\ I / (EPA-450/3-77-034 November 1977. TRANSPARENCY MASTERS INSTRUCTOR'S GUIDE FOR VEHICLE EMISSIONS CONTROL U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Air and Waste Management Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 ------- EPA-450/3-77-034 TRANSPARENCY MASTERS FOR USE WITH INSTRUCTOR'S GUIDE FOR VEHICLE EMISSIONS CONTROL B.D. Hayes, Project Director M.T. Maness, Associate Project Director R.A. Ragazzi, Principal Investigator Department of Industrial Sciences Colorado State University Fort Collins, Colorado 80523 EPA Grant No. T900621-01-0 EPA Project Officer: Bruce Hogarth Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Air and Waste Management Office of Air Quality Planning and Standards Control Programs Development Division Research Triangle Park, North Carolina 27711 November 1977 ------- Copies of this publication are available free of charge to Federal employees, current contractors and grantees, and nonprofit organizations - as supplies permit - from the Library Services Office (MD-35), Environmental Protection Agency, Research Triangle Park, North Carolina 27711; 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 the Department of Industrial Sciences, Colorado State University, Fort Collins, Colorado, 80523, through Grant No. T900621-01-0. The contents of this report are reproduced herein as received from Colorado State University. The opinions, findings, and conclusions expressed are those of the authors and not necessari- ly 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. Publication No. EPA-450/3-77-034 11 ------- CHOPPER SAMPLE IN SAMPLE CELL SAMPLE _ OUT DETECTOR IR SOURCES SEALED REFERENCE CELL - SIGNAL TO PREAMP INFRARED EXHAUST GAS ANALYZER 1 UNIT 2-Fig. 1 ------- HYDROCARBONS PPM. CARBON MONOXIDE PERCENT TYPICAL INFRARED EXHAUST GAS ANALYZER METERS ------- r CO % A B FACTORY 1/4 TURN SPECS RICH C D 1/2 TURN 3/4 TURN RICH RICH UNIT 3- Fig. 1 ------- HC PPM FACTORY 1/4 TURN SPECS RICH 1/2 TURN 3/4 TURN RICH RICH UNIT 3-Fig. 2 ------- 300- HC PPM 50- FACTORY +5° TIMING SPECS ADVANCE +10° TIMING +15° TIMING ADVANCE ADVANCE UNIT 3- Fig. 3 ------- r PCV VALVE HOSE SEALED OIL DIP STICK TYPE IV SYSTEM (CLOSED SYSTEM) FRESH AIR AIR INTAKE HOSE SEALED OIL FILLER CAP BLOW-BY GASES PCV. F1-. 1 ------- 3. PCV VALVE HOSE SEALED OIL DIP STICK TYPE IV SYSTEM (CLOSED SYSTEM) FRESH AIR HOSE SEALED OIL FILLER CAP BLOW-BY GASES PCV. Fig. 2 ------- PCV VALVE HOSE 00 SEALED OIL DIP STICK TYPE IV SYSTEM (CLOSED SYSTEM) FRESH AIR HOSE SEALED OIL FILLER CAP BLOW-BY GASES PCV. Fig. 3 ------- ENGINE OFF OR BACKFIRE VALVE BODY SPRING vo GROOVES PLUNGER OR VALVE (BACK POSITION) PCV. Fig. 4 ------- IDLING OR LOW SPEED SPRING PLUNGER OR VALVE VALVE BODY GROOVES (FORWARD POSITION) PCV. Fig. 5 ------- HIGHER SPEED (MIDDLE POSITION) SPRING PLUNGER OR VALVE VALVE BODY GROOVES J PCV. Fir. 6 ------- VALVE STUCK OPEN BODY- N> 0 MANIFOLD VACUUM PLUNGER J\/7 HOSE EXCESSIVE AIR FLOW AT IDLE PCV. Fig. 7 ------- VALVE STUCK CLOSED SLUDGE & OIL DEPOSITS GROOVES SPRING PLUNGER PCV. Fig. 8 ------- PCV OIL FILLER HOLE PCV. Fig. 9 ------- PCV INCLINED RAMP a BALL TESTER PLACE OVER OIL INLET PCV. Fin. 10 ------- CORRECT ADAPTER BE SURE TESTER IS VERTICAL ------- PCV VALUE CHECK PCV. Fig. 12 ------- THERMOSTATIC TYPE SPRING AIR FILTER 00 THERMOSTAT oo 00 00 00 00 00 00 oo oo TAC Fin. 1 ------- VACUUM MOTOR TYPE VACUUM MOTOR \o COLD AIR TO EXHAUST MANIFOLD SHROUD VACUUM HOSE TEMP SENSO JI HOT AIR AIR CLEANER TAG. Fig. 2 ------- DAMPER ASSEMBLY HOT AIR PIPE COLD AIR ENTERS ____ HEAT SHROUD EXHAUST MANIFOLD I . I AIR HEATED BY MANIFOLD TAG REDUCES HC B CO TAG. Fig. 3 ------- N> THERMOSTATIC TYPE DAMPER ASSEMBLY SPRING oo oo oo oo 00 00 oo oo nn THERMOSTAT HOT AIR PIPE TAG. Fig. 4 ------- VACUUM MOTOR VACUUM HOSE VACUUM MOTOR 10 N> TO EXHAUST MANIFOLD SHROUD TEMP SENSOtf Jl JL DAMPER ASSEMBLY TAG. Fig. 5 ------- ro HOT AIR MODE SPRING \ COLD AIR HEATED AIR AIR FILTER THERMOSTAT TO EXHAUST MANIFOLD SHROUD TAC. Fig. 6 ------- REGULATING MODE COLD AIR IV) HOT AIR TAG. Fig. 7 ------- COLD AIR MODE to TAG. Fig. 8 ------- INCOMING AIR BELOW SPECIFIED TEMPERATURE (APPROX. 100°) COLD AIR NJ ON t HOT AIR TAG. Fig. 9 ------- REGULATING MODE COLD AIR oo 00 oo oo r>r> HOT AIR TAG. Fig. 10 ------- COLD AIR MODE 10 00 TAG. Fig. ]1 ------- HEAT DOOR IN PARTIAL HEAT-OFF POSITION UNDER COLD ACCELERATION COLD AIR ro VACUUM MOTOR HOT AIR OVERRIDE TO MANIFOLD VACUUM TAG. Fig. 12 ------- VACUUM MOTOR TYPE AIR CLEANER DIAPHRAGM SPRING VACUUM MOTOR DIAPHRAGM \ DAMPER ASSEMBLY TO EXHAUST MANIFOLD SHROUD o TEMPERATURE SENSOR \ \ TO MANIFOLD V TAG. Fig. 13 ------- AIR BLEED VALVE CLOSED TEMPERATURE SENSING SPRING FULL VACUUM SIGNAL TO VACUUM MOTOR TO MANIFOLD VACUUM TAG. Fig. 14 ------- HOT AIR DELIVERY MODE DIAPHRAGM SPRING VACUUM MOTOR DIAPHRAGM \ CO ro TEMPERATURE SENSOR TAG. Fig. 15 ------- AIR BLEED OPEN TEMPERATURE SENSOR SPRING LOW OR NO VACUUM SIGNAL TO VACUUM MOTOR TO MANIFOLD VACUUM TAG. Fig. 16 ------- REGULATING MODE DIAPHRAGM SPRING VACUUM MOTOR Dl APH RAGM\ COLD AIR HEATEQ AIR \ o o AIR FILTER TEMPERATURE SENSOR TAG. Fig. 17 ------- CO (Jl AIR BLEED OPEN TEMPERATURE SENSOR SPRING LOW OR NO VACUUM SIGNAL TO VACUUM MOTOR TO MANIFOLD VACUUM TAG. Fig. ------- COLD AIR DELIVERY MODE DIAPHRAGM SPRING VACUUM MOTOR DIAPHRAGM \ HEATED AIR oo oo oo oo oo o oo FILTER TEMPERATURE SENSOR BLEEDING AIR 3"-8"Hg TAG. Fig. 19 ------- LOW VACUUM CONDITION VACUUM MOTOR DIAPHRAGM to DIAPHRAGM SPRING oo COLD AIR HEATED AIR 2"- AIR FILTER TEMPERATURE SENSOR TAG. Fin. 20 ------- HOT AIR DELIVERY MODE DIAPHRAGM SPRING VACUUM MOTOR DIAPH RAGM \ CO 00 TEMPERATURE SENSOR VACUUM DELAY VALVE HEATED AIR TAG. Fig. 21 ------- CO VO TO MANIFOLD VACUUM OPENING TO EXHAUST HEAT SHROUD HOT IDLE COMPENSATOR TEMPERATURE SENSOR TAG. Fig. 22 ------- THERMOSTATIC AIR CLEANER oo oo oo oo oo oo oo oo oo TAC. Fiy. 23 ------- VACUUM MOTOR AIR CLEANER VACUUM MOTOR TEMPERATURE SENSOR DAMPER ASSEMBLY TO MANIFOLD TAG. Fiy. 24 ------- PUMP DIVERTER VALVE MANIFOLD VACUUM SIGNAL LINE CHECK VALVE MANIFOLD AI.'I. Fin. 1 ------- AIR. Fig. 2 ------- r AIR. Fig. 3 ------- C/i VENT HIGH INTAKE MANIFOLD VACUUM SIGNAL AIR FLOW SEATED AIR. Fig. 4 ------- 5PSI VENT 5PSI AIR FLOW AIR. Fig. 5 ------- ^ =D INTAKE I MANIFOLD 10 VACUUM AIR SWITCHING VALVE AIR. Fig. 6 ------- 00 CHECK VALVE AIR. Fig. 7 ------- \0 AIR. Fig. 8 ------- Oi o DISTRIBUTION MANIFOLD CHECK VALVE AIR PUMP SIGNAL LINE TO INTAKE MANIFOLD^ GULP VALVE AIR DISCHARGE TO INTAKE MANIFOLD J AIR. Fig. 9 ------- AIR. Fig. 10 ------- AIR INLET FILTER Oi N> AIR. Fig. 11 ------- MANIFOLD VACUUM SIGNAL LINE PUMP 01 VISUALLY INSPECT ALL HOSES AIR. Fig. 12 ------- AIR. Fig. 13 ------- AIR. Fig. 14 ------- CAUTION: CHECK VALVE AND EXHAUST GASES ARE HOT! AIR. Fig. 75 ------- f nrrn UUIJ AIR. Fig. 16 ------- Ui 00 AIR TO INTAKE MANIFOLD AIR FROM PUMP AIR. Fir. 17 ------- VAPOR SAVER SYSTEM PURGE LINE VENT LINE FUEL TANK VENT LINE PRESSURE VACUUM SAFETY FILLER CAP Ui VO CHARCOAL CANISTER OVERFILL LIMITING VALVE LIQUID VAPOR SEPARATOR FEC. Fig. 1 ------- AIR SPACE PROVIDED FOR FUEL EXPANSION 10-12% OF TANK VOLUME FILLER NECK FUEL TANK FUEL FEC. Fin. 2 ------- PRESSURE-VACUUM RELIEF CAP TANK PRESSURE 1/2 - I PSI SEALING GASKET OUTER SHELL PRESSURE SPRING PRESSURE RELIEF LOCKING LIP VALVE (OPEN) VACUUM RELIEF u vu ' VALVE (CLOSED) VACUUM SPRING FEC. Fig. 3 ------- CAP RELIEVING TANK VACUUM VACUUM 1/4"-1/2" HG SEALING GASKET PRESSURE SPRING OUTER SHELL ro PRESSURE RELIEF VALVE (CLOSED) LOCKING LIP VACUUM RELIEF VALVE (OPEN) VACUUM SPRING FPC. PTQ. 4 ------- HORIZONTAL MOUNTED LIQUID VAPOR SEPARATOR 1 TO CHARCOAL CANISTER MOUNTING HOLE ON GJ LIQUID RETURN VAPOR VENT fc_ll^h» k^ ^^^•••r «M^ ^ • ^^ • » • ^ LINES ^^ FEC. Fig. 5 ------- BUILT-IN SEPARATOR RESTRICTOR ORIFICE VAPORS OUT FUEL VAPOR FUEL TANK FEC. Fig. 6 ------- Ol CHARCOAL CANISTER HOSE TO CARBURETOR OR AIR CLEANER CHARCOAL GRANULES HOSE TO FUEL TANK VENT CANISTER CASE ^FIBERGLAS FILTER OUTSIDE AIR FEC. Fig. 7 ------- r t i 11 AIR CLEANER TANK CARBON CANISTER FEC. Fig. 8 ------- CARBURETOR BOWL VENT DEMAND PURGE SYSTEM PORTED VACUUM FROM FUEL TANK RESTRICTED ORIFICE FEC. Fig. 9 ------- CO 1 CARBURETOR BOWL VENT PORTED VACUUM \ RESTRICTED ORIFICES PURGE VALVE PCV HOSE CONSTANT a DEMAND PURGE SYSTEM FROM FUEL TANK FEC. Fig. 70 ------- CARBURETOR TO CANISTER ON \O TO CARB. LIN CAPPED KAGE VENT VAPOR FUEL X o \ THROTTLE CLOSED FEC. Fig. 11 ------- TO CANISTER TO CARBURETOR LINKAGE CLOSED ANTI PERC VALVE CARBURETOR BOWL THROTTLE OPEN FEC. Fig. 12 ------- BOTTOM OF CANISTER FIBERGLAS FILTER FEC. Fig. 13 ------- N9 CARBURETOR AIR a FUEL TO VACUUM SOURCE EGR VALVE I FROM EXH. SYSTEM "-TO INTAKE MANIFOLD EGR. Fig. 1 ------- COOLANT TEMPERATURE OVERRIDE SWITCH E6R. Fig. 2 ------- EXHAUST BACK-PRESSURE SENSOR (TRANSDUCER) EGi?. Fig. .3 ------- C TO INTAKE MANIFOLD^> TO FGR VALVE C >ROM VENTURI VACUUM SIGNAL^> VACUUM AMPLIFIER EGR. Fig. 4 ------- PORTED VACUUM SYSTEM LOW COOLANT TEMPERATURE CARBURETOR E6R CTO SWITCH EGR VALVE VACUUM HOSES EGR. Fig. 5 ------- PORTED VACUUM SYSTEM COOLANT AT NORMAL OPERATING TEMPERATURE CARBURETOR EGR CTO SWITCH EGR VALVE VACUUM HOSES EGR. Fig. 6 ------- VENTURI VACUUM EGR SYSTEM CTO SWITCH VI 00 VACUUM / AMPLIFIER CARBURETOR VENTURI VACUUM LINE 00 o If INTAKE MANIFOLD VACUUM LINE EGR VALVE EGR. Fig. 7 ------- VO VENTURI VACUUM EGR SYSTEM CTO SWITCH CARBURETOR VENTURI VACUUM LINE\ VACUUM AMPLIFIER f » » »-^ If XINTAKE MANIFOLD VACUUM LINE EGR VALVE EGR. Fig. 8 ------- r ENGINE IDLING BACK PRESSURE SENSOR FILTER 00 o AIR DRAWN IN PORT OPEN CTO SWITCH EXHAUST GAS EXHAUST BACK PRESSURE SENSING TUB PORTED VACUUM I. EXHAUST BACK PRESSURE 2. SENSOR AIR BLEED OPEN (AIR DRAWN REDUCES VACUUM) 3. NO PORTED VACUUM SIGNAL 4.E6R VALVE CLOSED EGR. Fig. 9 ------- 00 ACCELERATION CLOSED AIR BLEED PORT EXHAUST GAS TO INTAKE MANIFOLD I. EXHAUST BACK PRESSURE HIGH 2. SENSOR AIR BLEED CLOSED 3. HIGH PORTED VACUUM SIGNAL 4. EGR VALVE OPEN EGR. F1g. 10 ------- FULL THROTTLE OPERATION 00 I. EXHAUST BACK PRESSURE HIGH 2. SENSOR AIR BLEED CLOSED 3. LOW PORTED VACUUM SIGNAL 4. EGR VALVE CLOSED ------- 00 E6R VALVE NOT PROPERLY CLOSED EGR. Fig. 12 ------- 00 EGR. Fig. 13 ------- 00 EGR VALVE EGR. Fig. 14 ------- PORTED VACUUM SYSTEM LOW COOLANT TEMPERATURE CARBURETOR EGR CTO SWITCH 00 EGR VALVE VACUUM HOSES EGR. Fig. 15 ------- VENTURI VACUUM EGR SYSTEM CTO SWITCH 00 -J CARBURETOR VACUUM/ AMPLIFIER VENTURI VACUUM INTAKE MANIFOLD VACUUM LINE EGR VALVE EGR. Fig. 16 ------- PORTED VACUUM SYSTEM COOLANT AT NORMAL OPERATING TEMPERATURE CARBURETOR 00 00 EGR VALVE VACUUM HOSES EGR. Fig. 77 ------- VENTURI VACUUM EGR SYSTEM CTO SWITCH 00 SO CARBURETOR VACUUM/ AMPLIFIER VENTURI VACUUM INTAKE MANIFOLD VACUUM LINE EGR VALVE J EGR. fig. 18 ------- ENGINE IDLING BACK PRESSURE SENSOR AIR DRAWN IN BLEED PORT OPEN CTO SWITCH EXHAUST GAS EXHAUST BACK PRESSURE SENSING TUB PORTED VACUUM I. EXHAUST BACK PRESSURE LO 2. SENSOR AIR BLEED OPEN (AIR DRAWN REDUCES VACUUM) 3. NO PORTED VACUUM SIGNAL 4. EGR VALVE CLOSED EGR. Fig. 19 ------- vo LARGER THROTTLE OPENING HOTTER EXHAUST TEMPERATURE SC. Fig. 1 ------- vo CARBURETOR TRANSMISSION SWITCH SOLENOID VACUUM SWITCH DISTRIBUTOR VACUUM ADVANCE UNIT IGNITION SC. Fiy. 2 ------- \o CARBURETOR TRANSMISSION SWITCH SOLENOID VACUUM SWITCH DISTRIBUTOR VACUUM ADVANCE UNIT IGNITION SC. Fig. 3 ------- VO •p- CARBURETOR TRANSMISSION SWITCH SOLENOID VACUUM SWITCH DISTRIBUTOR VACUUM ADVANCE UNIT IGNITION SC. Fig. 4 ------- VO Ui MANIFOLD VACUUM PORTED VACUUM 0°-I60°F TO IGNITION SWITCH OPEN OVER 35MPH OR HIGH GEARS SC. Fig. 5 ------- VO MANIFOLD VACUUM PORTED VACUUM ABOVE I60°F TO IGNITION SWITCH OPEN OVER 35MPH OR HIGH GEARS SC. Fig. 6 ------- BELOW 225°F-ABOVE I60°F vo MANIFOLD VACUUM HOT OVERRIDE PORTED VACUUM CTO PORTED VACUUM SC. Fig. 7 ------- ABOVE 225°F \£> 00 HOT OVERRIDE MANIFOLD VACUUM PORTED VACUUM CTO MANIFOLD VACUUM SC. Fig. 8 ------- TO DISTRIBUTOR PORTED VACUUM \o vD ti _A OSAC VALVE SC. Fiq. 9 ------- TO DISTRIBUTOR PORTED VACUUM 8 OSAC VALVE J SC. Fiq. 10 ------- r MANIFOLD VACUUM PORTED VACUUM TO IGNITION SWITCH SC. Fig. 11 ------- o to 0 VACUUM -3 2ND GEAR 1ST GEAR PORTED VACUUM 3RD GEAR SC. Fig. 12 ------- s SC. Fig. 13 ------- TESTING SPARK DELAY VALVE SC. Fig. 14 ------- TESTING SPARK DELAY VALVE g C SC. Fin. 15 ------- SC. Fig. 16 ------- SECONDARY COMBUSTION OR BURNING OCCURS IN THE CATALYTIC CONVERTER 1200° F TO MUFFLER CAT. Fiq. 1 ------- MONOLITH CONVERTER FLOW DIFFUSER EXHAUST GASES HONEYCOMB MONOLITH STAINLESS STEEL SHELL STAINLESS STEEL MESH J CAT. Fig. 2 ------- EXHAUST GAS FLOW-THRU PELLET-STYLE CATALYTIC CONVERTER EXHAUST GASES INSULATION \ INSULATION ALUMINUM OXIDE PELLETS COATED WITH PLATINUM AND PALLADIUM CAT. Fig. 3 ------- ADDITIONAL AIR IS SUPPLIED TO THE CATALYTIC CONVERTER BY- AIR INJECTION SYSTEMS LEAN AIR-FUEL RATIOS , CAT. Fig. 4 ------- EXCESSIVELY RICH MIXTURES CAN LEAD TO A DESTROYED CATALYTIC CONVERTER CAT. Fig. 5 ------- THERMACTOR WITH TVS SWITCH AND VACUUM DELAY VALVE EGR VALVE AIR CLEANER^ TVS SWITCH BELOW 60° F VACUUM DELAY VALVE PUMP BYPASS VALVE CHECK V VALVE TO SPARK PORT COLD ENGINE OPERATION CAT. Fig. 6 ------- THERMACTOR WITH TVS SWITCH AND VACUUM DELAY VALVE EGR VALVE AIR CLEANER^ TVS SWITCH ABOVE 60° F VACUUM DELAY VAL\ BYPASS VALVE CHECK VALVE AIR PUMP TO SPARK PORT WARM ENGINE OPERATION CAT. Fig. 7 ------- fTHERMACTOR WITH TVS SWITCH AND VACUUM DELAY VALVE E6R VALVE AIR CLEANER WITCH VACUUM DELAY VAL\ BYPASS VALVE NO VACUUM SIGNAL AIR \ PUMP CHECK VALVE OPERATION DURING EXTENDED IDLE OR EXTENDED DECELERATION CAT. Fig. 8 ------- HEAT SHIELDS INTERIOR INSULATING PADS HEAT SHIELDS CATALYTIC CONVERTER LOWER SHIELD CAT. Fig. 9 ------- LEADED FUEL DESTROYS CATALYST EFFECTIVENESS LEAD COATS THE CATALYST MAKING IT INEFFECTIVE CAT. Fig. 10 ------- TECHNICAL REPORT DATA (Please read Instructions on the reverse before completing) 1\ REPORT NO. 2. EPA-450/3-77-034 4. TITLE AND SUBTITLE Transparency Masters for use with Instructor's Guide for Vehicle Emission Control 7. AUTHOR(S) B.D. Hayes R?A. Ragazzi M.T. Manes s 9. PERFORMING ORGANIZATION NAME AND ADDRESS Department of Industrial Sciences Colorado University Fort Collins, Colorado 80523 12. SPONSORING AGENCY NAME AND ADDRESS Control Programs Development Division Office of Air Quality Planning and Standards Office of Air and Waste Management U.S. Environmental Protection Aeencv 15. SUPPLEMENTARY NOTES Research Triangle Park, N.C. 27711 3. RECIPIENT'S ACCESSION-NO. 5. REPORT DATE November ^77 6. PERFORMING ORGANIZATION CODE 8. PERFORMING ORGANIZATION REPORT NO. 10. PROGRAM ELEMENT NO. 11. CONTRACT/GRANT NO. T900621-01-0 13. TYPE OF REPORT AND PERIOD COVERED Final Rarjort 14.~S~P5Rs6R~rNG~A~GENCY CODE EPA 200/04 16. ABSTRACT 17. KEY WORDS AND DOCUMENT ANALYSIS a. DESCRIPTORS 18. DISTRIBUTION STATEMENT Release Unlimited fePA Form 2220-1 (9-73) „ - r,OVrRN,MFMT PRTNTINir. r»BPI b.lDENTIFIERS/OPEN ENDED TERMS 19. SECURITY CLASS (This Report) Unclassified 20. SECURITY CLASS (This page) Unclassified rp.i q?R .7U1?- ??u, c. COSATI Field/Group 21. NO. OF PAGES 118 22. PRICE ------- |