
information and re-entering the correct data.
Allows test to continue after it was stopped due
to an error detected by the EMS.
Note; This button should be activated by the
manager only«- -
Terminates (erases) all record of emissions test.
Note: This button should be activated by the manager
only when vehicle malfunction occurs during testing.
A-8
-------
ENTER QUEUE NUMBER
ENTER VEHICLE CLASS
ENTER INSP NO /CODE
ENTER LOUVER
ENTER SMOKE
KEYBOARD ERROR
SYSTEM ERROR
EMISSIONS FAILURE
FIGURE 6
EMISSIONS DATA ENTRY PANEL
A-9
-------
Button ID
Color
Function
SMOKE
blue
ENTER
NONE
red
green
Allows operator to:
a) inform EMS that smoke test information is
forthcoming
b) indicates smoke failure.
Signals inspector acceptance of the information
display; allows EMS to proceed in the test sequence.
Loads EMS programs.
Note: This button should be activated by manager only.
2.3.2 Instruction (enunciation) Lights:
Light Name
Enter Queue Number
Function
Prompts operator to enter or accept vehicle queue
number.
A. Automatic Mode - inspector has to enter
number via numeric keys.
B. In Backup Mode queue number will be displayed auto-
matically (previous test queue number +1). See
section B 3.2 for Operation Procedures.
Enter Vehicle Class . Prompts operator to enter or accept vehicle class.
A. Automatic Mode - number is displayed -
inspector presses ENTER button to accept.
Enter Inspector
Number
Enter Louver
Enter Smoke
Keyboard Error
System Error
Emissions Failure
B. In Backup Mode, inspector enters class
code via numeric keys.
Prompts operator to enter his inspector number
in special cases
Prompt operator to select louver opening.
Prompt operator to enter smoke test results,
as follows:
. Fail Smoke - press SMOKE key
. Pass Smoke - press CLEAR key
Indicates to operator an incorrect keyboard entry
has been made - operator must press CLEAR button
to extinguish "keyboard error" light and enter
correct information.
Prompts operator to a system malfunction - test
will stop. Testing cannot continue unless this
light is extinguished.
Will .indicate emissions failure upon special
request - normally does not apply.
A-10
-------
2.3.3 Numeric Display Windows:
Display Name Location
HC PPM top
CO %
middle
bottom
Function
a. Displays vehicle HC concentration in PPM -
upon special request.
b. Displays queue number entered when class
code is being entered.
a. Displays vehicle CO concentration in %
upon special request.
b. Displays the year portion of the class code.
a. Displays the numeric keys entry as they are
being activated.
b. Displays vehicle C02 concentration when
"sample" dilution error occurs.
c. Displays #Cyl, Wt.Class, and AI/CAT code
portion of class code.
A-ll
-------
3.0 TEST CUE PANEL (TCP)
3.1 The TCP (Figure 7, page A-13) is the operator/vehicle driver interface with
the EMS. The TCP's function is to indicate the actual emissions test
sequence.
3.2 The main parts of the TCP are:
. 4 "test sequence" instruction displays:
READY
TESTING
SET SPEED
TEST COMPLETE
. Two RPM Instruction Displays:
SET SPEED
ACTUAL SPEED
. Three Enunciation Lights:
SAMPLE DILUTION
BACKUP MODE
CONTROL MESSAGE
Note; The display marked "horsepower" is not being used.
3.3 The following is inspector-related information:
3.3.1 Test Sequence Displays:
Condition
Display
Name
F u n c t i on
READY
TESTING
SET SPEED
TEST
COMPLETE
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON indicates system is "ready" to begin an
emissions test. Emissions test can not begin
unless READY is illuminated.
ON indicates actual emissions test is proceeding
as normal.
ON indicates operator must change test RPM.
Engine RPM value is not correct and needs to be
increased or decreased for current test mode.
(See Section B.3.0)
ON indicates emissions test has been concluded.
A-12
-------
TESTING
SET
SPEED
ACTUAL
SPEED
HORSEPOWER
DILUTION
BACK-UP
MODE
FIGURE 7
TEST CUE PANEL (TCP-FRONT VIEW)
A-13
-------
3.3.2 RPM Instruction Display:
Units
RPM
Display
Name
Function
SET SPEED
DISPLAY
ACTUAL SPEED
DISPLAY
RPM
Display number is "target" speed of engine.
2500 display means "target" engine speed is
2500 RPM. No display means Idle RPM.
Displays real-time engine RPM value.
3.3.3 Enunciation Lights:
Display
Name
CONTROL
MESSAGE
SAMPLE
DILUTION
BACKUP MODE
Condition
ON/OFF
ON/OFF
ON/OFF
Function
ON indicates there has been an "ambient CO1
violation. Inspector to call manager..
1. ON indicates the sum of CO and C02 gas
concentrations is less than a predetermined
value.
2. Can indicate exhaust probe(s) have not
penetrated the exhaust pipe adequately.
3. Can indicate exhaust system is leaky
(i.e.; holes).
1. ON indicates EMS in the "backup" mode. The
emissions computer is off-line. Operator
must manually enter information with the
EDEP at position #2.
2. Emission printer is driven from EMS.
Note: When the EMS detects an error in
any of its subsystems during testing, the
TCP will be totally blank - inspector to
call manager.
A-14
-------
4.0 SCUFF GAUGE
4.1 The scuff gauge, Figure 8, below, is the device which will be used for
measuring vehicle front end alignment during the alignment checks.
4.2 The main parts of the scuff gauge are:
a. Driving plates - which will measure the vehicle front-end side drag.
Note: Activate switch is built into the driving plate, unit is
activated by the vehicle's front wheels and deactivated by the
vehicle's rear wheels.
b. Meter and control unit - will interpret driving plates movement
into displayed meter needle movement. Meter scale is in ft./mile.
METER AND CONTROL UNIT
FIGURE 8
SCUFF GAUGE
A-15
-------
5.0 DIGITAL ANALYZER
5.1 The digital analyzer (Figure 9, page A-17) is the device which is used
for measuring vehicle RPM during the propane injection checks.
5.2 The main parts of the digital analyzer are:
a. Control unit and meter.
b. RPM pickup.
5.3 Setup Procedures:
a. Switch "SW1" is placed in the RPM 2000 position.
b. Switch SW2 is used for other type of test - ignore.
c. Display window will display zeros.
d. RPM pickup is clamped to any plug wire.
Notes: 1. Unlike the EMS tach pickup,"digital analyzer" RPM
pickup can be clamped to the plug wire at any orientation.
2. Make sure RPM pickup does not come into contact
with metal while it is connected to vehicle.
e. Actual RPM reading will be displayed in the control unit display window.
f. At the end of each test, switch "SW1" is to be placed in the OFF position
to preserve unit's battery.
A-16
-------
o
o
DISPLAY
INPUT
200 VDC
MAX
COM
20 AMP
DC MAX
ONLY
\
6-32 x 1/8"
SUSCfUW
OFF
POINTER
POINTER
CYLINDCRS
O
/ I
FIGURE 9
DIGITAL ANALYZER CONTROL UNIT AND METER
A-17
-------
6.0 TIMING LIGHT
6.1 The timing light, Figure 10, page A-19, is the device which is used for
measuring the vehicle's ignition timing during the basic timing checks.
6.2 The main parts of the timing light are:
a. Timing light and meter.
. Strobe light source.
. Meter located at the back with 2 circular scales, outer scale -
degree advance, inner scale RPM - not used.
b. Push bottom switch - "SW1" - located at the top of the timing light
and meter handle; used to activate the light.
c. Advance control "R3" - located on the top right side of timing light
and meter handle; used to advance light strobing frequency.
d. Battery cable - used for applying power to unit via vehicle's battery.
Red clip is to be connected to positive battery terminal; black clip
is to be connected to negative battery terminal.
e. Inductive pickup - used for timing light firing pulse. Pickup is
clamped to No. 1 plug wire - no orientation needed.
A-18
-------
b POINTER i.'.ARK
^ , OM VIBRATION
L'-^ DAMPER PULLEY
.ill
TIMING LIGHT - PARTS & HOOK-UP
-------
7.0 AUXILIARY CATHODE RAY TERMINAL (CRT)
The CRT (ADDS Regent 100) located at Position #4 is the device which
allows the inspector to receive and send information to the auxiliary
computer (Alpha Micro).
7.1 Keyboard
Same as emission CRT.
7.2 Cursor
Same as emission CRT
7.3 Special Control Functions
CRT Key Function Name Description
Shift + Delete back space causes cursor to move to the
left within data field
Bar Line space/blank causes cursor to move to the
next entry within a data field
New Line - causes cursor to move to the
first entry on the next field
Note: Special Function applicable to the emission CRT should not be
used on the auxiliary CRT.'
7.4 CRT Display
There are four (4) applicable CRT displays:
a. PRE LOG-ON (Figure 11, page A-21)
b. LOG-ON screen display - Automatic Mode (Figure 12, page A-22)
c. LOG-ON screen display - Backup Mode (Figure 13, page A-23)
d. Queue card test information entry (Figure 14, page A-24)
e. Emission information entry screen display (Figure 15 , page A-25)
A-20
-------
PLEASE ENTER QUEUE NUMBER?
PO
FIGURE n
AUXILIARY CRT
PRE LOG-ON SCREEN DISPLAY
-------
QUEUE #999 - LICENSE PLATE ABC1234 YEAR 1979 MAKE FORD
VEHICLE ID# 1234ABC12345ABCD RESULT .PASS
IS THIS THE RIGHT QUEUE NUMBER?
IXJ
K5
FIGURE 12
AUXILIARY CRT
LOG-ON SCREEN DISPLAY (AUTOMATIC MODE)
-------
PLEASE ENTER QUEUE NUMBER 002
QUEUE NUMBER NOT FOUND
DO YOU WISH TO INPUT EMISSION DATA?
ro
Co
FIGURE 13
AUXILIARY CRT
LOG-ON SCREEN DISPLAY (BACKUP MODE)
-------
QUEUE #001
TIRE PRESSURE
1. RF
2. RR
3. LR
4. LF
ALIGNMENT (F/M)
5. READINGS
6. SPECIFICATION
F PROPANE INJECTION
IN>
7. INITIAL RPM
8. FINAL RPM
TIMING
9. READINGS
10. SPECIFICATION
ANY CHANGE?
FIGURE 14
AUXILIARY CRT
QUEUE CARD TEST INFORMATION ENTRY SCREEN DISPLAY
-------
ro
in
QUEUE 001
1. RESULTS
2. ECS FAILURE CDS
3. EMISN TEST FAIL CDS
4. REJECT CDS
5. TEST MODE
6. TEST #
7. DATE
8. TIME
9. LICENSE PLATE
10. VEHICLE I.D.#
11. YEAR
12. MAKE
13. CYLINDERS
14. WEIGHT
15. MILEAGE
16. AI/CAT
17. 1ST IDLE STND HC
18. 1ST IDLE STND CO
19. 1ST IDLE READ HC
20. 1ST IDLE READ CO
21. 1ST IDLE READ C02
22.
23.
24.
25.
26,
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
2500 RPM
2500 RPM
2500 RPM
2500 RPM
2500 RPM
2ND IDLE
2ND IDLE
2ND IDLE
2ND IDLE
2ND IDLE
IDLE RPM
IDLE RPM
CUST
PCS ID
EMS ID
SMOKE
RETEST
STND HC
STND CO
READ HC
READ CO
READ C02
STND HC
STND CO
READ HC
READ CO
READ C02
LIMIT
READINGS
ANY CHANGE?
FIGURE 15
AUXILILARY CRT
EMISSION INFORMATION ENTRY SCREEN DISPLAY
-------
SECTION B. - INSPECTION TASKS
1.0 REGISTRATION INFORMATION AND TEST SUITABILITY ENTRY
The following procedures are performed on the emission CRT at Position 1:
1.1 Required Conditions:
a. Emission computer operational
b. Emission CRT operational
c. CRT in PRE LOG-ON state (Figure 1, page A-3).
1.2 Log-On:
a. Key in the 3-digit queue card number.
b. Press the NEW LINE key.
c. CRT displays registration entry format (Figure 2, page A-4).
Note; T. If CRT does not display registration format, a
message will appear on the screen.
2. Possible messages and inspector responses are:
Message Explanation Inspector Response
**INVALID** Queue number entered is not a 1) press ESC+1
3-digit number (000 is an invalid ^ repeat step 1>2
Gn ulrjr )
**WAIT** Computer cannot receive another call manager
test.
**BUSY** Queue number is being used by 1) log-off (ESC+2)
other equipment.
2) change queue card
3) repeat step 1.2
**NOT FOUND** Not applicable call manager
FULL** Not aPPllcable call manager
**FLOPPY
ERROR** Not aPPlicable' call manager
Note: If the queue number displayed does not agree with the queue card
(wrong number entered) and the data field is empty, 1) depress ECS+8
keys - this "cancels" the queue number. 2) repeat step 1.2.
B-l
-------
1.3 Entries of Registration Information:
Note: A marker on the display of the CRT called a "cursor" indicates
where the next keyed-in entry will go. The control of the cursor is
explained in Section A paragraphs 1.1 thru 1.4.
1. "YEAR" Field
a. Key in the letter "M" followed by the last two digits of
the model year. Example: "1979 vehicle - M79"
b. Verify the display.
c. Depress the "NEW LINE" key.
2. "MAKE" Field
a. Key in the vehicle make as listed in Appendix #1 (Vehicle
Make Abbreviation List).
b. Verify the display.
c. Depress the "NEW LINE" key.
Note 1: If vehicle is a truck, "MAKE" entry is to have the letter
"T" inserted at the end of this field.
2: If vehicle is a van, "MAKE" entry is to have a letter "V"
inserted at the end of this field.
3. "RETEST" Field
a. Key in one numeric digit, as follows:
. A zero value (0) signifies test to be performed on vehicle
is the first test.
. A numeric value "1-9" signifies retest value.
Note 1: For vehicles returning for retests, owners
must have previous test VIR forms.
2. The retest value entered should be the value that
appears on the previous VIR form incremented by one (1).
Example: Previous VIR has 1" in retest block -
enter "2" in this field.
B-2
-------
b. Verify the display.
c. Depress the "NEW LINE" key.
4. "PLATE" Field
a. Key in the license plate number as follows:
License Plate Key In.
ABC 123 AJ3C.J. 2.1__
AB 123 AiiH
out of state ±£i±
no plate on vehicle N.O. HI.
Note: If license plate consists of more than eight digits or
letters, enter only the first eight.
b. Verify the display.
c. Depress the "NEW LINE" key.
5. "VIN" Field
a. Key in the VIN number.
Note: One to sixteen alpha numeric characters with no spaces
between characters.
b. Verify the display.
c. Depress the "NEW LINE" key.
Note: If VIN number cannot be obtained, key in "999" in this field.
6. "ODOMETER" Field
a. Obtain odometer reading as follows:
Read vehicle's odometer to the lowest thousands of miles
and enter in the "ODOM" field as follows:
Examples of Readings Key In
00,999 £££
38,800 Q3_8
138,800 ±3.8
Note: The actual odometer reading is to be used at all times
even if vehicle is suspected of having gone over 100,000 miles.
B-3
-------
b. Verify the display.
c. Depress the "NEW LINE" key.
7. "CUST" Field
Depress "NEW LINE" key to pass this field.
8. "WEIGHT" Field
This field will always display the digit zero (0).
9. "CYL" Field
a. Ask driver the number of cylinders in his vehicle.
b. If driver does not know, request driver to open hood latch.
c. Lift hood and verify number of cylinders.
d. Lower hood. Do not close shut.
e. Key in the number of cylinders.
Note: Two numeric characters represent the number of cylinders
for the inspected vehicle Possible values "ID 4." up to "1_2_",
f. Verify the display.
g. Depress the "NEW LINE" key.
10. "AIC" Field (Air Injection/Catalytic Converter)
a. Key in the appropriate numeric character based on the table below:
0 = no air injection, no catalytic converter
1 = air injection, no catalytic converter
2 = no air injection, catalytic converter
3 = air injection, catalytic converter
b. Verify the display.
c. Depress the "NEW LINE" key.
Note: All other fields should be left with no entries () after
the field name, unless retest field has an entry other than zero (0).
B-4
-------
1.4 Entries of Reinspection Information
Notes: 1. The following fields should be entered only if "RETEST"
field is other than zero (0):
2. If retest field is "0" proceed to Section 1.5 - "Test
Suitability Checks".
3. Use previous test VIR form as data base.
4. For the location of the information to be entered from
the VIR, refer to Figure 16, page B-6.
1. "STATION" (Field 1 - see Figure 16)
a. Key in the three (3) alpha numeric station code - this
should always be "DB1".
b. Verify the display.
c. Depress "NEW LINE".
2, "LANE" (Field 2 - see Figure 16)
a. Key in the one-digit lane number - this should always be "1".
b. Verify the display.
c. Press "NEW LINE".
3. "MODE" (Field 3 - see Figure 16)
a. Key in the one (1) mode code - this should always be "A" or "S",
b. Verify the display.
c. Press "NEW LINE".
4. "DATE" (Field 5 - see Figure 16)
a. Key in the six (6) digit date.
b. Verify the display
c. Press "NEW LINE".
5. "TEST NO." (Field 4 - see Figure 16)
a. Key in the three (3) digit test number.
Note: If test number is "1" key in "001".
B-5
-------
VEHICLE INFORMATION REPORT
0000001 & UP
TEXAS MOTOR VEHICLE EMISSION CONTROL PILOT TESTING PROGRAM
Thank you for participating in the Texas Motor Vehicle Emission Control Pilot Testing Program. This pro-
gram is part of a State study of ways to increase the effectiveness of motor vehicle pollution controls and
depends on voluntary public participation. The test readings from your vehicle and other vehicles will be
used to prepare recommendations to the Texas Legislature.
The test readings from your vehicle are typed in the block labeled "Emissions Test Data". For comparison.
diagnostic values have been typed above your readings, in the shaded areas. These values are experimental
and reflect values which vehicles the same age as yours can usually meet if they are operating properly. If
your vehicle is not meeting one or more of the diagnostic values, a " "Je " will have been typed next to the
corresponding test reading(s).
SEE REVERSE SIDE FOR FURTHER INFORMATION
QUEUE NO.
(FIELDS)-
rSTATION NO.
1
V
LANE NO.
2
TEST MODE
3
TEST NO.
4
DATE
5
TIME "
6
LICENSE PLATE
V
VEHICLE INF
VEHICLE IDENTIFICATION NO.
ORMATK
YEAR
DN
MAKE
CYL
MILEAGE
,000
J
TEST SUMMARY
[ I No operating problems detected.
Your vehicle may have an operating problem. See block labeled "Emissions Test Data" and
other side for further information.
I I See bottom block for fuel economy tips.
I I Your vehicle was not tested for the following reason(s):
FIGURE 16
VIR - TOP HALF
B-6
-------
b. Verify the display.
c. Press "NEW LINE".
6. "TUNE HC" - "TUNE CO" Fields
a. Press "NEW LINE" one at a time to move cursor through these
fields. Do not enter any code.
Note: Steps 7-11 information is to be entered if available
from a repair facility's paper work; if no paper work available
do not enter.
7. "REP ID" Field
a. Key in the repair facility numeric code.
Note: If you enter any numbers, make sure that the number is
8 digits long - add zeros (0) before the number.
Example: Facility code 123, enter "00000123"
b. Verify the display.
c. Press "NEW LINE".
8. "REP RPM" Field
a. Key in the vehicle RPM after repair.
Note: This field should also be 8 digits. Follow example above.
b. Verify the display.
c. Press "NEW LINE".
9. "$ PARTS" Field
a. Key in the amount (whole number) spent on parts.
b. Verify the display.
c. Press "NEW LINE".
10. "$ LABOR" Field
a. Key in the amount (whole number) spent on repair labor.
b. Verify the display.
c. Press "NEW LINE".
B-7
-------
11. "RPM GAIN" Field
a. Key in the RPM gain for mechanic propane injection check.
b. Verify the display.
c. Press "NEW LINE".
1.5 Test Suitability Check
1. Visually observe vehicle and determine if the following conditions exist:
a. Excessive oil or fuel leaks.
Note: Fluids dripping should be identified as to their content;
water, oil, or gas. If it is water or oil or nonhazardous
material, the vehicle should be tested. If there is fuel
leaking in any quantity, the vehicle should be rejected.
Should the fuel leak be a continuous stream, notify the
supervisor for a final decision on whether the vehicle
should be tested or rejected.
b. Defective tire.
c. Excessive leaking or inaccessible exhaust systems.
d. Any condition, in the inspector's supervisor's opinion, that
will invalidate the vehicle test results.
Note: If you are unsure about the vehicle's test suitability,
call manager.
2. If any of the above conditions exist, vehicle is unsuitable for testing.
Proceed to step 3. If vehicle is suitable for testing, proceed to
step 1.6 (Log-off).
3. Safety Failure Entry
a. Press "ESC+5".
b. Verify that CRT displays the "SAFETY SCREEN", Figure 3, page A-5.
c. Identify the code which describes why the vehicle is unsuitable
for testing.
d. Enter above code.
B-8
-------
e. Verify entry.
f. Press "NEW LINE".
g. Repeat steps c-f if vehicle is unsuitable for test due to additional items.
1.6 Log-Off
a. Press ESC+2.
b. Verify that CRT screen is in the "PRE LOG-ON" state.
c. If CRT does not revert to "PRE.LOG-ON" the cursor will point to
the field with the error - correct and repeat step 1.6.
Note 1: Any correction has to be followed by "NEW LINE" before
Log-Off can be performed. In addition, the entire field
must be completely re-entered.
B-9
-------
2.0 TIRE PRESSURE CHECKS
The following procedures are performed on each vehicle. All data entries
are manually recorded on the queue card.
2.1 Required Conditions
a. Registration and test suitability successfully completed.
2.2 Prior to actual check, perform the following:
a. Record the date and vehicle plate number in the appropriate place
on the queue card.
b. Briefly verify that all tire stems are accessible for checking.
. If one or more tires are inaccessible, check is bypassed -
record the code "NT" - No Test - in the field marked "RIGHT FRONT".
. If all tire stems are accessible, proceed to step c.
c. Inform driver of the tire pressure check and ask permission to:
. Check tires.
. Inflate tires to the upper pressure limit of 28 psi if they
are below the lower limit of 20 psi.
d. If driver refuses either of the above conditions, bypass tire pressure
check and record the code "TR" - Test Refused - in the field marked
"RIGHT FRONT".
. If driver agrees to the above, perform the check.
2.3 Tire Checks
a. Use the stand-alone tire pressure gauge to cheek and record the tire
pressure in psi in the appropriate place on the queue card.
b. On all tires found to have less than the lower pressure limit of
20 psi, add air up to the upper pressure limit of 28 psi using the
facility's air supply hose and gauge.
Note 1: Air is to be added to both front or rear tires, even if
only one of the pairs is below the lower limit.
2. Some small vehicles are exempt from tire pressure testing (Table B-l).
Enter the code "NT" in the field marked "RIGHT FRONT".
B-10
-------
TABLE B-1
VEHICLES EXEMPT FROM
TIRE CHECKS
1. Volkswagen (Beetle)
2.
3.
4.
5.
6.
7.
B-ll
-------
3.0 EMISSIONS TESTING
This section will cover the emissions testing procedure for two operational
modes:
. AUTOMATIC Mode
. BACKUP Mode
3.1 Automatic Mode
3.1.1 Required Equipment:
a. Emission computer operational.
b. EMS, EDEP and TCP operational.
c. Registration information entered prior to emissions test.
3.1.2 Pretest Conditions
a. TCP indicates READY.
b. EDEP "ENTER QUEUE NUMBER" enunciation light is on.
3.1.3 Test Procedure:
Step
a. Raise vehicle hood and secure it in the
"open" position.
b. Locate spark plug wire and make tach
connection.
CAUTION: Be sure tach pickup is
connected to a spark plug wire and not
the coil wire or vacuum hose.
c. Examine tail pipe configuration to
determine if any special tail pipe
adapters are required.
Note: For a valid exhaust sample the
probe must be inserted a minimum of 6
inches. Any less than this and an exhaust
extension adapter is required.
d. Remove probe from holder and insert
probe(s) into tail pipe(s) using
adapters as required.
e. On the EDEP, key in the numeric queue
number from the queue card.
Response
none
none
none
none
On the EDEP the queue number
appears in display #3 (lower)
B-12
-------
Step
f. On the EDEP, depress the following key:
"SMOKE" - if vehicle's excessive smoke
is to be checked.
"ENTER" - if no smoke observation needed.
Response
Note: If the "KEYBOARD ERROR"
enunciator is on, depress the
"CLEAR" key and start again at
step "e.".
g. Verify the "VEHICLE CLASS" is correct.
On the EDEP:
1. The queue number moves
to display #1 (upper).
2. The vehicle class appears
in display #3.
3. The "ENTER VEHICLE CLASS"
enunciator light is on.
On the EDEP the correct vehicle
class code is displayed in
displays #2 and #3, as follows:
h. Press "ENTER".
EDEP display
windows
*
Where YY = last digits of model
year
W always = 0
CC = number of cylinders 04-12
A = AIC code (0-3)
Note: If "VEHICLE CLASS" display
is incorrect, call manager.
On EDEP the "ENTER LOUVER"
enunciator light is on.
B-13
-------
Step
Response
Observe vehicle and press the louver
selection key as follows:
"A" - closest louver opening
"B" - furthest louver opening
"N" - no louver opening
Press "ENTER".
First Idle Test
Notes: 1. The first idle test mode
has started. CAUTION: Maintain an
idle condition in neutral. Do not
accelerate.
2. The cue to operate the
vehicle at idle is the "TESTING1 light
on and the "SET SPEED" display blank.
3. If vehicle is to be
observed for excessive smoke, it should
be done during the emissions test.
j. 2500 RPM Test
k. Accelerate engine (in "neutral")
until indicated actual RPM, as
shown on the TCP, is between
2300-2700 RPM.
Note: If during the "2500 RPM Test"
engine RPM is out of the above values,
the "SET SPEED" will illuminate and
the test will be stopped until RPM
is corrected.
B-14
Appropriate louver action.
On the Test Cue Panel (TCP)
1. The "READY" light goes out.
2. The "TESTING" indicator
light is on.
3. "ACTUAL SPEED" display shows
engine's RPM.
Note: a) If "SET SPEED" light
illuminates on the TCP the EMS
is not receiving RPM signal;
verify tach connection.
b) If light still
illuminates, select a different
plug wire.
c) If light still
illuminates, call manager.
. On the TCP the "TESTING"
. light continues to illuminate.
, The "SET SPEED" light will
illuminate.
. "2500" will appear on the
"SET SPEED" display.
. "ACTUAL SPEED" window
displays engine RPM.
When proper RPM has been
obtained, "SET SPEED" light
will extinguish.
-------
Step
1. Second Idle
Decelerate engine until the engine has
established a normal idle condition;
and with footbrake on, put transmission
in "drive" for automatic transmissions.
m. When Emission Test Finished
(and no smoke observation was
selected in step f.)
n. When Emission Test Finished
(and smoke observation was
selected in step f.)
o. Press the following:
. "SMOKE" if vehicle failed
smoke observation.
. "CLEAR" if vehicle passed
smoke observation.
p. When All Testing at EMS Finished
Remove probe(s) from tailpipe(s)
and place probe(s) on holder.
Response
On the TCP "SET SPEED" will
illuminate.
. The "SET SPEED" will extinguish
. The "TESTING" light continues
to illuminate.
. "ACTUAL SPEED" displays engine
RPM.
. The "TESTING" light will
extinguish and the "TEST
COMPLETE" light will come on.
. On EDEP the "SMOKE" enunciator
light is on.
The "TESTING" light will
extinguish and the "TEST
COMPLETE" light will come on.
After the purge cycle, the
"ENTER QUEUE NUMBER" indicator
on the EDEP light will
illuminate, and "READY" light
on TCP will illuminate.
Remove RPM probe, lower hood and
secure on first latch.
General Notes: 1. If at any time during the emissions test
the "SAMPLE DILUTION" indicator should illuminate:
. Check to see if probe is properly installed.
. If probe is properly installed, call manager.
2. If the vehicle malfunctions in some way
which prevents start or completion of the testing, call manager.
3. If "TESTING" light extinguishes during any
portion of the test, call manager.
B-15
-------
3.2 Backup Mode
3.2.1 Required Equipment:
a. EMS, EDEP and TCP operational.
b. Emission computer and console printer connected to EMS.
is used in this printer.
3.2.2 Prestest Conditions:
a. EMS in backup mode.
b. EDEP "ENTER QUEUE NUMBER" enunciation light is on.
c. The number "1" appears in the lower EDEP display.
3.2.3 Test Procedure:
Temporary VIR
Step
a. Raise vehicle hood and secure it in
the "open" position.
b. Locate spark plug wire and make tach
connection.
CAUTION: Be sure tach pickup is
connected to a spark plug wire and
not the coil wire or vacuum hose.
c. Examine tailpipe configuration to
determine if any special tailpipe
adapters are required.
Note: For a valid exhaust sample the
probe must be inserted a minimum of 6
inches. Any less than this and an ex-
haust extension adapter is required.
d. Remove probe from holder and insert
probe(s) into tailpipe(s) using
adapters as required.
e. Clear display and enter Queue Card
Number.
R e s p o n s e
none
none
none
none
EDEP displays an internal queue
number in the lower window.
Note: Number will start at "1"
for first test.
B-16
-------
Step
f. On EDEP press the following:
. "SMOKE" if vehicle's excessive
smoke is to be checked.
. "ENTER" if no smoke observation
needed.
Response
EDEP will display the following:
B-17
-------
Step
Response
g. On EDEP press "CLEAR".
h. On EDEP enter Vehicle Weight Class
as follows:
YY last digit of model year
W always = 0
CC number of cylinders
A AIC code (0-3)
Note.: Refer to Section B1.3, step 10
for AIC code selection.
i. Verify EDEP display and press "ENTER",
EDEP displays are blank.
EDEP displays:
Enter your inspector number (no more
than 3 digits).
Press "ENTER".
k. Observe vehicle and press the louver
selection key as follows:
"A" - closest louver opening
"B" - farthest louver opening
"N" - no louver opening
Press "ENTER".
YY
WCCA
Notes: 1. If vehicle class
display is incorrect, press
"CLEAR" and repeat step h.
2. If the "KEYBAORD
ERROR" enunciator is on, depress
the "CLEAR" key and repeat
step e.
On EDEP the "ENTER INSPECTOR
NUMBER" enunciation light is
on.
On EDEP the "ENTER LOUVER"
enunciator light is on.
Appropriate louver action.
B-18
-------
Step
Response
1. First Idle Test
Press "ENTER" on EDEP.
Notes: 1. The first idle test mode
has started. CAUTION: Maintain an idle
condition in "neutral". Don't accelerate.
2. The cue to operate the vehicle
at idle is the "TESTING" light on and
the "SET SPEED" display blank.
3. If vehicle is to be observed
for excessive smoke, it should be done
during the emissions test.
m. 2500 RPM Test
n. Accelerate engine (in "neutral")
until indicated actual RPM as
shown on the TCP, is between
2300-2700 RPM.
Note: If during the "2500 RPM Test"
engine RPM is out of the above values,
the "SET SPEED" will illuminate and
the test will be stopped until RPM
is corrected.
On the Test Cue Panel (TCP):
1. The "READY" light goes out.
2. The "TESTING" indicator
light is on.
3. "ACTUAL SPEED" display shows
engine's RPM.
Note: a) If "SET SPEED" light
illuminates on the TCP, the EMS
is not receiving RPM signal;
verify tach connection.
b) If light still
illuminates, select a different
plug wire.
c) If light still
illuminates, call manager.
. On the TCP the testing light
continues to illuminate.
. The "SET SPEED" light will
illuminate.
. "2500" will appear in the
"SET SPEED" display.
. "ACTUAL SPEED" window displays
engine RPM.
. When proper RPM has been
obtained, "SET SPEED" light
will extinguish.
When proper RPM has been
obtained, "SET SPEED" light
will extinguish.
B-19
-------
Step
o. Second Idle
Decelerate engine until the engine has
established a normal idle condition;
and with footbrake on, put transmission
in "drive" for automatic transmissions.
p. When Emission Test Finished
(and no smoke observation was selected
in step f.).
q. When Emission Test Finished
(and smoke observation was
selected in step f.).
r. Press the following:
"SMOKE" if vehicle failed smoke.
observation.
"CLEAR" if vehicle passed smoke
observation.
s. When All Testing at EMS Finished
Remove probe(s) from tailpipe(s) and
place probe(s) on holder.
Response
On the TCP "SET SPEED" will
illuminate.
The "SET SPEED" will extinguish
The "TESTING" light continues
to illuminate.
"ACTUAL SPEED" displays engine
RPM.
The "TESTING" light will
extinguish and the. "TEST
COMPLETE" light will come on
after the printer finishes
the temporary VIR print.
On EDEP the "SMOKE" enunciator
light is on.
The "TESTING" light will
extinguish and the "TEST
COMPLETE" light will come on
after the printer finishes
the temporary VIR print.
After the purge, cycle, the
"ENTER QUEUE NUMBER" indicator
on the EDEP will illuminate,
and "READY" light on TCP will
illuminate.
t. Remove RPM probe, lower hood and
secure on first latch.
B-20
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Step Response
u. Close hood. Be sure hood is closed
firmly and secured!
General Notes: 1. If at any time during
the emissions test the "SAMPLE DILUTION"
indicator should illuminate:
. Check to see if probe is
properly installed.
. If probe is properly installed,
call manager.
2. If the vehicle mal-
functions in some way which prevents
start or completion of the testing,
call manager.
3. If "TESTING" light
extinguishes during any portion of
the test, call manager.
B-21
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4.0 ALIGNMENT CHECKS
This section will describe the alignment checks performed on each vehicle.
4.1 Required Conditions
a. Scuff gauge operational.
b. Scuff gauge is reset - meter needle at center.
4.2 Checks and Data Recording
a. Drive vehicle at a speed not to exceed 3 MPH until front wheels
clear the scuff gauge.
b. Stop vehicle before rear wheels are on scuff gauge.
Note: If rear wheels are on gauge they will reset the reading.
. Move vehicle cautiously until front wheels clear the gauge.
. Repeat step a.
c. Observe the scuff gauge meter and record the side drag to the nearest
multiple of 5's (5, 15, etc.) as indicated by the scuff
gauge meter needle (readings are in ft./mile). Record reading on the
queue card under the header "Alignment Data".
Note: You do not have to indicate the direction of the side drag.
d. Record the alignment test specification (ex.- 010 [10 ft/mile] on the
queue card under the header "Alignment - Specs".
B-22
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5.0 EMISSION CONTROL SYSTEM (ECS) CHECKS
The following procedures are performed on the emission CRT at Position 3:
5.1 Required Conditions
a. Emission - computer operational
b. Emission CRT operational and in PRE-LOG on state (Figure I , page A-3)
c. Test at Position 1 and 2 is completed.
5.2 Log-On
a. Key in the 3-digit queue number followed by the letter "E".
b. Press NEW LINE key,
c. CRT will display ECS SCREEN DISPLAY (Figure 4, page A-6).
Note: If any other display appears, refer to Section B, step 1.2.
5.3 Verify that the vehicle information displayed on line 2 of the screen matches
vehicle.
. If not, verify queue number display. If queue number OK, call manager.
Note: The screen display has 2 sections:
. First Digit - (letters A - F) identify items that have to
be checked on every vehicle. These items are as follows:
A. PCV - Positive Crankcase Ventilation
B. AI - Air Injection
C. EGR - Exhaust Gas Recirculation Valve
D. FE - Fuel Evaporative
E. CAT CON - Catalytic Converter
F. FUEL RPS - Fuel Restrictor
. Second Digit (numbers 1-4) identifies the condition of the
items listed above. These items are as follows:
1. Modified
2. Disconnected or Bypass
3. Missing
4. Not Inspected
B-23
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5.4 With the aid of the ECS Reference Table, locate the items that are part
of the original equipment for this vehicle.
5.5 Check if the above items were:
. modified
. disconnected or bypassed
. missing
, not inspected
5.6 Code Entry
a. Select the appropriate first digit and second digit for all "failed"
items checked.
b. Key in the appropriate code selected above.
c. Press "NEW LINE".
d. Repeat steps a. - c. for additional "failed" items.
e. Enter your inspector number in the field marked "ECS ID".
f. Press "NEW LINE".
Notes; 1. You must enter your inspector number even if all
items are found to be OK and no failure code is entered.
2. When checking the fuel restrictor, enter the code
"F4" (Fuel Restrictor - not inspected) if fuel tank nozzle
is inaccessible due to a locked cap or door.
5.7 Emission Inspection - Termination
a. Press the "ESC+6" (exit) key.
b. Verify screen reverts to PRE-LOG on condition.
B-24
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6.0 PROPANE INJECTION CHECKS
6.1 The following procedures are performed on each vehicle. All data entries
are manually recorded on the queue card.
6.1 Required Conditions
a. All testing at Position 1 - 3 successfully completed.
b. "Digital analyzer" operational.
c. Propane gas cylinder and related hardware operational.
6.2 Prior to actual checks, perform the following:
a. Verify that "digital analyzer"and propane gas cylinder are operational,
. If one or both not operational, test cannot be performed.
Record the code "NT" (no test) on the queue card under the
header "Propane Gain - Initial PPM".
. If above equipment operational, proceed to step b.
b. Open vehicle hood and locate intake port of air cleaner housing.
. If intake port is not readily accessible .without use of tools,
test will not be performed. Record the code "AB" (abort) on
the queue card under the header "Propane Gain - Initial RPM".
. If intake port is accessible directly or can be made accessible
by disconnecting and reconnecting of an air duct without use of
tools and probable damage to any part of the vehicle, test is
to be performed. Proceed to step 6.3.
6.3 Perform the following steps for the propane injection checks:
«
a. Connect exhaust removal hose(s) to vehicle tailpipe(s).
b. Connect the'tiigital analyzer" RPM pickup to any spark plug wire.
Note: Make sure RPM pickup does not come in contact with any metal.
c. Verify that switch SW1 on "digital analyzer" is in the "RPM 2000"
position.
B-25
-------
d. Place vehicle in "park" or "neutral" with parking brake applied
and air conditioning off.
e. Start engine - momentarily press and release accelerator pedal to
stabilize engine RPM.
f. Record stabilized engine RPM on the queue card under the header
"Propane Gain - Initial RPM".
g. Turn on main valve of propane cylinder and insert injection tube
into air cleaner intake port.
h. Slowly open the needle valve at the air cleaner end of injection tube.
i. Observe RPM as it is being displayed on the "digital analyzer display".
Record displayed RPM on the queue card under the header "Propane Gain -
Final RPM" as follows:
. RPM increases - reaches a peak then decreases. Record peak RPM value.
. RPM decreases (never any RPM gain). Record lowest value of RPM.
Note: If vehicle stalls, RPM display will be zero. Record the
value displayed prior to vehicle stall.
. RPM increases and stays at a constant RPM level. Record constant
RPM value.
. RPM increases until vehicle stalls. Record RPM value prior to
vehicle stall.
j. Shut off needle valve and main propane cylinder valve. Remove injection
tube from air cleaner intake port.
k. Turn engine off.
1. Disconnect RPM pickup. Place switch SW1 on "digital analyzer" in the OFF
position.
m. Reconnect all tubes or hoses removed from air cleaner prior to test.
n. If timing test is to be performed, dp not disconnect exhaust removal hose.
Do not close hood.
o. If timing test is not being performed, disconnect exhaust removal hose,
close hood and verify that it is latched properly.
B-26
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7.0 BASIC TIMING CHECKS
7.1 The following procedures are performed on each vehicle. All data entries
are manually recorded on the queue card.
7.2 Required Conditions
a. All testing at Position 1 - Position 3 successfully completed.
b. Timing light operational.
7.2 Prior to actual checks, perform the following:
a. Verify with manager if timing test is to be performed and that
equipment is operational.
. If test is not to be performed, record "NT" (no test) on the
queue card under the header "Ignition Timing - Timing".
. If test is to be performed, proceed to b.
b. Open vehicle hood (hood may be open already from propane injection checks).
c. With the use of "Mitchell Manual" locate:
. emission label
. timing indicator
Note: Clean area if necessary and identify "TDC" (top, dead center)
or 0 marks.
d. If emission label is not present (or cannot be located), record the
code "NA" (not available) on the queue card under the header "Ignition
Timing - Timing".
. If the timing marks or the TDC marks cannot be cleaned or located,
record the code "AB" (abort) on the queue card under the header
"Ignition Timing - Timing".
. If above is present and identified, proceed to step 7.3.
7.3 Perform the following steps for the basic timing checks:
a. Record the vehicle ignition timing specification as it appears on
the timing label under the header "Ignition Timing - Specs".
Note: 1. Timing advance is recorded with (+) sign.
2. Timing retard is recorded with (-) sign.
B-27
-------
b. Connect exhaust removal hose(s) to vehicle's tailpipe(s).
c. With the use of "Mitchell Manual" identify spark plug No. 1.
d. Connect timing light per setup in Section A. 6.0 (Figure 10, page A-19).
Note: 1. Make sure to route all cables away from any moving
engine parts.
2. Vehicle is to be tested with all vacuum hoses connected
as received.
e. Place vehicle in "park" or "neutral" with parking brake applied
and air conditioning off.
f. Start engine; momentarily press and release accelerator pedal to
stabilize engine "idle RPM".
g. Aim timing light toward timing mark and press the "pushbutton switch SW1",
h. Rotate the "advance control knob R-3" until timing marks on engine is
aligned with the TDC or 0 mark.
i. Observe at outer scale on the timing light meter and record the timing
advance, as indicated by the meter needle, on the queue card under the
header "Ignition Timing" on line labeled "Timing".
Note: 1. If vehicle has a retarded timing specification, advance
control knob R-3 is to be moved to zero advance and the actual degrees
of engine retardation are to be read directly from the vehicle timing
marks. Remember to place a (-) sign before readings.
2. If vehicle's timing cannot be determined, record the code
"AB" (abort) on the queue card under the header "Ignition Timing -
Timing".
j. Turn engine off and disconnect timing light hookup.
k. Close hood and verify that it is latched properly.
1. Disconnect exhaust removal hose(s).
B-28
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8.0 QUEUE CARD TEST INFORMATION ENTRY
8.1 Required Conditions
a. Emission computer operational.
b. Auxiliary computer operational.
c. Auxiliary CRT operational and In PRE LOG-ON state (Figure 11, page A-21).
d. All testing at Position 1 - 3 completed (EXIT at Position 3).
8.2 Log-On
a. Key in the 3-digit queue card number.
b. Press "NEW LINE".
c. CRT will display the LOG-ON SCREEN FORMAT - AUTOMATIC MODE (Fig. T2, page A-22
d. Verify that-the following information as displayed matches the vehicle:
. queue number
. license plate
. year
. make
e. If above information matches vehicle, enter "Y" (yes) following the
displayed question, "IS THIS THE RIGHT QUEUE NUMBER?". CRT will display
"QUEUE CARD TEST INFORMATION DISPLAY" (Figure U, page A-24). Proceed to
step 8.3.
f. If above information does not match vehicle:
. Check queue number display for entry error.
. Enter "N" (no) following the displayed question, "IS THIS THE RIGHT
QUEUE NUMBER?".
. Repeat steps a. - e.
. If queue number displayed is correct and information displayed does not
match vehicle, call manager.
Note: If CRT display in step c. above, the LOG-ON SCREEN DISPLAY
BACKUP Mode (Figure 13* page A-23, proceed as follows:
B-29
-------
. Enter "IT following the displayed question, "DO YOU WISH
TO INPUT EMISSION DATA?".
. Screen will revert to PRE-LOG-ON state.
. Verify correct entry of Queue # by repeating steps a. - b. above.
. Request Position 3 inspector to LOG-ON and "EXIT" (ESC 6) if
Position 3 CRT displays valid data.
. If CRT display continues to be the LOG-ON SCREEN DISPLAY-BACKUP,
call manager.
8.3 Test Data Entry
a. Enter the information that appears on the queue card into the CRT.
Note: Each field entry is followed by "NEW LINE".
b. Verify the entries as they appear on the screen:
. If all entries are correct and present:
. Enter "N" (no) following the displayed question, "ANY CHANGE?".
. CRT screen will display "PRINTING, WRITING TO FLOPPY" and
then will revert to PRE-LOG on state.
. If any correction is to be made:
. Enter "Y" (yes) following the displayed question, "ANY CHANGE?".
. Enter the line number (1-10) following the display "WHAT #?".
. Make correction.
. Repeat step b.
B-30
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9.0 MANUALLY-ENTERED EMISSION DATA
This section will cover the manually-entered emission data procedures for
two cases:
Into the Emission computer (lane operation is SEMI AUTOMATIC MODE).
. Into the Auxiliary computer (lane operation is BACK-UP MODE).
9.1 Emission Data Entries Into the Emission Computer
9.1.1 Required Condition
a. Emission computer and CRT OK .
b. EMS not operational.
c. Auxiliary computer and CRT OK.
d. Position 1 test and entries as normal (queue number entry followed by RM).
e. Emission test performed using Back-up analyzer "Computerized Emission
Analyzer CEA 600".
Note: ECS checks and entries are part of this section's entries when operating
under the above conditions.
9.1.2 Log-On
a. Enter the 3-digit queue number followed by RM. Example: "001RM".
b. Press "NEW LINE".
c. Verify display (REGISTRATION ENTRY SCREEN WITH DATA) matches vehicle.
o If not, LOG-OFF and repeat step a.
d. Press "ESC+5". CRT will display the MANUALLY-ENTERED EMISSION DATA
SCREEN (Figure 5, page A-7).
9.1.3 Data Entries
a. Press "ESC+7" - CRT will display the appropriate limits for the vehicle
under the three test modes as follows:
. MODE I - 1st Idle
. MODE II - 2500 RPM
. MODE III - 2nd Idle
B-31
-------
b. Press "ESC+4" (home). Cursor will move to the field marked "TYPE".
c. Enter "I" plus "NEW LINE".
Note: 1. The data for the entries in steps d.-g. appears on the paper tape
generated by the "CEA 600" during the emission test.
2. All field entries are followed by "NEW LINE".
d. Enter the 2nd idle RPM into the field marked "IDLE SP".
e. Perform the following for the Mode I HC readings:
. Advance cursor to the field marked "HC" by pressing "NEW LINE".
. Identify reading on paper tape.
. Enter reading.
. Compare reading entered to displayed limit.
. Enter "*" if reading is above limits.
. Press "NEW LINE."
f. Repeat step e. for:
. Mode I - CO
. Mode II - HC and CO
. Mode III - HC and CO
g. Repeat step e. for Mode I - III C02 readings.
Note: There are no limits for C02» therefore no "*" entries
are to follow any C02 entries.
h. Press "ESC+7" and verify that "RESULT" field shows PASS or FAIL.
i. Verify the "MESSAGE" field contains codes if results field marked "FAIL".
j. Enter your ID number in the field marked "ECS ID".
k. Perform ECS checks (Section 5.0) with the following exceptions:
. Refer to Figure 4, page A-6 for ECS Failure Code Identification.
. Enter failure code(s) on the CRT display used in this section.
. Do not EXIT (ESC-6).
B-32
-------
1. Press "ESC+7" and verify that results are:
. PASS - only if no ECS code or readings above limits
are displayed.
m. Press "ESC+6" (Exit). CRT will revert to PRE LOG-ON state.
9.2 Emission Data Entries Into the Auxiliary Computer
9.2.1 Required Conditions
a. Emission computer and CRT not operational.
b. EMS operational and in BACK-UP mode.
c. Emission computer printer connected to EMS; temporary VIR is
used in the printer.
d. Auxiliary computer and CRT operational.
e. All entries to the emission computer are by-passed.
Note: Refer to Section C for detailed operation.
f. Auxiliary CRT in PRE LOG-ON state (Figure 11, page A-21).
9.2.2 LOG-ON
a. Key in the 3-digit queue number.
b. Press "NEW LINE".
c. CRT will display the"LOG-ON SCREEN DISPLAY-BACK-UP"mode (Figure 13, page A-23).
d. Verify queue number displayed is correct.
, If correct, continue.
. If not correct, enter "N" (no) following the displayed question,
"DO YOU WISH TO ENTER EMISSION DATA?". Repeat step a.
f. CRT will display the "EMISSION INFORMATION ENTRY SCREEN" (Figure 15, pageA-25).
9.2.3 Data Entries
a. Follow the table below in order to identify the "SOURCE ENTRY" for each field.
Note 1; All fields which have a "SOURCE ENTRY" marked "REG/VEH"
(Registration or Vehicle) should be entered with the same guidelines
specified in Section B-1.0 (Registration Information and Test Suitability
Entry).
B-33
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Note 2: All fields which have a "SOURCE ENTRY" marked "TEMP VIR-#"
should be entered as appears on the Temporary VIR (Figure 17, page
B-36).
Note 3: CRT display will be bright on the line where the next entry
is expected.
CRT FIELD
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
CRT FIELD
NAME
RESULTS
ECS FAILURE CDS
EMISSION TEST
FAILURE CODES
REJECT CODES
TEST MODE
TEST #
DATE
TIME
LICENSE PLATE
VEHICLE ID #
YEAR
MAKE
CYLINDERS
WEIGHT
MILEAGE
AI/CAT
1ST IDLE STND HC
1ST IDLE STND CO
1ST IDLE READ HC
1ST IDLE READ CO
1ST IDLE READ C02
2500 RPM STND HC
2500 RPM STND CO
2500 RPM READ HC
SOURCE ENTRY
Temp VIR -#1
Temp VIR - 2
Temp VIR - 3
see note foll-
owing table
Temp VIR - 8
Temp VIR - 9
Temp VIR -10
Temp VIR -11
Reg/Veh
Reg/Veh
Reg/Veh
Reg/Veh
Temp VIR -16
Temp VIR -17
Reg/Veh
Temp VIR -19
Temp VIR -20
Temp VIR -21
Temp VIR -24
Temp VIR -25
Temp VIR -26
Temp VIR -22
Temp VIR -23
Temp VIR -27
COMMENTS
Pos.3 manually recorded
ii ii ii
-
Pos.l manually recorded
code
-
-
'
-
-
-
-
-
-
Always 0
-
-
-
-
Including "*" if present
n
- '
-
-
Including "*" if present
B-34
-------
CRT FIELD
NUMBER
25
26
27
28
29
30
31
32
33
34
35
36
37
38
CRT FIELD
NAME
2500 RPM READ HC
2500 RPM READ COz
2ND IDLE STND HC
2ND IDLE STND CO
2ND IDLE READ HC
2ND IDLE READ CO
2ND IDLE READ C0£
IDLE RPM LIMIT
IDLE RPM READINGS
CUST
ECS ID
EMS ID
SMOKE
RETEST
SOURCE ENTRY
Temp VI R -28
Temp VI R -29
Temp VI R -30
Temp VI R -31
Temp VI R -33
Temp VIR -34
Temp VIR -35
Temp VIR -32
Temp VIR -36
Reg/Veh
Temp VIR -38
Temp VIR -39
Temp VIR -40
Reg/Veh
COMMENTS
Including "*" if present
-
-
-
Including "*" if present
ii
-
-
-
-
Pos. 3 Manually recorded
-
-
-
Note; a) If vehicle is rejected, only the following lines are to be entered:
1, 4-16, 34, 38.
b) When all entries are completed, CRT will display (lower right)
"ANY CHANGE?".
c) Verify the displayed entries:
. If no entry changes required, enter "N" (no). CRT will
. display the queue card test information entry screen.
. If entry changes required, enter "Y" (yes) and the line
number where corrections are needed following the question,
"WHAT #?".
d) Repeat step c.
B-35
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FIGURE 17 - TEMPORARY VIR
f EMISSION CONTROL SYSTEMS (ECS) ^
FAILURE CODES
A
B
C
D
E
F
G
H
1
J
\
FIRST CHARACTER
Crankcase Ventilation System
Air Injection System
Engine Modification
Air Preheat /Air Cleaner
Ignition Spark Control
Exhaust Gas Recirculation
Fuel Evaporative System
Exhaust Converter
Retrofit Exhaust Control
Retrofit NOX Control
SECOND CHARACTER
1 Modified: Device or
System not ARB-approved
2 Disconnected'By-passed
3 Missing
4 Inoperative EGR Valve
J
FINAL RESULTS
EMISSION TEST
FAILURE CODES
Excessive Smoke
Perform Low Emission Tune-up
Idle RPM Excessive
Idle Air. Fuel Mixture Rich
Misfire at Idle
EMISSION TEST FAILURE CODE
REJECT REASON
QUEUE NO.
STATION NO.
6
LANE NO.
7
TEST MODE
8
TEST NO.
9
DATE
10
TIME
11
VEHICLE INFORMATION
LICENSE PLATE
12
VEHICLE IDENTIFICATION NO.
15
YEAR
14
MAKE
15
CYL
16
WT
17
MILEAGE
18 >000
AI/CAT
19
STATE
STANDARD
HC (ppm)
20
EMISSION o/l
READINGS L"l
STATE
STANDARD
EMISSION
READINGS
V
CUST
37
HC (ppm)
30
33
. L 1
EM
1ST IDLE
CO (%)
21
25
2ND IDLE
CO (%)
31:
34
38
ECS
10
ISSION
INSPECTION INFORMATION >
2500 RPM
OFFICIAL
USE
ONLY
26
OFFICIAL
USE
ONLY
35
39
EMS
ID
HC (ppm)
22
27
LIMIT
READING
CO (%)
23
28
IDLE
RPM
OFFICIAL
USE
ONLY
29
32
36
DUAL CERT
RRR
SMOKE
40
RETEST
)
41
B-36
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10.0 EGR FUNCTIONAL CHECK
The EGR functional check will be performed on vehicles at Position 4, the
propane check position. It will be performed whenever the arrival rate of
cars is low enough that the propane inspectors can perform the EGR functional
check after the propane and spark timing check without causing the queue
outside the station to exceed two cars. The Contractor will consult with
the Project Officer as to other circumstances under which the EGR functional
check may be omitted. The Project Officer will supply a standard form to be
filled in by the inspector whenever a vehicle is given an EGR functional check.
The EGR functional check need only be done on 1973 and later model year light
duty vehicles which have as part of their original equipment an exhaust gas
recirculation (EGR) system. In addition, any vehicle determined by the
inspector to have an EGR system which is disconnected need not be inspected.
Such instances will be noted by the inspector on the standard form provided
by the Project Officer.
With a tachometer attached and the engine idling in neutral or park gear, the
vacuum supply line to the EGR valve will be completely closed off by pinching
the vacuum supply hose with a smooth jaw clamping device, i.e.; a pair of
smooth jaw pliers. (CAUTION - The use of serrated jaw pliers may rupture the
vacuum hose.) The Contractor will keep a limited supply of a variety of
vacuum hoses commonly used for EGR systems in the event that a hose is damaged
by this procedure. The inspector will note instances of hose damage on the
standard form provided by the Project Officer. If the rate of this type of
damage becomes significant, the Contractor will notify the Project Officer.
All effort will be made to avoid damage to any hoses, wires, etc. as the result
of this check. If in the opinion of the inspector the EGR vacuum supply hose
appears to be easily damaged by clamping, then the EGR functional check will
B-37
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not be performed on that vehicle and its omission will be noted on the
form. The standard form, with the appropriate data filled in and the
appropriate boxes checked, will be filled out for each vehicle on which
an EGR functional check is attempted.
With the vacuum supply line to the EGR valve completely closed off, the
inspector will increase the engine speed to 2000 rpm (3000 rpm on GM L-4
engines). While holding the throttle position steady at that engine speed
the inspector will release the clamping device and observe and record the
resulting change in engine speed in the appropriate space on the form supplied
by the Project Officer.
B-38
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EGR FUNCTIONAL CHECK
(All 1973 and Later Model Year Light Duty Vehicles)
Date:
License No:
Queue No.:
1. Connect tachometer to engine.
2. With engine idling in neutral or park, completely close-off the vacuum
supply to the EGR valve by pinching the vacuum supply hose with a smooth jaw
clamping device, e.g., pair of smooth jaw pliers. CAUTION - The use of
serrated jaw pliers may rupture vacuum hose..
3. Increase engine speed to 2000 rpm.*
4. Hold the throttle steady, release clamp, record engine speed:
5. Comments:
(~J L-4 General Motors (use 3000 rpra)
Q Other (use 2000 rpm)
Q Vacuum hose not flexable enough to clamp, test aborted
Test aborted due to fragile-looking vacuum hose
Vacuum hose disconnected, test aborted
Vacuum hose damaged during test attempt
EGR Vacuum lines inaccessible
*L-4 General Motors vehicles use 3000 rpm
fi-39
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SECTION C - OPERATION PROCEDURES
INTRODUCTION
This section will cover the tasks to be performed under four basic operational
modes as follows:
The operational modes are based on the operation of the three (3) main units
in the inspection facility:
. emission computer
. EMS
. auxiliary computer
The following table will describe the conditions for each mode.
MODE
EMISSION COMPUTER
E.M.S
AUXILIARY COMPUTER
AUTOMATIC
BACK-UP
SEMI-AUTOMATIC
DEFERRED
Operational
Operational
Operational
Operational
Operational
Operational
Operational
Operational
Operational
C-l
-------
1.0 AUTOMATIC MODE
1.1 Required Conditions
a. emission computer - operational
b. EMS - operational
c. auxiliary computer - operational
1.2 The following is the position-related tasks sequence:
1.2.1 Position 1
a. Registration information and test suitability entries (Section B. 1.0).
b. Tire pressure checks (Section B. 2.0).
1.2,2 Position 2
a. Emission testing - Automatic Mode (Section B. 3.1).
1.2.3 Position 3
a. Alignment checks (Section B. 4.0).
b. ECS checks (Section B. 5.0).
1.2.4 Position 4
a. Propane injection checks (Section B. 6.0).
b. Basic timing checks (Section B. 7.0).
c. Queue card test information entry (Section B. 8.0).
d. EGR Functional test (Section B. 10.0).
1.3 Comment
a. Position 4 inspector is to observe VIR; if the code "TTT" appears on the
bottom line, Vehicle Failed Timing Checks, hand driver "Special
Timing" handout.
b. Position 1 inspector is required to collect returned VIR whenever test
is a retest.
c. Position 4 inspector is required to attach queue card to copy of VIR.
d. Position 4 inspector is required to keep above copy until end of day.
C-2
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2.0 BACK-UP MODE
2.1 Required Conditions
a. emission computer down
b. EMS operational
c. auxiliary computer operational
d. emission computer console printer is connected to EMS,
Temporary VIR is used in this printer.
2.2 The following is the position-related task sequence:
2.2.1 Position 1
a. Perform only the "Test Suitability" portion of the Registration
Information and Test Suitability entry (Section B. 1.5).
." Use Figure 3, page A-5 for code identification.
. Record Failure code on lower part of queue card - vehicle to
proceed directly to Position 4.
b. Tire pressure checks (Section B. 2.0).
2.2.2 Position 2
a. Emission testing Back-up mode (Section B. 3.2).
2.2.3 Position 3
a. Alignment checks (Section B. 4.0).
b. ECS checks (Section B. 5.0).
. Use Figure 4, page A-6, for ECS code identification.
. Record ECS Failure codes on Temporary VIR (block marked
"ECS Failure Codes").
. Calculate and record "Final Results" as follows:
Final Result - PASS if
i. No ECS Failure code
11. HC and CO readings below limit (No "*") for the 2nd Idle.
Final Result FAIL if ECS codes are present or either HC or CO
above limit on 2nd Idle.
. Record your ID# in the block marked "EMSID".
C-3
-------
2.2.4 Position 4
a. Propane injection checks (Section B. 6.0).
b. Basic timing checks (Section B. 7.0).
c. Manually-entered emission data - into auxiliary computer (Section B. 9.2).
d. Queue card test information entries (Section B. 8.0).
e. EGR functional checks (Section B. 10.0).
2.2.5 Comment
a. Position 4 inspector is to observe VIR. If the code "TTT" appears on
the bottom line, Vehicle Failed Timing Checks. Hand driver "Special
Timing" handout.
b. Position 4 inspector is required to collect returned VIR.
c. Position 4 inspector is required to attach queue card and Temporary VIR
to copy of Final VIR.
d. Position 4 inspector is required to keep above copy until end of day.
C-4
-------
3.0 SEMI-AUTOMATIC MODE
3.1 Required Conditions
a. emission computer - operational
b. EMS down
c. auxiliary computer operational
d. emission testing is performed with the "CEA-600".
3.2 The following is the position-related task sequence:
Position 1
a. Registration information and test suitability entries (Section B. 1.0).
b. Tire pressure checks (Section B. 2.0).
Position 2
a. Emission testing - refer to Operating Procedure for "CEA-600".
Position 3
a. Alignment checks (Section B. 4.0).
b. Manually-entered emission data - into emission computer (Section B. 9.1).
Note: ECS checks and entries are part of Section 9.1 in this
operational mode.
Position 4
a. Propane injection checks (Section B. 6.0).
b. Task timing checks (Section B. 7.0).
c. Queue card test information entries (Section B. 8.0).
d. EGR functional checks (Section B. 10.0).
3.3 Comments
a. Position 4 inspector is to observe VIR. If the code "TTT" appears on
the bottom line, Vehicle Failed Timing Checks, hand driver "Special
Timing" handout.
b. Position 4 inspector is required to collect returned VIR..
c. Position 4 inspector is required to attach queue card to copy of VIR.
d. Position 4 inspector is required to keep above copy until end of day.
C-5
-------
4.0 DEFERRED MODE
4.1 Required Conditions^
a. emission computer operational
b. operational
c. auxiliary computer down
d. VIR printer is connected to the emission computer at Position 3.
Temporary VIR is used.
4.2 The following is the position-related task sequence:
Position 1 - Position 3
a. Perform tasks in the same order as Automatic Mode (Section C. 1.0).
Note: When ECS check (Section B. 5.0) is completed, Temporary VIR
will be printed via the Position 3 printer.
Position 4
a. Propane injection checks (Section C. 6.0).
b. Basic timing checks (Section C. 7.0).
c. EGR functional test (Section B. 10.0).
d. Position 4 inspector is to perform the following additional tasks:
. Inform driver of equipment malfunction and notify him that
Final Test Results will be mailed.
. Request driver to write his mailing address on the mailing label.
. Collect returned VIR.
. Attach mailing label to Temporary VIR, Queue Card (and returned VIR),
. Keep above paperwork until the end of the day.
4.3 Prior Test VIR Handling
This procedure is to be followed when the auxiliary computer is operational
and available for prior test VIR printing and mailing.
a. Perform manually-entered emission data into auxiliary computer
(Section B. 9.2).
C-6
-------
b. Perform queue card test information entries (Section B. 8.0).
c. Place white copy of VIR and all handout material in an envelope.
d. Place driver's address label and stamp on envelope and mail.
e. Attach copy of VIR to test paperwork.
C-7
-------
APPENDIX #1
VEHICLE-MAKE ABBREVIATION LIST
The following table defines the vehicle make and the corresponding
entered in the
ft A K .E
AMC
RAMBLER
AMX
REBEL
AMERICAN
AMBASSADOR
JAVELIN
GREMLIN
HORNET
MATADOR
PACER
BUICK
ELECTRA
RIVIERA
LE SABRE
SKYHAWK
SPECIAL
SKYLARK
APOLLO
REGAL
D-50 PICKUP
DODGE
DART
CHALLENGER
CHARGER
Make Field (Section A., 1.0, number 2.).
DOMESTIC CARS
ABBV. CODE
AMC
RAMB
AMX
REBE
AMER
AMBA
JAVE
GREM
HORN
MATA
PACE
BUIC
ELEC
RIVI
LESA
SKYH
SPEC
SKYL
APOL
REGA
DOOM
DODG
DART
CHAL
CHAR
M. A K. E
CADILLAC
CHEVROLET
CAMARO
CHEVELLE
CORVETTE
NOVA
MALIBU
MONTE CARLO
VEGA
MONZA
CHEVETTE
CHRYSLER
CROWN
IMPERIAL
LE BARON
CORDOBA
MONI
CHECKER
MARATHON
TAXI
STUDEBAKER
CHEVROLET TRUCK
D_r DODGE TRUCK
code to be
ABBV. CODE
CADI
CHEV
CAMA
CHEL
CORV
NOVA
MALI
MONT
VEGA
MONZ
CHEV
CHRY
CORW
IMPE
LEBA
CORB
OMNI
CHEC
MART
TAXI
STUD
CHEV
DODG
-------
APPENDIX #1 (Cont'd)
DOMESTIC CARS (cont'd)
MAKE
ABBV. CODE
ASPEN
MONACO
FORD
MAVERICK
FALCON
MUSTANG
TORINO
PINTO
THUNDERBIRD
GRANADA
FAIRMONT
FIESTA
MERCURY
COMET
COUGAR
ZEPHER
MONTEGO
BOBCAT
MONARCH
MARQUIS
LINCOLN
OLDSMOBILE
OMEGA
CUTLASS
TORONADO
STARFIRE
ASPE
MONC
FORD
MAVE
FALC
MUST
TORI
PINT
THUN
GRAN
FAIR
FIES
MERC
COME
COUG
ZEPH
MONG
BOBC
MONA
MARQ
LINC
OLDS
OMEG
CUTL
ORO
STAR
MAKE
FORD TRUCK
GMC TRUCK
INTERNATIONAL
TRUCK
JEEP TRUCK
PLYMOUTH
TRUCK
AUSTIN
AMERICA
AUSTIN HEALEY
SPRINT
AUSTIN
MARINA
ALFA ROMEO
AUDI
ARROW
BMW
CAPRI
CITROEN
COLT
CORTINA
COURIER
CRICKET
ABBV. CODE
FORD
GMC
INTE
JEEP
PLYM
AUSA
AUSH
AUSM
ALFA
AUDI
ARRO
BMW
CAPR
CITR
COLT
CORT
COURT
CRIC
D-2
-------
APPENDIX #1 (Cont'd)
DOMESTIC CARS (Cont'd)
MAKE
PONTIAC
TEMPEST
FIREBIRD
VENTURA
LE MANS
ASTRE
SUNBIRD
PHOENIX
DATSUN
DATSUN TRUCK
FIAT
HONDA
JAGUAR
JENSEN-HEALEY
JENSEN-
INTERCEPTOR
LANCIA
LOTUS
LUV
MAZDA TRUCK
MAZDA
MERCEDES-BENZ
MG
OPEL
NOTE.:
ABBV. CODE
PONT ,
TEMP
FIRE
VENT
LEMA
ASTR
SUNB
PHOE
FOREIGN CARS
DATS
.DATS
FIAT
HOND
JAGU
JENH
JEN I
LANC
LOTU
LUV
MAZD
MAZD
MERB
MG
OPEL
MAKE
PLYMOUTH
VALIANT
BARRACUDA
BELVEDERE
FURY
DUSTER
VOLARE
HORIZON
CHAMP
PEUGEOT
PANTERA
PORSCHE
RENAULT
ROLLS
BENTLY
ROVER
SAAB
SIMCA
SUBARU
TOYOTA TRUCK
TOYOTA
TRIUMPH
VOLKSWAGON
VOLVO
ABV. CODE
PLYM
VALI
BARR
BELV
FURY
DUST
VOLA
HORI
CHAM
PEUG
PANT
PORS
RENA
ROLL
BENT
ROVE
SAAB
SIMC
SUBA
TOYO
TOYO
TRIU
VOLK
VOLV
Remember - above entries are to be followed with
1) "T" for trucks
2) "V" for vans
D-3
-------
APPENDIX "B"
EPA/HOUSTON DEFIO PROGRAM
PERIODIC MAINTENANCE MANUAL
DAILY
#
WEEKLY
#
MONTHLY
PREPARED BY:
A/of lot
F \IA r~f" AJ
NAFTALI AMIR
APPROVED BY:
A, J, N2RIGO
RELEASE DATE: 2/1/80
-------
INTRODUCTION
1. This manual covers the step-by-step procedures for the
periodic maintenance to be performed in the EPA/Houston
Demo Program.
2. Whenever a scheduled maintenance is performed, the
appropriate check list is to be initialed and approved
by the Operations Administrator.
3. Each scheduled periodic maintenance check list is unique
and does not eliminate the performance of other check
lists. Example: Performing Monthly periodic maintenance
does not exclude the performance of the Weekly periodic
maintenance and the Daily periodic maintenance.
-------
EPA/HOUSTON DEMO PROGRAM
DAILY CHECK LIST
Initial
E.M.S.
1. Check tape load operation
2. Check Maintenance Relay Panel for proper indications
3. Check sample system for proper flow
4. Check for proper gas and ambient temperatures . .
5. Check for proper filter and gas pressure ....
D.E.C.
1. Vacuum all LA-35 and LA-36 printers . . .
2. Check and adjust VIR forms line-out on printer
CLAYTON EQUIPMENT
1. Check louvers for proper operation . . .
MISCELLANEOUS
1. Vacuum all CRTs and check for proper operation
2. Check CO monitor operation
3. Check probes and external hoses
4. Check facility air systems ......
5. Drain any condensation from air compressor .
COMMENTS:
Date performed: / / By:
Approved:
-1-
-------
STEP
E.M.S.
PROCEDURE
2.
3.
Check tape load operation
a. Insert the tape into the
drive with the label facing
away from the EMS, and the
notch at the top off center
to the right.
Check Maintenance Relay Panel
Check sample system for proper
flow
a. Load latest revision of
"Lane" tape.
Note.: Be sure the "MODE1
switch on the EMS Relay
Maintenance Panel is in
the "AUTO" position. If
not, all system data will
have to be manually entered.
b. "WAKE UP" EMS by pressing
#1, 2, 3, 4, 5 pushbuttons.
c. Press "ENTER" pushbutton.
d; Press "ENTER" pushbutton.
e. Press "ENTER" pushbutton.
f. Press "ENTER" pushbutton.
g. Press #9, 9, 6, 6
pushbuttons
h. Press "ENTER" pushbutton.
i. Press #9 pushbutton.
INDICATION
If the tape is not installed properly,
the small tape drive wire will not fall
into the tape cassette notch on top.
"ON-EMISSIONS PROCESSOR OK". LED should
be on. All other LEDs must be off. All
switches should be in the "AUTO" position.
The "LOUVER MANUAL" switch should be in
the "CLOSE, NONE" position.
EDEP will display blank
blank
"2345"
EDEP will display "IDLE"
" PR"
"01.07" (or latest
tape revision)
EDEP will display "SYS"
blank
lane ID#
EDEP will display "DATE"
month
day and year
"ENTER QUEUE NUMBER". LED will light
on EDEP.
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
it gn
-2-
-------
STEP
E.M.S.
3.
PROCEDURE
4.
Check sample system (cont'd)
j. Press "ENTER" pushbutton
The difference
between Gas and Filter
pressure should be within
1.0 inches of mercury
(in. Hg. ). Normal readings
should be between 29.0 and
31.0 in. Hg.
k. Press #2, 3, 8, and "SMOKE"
pushbuttons.
1. Press #2, 3, 8, 9 push-
buttons.
Check for proper gas and
ambient temperatures
a. Press #0 pushbutton.
b. Press #9, 9, 6, 6 push-
buttons.
c. Press "ENTER" pushbutton.
d. Press #1 pushbutton.
e. Press "ENTER" pushbutton.
f. Press #1 pushbutton.
g. Press "ENTER" pushbutton.
h. Press #1 and 6 pushbuttons.
i. Press "ENTER" pushbutton.
j. Press #1 pushbutton.
-3-
INPICATION
EDEP will display blank
Gas pressure
Filter pressure
Pumps will shut off.
EDEP will display approximately 18.5
in. Hg. Filter pressure in window #3.
FLOW INDICATORS will indicate 8.0 + 1.0
SCFH.
VACUUM GAUGE will indicate approximately
10.5 in. Hg.
EDEP will indicate filter pressure in
window #3. It should not change more
than 0.5 in. Hg. from the previous step.
Note.'- If the conditions in steps
"K." and "1." cannot.be met,
refer to step 5. "Check for
proper filter and gas
pressure".
"ENTER QUEUE NUMBER" LED will light on
the EDEP.
EDEP will display "9966" in window
#3.
EDEP will display "FUNC" in window #1.
EDEP will display "1" in window #3.
EDEP will display "DISP" in window #1.
EDEP will display "1" in window #3.
EDEP will display "CHAN" in window #2.
EDEP will display #16 in window #3.
EDEP will display "GAS TEMPERATURE" in
window #1.
EDEP will display "DISP" in window #1.
-------
STEP
E.M.S.
4.
PROCEDURE
5.
Check for proper gas ...(cont'd)
k. Press #2 pushbutton.
1. Press "ENTER" pushbutton.
m. Press #5 pushbutton.
n. Press "ENTER" pushbutton.
Note.: Gas temperature should
be approximately 33°C and the
ambient temperature should be
approximately 26°C (after the
EMS has stabilized). A change
of more than 8°C should be
rep9rted to Operations
Administrator.
Check for proper filter and gas
pressure
a. Press #1 pushbutton.
b. Press #1 pushbutton.
c. Press "ENTER" pushbutton.
d. Press #1 pushbutton.
e. Press "ENTER" pushbutton.
f. Press #1 pushbutton.
g. Press #2 pushbutton.
h. Press "ENTER" pushbutton.
i. Press #1 and 5 pushbuttons.
j. Press "ENTER" pushbutton.
Note.: Filter pressure should
be between 16 and 22 in. Hg.
Gas pressure should be between
27 and 32 in. Hg. If not,
report the out-of-tolerance
condition to Operations
Administrator.
-4-
INVICAT10N
EDEP will display "2" in window #3.
EDEP will display "CHAN" in window #2.
EDEP will display "5" in window #3.
EDEP will display GAS TEMPERATURE in
window #1, and AMBIENT TEMPERATURE in
window #2.
EDEP will display "DISP" in window #1.
EDEP will display "1" in window #3.
EDEP will display "CHAN" in window #2.
EDEP will display "1" in window #3.
EDEP will display FILTER PRESSURE in
window #1.
EDEP will display "DISP" in window #1.
EDEP will display "2" in window #3.
EDEP will display "CHAN" in window #2.
EDEP will display "15" in window #3.
EDEP will display FILTER PRESSURE in
window #1, and GAS PRESSURE in window #2.
-------
STEP
D.E.C
1.
P R 0 C E V U R E
I W V 1 C A T I 0 W
2.
CLAYTON
1.
Vacuum all LA-35 & LA-36
printers
a. Turn printers off.
b. Vacuum keyboard thoroughly;
be sure not to vacuum up
any keys.
c. Turn printer on. All
control keys should be
up except "300" under
"BAUD RATE".
Check and adjust VIR forms line-
out on printer
a. The VIR should have one empty
paper feed hole past the
paper feed tractor on both
sides.
Check louvers for proper
operation _
a. Load "Lane" tape.
b. Perform "WAKE UP" procedure.
c. Press #9, 9, 6, 6
pushbuttons.
d. Press "ENTER" pushbutton.
e. Press #4 pushbutton.
f. Press "ENTER" pushbutton.
g. Press #1 and 1 pushbuttons.
The "STD. CHARA" LED should be "ON" for
the LA-36 only. All other LEDs should
be "OFF" on both type printers.
"ENTER QUEUE NUMBER" LED will light on
EDEP on completion of "WAKE UP".
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
EDEP will display "DISC"
blank
blank
EDEP will display "DISC"
blank
h. Press "ENTER" pushbutton.
EDEP will display " 11"
"s-r "
blank
-5-
-------
STEP
CLAYTON
PROCEDURE
1. Check louvers ... (cont'd)
i. Press #1 pushbutton.
J. Press "ENTER" pushbutton.
k. Press #4 pushbutton.
1. Press #1 and 1 pushbuttons.
m. Press "ENTER" pushbutton.
n. Press #2 pushbutton.
o. Press "ENTER" pushbutton.
p. Press #0 pushbutton.
q. Repeat steps c. - p. for
louver "B". Press #1 and
2 pushbuttons in steps g.
and 1.
Note.:
Check each louver pit
for evidence of oil
leaks as this procedure
is accomplished.
MISCELLANEOUS
1. Vacuum all CRTs and check for
proper operation
a. Make sure the station
processor is initialized and
lane operations started.
b. Thoroughly vacuum the CRT
using the brush attachment.
Include the screen and all
of the cover as well as the
keyboard.
c. Turn the brightness up.
1 N V I C A T I 0 N
EDEP will display "11"
"
i n
"s-r "
EDEP will go blank in all windows.
Louver "A" will open slowly, it should
take about 3 seconds.
EDEP will display "DISC"
blank
blank
EDEP will display "DISC"
blank
EDEP will display " 11"
"s-r "
blank
EDEP will display " 11"
r "
2"
"s-r "
EDEP will go blank. Louver "A"
will close slowly, about 2 seconds.
"ENTER QUEUE NUMBER" LED will light
on EDEP.
EDEP will display "12" in all steps
where "11" was previously displayed.
-6-
CRT will display "QUEUE " in the
upper left corner.
-------
STEP
MISC.
1.
PROCEDURE
Vacuum all CRTs ... (cont'd)
d. Press #9, 9, 9 pushbutton.
e. Press return to Newline
pushbutton.
f. Press "ESC" and #8
pushbuttons.
Check CO monitor operation :
a. Check operate light.
b. Put "OPERATE/ZERO" switch
in "ZERO" position.
c. Put "OPERATE/ZERO" switch
in "OPERATE" position.
d. Put "CALIBRATE/OPERATE"
valve in "CALIBRATE
position.
e. Put "CALIBRATE/OPERATE"
valve in "OPERATE" position.
Check probes and external hoses
a. Check probes for cracks and
breaks.
b. Check flexible tips by
grasping the base and
applying a slight twisting
pressure to tip.
c. Check non-flex tips by
grasping the base below
union coupler, then apply
slight twisting pressure
to tip.
d. Check EMS hoses, extension
hoses, and dual hoses for
loose fittings, cracks or
soft spots.
I N V 1 C A T 1 0 N
CRT will display "QUEUE Hl_ "
CRT will display registration format.
The format should nearly cover the
entire screen
CRT will momentarily display "CANCEL"
in the upper right corner. The screen
will then go blank except for
"QUEUE " in the upper right
corner.
Green Operate LED should be illuminated.
Green Operate LED should go off.
Meter needle should jump slightly.
Green operate LED should go on.
Place your finger over the bottom port
of valve and feel for slight suction.
The tip should not turn.
The tip should not turn.
-7-
-------
STEP PROCEDURE
MISC.
4. Check facility air systems
a. Check station A/C.
b. Check each exhaust fan by
turning them on separately,
then off.
c. Turn on all exhaust fans,
one at a time.
5. Drain any condensation from
air compressor
a. Open compressor outside
INDICATION
Temperature should be at a reasonable
comfortable setting.
Listen for the sound of the fan
starting.
Check all breakers after fans are on
to make sure none are tripped.
Watch outside drain until the water
stops draining.
-8-
-------
EPA/HOUSTON DEMO PROGRAM
WEEKLY CHECK LIST
Initial
E.M.S.
1. Vacuum air vapor condenser
2. Vacuum all easily accessible areas In EMS cabinet
3. Check EMS A/C
4. Perform sample system leak check
5. Perform leak check on calibration system and
solenoid valve #5
6. Perform EMS health check .
7. Check all solenoids using lane tape
8. Calibrate HC/CO and C0£ analyzers
9. Perform RPM check
D.E.C.
1. Vacuum inside printers . .
MISCELLANEOUS
Check oil in air compressor
COMMENTS:
Date performed: / / By:
Approved:
-1-
-------
STEP P R 0 C E V U R E
E.M.S.
1. Vacuum air vapor condenser
a. Turn EMS off.
Note.: In all of the following
steps extreme caution must
be exercised to prevent
bending the fan blades or
the condenser fins with your
hands or the vacuum cleaner
accessories.
b. Turn off the EMS A/C unit.
c. Open all EMS doors.
d. Using the vacuum's soft brush
accessory, vacuum fins and
fan blades and condenser.
2. Vacuum all easily accessible
areas in EMS cabinet
a. After completion, turn EMS
back on and reload Lane tape.
3. Check EMS A/C
a. Check IDU processor mother
board for white crystalized
deposits.
b. Check for puddles or signs
of dried up puddles.
4. Perform sample system leak check
Note.: Ensure the latest revision
of the "Lane" tape is
loaded and the "ENTER QUEUE
NUMBER" LED on the EDEP is
illuminated before
proceeding.
a. Remove sample system probe
assembly from the quick-
disconnect port on the sample
hose and insert the probe
hose plug.
INDICATION
Red light in power button will extinguish.
Fan in condenser will stop.
A/C will stop.
Fan blades and condenser fins will be
free of dust and dirt.
All easily accessible areas will be
free of dust and dirt.
-2-
-------
STEP PROCEDURE
E.M.S.
4. Perform sample system ...(cont'd
b. Press #9, 9, 6, 6
pushbuttons.
c. Press "ENTER" push-
button.
d. Press #9 pushbutton.
e. Press "ENTER" push-
button.
f. Press #2, 3, 8, and
"SMOKE" pushbuttons.
g. Allow vacuum gauge on EMS
Filter Panel to stabilize.
h. Press "SMOKE" pushbutton.
i. Monitor the vacuum gauge
on the filter panel.
INDICATION
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
it gn
EDEP will display blank
Gas pressure
Filter pressure
Mote.: Gas and Filter pressure
should be within 27-32 in. Hg.
and the pumps should be off.
EDEP will display blank
Gas pressure
Filter pressure
Note.: Gas pressure will remain at
the previous reading and Filter
pressure will decrease to
approximately 4-6 in. Hg. If
these readings are not within
limits, correct the leak.
Vacuum gauge on filter panel will
indicate 25 t 1 in. Hg.
EDEP will display blank
Gas pressure
Filter pressure
Both pumps will shut off.
Note.: Gas pressure should-remain steady
while Filter pressure slowly
increases as the vacuum gauge
reading decreases.
Vacuum gauge will indicate a maximum
change of 3 in. Hg. in 15 seconds.
Note.: If the rate of change is greater
than 3 in. Hg. in 15 seconds,
correct the leak.
-3-
-------
STEP PROCEDURE
E.M.S.
4. Perform sample system ...(cont'd)
j. Remove probe plug from
sample system quick-
disconnect.
k. Press "SMOKE" pushbutton.
1. Press #0 pushbutton.
5. Perform leak cheek on calibration
system and solenoid valve #5
a. Turn BV 1, (N^/Ambient Air)
to the N2 position.
b. Plug the portable vacuum gauge
into the "ZERO GAS" port.
c. Press #9, 9, 6, 6 pushbuttons.
d. Press "ENTER" pushbutton.
e. Press #9 pushbutton.
f. Press "ENTER" pushbutton.
Remove the portable vacuum
gauge from the "ZERO GAS"
port, and remove the vacuum
from the gauge by opening
the plunger.
INPICATI0N
EDEP will display blank
Gas pressure
Filter pressure
EDEP will go blank except the
"ENTER QUEUE NUMBER" LED will light.
Portable vacuum gauge should read
approximately 20 in. Hg.
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
EDEP will display blank
Gas pressure
Filter pressure
Note.: The pump will stop; Gas pressure
(about 27-32 in. Hg.) and Filter
pressure (about 9.5 in. Hg.) will
be displayed. Filter pressure
should slowly increase while
vacuum gauge slowly decreases.
Vacuum or Filter pressure should
not change more than 3 in. Hg. in
15 seconds.
Portable vacuum gauge will indicate zero.
-4-
-------
STEP PROCEDURE INDICATION
E.M.S.
5. Perform leak check ... (cont'd)
h. Plug the portable vacuum
gauge in the "CAL GAS" port.
i. Turn BV 1 to Ambient Air
position.
j. Press "SMOKE" pushbutton.
k. Turn BV 1 to the N2 position.
1 . Press #0 pushbutton and turn
BV 1 to ambient air position.
6. Perform E.M.S. Health Check
Using "EDEP", check all analog
channels for proper readings
(see Table #1).
a. Press #9, 9, 6, 6 pushbuttons.
b. Press "ENTER" pushbutton.
c. Press #1 pushbutton.
d. Press "ENTER" pushbutton.
e. Press #1 pushbutton.
f. Press "ENTER" pushbutton.
g. Press #1 pushbutton.
h. Press "ENTER" pushbutton.
Filter pressure will go to about the
same reading as gas pressure.
Portable vacuum gauge should stay at
zero while filter pressure goes back to
about 9.5 in. Hg.
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
H i H
EDEP will display "DISP"
blank
blank
EDEP will display "DISP"
blank
H i n
EDEP will display blank
"CHAN"
blank
EDEP will display blank
"CHAN"
n 1 ii
EDEP will display Filter pressure
blank
L T 1.
-5-
-------
STEP
PROCEDURE
E.M.S. Perfonn E.M.S. Health ...(cont'd)
INDICATION
Repeat step d. - h. for each
channel. Substitute #1 for
"ENTER" in step d. when
repeating.
Press #0 pushbutton after all
channels are checked.
Note.'- See Table 1 for limits on all
channels.
"ENTER QUEUE NUMBER" LED will light.
CHANNEL
12
5
16
15
1
4
10
8
3
2
7
9
6
7.
A / D
0001
0002
0003
0004
0005
0006
0007
0008
0009
OOOA
OOOb
OOOC
OOOd
Check all
Lane tape
TABLE 1
HEALTH CHECK LIMITS
NAME
CAL VOLTAGE
AMBIENT TEMPERATURE
GAS TEMPERATURE
GAS PRESSURE
FILTER PRESSURE
HC REFERENCE VOLTAGE
CO REFERENCE VOLTAGE
C02 REFERENCE VOLTAGE
HC SAMPLE VOLTAGE
CO SAMPLE VOLTAGE
COe SAMPLE VOLTAGE
NOX CONCENTRATION
AMBIENT CO
solenoids using
L
OPEN
16°C
0°C
27 -
16 -
7.5
7.5
7.5
6.8
6.8
6.8
0 -
0 -
I M I T S
- 32°C
- 45°C
32 in. Hg.
22 in. Hg.
- 9.0 V
- 9..0 V
- 9.0 V
- 9.5 V
- 9.5 V
- 9.5 V
100 ppm
350 ppm
a. Press #9, 9, 6, 6 pushbuttons
b. Press "ENTER" pushbutton.
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
-6-
-------
STEP
7.
PROCEDURE
Check all solenoids ... (cont'd)
c. Press #9 pushbutton.
d. Press "ENTER" pushbutton.
e. Press #1 thru #9 and
"OVERRIDE" for #10, "CLEAR"
for #11, and "ABORT" for
#12 pushbuttons, twice each,
ensuring that each solenoid
energizes or de-energizes
with each push of each
button.
f. Press #0 pushbutton.
INDICATION
EDEP will display "FUNC"
blank
II nil
EDEP will display blank
Gas pressure
Filter pressure
Mote.: Ensure that pumps are OFF, if not,
press "SMOKE" to shut pumps off.
For solenoids 1 & 6 and 3 & 7
and 9 & 13, which operate together
you must put your hand on each
solenoid to make sure you feel it
operate.
EDEP will go blank and the "ENTER QUEUE
NUMBER" LED will be illuminated.
8. Calibrate HC/CO and C02 Analyzers
Procedures
8.1 General Information
a. Span Gas Values
The approximate span gas values utilized are as follows:
HC - 3100 ppm Propane (balance is N2)
CO - 8% (balance N2)
C02 - 7% (balance N2)
No^e; These values are for reference only. The actual named
concentration is used for calibration.
b. "NAMED" Calibration Gas Values
The values to be used during span calibration checks are the values that
appear on gas naming facility labels attached to each HC and CO cylinder.
Note.: Do not use any cylinders (HC and CO) if labels are missing or
mutilated; notify Supervisor if this occurs.
c. Cylinder Bottle Pressure
IMPORTANT ! Span gas cylinders shall not be utilized if cylinder pressure
is below 200 psi.
-7-
-------
STEP
PROCEDURE
INDICATION
d. Equipment Required
HC - Named Gas
CO - Named gas
C02 - 7% gas
8.2 a. Obtain Span Calibration form.
N2 - 99.99% gas
Regulators and gas lines
Lane tape
b. Obtain and record gas bottle
serial numbers and
concentrations
c. Turn ON all gas cylinders
connected with regulators.
d. Obtain and record analyzer
serial numbers and HC analyzer
conversion factor.
No-te; The conversion factor
may be obtained from the front
panel of the HC/CO analyzer.
If more than one label number
is present, notify Supervisor.
This factor will be recorded
as a three-digit decimal
number, less than one; e.g.,
(.XXX).
e. Calculate and record the HC
analyzer Hexane reading.
Note.: This reading will be
the measured HC displayed
during Span check or calibra-
tion. Calculate the HC
analyzer Hexane reading multi-
plying the named Propane
cylinder (bottle) concentration
times the HC analyzer con-
version factor.
Example; Cylinder "Names"
concentration 3050 ppm Hexane &
conversion factor .495:
3050 X .495 =1509.75
Record rounded number 1510;
use no decimal point and round
to the nearest number.
f. Enter Queue number 9999 and
press "ENTER" pushbutton.
Lane tape must be loaded
and "ENTER QUEUE NUMBER" LED
will be on.
All regulator gauges will indicate a
minimum of 3 psi and a maximum of 5 psi.
EDEP will display "HC-C"
blank
Concentration
-8-
-------
STEP
E.M.S.
8.2
PROCEDURE
g. Press "ENTER" pushbutton.
Position the AMBIENT/N2 valve
on the EMS to the N2 position.
If flow meters do not
indicate 8 + 1 SCFH,
adjust needle valve
labeled N2 to obtain
proper reading.
i. Press "ENTER" pushbutton.
j. Wait approximately 60 seconds.
Verify that analyzer
has been in flow mode
for at least 30 seconds
before proceeding to
step k.
k. Press "ENTER" pushbutton.
Note.: Turn appropriate manual
valve to full ON
position and verify that
proper flow meter(s)
indicates 8 + 1 SCFH.
If indication is not
within limits, adjust
needle valve directly
below manual valve for
proper indication.
1. Wait approximately 60 seconds.
-9-
INVICAT10N
EDEP will display "HC-A"
blank
Ana. ser. no.
Note.: If displayed analyzer serial
number differs from the number
in step 4., notify Supervisor
before proceeding to next step.
All three flow meters will indicate
8 + 1 SCFH.
EDEP will display "HC-0"
"FLO "
"ADJ "
EDEP will display "HC-0"
"FLO "
"RDY?"
Note.: "RDY?" display asks calibrator if
gas flow is correct and is EMS
ready for next step.
EDEP will display "HC-S"
"FLO "
"ADJ "
EDEP will display "HC-S"
"FLO "
"RDY?"
-------
STEP
E.M.S.
8.2
PROCEDURE
(cont'd)
m. Press "ENTER" pushbutton.
Note.: Record readings on Span
Calibration form for
analyzer under test. If
adjustment of "ANALYZER
SPAN READING" is required,
record reading before and
after adjustment.
Repeat steps a. thru m. for
C02 Analyzers except do not
enter "9999". Press "ENTER"
key only. Step 7. will not be
displayed during CO Analyzer
check.
After CC"2 Analyzer has been
checked, press "ENTER" key.
p. Close all manual valves on
EMS.
q. Position AMBIENT/N2 manual
valve on the EMS to AMBIENT
position.
r. Close all gas cylinder valves.
s. Record cylinder pressures on
Calibration form.
1 N V 1 C A T I 0 N
EDEP will display "HC-RESULTS CODE"
"ANALYZER ZERO READING"
Note.: Result code denotes ANALYZER status
as follows:
"P" = Analyzer readings are within
HTS required limits.
"H" = Analyzer readings exceed
HTS limits.
11F" = Analyzer readings exceed
State limits.
Note.: Analyzer zero reading must be "0000
If any other reading is displayed,
notify Supervisor immediately befor
proceeding.
Note.: If Results Code is "H" or "F",
refer to section 8.3 for adjustment
procedures.
EDEP will momentarily display "DELY"
blank
blank
Note.: "DELY" denotes EMS transfer of
calibration data to station
processor.
EDEP "ENTER QUEUE NUMBER" indicator
will be illuminated.
-10-
-------
STEP
PROCEDURE
Analyzer Adjustment Procedures
8.3 Note.'- The following procedures are
to be performed only when
the results obtained in
section 8.2 step m. are
either "H" or "P.
a. If result code is "H" and
adjustment is to be performed,
press "CLEAR" pushbutton. If
result code is "F" and adjust-
ment is to be performed, press
"ENTER" key.
b. Press "ENTER" key on EDEP.
Adjust the appropriate
analyzer front panel potentio-
meter until the "Analyzer Span
Gas Reading" displayed in step
6. is the same concentration
value for calibration as the
value recorded on the Span
Calibration form.
d. Press "ENTER" key on EDEP.
INDICATION
EDEP will display "HC-0"
blank
blank
After approximately 30 seconds
the EDEP will automatically
display the following:
"HC-0"
"RESULTS CODE"
"VALUE OF ANALYZER ZERO READING"
If value of Analyzer Zero Reading
is other than "0000", check with
Supervisor before proceeding to
step b.
EDEP will display "HC-S"
blank
blank
After approximately 30 seconds, the
EDEP will display the following:
Note.: "HC-S"
"RESULTS CODE"
"ANALYZER SPAN GAS READING"
The analyzer is now in the ADJUST
mode. Proceed to step c.
EDEP will display "HC-S"
"RESULTS CODE"
"ANALYZER SPAN GAS
READING"
Note.: As adjustment is made, "Analyzer
Span Gas Reading" will approach
the desired concentration value.
If value before is within HTS
limits, the Results code displayed
will change to "P".
EDEP will display "DELY"
blank
blank
-11-
-------
STEP
E.M.S.
PROCEDURE
9.
d. (cont'd)
Steps a thru d are to
to be performed for
each analyzer under
test that displays an
"H" or "F" when per-
forming step m.,
section 8.2.
e. Press "ENTER" key on EDEP.
Perform RPM checks
Using EDEP and TCP, perform the
following:
a. Place RMP (Relay Maintenance
Panel) mode switch in the
"BACKUP" position.
b. Turn off DEC printer on
the lane on which you are
performing this test.
c. Press #9, 9,9 pushbuttons.
d. Press "ENTER" pushbutton.
e. Press "CLEAR" pushbutton.
INDICATION
"DELY" display denotes EMS check
of the Calibration adjustment.
In this mode the EMS will auto-
matically flow Zero and Span gases,
The EMS will remain in this mode
for approximately 60 seconds and
then display the following:
"HC-RESULTS CODE"
"ANALYZER ZERO READING"
"ANALYZER SPAN GAS READING"
Verify that the results code
reading is "P". If not, repeat
steps a. thru d. above until a
"P" results code is obtained.
Note:
EMS will proceed with Span Calibration.
"READY" light will be illuminated on
the TCP.
None (except STD. CHARA.). LED will
extinguish on LA-36 printers.
EDEP will display blank
blank
" 999"
TCP - "READY" light on.
EDEP will display " 999"
"00 "
TCP "READY & BACKUPirlTghts will be on
EDEP will display " 999"
blank
blank
TCP - "READY & BACKUP" lights on.
-12-
-------
STEP PROCEDURE
E.M.S.
9. Perform RPM checks (cont'd)
f. Press #7, 7, 0, 0, 8, 0
pushbuttons.
g. Press "ENTER" pushbutton.
h. Press #5 pushbutton.
i. Press "ENTER" pushbutton.
j. Press "ENTER" pushbutton.
k. Turn on the Portable Variable
Tach Generator and hook up
and set for 2500 rpm range.
1. Press "OVERRIDE" pushbutton.
m. Press #5 and "ENTER"
pushbuttons.
n. Immediately switch the Tach
Generator to 3000 rpm range.
o. Vary the Tach Gen settings
back and forth while watching
the TCP number readout.
Ho to.: Do not stay on 2500 rpm
range long or TCP read-
out will go off.
p. Press "RESTART" pushbutton.
.13.
INDICATION
EDEP will display " 999"
n 77..
"0080"
TCP - "READY & BACKUP" lights on.
EDEP will go blank and "ENTER INSP.
NO./CODE" LED will light.
TCP - "READY & BACKUP" lights on.
EDEP will display blank
blank
n 5..
TCP - "READY & BACKUP" lights on.
EDEP "ENTER LOUVER" LED will light.
TCP - "READY & BACKUP" lights on.
EDEP will go blank.
TCP - "TESTING, SET SPEED, & BACKUP"
lights will come on.
EDEP "SYSTEM ERROR" LED will light.
TCP - "SET SPEED" light will go off and
"SAMPLE DILUTION" will come on.
EDEP "ENTER INSP. NO./CODE" LED will
light.
TCP - "TESTING, SAMPLE DILUTION & BACKUP"
lights will be on.
EDEP will go blank.
TCP - "SAMPLE DILUTION" light will go
off and "SET SPEED" numbers and
"ACTUAL SPEED" numbers will come on.
TCP "SET SPEED" light will come on.
TCP numbers should follow Tach Gen
settings.
EDEP will display blank
blank
" 999"
"ENTER QUEUE NUMBER" LED will be on.
TCP - "READY & BACKUP" lights will be on.
-------
STEP PROCEDURE
E.M.S.
10. Perform RPM checks (cont'd)
q. Switch the Mode switch to
the Auto position.
r. Press "CLEAR" pushbutton.
s. Press #9, 9, 6, 6 pushbuttons.
t. Press "ENTER" pushbutton.
u. Press #8 pushbutton.
v. Press "ENTER" pushbutton.
D.E.C.
1.
w. Vary the Tach Generator
settings.
Press #0 pushbutton and
unhook the Tach. Generator.
Vacuum inside printers
a. Open hinged cover and lift it
off the unit.
b. Remove hold-down screws from
dust cover.
c. Lift the cover off by lifting
the right side and tilting it
off the left side.
The cover cannot be
lifted straight off
because of the manual
paper feed.
-14-
I W V 1 C A T I 0 N
EDEP will go blank.
EDEP will display blank
blank
"9966"
EDEP will display "FUNC"
blank
blank
EDEP will display "FUNC"
blank
11 8"
EDEP will display blank
blank
RPM
Note.: EDEP will display what you
have selected on the Portable
Tach Generator.
EDEP will display blank
blank
RPM
EDEP will go blank with the "ENTER
QUEUE NUMBER" LED on.
-------
STEP PROCEDURE
D.E.C.
1. Vacuum inside printers (cont'd)
d. Turn unit off.
e. Vacuum entire upper area of
printer.
f. Open rear door of printer.
g. Vacuum inside louver section
of printer.
h. Close rear door.
i. Replace dust cover by reversal
of removal procedure.
j. Replace hold-down screws
(start screws by hand, being
careful not to strip them).
k. Replace lift cover by reversal
of removal procedure.
MISCELLANEOUS
1. Check oil in air compressor
a. Remove plug from compressor
sump.
b. Add oil if necessary.
c. Replace compressor sump plug.
2. Fill out and turn in Parts Request
form (when applicable).
INDICATION
None, except "STD. CHARA." LED will
extinguish on LA-36s.
All dirt and dust will be removed.
All dirt and dust will be removed.
Cover should be seated on all four sides
Oil should be up to the bottom of plug
hole. The oil should be clean. Look at
oil for dirt or metal shavings.
-15-
-------
EPA/HOUSTON DEMO PROGRAM
MONTHLY CHECK LIST
Initial
E.M.S.
1. Check and vacuum Air Conditioner
2. Clean Ambient air filter
3. Inspect entire EMS for:
a. loose connections
b. cracked hoses . . . .
c. dirt or moisture
4. Clean tape heads and pinch roller on EMS tape drive
5. Check Hexane Propane conversion factor
CLAYTON EQUIPMENT
1. Check exhaust louvers
2. Check hoses, tubing, tank assembly and solenoids
on exhaust louver
MISCELLANEOUS
1. Inspect Air Compressor
2. Clean the condition of all facility air moving
equipment on the roof
3. Clean external portion of CO Monitor
4. Calibrate CO Monitor
5. Calibrate Portable Analyzer . . .
6. Check external test equipment:
a. scuff gauge
b. Digital analyzer (RPM section)
c. timing light
COMMENTS:
Date performed: / / By:
Approved:
-------
STEP
E.M.S.
1.
PROCEDURE
2.
3.
Check and vacuum air conditioner
a. Turn off A/C at breaker panel
b. Remove four cover hold-down
screws.
c. Remove cover.
d. Vacuum entire unit including
heat exchanger fins.
Note.: Exercise caution not to
damage fins with vacuum
accessory tools. Also, be
careful of your hands
around fins, they are
sharp and will cut your
hands.
Clean Ambient air filter
a. Remove drain hose.
b. Twist sediment bowl counter-
clockwise to remove.
c. Remove ceramic filter and
retainer nut.
d. Thoroughly wash filter in
warm soapy water.
e. Blow the water out of the
filter.
f. Clean sediment bowl.
g. Replace filter and retainer
nut.
h. Replace sediment bowl.
i. Replace drain hose.
Inspect entire EMS for:
a. Loose connections on all
tubing fittings and all
electrical connections.
INDICATION
Air conditioner will stop.
Entire unit should be free of dust
and dirt.
Note.: Report any water puddles or signs
of water having set or puddled to
Maintenance headquarters.
Filler and nut will drop out of the
housing.
The filter should be clean and dry. Plug
up one end and blow through it; there
should not be too much resistance.
Bowl should be free of dust and dirt.
-2-
-------
STEP
E.M.S.
3.
PROCEDURE
.4.
5.
Inspect entire EMS for: (cont'd)
b. Cracked, kinked, or
deteriorated hoses.
c. Excessive dirt or moisture.
Clean tape heads and pinch
roller on EMS tape drive
a. Remove tape.
b. Using standard tape head
cleaner and cotton swabs,
clean the head and the entire
pinch roller.
c. Inspect the roller for
grooves.
Check Hexane/Propane conversion
factor
a. Load CALCAL tape and put in
a 30-second delay.
b. Set EDEP to display corrected
concentration.
c. Calibrate HC analyzer using
Hexane, to exact readings on
the bottle tag. Record
readings.
d. Read concentration again using
station Propane; don't adjust.
Record reading.
e. Calculate C.F. by dividing
Hexane readings (step d.) by
the Propane reading (step f.).
f. Computed conversion factor is
t .005 of conversion factor
listed on analyzer. If not,
change the CF number on the
analyzer and in the station
Processor.
INDICATION
See CALCAL Tope Ptocedu^e at the. end
o\ thU Monthly Chuck Lut.
EDEP will display blank
corrected con.
blank
EDEP will display blank
"HEXANE"
blank
EDEQ will display blank
"PROPANE"
blank
CF = 1800 ppm Hexane _
3600 ppm Propane
-3-
-------
STEP
CLAYTON
1.
PROCEDURE
2.
Check exhaust louvers
a. Check for leaks at shaft end
of cylinder assembly.
b. Check cable and linkage.
Use SAE 30 W engine oil to
lubricate louver hinges,
sheave and pulley bearings
cylinder shutter shaft pivot
point.
Npxte: Hinges of lower louver
are reached through holes
provided in frame by using
tubing to place lubricant.
d.
Check tank level. System uses
automatic transmission fluid
(Mobil ATF200 or equal). Make
this check with louver B open
so tanks are viable. (It may
be necessary to remove floor
slats and clean sight tubes to
accomplish this task.)
If tanks require
replenishment, be sure to
use safety bolts.
Check hoses, tubing, tank assembly
and solenoids on Exhaust Pit
Louvers _
a. With EMS on, switch louver
switch to "Manual" on Relay
Maintenance Panel (RMP).
b. Press louver control Code B
on EDEP.
c. Louver end plates each have
holes in them. Place
a one-half inch by four inch
bolt in the hole with a nut
on each side with the bolt
extending over the pavement
edge of the louver pit. This
is to prevent louver lowering
while you are working.
-4-
INDICATION
Leaks around shaft.
Slack or frayed cable, loose pulleys,
nuts, and bolts.
Tanks are filled to plug level. Add fluid
when level is below the "add" point
(approximately one inch from connector
11 on left tank and two inches from
connector 14 on right tank).
Note.: On some units the lines may be
reversed, in which case the levels
on the tanks will be opposite.
Louver B will open.
-------
STEP
CLAYTON
2.
PROCEDURE
Check hoses, tubing,... (cont'd)
d. Remove floor slats.
e. Check and replace deteriorated
hoses and tubing.
f. Replace floor slats.
g. Remove safety bolts.
h. Switch control switch to
A open.
i. Install safety bolts.
j. Remove floor slats.
k. Turn EMS power off.
1. Remove solenoid junction box
cover.
m. Check solenoids for loose
wires.
n. Replace solenoid junction
box cover.
o. Replace floor slats.
p. Turn EMS on and load Lane
tape.
MISCELLANEOUS
Inspect Air Compressor
a. Clean intake air cleaner.
Turn the filter plate until
you can pull it out. Pull
filter out and thoroughly
vacuum it. Replace filter
and retainer plate. Repeat
this step for both compressors
where applicable.
b. Check belt tension. Turn
compressor off. Reach up
from the bottom and pull on
the belts, you should not be
able to pull them more than
1 inch with a moderate pull.
INDICATION
Hoses or tubing cracked or soft.
Wires or screws on terminals loose.
"ENTER QUEUE NUMBER" LED will be
illuminated.
Outside of filter will be free of
dirt.
-5-
-------
STEP
PROCEDURE
MISCELLANEOUS
Inspect Air Compressor (cont'd)
c. Check that all screws and
nuts are tight.
d. Lubrication (yearly). Ball
bearing motors that have
grease fittings and plugs
near the bearings are to be
repacked with grease once a
year. Use the best grade of
ball bearing grease available
Check the condition of all
facility air moving equipment
on the roof
Remove air conditioning filters
and replace if necessary.
Clean external portion of CO
Monitor
a. Clean exterior of CO Monitor
with a soft rag or paper
towel and a liquid cleaning
agent.
Calibrate CO Monitor
a. Position CO Monitor power
on/off switch to the OFF
position.
b. Remove front panel cover.
c. Turn OFF circuit breaker
for CO Monitor under-
test.
d. Turn ON circuit breaker
for CO monitor under
test.
e. Position CO monitor power
on/off switch to the ON
position.
f. Rotate the selector valve
180° from the calibrate
position.
IWPICATIOW
Air filter should be clean.
Green power ON indicator will not be
illuminated.
Panel meter needle will indicate zero.
If needle does not indicate
zero, adjust the potentiometer
on panel meter housing for zero.
Green power ON indicator will illuminate.
-6-
-------
STEP
PROCEDURE
I N V 1 C A T I 0 N
MISCELLANEOUS
h.
i.
Rotate the span potentiometer
located on front panel to the
center of its travel.
Rotate the zero potentio-
meter until the red alarm
light illuminates.
Connect a DVM to test jacks
located on right side of
panel meter. Ensure that the
red probe is connected to the
red jack and that the black
probe is connected to the black
jack. Set DVM function control
for DC volts and the range switch
to 2. Turn ON the DVM.
j. Remove the DMV probes from
the test jacks.
k. Rotate the selector valve 130°
to the Calibrate position.
Panel meter needle should indicate
300 ppm.
Note.'- If above indication is not obtained
adjust the alarm potentiometer on
the front panel to obtain a reading
of 300 ppm when the red light
illuminates.
DVM will indicate zero volts.
A/pxte-' If DVM does not indicate zero volts
adjust the zero potentiometer on
CO Monitor front panel for zero
volts indication on the DVM.
1. Fill the sample bag with
300 ppm CO gas.
m. Connect the sample gas bag to
the CO Monitor Intake Port.
C A U T I 0 M
Never connect the Pressurized
Span Gas Cylinder directly to
the CO Monitor Intake Port.
Excessive pressure will damage
the CO Monitor.
n. Remove the sample gas bag
from the CO Monitor Intake
Port.
o. Position the Selector Valve
to the OPERATE position.
p. Replace the front panel cover.
Panel meter will indicate 300 ppm.
Note.: If the meter does not indicate
300, adjust the Span potentiometer
to obtain an indication of 300 ppm=
-7-
-------
STEP
5.
6.
PROCEDURE
INDICATION
Calibrate Portable Analyzer
Follow CEA600 operation/calibration
procedures.
Check External Test Equipment
a. scuff gauge
b. Digital analyzer (RPM section)
c. timing lights
Follow recommended calibration/
operation checks on above equipment.
Note.* Refer to Manufacturer's manual.
-8-
-------
CALCAL TAPE PROCEDURE
OPERATION PROCEDURES
1. This section will describe the operation procedures for the use of
CALCAL tape. There are two (2) sections in the procedure.
' Flow Adjustment - which will allow setting and adjusting of all
flow prior to the actual test.
* Test - which will allow for the actual analyzer testing and
recording of results.
NOTE: All entries and displays in the following procedure are
on the EMS E.D.E.P.
2. Procedures
2.1 Flow Adjustment
2.1.1 Load CALCAL tape into the EMS - when tape is loaded properly
E.D.E.P. will display "CCAL"
"PR--"
"01.01"
2.1.2 Press ENTER - E.D.E.P. blank
If an external N2 cylinder is used, connect it to the external
N2 quick disconnect on the EMS; rotate the ambient N/2 valve
on the EMS to OFF position.
2.1.3 Connect the appropriate gas cylinder (HC, CO, C02) to the
external "CAL" port quick disconnect on the EMS.
2.1.4 Press ENTER - after 5-second delay, and E.D.E.P. blank, open N2
cylinder regulator and make sure that analyzer's flow meter
indicates 8CFH and the cylinder regulated pressure does not
exceed 4 psi (adjust flow with the cylinder pressure regulator
or attach cylinder needle valve).
2.1.5 Press #2 - E.D.E.P. will display "FLO"
2.1.6 Depending upon the analyzer to be tested, press the following:
HC Analyzer - press #4 - E.D.E.P. will display #4
CO Analyzer - press #5 - E.D.E.P. will display #5
Analyzer - press #6 - E.D.E.P. will display #6
-------
- 2 -
2.1.7 Press ENTER - E.D.E.P. blank
2.1.8 Open the gas cylinder connected at step 2.1.4 and adjust the
regulator. Make sure the selected analyzer (step 2.1.6) flow
is 8CFH and that the cylinder regulated pressure does not
exceed 4 psi (adjust flow with cylinder flow pressure regulator
or attached cylinder middle valve).
2.1.9 Press #2 E.D.E.P. will display "FLO"
2.1.10 Press #3 E.D.E.P. will display "3"
2.1.11 Disconnect external N2 cylinder. Rotate ambient/N2 valve on
the EMS to AMBIENT and press ENTER - E.D.E.P. blank - this
will put the analyzers on purge until the testing continues.
2.2 TEST
2.2.1 Press #1 - E.D.E.P. will display "GAS"
2.2.2 Depending upon the analyzer to be tested, press the following:
' HC Analyzer - press #1 - E.D.E.P. will display, "DISP"
' CO Analyzer - press #2 - E.D.E.P. will display "CO"
' C02 Analyzer - press #3 - E.D.E.P. will display "C02"
2.2.3 Press #3 E.D.E.P. will display, "DISP"
2.2.4 Press #2 E.D.E.P. will display "2"
2.2.5 Press ENTER - E.D.E.P. will display "DATA"
2.2.6 Press #5 - E.D.E.P. will display "5"
2.2.7 Press ENTER - E.D.E.P. will display previous reading - disregard
2.2.8 Press #5 - E.D.E.P. will display "DELY"
2.2.9 Press #50 - E.D.E.P. will display "50"
2.2.10 Press ENTER - E.D.E.P. will display analyzer previous reading - disregard
2.2.11 Press #2 - E.D.E.P. will display "FLO"
2.2.12 Press #3 - E.D.E.P. will display "3"
2.2.13 Connect N2 cylinder, rotate ambient/N2 valve to OFF position -
press ENTER - E.D.E.P. will display decreasing delay time.
-------
- 3 -
2.2.14 When delay reaches 0 window #2 on E.D.E.P. will display the
zero value for the selected analyzer.
2.2.15 Press #5 - E.D.E.P. will display "DELY"
2.2.16 Press #20 - E.D.E.P. will display "20"
2.2.17 Press ENTER - E.D.E.P. will display previous reading - disregard
2.2.18 Press #2 - E.D.E.P. will display "FLO"
2.2.19 Depending upon the analyzer to be tested, press the following:
HC Analyzer - press #4 - E.D.E.P. will display #4
CO Analyzer - press #5 - E.D.E.P. will display #5
C02 Analyzer - press #6 - E.D.E.P. will display #6
NOTE: Make sure that you have selected the same analyzer as
was selected in steps 2.1.6 and 2.2.2
2.2.20 Press ENTER - E.D.E.P. will display decreasing delay time.
When delay reaches 0, window #2 will display the cylinder
gas concentration.
2.2.21 When display stablizes, record reading.
2.2.22 Repeat steps 2.2.8 thru 2.2.21 for additional readings.
2.2.23 When all testing is complete,
shut off gas cylinders
' disconnect gas cylinder
' reload CALCAL tape or lane tape into EMS
-------
APPENDIX "C"
HOUSTON/EPA DEMONSTRATION PROGRAM
REPORTING GUIDELINES
RELEASE DATE: 2/25/so
REVISED: s/12/so
PREPARED BY:
APPROVED BY:
NAFTALI AMIR
A, J, ARRIGO
-------
1.0 SCOPE
This document will establish the methods and procedures for various
reports to be generated by the Houston/EPA Demonstration Program
Manager.
2.0 GENERAL INFORMATION
2.1 In general, all reports required to be submitted to EPA, as per Exhibit
"B" "Reports of Work" of the Contract between EPA and Hamilton Test
Systems, will be generated from Hamilton Test Systems motor vehicle
inspection headquarters in Phoenix.
2.2 It is the responsibility of the Program Manager to provide the data
needed for the above reports to MVI Headquarters.
2.3 In order to assist the Program Manager in the above task, various
documents have been designed as follows:
. Daily Operation Log
. Weekly Status Report
. Monthly Report Work Sheet - Hourly Tests
. Monthly Report Work Sheet - Hourly Queues
2.4 The following table will cover the number of weeks to be included
in each monthly report:
Month # of Weeks Week #
Mar
Apr
May
Jun
Jul
Aug
4
5
4
4
5
4
. 1-4
5-9
10-13
14-17
18-22
23-26
-1-
-------
3.0 DAILY OPERATIONS LOG (Figure 1)
3.1 General
This form will be used for recording the Daily Operation. Log data,
per contract. Each form will be used for the daily data within an
operation week.
3.2 Copies and Submittals
a. The Daily Operation Log is to be filled out in duplicate and
filed (both copies) at the station.
b. The original is to be mailed to MVI Headquarters within 3
days following the operation week # for the particular report-
ing month (see table in paragraph 2.4).
3.3 Data Recording
a. A new form specifying operation week # is to be used for each
week.
Note: Following entries are to be made on a daily basis:
b. Record the date, opening time, closing time, and total operating
hours in section I "GENERAL."
c. Numerically, specify the personnel at work in section II
"PERSONNEL."
d. Request all visitors to fill in their name, organization and
purpose of visit in section III "VISITOR INFORMATION."
e. Use the "COMMENTS" section for a brief narrative (specify dates)
on unusual happenings or conditions.
-2-
-------
4.0 WEEKLY STATUS REPORT (Figure 2)
4.1 General
This form will be used for recording vehicle inspection status
for the Weekly Status Report.
4.2 Copies and Submittals
a. The Weekly Status Report is to be filled out in duplicate.
b. At the end of the operation week, top copy is to be sent to:
Mr. David Brzezinski
Project Officer
Inspection and Maintenance Staff
Emission Control Technology Division
ENVIRONMENTAL PROTECTION AGENCY
2565 Plymouth Road
Ann Arbor, Michigan 48105
c. Follow procedure for submittal of the Daily Operation Log for
the remaining copy of the Weekly Status Report.
4.3 Data of Recording
a. A new form specifying operation week # is to be used for each
week.
b. Record the date for each day.
Note: The following steps are to be performed on a daily
basis when all testing has been completed.
c. Substitute a blank computer paper for the VIR in the VIR printer.
d. Request display and print of the inspection status from the
auxiliary computer (Alpha Micro).
e. Record on the Weekly Status Report the appropriate inspection
categories.
-3-
-------
4.4 Comments
a. Total tests are the sum of all tests performed during the
day. Total tests = (HTS tests) + (Initial tests) + (Retests),
b. HTS tests are all tests with "customer" field entry of HTS.
c. Initial tests are all tests where "customer" field entries
are not HTS and "retest" field entry = 0.
d. Retests are all tests where "customer" field entries are not
HTS, and "retest" field entries are other than 0.
e. Due to a multiple failure possibility on a vehicle, the sum
of various passed, failed, and rejected values will not equal
the total test under the initial or retest categories.
-4-
-------
5.0 MONTHLY REPORT WORK SHEET - HOURLY TEST (Figure 3)
5.1 General
This form will be used for recording hourly test data for the
Monthly Progress Report. Each form will be used for the daily
data within an operation week.
5.2 Copies and Submittals
Follow the procedures established for the Daily Operation Log.
5.3 Data Recording
(Refer to Figures 4 and 5 for a sample of completed work sheets
for two consecutive weeks.)
a. Raw data for this report is to be generated automatically by
the hour at the emission computer (DEC 11/34).
Note: Steps b. ^through d. below should be performed
immediately after the previous week's Work Sheet has
been completed.
b. Record the operational week number, start date and end date
for the coming week.
c. Copy line #10 (Cumulative Hourly Total Test) from previous
week's Work Sheet onto line #9 (Total Hourly Test - Previous
Week) for the coming week's Work Sheet.
d. Copy line #12 (Cumulative Days) from previous week's Work
Sheet onto line #11 (Number of Days Previous Report) for the
coming week's Work Sheet.
e. On the appropriate day (lines #1 through #5), record the
valid hoursly inspections as they appear on the Hourly Status
Report (Figure 6).
-5-
-------
Motes: 1. Valid inspections are: (overall inspection -
totals) - (overall inspection - aborted).
2. All tests performed after the official operating
hours (due to overload) should be included
together with the value for the last hour.
3. Remember - each hourly status, list all test
performed from the beginning of the day. You
must subtract current hour's status values from
previous hours to find the actual inspection for
a particular hour.
5.4 Calculation
The following are to be performed at the end of the week:
a. Sum all the values in each vertical column and record on line
#6 (Total Hourly Test Present Week).
b. Record on line #7 (Total Days Present Week) the number of
working days for each hour.
Note: 1. Due to the varied daily operating hours, line #7
"Total Day Present Week" for a normal operating
week is as follows:
Hours of Day Line #7 Days Included
09:00 5 Tue. - Sat.
10:00 5 Tue. - Sat.
11:00 5 Tue. - Sat.
12:00 5 Tue. - Sat.
13:00 5 Tue. - Sat.
14:00 5 Tue. - Sat.
15:00 4 Tue. - Fri.
16:00 4 Tue. - Fri.
17:00 4 Tue. - Fri.
18:00 1 Thu.
19:00 1 Thu.
20:00 i Thu.
-6-
-------
Note: 2. Line #7 is also to be adjusted if testing was
not conducted as normal (see Example).
Example.: If on Wednesday testing stopped at 16:00 due to
equipment malfunction, then the value on line #7 for the
17:00 entry should be 3.
c. Divide each entry on line #6 by appropriate entry on line #7
and record the answer on line #8 (Average Hourly Test Current
Week).
d. Add each entry on line #6 to previously recorded entries on
line #9. Record answer on line #10 (Cumulative Hourly Total
Test).
e. Add each entry on line #7 to previously recorded entries on
line #11. Record answer on line #12 (Cumulative Days).
f. Divide each entry on line #10 by the appropriate entry on
line #12 and record answer on line #13 (Average Cumulative Hourly
Test).
5.5 Comment
The following is the explanation of the Work Sheet data shown on
Figure 3.
a. The number in the box marked (i) is the "Number of Valid
Inspections Performed in Each Week."
b. The number in the box marked (ii) is the "Cumulative Number
of Valid Inspections as of Each Week."
c. Line #8 (iii) is the "Average Inspection Rate as a Function
of the Hour of the Day."
d. Line #13 (iv) is the "for all the months since the start of
the operational phase taken together the average inspection
rate as a function of the hour of the day."
-------
6.0 MONTHLY REPORT WORK SHEET - HOURLY QUEUE (Figure 7)
6.1 General
This form will be used for recording the hourly queue length data
for the Monthly Progress Report. Each form will be used for the
daily data within an operational week.
6.2 Copies and Submittals
Same as for Daily Operation Log.
6.3 Data Recording
Note: Steps a. through c. below should be performed immediately
after the previous week's Work Sheet has been completed.
a. Record the operational week number, start date and end date
for the coming week.
b. Copy line #10 (Cumulative Hourly Total Queue) from previous
week's Work Sheet onto line #9 (Total Hourly Queue - Previous
Week) for the coming week's Work Sheet.
c. Copy line #12 (Cumulative Days) from previous week's Work
Sheet onto line #11 (number of Days Previous Report) for the
coming week's Work Sheet.
d. On the appropriate day (lines #1 through #5), record the valid
hourly queue length (number of vehicles in queue).
6.4 Calculation
The following are to be performed at the end of the week:
a. Sum all the values in each vertical column and record on
line #6 (Total Hourly Queue Present Week).
b. Record on line #7 (Total Days Present Week) the number of
working days for each hour.
-8-
-------
Line #7
5
5
5
5
5
5
4
4
4
1
1
1
. Days Included
Tue. - Sat.
Tue. - Sat.
Tue. - Sat.
Tue. - Sat.
Tue. - Sat.
Tue. - Sat.
Tue. - Fri.
Tue. - Fri.
Tue. - Fri.
Thu.
Thu.
Thu.
Note: 1. Due to the varied daily operating hours, line #7
"Total Day Present Week" for a normal operating
week is as follows:
Hours of Day
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
Note: 2. Line #7 is also to be adjusted if testing was
not conducted as normal (see Example).
Example: If on Wednesday testing stopped at 16:00 due to
equipment malfunction, then the value on line #7 for the
17:00 entry should be 3.
c. Divide each entry on line #6 by appropriate entry on line #7
and record the answer on line #8 (Average Hourly Queue Current
Week).
d. Add each entry on line #6 to previously recorded entries on
line #9. Record answer on line #10 (Cumulative Hourly Total
Queue).
e. Add each entry on line #7 to previously recorded entries on
line #11. Record answer on line #12 (Cumulative Days).
f. Divide each entry on line #10 by the appropriate entry on
line #12 and record answer on line #13 (Average Cumulative Hourly
Queue).
-9-
-------
6.5 Comments
The following is the explanation of the Work Sheet data shown on
Figure 7.
a. Line #8 (iii) is the "average queue length as a function of
the hour of the day."
b. Line #13 (iv) is the "for all the months since the start of
the operational phase taken together the average queue length
as a function of the hour of the day."
-10-
-------
HOUSTON/EPA DEMONSTRATION PROGRAM
O
O
UJ
to
UJ
WEEKLY STATUS REPORT
WEEK #
DAY:
DATE:
TOTAL TESTS:
H.T.S, TESTS:
INITIAL TESTS (TOTAL):
PASSED:
FAILED EMISSIONS:
FAILED ECS:
FAILED PROPANE:
FAILED FUEL ECON:
REJECTS:
TUE.
WEP.
THU.
I I
FRI
SAT.
/ /
WEEKLY
TOTALS
o
o
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RETEST (TOTAL)
PASSED:
FAILED EMISSIONS:
FAILED ECS:
FAILED PROPANE:
FAILED FUEL ECONOMY:
REJECTS:
COMMENTS:
date*)
-------
HOUSTON/EPA DEMONSTRATION PROGRAM
DAILY OPERATION LOG
WEEK #
I GENERAL
DAY:
DATE :
OPENING TIME:
CLOSING TIME:
TOTAL OPERATING HRS:
II PERSONNEL
PROGRAM MANAGER
ASST, MANAGER
INSPECTORS
III VISITORS
INFORMATION
NAME:
ORGANIZATION:
PURPOSE:
NAME:
ORGANIZATION:
PURPOSE:
NAME:
ORGANIZATION:
PURPOSE:
NAME:
ORGANIZATION:
PURPOSE:
THE .
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COMMENTS : (SPECIFY DATES)
-------
HOUSTON E.P.A. DEMONSTRATION PROGRAM
MONTHLY REPORT - WORK SHEET - HOURLY TESTS
WEEK #\.
START DATE: / / END DATE: / /
LINE ^\HOUR OF DAY
# LINE ITEMSX^
1
2
3
H
5
6
7
8
9
10
11
12
13
TUESDAY - HOURLY TEST
WEDNESDAY - HOURLY TEST
THURSDAY - HOURLY TEST
FRIDAY - HOURLY TEST
SATURDAY - HOURLY TEST
TOTAL HOURLY TEST
PRESENT WEEK (LINES 1-5)
TOTAL DAYS PRESENT WEEK
AVERAGE HOURLY TEST
CURRENT WEEK (LINES 6 17)
TOTAL HOURLY TEST
PREVIOUS REPORT (LINE ID)
CUMULATIVE HOURLY TOTAL
TEST (LINES 6+9)
NUMBER OF DAY PREVIOUS
REPORT (LINE 12)
CUMULATIVE DAYS
(LINES 7 + 11)
AVERAGE CUMULATIVE
HOURLY TEST (10 -. 12)
09:00
10:00
11:00
12:00
-
13:00
11:00
4
15:00
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16:00
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17:00
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20:00
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TOTALS
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-------
HOUSTON E.P.A. DEMONSTRATION PROGRAM
f4.Qu.iie. 4
MONTHLY REPORT - WORK SHEET - HOURLY TESTS
WEEK #: //
LINE ^v HOUR OF DAY
# LINE ITEMSX^
1
2
3
H
5
6
7
8
9
10
11
12
13
TUESDAY - HOURLY TEST
WEDNESDAY - HOURLY TEST
THURSDAY - HOURLY TEST
FRIDAY - HOURLY TEST
SATURDAY - HOURLY TEST
TOTAL HOURLY TEST
PRESENT WEEK (LINES 145)
TOTAL DAYS PRESENT WEEK
AVERAGE HOURLY TEST
CURRENT WEEK (LINES 6 *7)
TOTAL HOURLY TEST
PREVIOUS IMPORT (LINE 10)
CUMULATIVE HOURLY TOTAL
TEST (LINES 6+9)
NUMBER OF DAY PREVIOUS
REPORT (LINE 12)
CUMULATIVE DAYS
(LINES 7 + 11)
AVERAGE CUMULATIVE
HOURLY TEST (10412)
START DATE:JJM?P END DATE
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HOUSTON E.P.A. DEMONSTRATION PROGRAM
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WEDNESDAY - HOURLY TEST
THURSDAY - HOURLY TEST
FRIDAY - HOURLY TEST
SATURDAY - HOURLY TEST
TOTAL HOURLY TEST
PRESENT WEEK (LINES 145)
TOTAL DAYS PRESENT WEEK
AVERAGE HOURLY TEST
CURRENT WEEK (LINES 6 *7)
TOTAL HOURLY TEST
PREVIOUS REPORT (LINE 10)
CUMULATIVE HOURLY TOTAL
TEST (LINES 6+9)
NUMSER OF DAY PREVIOUS
REPORT (LINE 12)
CUMULATIVE DAYS
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AVERAGE CUMULATIVE
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HOUSTON E.P.A. DEMONSTRATION PROGRAM
MONTHLY REPORT - WORK SHEET - HOURLY QUEUE
WEEK #:.
START DATE: / / END DATE: / /
LINE N. HOUR OF DAY
# LINE ITEMS/X^
1
2
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4
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TUESDAY - HOURLY QUEUE
WEDNESDAY - HOURLY QUEUE
THURSDAY - HOURLY QUEUE
FRIDAY - HOURLY QUEUE
SATURDAY - HOURLY QUEUE
TOTAL HOURLY QUEUE
PRESENT WEEK (LINES 1-5)
TOTAL DAYS PRESENT WEEK
AVERAGE HOURLY QUEUE
CURRENT WEEK (LINES 6 *7)
TOTAL HOURLY QUEUE
PREVIOUS REPORT (LINE 10)
CUMULATIVE HOURLY TOTAL
QUEUE (LINES 6 + 9)
NUMBER OF DAY PREVIOUS
REPORT (LINE 12)
CUMULATIVE DAYS
(LINES 7 + 11)
AVERAGE CUMULATIVE
HOURLY QUEUE (10 i 12)
09:00
10:00
11:00
12:00
13:00
11:00
15:00
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17:00
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-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-460/3-80-026
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Operation of a Pilot Motor Vehicle Inspection Station
in Houston, Texas
5. REPORT DATE
November, 1980
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Anthony J. Arrigo
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Hamilton Test Systems, Inc.
2303 E. Thomas Road
Phoenix, Arizona 85016
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-03-2894
12. SPONSORING AGENCY NAME AND ADDRESS
U. S. Environmental Protection Agency
Office of Air, Noise and Radiation
Office of Mobile Source Air Pollution Control
Ann Arbor, Michigan 48105
13. TYPE OF REPORT AND PERIOD COVERED
Final Report
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16.ABSTRACT jn conjunction with an EPA project to assess methods, costs, projected effec
tiveness and acceptability of various motor vehicle exhaust emissions Inspection and
maintenance (I/M) alternatives, and to support the State of Texas in complying with
its implementation plan, the Office of Mobile Source Air Pollution Control of the.U.S
Environmental Protection Agency assisted the Texas Air Control Board in establishing
pilot motor vehicle emissions inspection and maintenance program in Houston, Texas.
A portion of the program involved the operation of a centralized vehicle emissions in-
spection station which performed idle tests, underhood inspections of emission control
systems and components, and physical/functional I/M tests to simulate the operation o:
the various alternative configurations for the legislatively mandated I/M program.
The contract for the centralized concept was conducted by Hamilton Test Systems, Inc.
of Phoenix, Arizona.
The purpose of the contract was to assist the Texas Air Control Board in evaluating
the cost and technical details of operating a centralized vehicle emissions inspectioi
station using an underhood inspection of emission control systems and components with
either an idle mode tail pipe emission test or a "physical/functional" test procedure
A total of 4,647 vehicles was tested using one or both procedures during the span of
the contract. Each vehicle was to be determined to have "passed" or "failed" using
criteria established by the EPA. Specific instructions regarding test procedures,
cutpoints, data handling and reporting were also provided by EPA. Hamilton Test
Systems (HTS) was responsible only for the set up and operation of the inspection
station. HTS was not responsible for soliciting vehicles for participation in the
pilot I/M program, or for evaluation and analysis of test data.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
In-Use Vehicles
Inspection Maintenance
Program
Propane Gain
Tire Pressure
Computerized Emission
Measurement
18. DISTRIBUTION STATEMENT
Release Unlimited
19. SECURITY CLASS (ThisReport)'
Unclassified
21. NO. OF PAGES
221
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
-------
INSTRUCTIONS
1. REPORT NUMBER
Insert the EPA report number as it appears on the cover of the publication.
2. LEAVE BLANK
3; RECIPIENTS ACCESSION NUMBER
Reserved for use by each report recipient.
4: TITLE AND SUBTITLE
Title should indicate clearly and briefly the subject coverage of the report, and be displayed prominently. Set subtitle, if used, in smaller
type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary title, add volume
number and include subtitle for the specific title.
5. REPORT DATE
Each report shall carry a date indicating at least month and year. Indicate the basis on which it was selected (e.g., date of issue, date of
approval, date of preparation, etc.).
6. PERFORMING ORGANIZATION CODE
Leave blank.
7. AUTHOR(S)
Give name(s) in conventional order (John R. Doe, J. Robert Doe, etc.). List author's affiliation if it differs from the performing organi-
zation.
8. PERFORMING ORGANIZATION REPORT NUMBER
Insert if performing organization wishes to assign this number.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Give name, street, city, state, and ZIP code. List no more than two levels of an organizational hirearchy.
10. PROGRAM ELEMENT NUMBER
Use the program element number under which the report was prepared. Subordinate numbers may be included in parentheses.
11. CONTRACT/GRANT NUMBER
Insert contract or grant number under which report was prepared.
12. SPONSORING AGENCY NAME AND ADDRESS
Include ZIP code.
13. TYPE OF REPORT AND PERIOD COVERED
Indicate interim final, etc., and if applicable, dates covered.
14. SPONSORING AGENCY CODE
Leave blank.
15. SUPPLEMENTARY NOTES
Enter information not included elsewhere but useful, such as: Prepared in cooperation with, Translation of, Presented at conference of,
To be published in, Supersedes, Supplements, etc.
16. ABSTRACT
Include a brief (200 words or less) factual summary of the most significant information contained in the report. If the report contains a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper authorized terms that identify the major
concept of the research and are sufficiently specific and precise to be used as index entries for cataloging.
(b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc. Use open-
ended terms written hi descriptor form for those subjects for which no descriptor exists.
(c) COSATI FIELD GROUP - Field and group assignments are to be taken from the 1965 COSATI Subject Category List. Since the ma-
jority of documents are multidisciplinary in nature, the Primary Field/Group assignment(s) will be specific discipline, area of human
endeavor, or type of physical object. The application(s) will be cross-referenced with secondary Field/Group assignments that will follow
the primary posting(s).
18. DISTRIBUTION STATEMENT
Denote releasability to the public or limitation for reasons other than security for example "Release Unlimited." Cite any availability to
the public, with address and price. /
19. & 20. SECURITY CLASSIFICATION
DO NOT submit classified reports to the National Technical Information service.
21. NUMBER OF PAGES
Insert the total number of pages, including this one and unnumbered pages, but exclude distribution list, if any.
22. PRICE
Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
EPA Form 2220-1 (9-73) (ReverM)
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