EPA-460/3-75-003-a
April 1975
FTP/SHORT CYCLE
CORRELATION TESTING
FOR 207 (b) IMPLEMENTATION -
CATALYST EQUIPPED VEHICLES
VOLUME 1
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
Ann Arbor, Michigan 48105
-------
EPA-460/3-75-003-a
FTP/SHORT CYCLE
CORRELATION TESTING
FOR 207 (b) IMPLEMENTATION
CATALYST EQUIPPED VEHICLES
VOLUME 1
Prepared by
J. A. Gunderson
Olson Laboratories, Inc.
421 East Cerritos Avenue
Anaheim, California 92805
Contract No. 68-03-0452
EPA Project Officer:
F. Peter Hutchins
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
Ann Arbor, Michigan 48105
April 1975
-------
This report is issued by the Environmental Protection Agency to report
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 - as supplies permit - from
the Air Pollution Technical Information Center, 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
Olson Laboratories, Inc. , Anaheim, California 92805, in fulfillment of Contract No.
68-03-0452. The contents of this report are reproduced herein as
received from Olson Laboratories, 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.
Publication No. EPA-460/3-75-003~a
11
-------
TABLE OF CONTENTS
Section Page
1 INTRODUCTION AND SUMMARY 1-1
2 TEST PROCEDURE 2-1
2-1 General 2-1
2-2 Fuel 2-1
2-3 Testing Sequence 2-2
2.3.1 Short Test Sequence 2-6
2.3.2 Soak - 6 Minutes 2-7
2.4 Test Descriptions 2-8
2.4.1 Federal Test Procedure 2-8
2.4.2 Clayton Key Mode 2-8
2.4.3 Federal Three Mode 2-9
2.4.4 High-Speed Unloaded Test '2-9
2.4.5 Federal Short-Cycle 2-10
2.4.6 Composite of N.J. ACID Test and
N.Y. Short Test 2-10
2.4.7 Defect Tests 2-11
2.5 Procedural Precautions 2-12
2.5.1 Dynamometer Warm-Up 2-12
2.5.2 Pedal Operation 2-12
2.5.3 Invalid Tests 2-12
3 TEST EQUIPMENT 3-1
3.1 Major Equipment 3-1
3.2 Calibration 3-14
4 DATA PREPARATION 4-1
4.1 Test Data 4-1
4.2 Reports 4-3
4.3 Vehicle Use and Maintenance History . . 4-3
4.3.1 Vehicle Use 4-4
4.3.2 Vehicle Maintenance 4-5
4.3.3 Component Retrofit 4-11
4.3.4 Additives and Misfuels 4-11
I i
-------
FIGURES
Figure
Page
1-la
1-lb
2-1
2-2
2-3
3-1
3-2
3-3
3-4
Test Sequence
Test Sequence-Short
As-Received Inspection Form .
Emissions Recording Form 1 .
Emissions Recording Form 2 .
Analyzer Curve Generation Date
Propane Injection Test
Mass Start-Up Check Sheet
7-Mode Start-Up Check Sheet .
1-6
2-3
2-4
2-5
3-6
3-7
3-8
3-9
Table
TABLES
2-1
4-1
4-2
4-3
Defect Test Results
Required Service Intervals
Scheduled Maintenance Actions
Misfuels and Additives
2-13
4-6
4-9
4-12
i i i
-------
APPENDIXES (Volume II)
A Emission Test Results
B Test Fuel Analysis
C Analyzer Calibration Curves
D CVS Calibration Curve
E Dynamometer Calibration Curves
F Ford Catalyst Test Vehicle Maintenance History
IV
-------
Section 1
INTRODUCTION AND SUMMARY
The objective of the work performed under this
contract was to provide test data leading to the identi-
fication of which of five existing short-cycle emissions
tests is most capable of being "correlated" with the Federal
Test Procedure (FTP) as used for the certification of 1975
model year and later light-duty vehicles. The FTP is des-
cribed in detail in the Federal Register, Volume 37, Num-
ber 221, Section 85.075-9 through Section 85.075-26. The
five short-cycle emission tests are:
1. Clayton Key Mode - Volumetric Procedure
2. Federal Three-Mode - Volumetric Procedure
3. Unloaded Test, High Speed (2,500 rpm) and
Idle (Derived from 1 and 2) - Volumetric
Procedure
4. Federal Short Cycle (9-Mode) - CVS Procedure
5. Composite N.J. ACID/N.Y. Short Test - CVS
Procedure
All testing was performed at the Olson Laboratories'
facility, Anaheim, California.
1-1
-------
Fifty-eight catalyst equipped experimental vehi-
cles owned by the Ford Motor Company and located at Pico
Rivera, California, were tested in the program through
December. In January and February, ten additional test
series were performed. Five of these vehicles, owned by
the State of California, are former Ford Motor Company
experimental vehicles in the same configuration as all others
in this test program. The other five test series were per-
formed on two previously untested vehicles in the first
fleet of fifty and on three vehicles that had been previ-
ously tested, but whose tests were invalid. All of the
vehicles were loaned to EPA and Olson for the duration of
testing.
The Ford Motor Company representative who supported
this test program is:
M. G. "Pete" Noll
Catalyst Task Force Leader
8900 East Washington Boulevard
Pico Rivera, California 90666
(213) 949-3470 or (800) 352-8979
Alternate
John Sundstrom
Engine Division, Engineer
Same address and telephone number
The Catalyst Task Force was transferred to Dearborn,
Michigan in December 1974.
All vehicles tested met the EPA definition of a
light-duty vehicle and were standard size (Class IV). Each
vehicle was identified by an eight-character code using
four characters for Ford's ID code, a 4 for Class IV, a 1
for Group I and a two-digit car number from 01 to 70. All
vehicles were Ford Galaxie, Four-door sedans, equipped as
follows:
1-2
-------
400 cubic inch displacement V-8
2-venturii carburetor
Exhaust control system types
Air injection
Catalytic reactor
Exhaust gas recirculation
Canister-type evaporative system
Automatic transmission (C-6)
3.0-to-l rear axle ratio
HR78 x 15 radial ply tires
Air conditioning
Power steering
Power brakes
Forty-eight vehicles were tested in the initially
scheduled group of tests ending 30 October 1974. Due to
undetected instrumentation problems, many of these tests
were found to be invalid. The problem was not identified
until after these tests were completed. Ten additional
vehicles were tested (after correcting the instrument prob-
lems) from 11 December to 16 December 1974, with ten more
test series completed on seven untested and three previously
tested vehicles from 22 January to 19 February 1975.
A computer listing of the accepted test data is
given, in Olson identification number order (4101 to 4170),
in Appendix A. Two vehicles, T2544141 and T1754149, were
not tested in the first test group due to time constraints.
They were tested with the January group.
These two vehicles, along with three other vehicles,
are being held at Olson-Anaheim for additional testing under
Task Order 05. The vehicles being retained are:
1-3
-------
Initial
Olson ID
4141
4142
4144
4149
4150
New
Olson ID
4169
4165
4170
4162
4164
Task Order 02
Final Mileage
11,432
9,975
25,117
9,120
23,307
Ford ID
T254
T236
T161
T175
T210
An initial group of six vehicles was acquired from
Ford. As each vehicle test was completed, it was exchanged
at the Ford Pico Rivera plant on a one-for one basis.
The vehicles were tested using Indolene Clear
fuel. The as-received tank fuel was drained completely and
the tank was then filled to approximately 80 percent of
tank volume with the test fuel. Each vehicle was run for
approximately 10 minutes to replace the fuel in the fuel
lines and carburetor.
As-received engine parameters were measured and
recorded. The first 48 vehicles were pre-conditioned by
running through the short test sequence defined in section
2.3. The remaining vehicles were pre-conditioned using
the LA-4 driving cycle. This was followed by an FTP Cold
Soak prior to the FTP emissions test. The sequence of
events for each vehicle is shown in Figure 1-1. After com-
pletion of both 1975 FTP tests on a given vehicle, the
results were compared to ensure that the deviation from
the mean for HC, CO, or NO was less than 15 percent for
X
any one pollutant. If it was greater than 15 percent, the
Project Officer was queried about a retest before returning
the vehicle to Ford.
An additional FTP and Short Sequence test was
authorized on the following vehicles:
Ford ID Olson ID
T243 4103
T048 4104
T173 4113
1-4
-------
ACQUIRE
VEHICLE AT
PICO RIVERA
DRIVE TO
OLSON'S ANAHEIM
TEST FACILITY
DRAIN FUEL
TANK
FILL TANK TO
80% ( TO EVEN
GALLON) WITH
INDOLENE-CLEAR
RUN CAR
10 MINUTES
TO PURGE
FUEL SYSTEM
PERFORM
ENGINE
PARAMETER
CHECK
PERFORM SHORT
TEST SEQUENCE
(SEE FIG Ib) OR
LA-Jf TEST FOR
VEHICLES 51-60
COLD SOAK
>12 HOURS
<2k HOURS
PERFORM
'75 CVS FTP
PERFORM
SHORT TEST
SEQUENCE
COLD SOAK
>12 HOURS
<36 HOURS
PERFORM
'75 CVS FTP
PERFORM
SHORT TEST
SEQUENCE
CHECK DEV
OF TWO FTP
TEST RESULTS
POLLUTANT
*/
NO
RETURN
VEHICLE TO
PICO RIVERA
Figure 1-la. TEST SEQUENCE
NO
PERFORM
'75 CVS FTP
RETEST
REQUESTED
COLD SOAK
<36 HOURS
FROM LAST
SHORT TEST
SEQUENCE
-------
6-MINUTE SOAK
3-MINUTE SOAK,
HOOD CLOSED,
FAN ON
3-MINUTE SOAK,
ENGINE IDLING,
FAN OFF
J
KEY MODE TEST
(IDLE IN DRIVE)
- VOLUMETRIC
2500 RPM
T£ CT
VOLUMETRIC
6-MINUTE
SOAK
FEDERAL
SHORT CYCLE
- CVS
6-MINUTE
SOAK
FEDERAL 3-MODE
(IDLE IN
NEUTRAL)
- VOLUMETRIC
6-MINUTE
SOAK
N.J./N.Y.
COMPOSITE
TEST - CVS
PERFORM
DEFECT
TEST
NOTIFY
PROJECT
OFFICER
SEQUENCE
COMPLETE
Figure 1-lb. TEST SEQUENCE - SHORT
-------
A number of vehicles were subsequently found to
deviate from their mean FTP values by more than 15 percent
The EPA Project Officer was notified in each case, but a
third FTP was not authorized in any of these cases. These
vehicles are:
Ford ID
Olson ID
T026
T164
T257
4118
4122
4129
Ford ID
T065
T099
Olson ID
4134
4139
All other data were visually scanned for com-
pleteness prior to returning the vehicle.
All data were recorded on forms from which key-
punched cards were produced. These cards were input to a
computer program that checked for completeness and correct-
ness of sequence. The program then converted volumetric
data to mass units, as required. The program produced a
printed report for EPA and punched a set of cards to an
EPA authorized format. A printed report of all test re-
sults was prepared from this program and is included in
Appendix A (Volume II).
1-7
-------
Section 2
TEST PROCEDURE
2 .1 GENERAL
Many of the vehicles used in this program had been
in storage for some time. Prior to the loan of these vehicles
for testing, the Ford Motor Company prepared each one in the
following manner. Vehicles that had not been operated recently
were driven approximately 100 miles and then given a complete
engine diagnosis. Timing and idle speed were set to specifi-
cation, and the air pump belt tension and catalyst over-
temperature sensing systems were checked. Corrections were
made where necessary.
Upon receipt at Olson, each vehicle was given a
distinct identification number which permits identification
as to class, group and number within the group. The first
four characters use Ford's identifying number, while the
last four digits are Olson's identifying number. The test
results identify the source vehicle and the number of the
test on that vehicle.
2.2 FUEL
All vehicles were tested with Indolene Clear fuel,
inspected in accordance with 37 Federal Register 221,
2-1
-------
Section 85.073-10 and SAE Technical Report J171, para-
graph 2.1. Each batch of fuel used in the program was
analyzed as reported in Appendix B.
2.3 TESTING SEQUENCE
The following procedure applies to all vehicles
tested under this program, unless otherwise noted (also see
Figure 1-la). The as-received fuel was drained from the
vehicle tank following vehicle receipt. The gas tank was
then filled to approximately 80 percent capacity (to the
nearest gallon) with the test fuel. The vehicle was then
operated either on the street or on a dynamometer for
approximately ten (10) minutes to both purge the fuel system
of as-received fuel and to prepare the vehicle for the as-
received, state-of-tune inspection. Upon completion of the
10 minute operating period, the vehicle was inspected to
determine its as-received state-of-tune. The results of
this inspection were then recorded on the form shown in
Figure 2-1. Following the vehicle engine parameter inspec-
tion, a vehicle preconditioning was performed consisting of
one short test sequence (emissions being recorded on the
forms shown in Figures 2-2 and 2-3). The preconditioning
for the vehicles tested in December,, January and February
consisted of one LA-4 driving cycle with no collection of
emissions data. The vehicles were then cold-soaked in
preparation for emissions testing in accordance with the
Federal Test Procedure (vehicle fueling and fuel heating
excluded).
The FTP was then run after at least a 12-hour
soak but less than 24 hours. Following the FTP emissions
test, the vehicle was tested in accordance with the short
test sequence. This short test sequence constituted the
2-2
-------
Laboratories, InC. Testing Services Division
11
CARD
33
MO
i i i i
13 15
LJ L
DAY YR
18
22
MFC
46
25
YR
48
MAKE/MODEL
56 57
U L_^_
CYL CID
SERIAL NUMBER
i 60 . 62
t\J 1 U£
U I.I.
BBL
EXHAUST CONTROLS
ST LICENSE NUMBER
LJ L
71 73
U
EVP
i i 1
VEHICLE NO.
DC
HI
O
in
o
o
z
Hi
3
LU
0
Wamp AHHress
Citv State Zip
Phone Comment":
Date Time Srhpriiiled By
Directions:
26
30
35
1 11 13 15 18 20 22 24
l5l LJ LJ LJ U U U U I .. I I .... I I I
MO DAY YR
45 52
I I I i i i I
A/C P/S P/B TR
57 62
TR TYPE
66
AXLE
73
TIRE SIZE
ODOMETER
i i I
DWELL
i i » i
TIMING
I . . I I .... I I ... I ... i
RPM
C0,%
VEHICLE NO.
PERFORMANCE SCHEDULE
Ready for Inspection I I
Accept I 1
Pre-lnspection Complete Rejert | [
Mechanic
1st Test Complete J I
Run No
Cold Snak Tims In Time n..t
2nd Test Complete \~~]
Run No
Cold Snalf TiT'-t" TimaOut
3rd Test Complete * | |
Run No - - [ [
Car Returned HZl
VEHICLE INSPECTION
OK Bid COMMENTS
1] nj| i PUP! | II I
7] Radiator Level I II I
3] Condition of Hoses I II I
4] Transmission Level I 1 1 I
Rl PrV Valve I 1 1 I
fi] Ignition Wires I II I
71 Belts 1 II 1
R] Tirps 1 |l 1
Q] Fyhaust System 1 II 1
10] Rrakes I 1 1 I
11] Air Cleaner I II I
19] nthpr I II I
\
DATE/TIME
- J
Figure 2-1
2-3
-------
OlSOn Laboratories, InC. Testing Services Division
U
11 13
15
I I I I
18
21
24
30
35
40
I
I
CARD R/T
RUN NO.
MO DAY
YR
WB
DB
45
P.I.C..
T.D.
BARO
I I I I
INERTIA
73
IHP
AHP
I I I
ODOMETER
VEHICLE NO.
tel U
CARD R/T
11
i i i l i
17
43
46
TEMP
RUN NO.
I I I I
V/REV
52
i i j l
P IN
I I I I
REV
22
23
33
HC. PPM
I
58
J I
HC. PPM
CO, PPM CO2, %
SAMPLE
62 66
I . . I I
NOX. PPM
71 73
CO. PPM CO2. %
BACKGROUND
I I I
I I 1
NOX, PPM
VEHICLE NO.
lEl U
11
17
22
28
33
i i i l
l
w
CARD R/T RUN NO.
43 46
52
l i
I i I
TEMP
V/REV
P IN
I I I I
REV
HC. PPM
I I I
58
CO'PPM SAMPLE C°2'*
62 66
NOX, PPM
71 73
I
HC. PPM
J I
J I
CO. PPM CO2,
BACKG ROUND
I
NO,, PPM
VEHICLE NO.
U
11
17
22
28
33
CARD R/T RUN NO.
43 46
52
l i
I I l
TEMP
V/REV
P IN
I I I I
REV
HC, PPM
i I
CO, PPM
58
62
SAMPLE
66
... . I I
CO2. %
NOX, PPM
71 73
J I
HC, PPM
CO, PPM C02. %
BACKGROUND
I
NOX, PPM
VEHICLE NO.
i
J
I I
11 14
HI
19
j l
I *
25
CARD R/T RUN NO.
30 33 38
44
LO
MPH HC, PPM
CO, %
NO, PPM
MPH HC, PPM CO, %
49 52 57
IDLE I . I I i i i I Li
MPH HC, PPM CO, %
NO, PPM
63 73
NO, PPM
J L__J_
VEHICLE NO.
-------
OlSOn Laboratories, InC. Testing Services Division
K§
If
"z
1 '2
y u
11
i
17
22
28
CARD R/T RUN NO.
43 46
I I I I
52
TEMP
P IN
I 1 I
HC. PPM
I I
33
I I
i
58
CO'PPM SAMPLE C°2'*
62
66
NOX. PPM
71 73
J I
V/REV
REV
HC. PPM
I » I I
CO, PPM C02. %
BACKGROUND
I I i
NOK, PPM
VEHICLE NO.
1
11
16
21
27
'
(0
ui
O
W
M U
CARD R/T
48
32
37
I I l
RUN NO.
I 1 I
RPM
43
i I i
HC, PPM C0,%
BEFORE CATALYST
NO, PPM
i i i
HC. PPM
AT TAIL PIPE
73
I I I I I I I I I I I I I I I I I I I I I I I I
COMMENTS
l 1*1 i
CO,%
i i i
i
NO. PPM
VEHICLE NO
-------
vehicle preconditioning for the second FTP emissions test on
the vehicle. Following the completion of the second FTP on
the vehicle, another short test sequence was performed.
Before returning the completed vehicle to Ford,
the two FTP emissions tests were checked to ensure that the
results were repeated to within. 15 percent of the mean for
each pollutant. If this criterion was not met, the EPA
Project Officer was notified, at which time he had the
option to verbally request that one additional FTP emissions
test be performed. In no case was the cold soak following
the second or third short test sequence to be allowed to
exceed 36 hours before performing the subsequent FTP. This
required a preconditioning rerun of the short test sequence
(without data recording) in some cases.
One vehicle (T0264118) was returned to Ford; and
it was subsequently found that the soak periods between major
test sequences had exceeded the maximum of 24 hours prior
to the first FTP and 36 hours prior to the second FTP. The
vehicle was returned to Olson for a complete retest. The
test results of this second group of tests were reported.
2.3.1 Short Test Sequence
The short test sequence consists of the following
tests and soak periods in the order shown (also see Figure
Ib) :
1) Soak - 6 minutes
2) Clayton Key Mode (Idle in drive)
3) Soak - 6 minutes
4) Federal Three-Mode (Idle in neutral)
5) High-Speed Unloaded Test (2500 rpm)
2-6
-------
6) Soak - 6 minutes
7) Federal Short-Cycle
8) Soak - 6 minutes
9) New Jersey/New York Composite Cycle
10) Defect Test for specific vehicles during
final short test sequence
Mass analysis of the exhaust samples taken during
the Federal Short-Cycle and NJ/NY Composite Cycle was found
to be difficult due to the small sample volume obtained.
In many cases, the volume was depleted before analyzer
stabilization could be obtained. To solve this problem,
two tests were run, one-after-another, for each of the
two cycles for the last 20 vehicles tested, with the result
that twice the volume was collected over twice the cycle
driving distance. These factors-of-two cancel in the mass
calculation. The doubled volume was found to be sufficient
to ensure instrument stabilization.
2.3.2 Soak - 6 Minutes
The 6 minute soak procedure is performed as
follows. After the completion of the preceding test, the
vehicle engine is stopped, the vehicle hood is closed if
it was open, and the auxiliary air cooling fan is turned on
if it was not previously in use. The fan remains in opera-
tion for three (3) minutes. At the end of 3 minutes, the
auxiliary air fan is turned off and the vehicle's engine
is started. The engine is allowed to idle in neutral for
three (3) minutes. Upon the completion of this 3-minute
idle period, the next test in the sequence is initiated.
2-7
-------
2.4
TEST DESCRIPTIONS
2.4.1
Federal Test Procedure
The Federal Test Procedure is performed as des-
cribed in Federal Register, Volume 37, Number 221, Section
85.075-9 through 85.075-26 (evaporative emissions testing
is excluded). Vehicle preconditioning for vehicles 4101
to 4150 consisted of one short test sequence as described
in 2.3.1, or, for vehicles- 4151 to 4170, an initial LA-4
driving cycle. In addition to the bag emissions data taken
during the FTP, continuous trace data was recorded for HC,
CO, CO and NO .
2.4.2
Clayton Key Mode
This short test consists of three steady state
operating conditions, as described below, from which
exhaust samples are taken by the volumetric procedure. HC
and CO values are obtained using a Horiba Instruments GSM
300; and NO values are obtained from the continuous trace
information. The vehicle is operated in each mode until
the exhaust emissions stabilize. The vehicle hood is closed
and the auxiliary cooling fan is not in operation while con-
ducting this test.
For this class of vehicle (5000 Ib):
Transmission
Range
Dyno Load
hp @ mph
High Speed
Cruise
mph
Low Speed
Cruise
mph
Idle
Drive
30 @ 50
48 to 50
32 to 35
Automatic
Transmission
in Drive
2-8
-------
2.4.3
Federal Three Mode
This short test consists of three steady state
operating modes (similar to Clayton Key Mode) with the
dynamometer loads simulating the average power which occurs
at the appropriate speed on the FTP. Emissions are mea-
sured by the volumetric procedure for each mode as des-
cribed for the Key Mode Test. The vehicle is operated in
each mode until the emissions stabilize with the hood closed
and no auxiliary cooling fan in use.
For this class of vehicle (5000 Ib):
Transmission
Range
Drive
High Speed
Mode
Speed Load
mph hp
50
36
Low Speed
Mode
Speed Load Idle
mph hp Mode
30
18
Automatic
Transmission
in Neutral
2.4.4
High-Speed Unloaded Test
HC, CO and NO exhaust emissions are measured by
the volumetric procedure at an engine speed of 2500 rpm with
the transmission in neutral. The vehicle is operated in
this mode until the emissions stabilize. The vehicle hood
is closed and there is no auxiliary cooling fan in use while
conducting this test.
2-9
-------
2.4.5
Federal Short-Cycle
This is a 9-mode, CVS test of 125 seconds duration
which follows the driving schedule shown below:
Mode
0-16 mph acceleration
16 - 29 mph acceleration
29 mph cruise
29 - 37 mph acceleration
37 - 42 mph acceleration
42 - 37 mph deceleration
37 - 20 mph deceleration
20 - 0 mph deceleration
idle
Time in Mode
(seconds)
6
23
10
18
4.5
2.5
32
7.5
21.5
125.0 seconds total
The dynamometer loadings and transmission shift
points follow the procedure as required for the FTP.
During the performance of the Federal Short
Cycle, the vehicle hood is closed and the auxiliary cooling
fan is not in operation.
2.4.6
Composite of N.J. ACID Test and N.Y. Short Test
This is a six mode, CVS test of 75 seconds dura-
tion which follows the driving cycle shown below:
2-10
-------
During the performance of the Federal Short
Cycle, the vehicle hood is closed and the auxiliary cooling
fan is not to in operation.
2.4.6 Composite of N.J. ACID Test and N.Y. Short Test
This is a six mode, CVS test of 75 seconds dura-
tion which follows the driving cycle shown below:
Mode Time in Mode
(seconds)
Idle 22
0-30 mph acceleration 15
30 mph cruise 15
30 - 10 mph deceleration 12
10 mph cruise 7
10 - 0 mph deceleration 4_
75 seconds total
All vehicles are tested at an inertia weight of
3000 Ib. and 3.5 hp @ 30 mph. This test is performed with
the vehicle hood closed and without the use of an auxiliary
air cooling fan.
2.^.7 Defect Tests
Permission was obtained from Ford Motor Company to
simulate an engine defect. The following test procedure was
used on five (5) vehicles.
Ignition failure on one cylinder (the same for
each vehicle) was simulated for thirty (30) seconds at idle,
2-11
-------
in drive, while tailpipe emissions were sampled. Samples
were also taken by repeating the test with the probe inserted
ahead of the catalyst at existing sample points.
HC, CO and NO were recorded as continuous traces
on strip charts during the running of these tests.
For the first vehicle tested, the defect was
simulated until emission levels stabilized. The Project
Officer was notified of the results on this first vehicle
as soon as it was completed. The test results are shown
in Tabel 2-1.
2.5 PROCEDURAL PRECAUTIONS
2.5.1 Dynamometer Warm Up
If the dynamometer had not been operated during
the two-hour period immediately preceding the test, it was
warmed up for 15 minutes by operating it at 30 mph using a
non-test vehicle. A non-test vehicle is defined as a vehi-
cle not scheduled for any emission test in the following
12 hours.
2.5.2 Pedal Operation
All operation of the accelerator and brake pedals
was accomplished with the right foot only-
2.5.3 Invalid Tests
Departure from the driver's trace beyond the
limits allowed normally causes an invalid test. Those
departures which were, generally due to malfunctioning
vehicles were immediately noted on the trace itself. Those
few departures that were due to driver error were repeated.
2-12
-------
Table 2-1 DEFECT TEST RESULTS
BEFORE CATALYST AT TAIL PIPE
to
1
Vehicle No.
T2464135
T0564137
T1624138
TO 9*9413 9
T0914147
RPM
630
600
650
640
700
HC,ppm
2000
1470
1240
1800
1120
CO, %
0.20
0.05
0.16
0.06
0.07
NO / ppm
65
79
133
52
133
HC , ppm
750
630
620
650
230
CO, %
0.05
0.04
0.05
0.04
0.04
NO , ppm
92
160
214
79
146
-------
Section 3
TEST EQUIPMENT
3.1 MAJOR EQUIPMENT
Hydrocarbon (HC) measurements were made by flame
ionization instrumentation (FID), carbon monoxide (CO) and
carbon dioxide (CO?) by NDIR instrumentation, and nitrogen
oxides (NO ) measurement by the chemiluminescence (CL)
«ri
method. The following major equipment was used:
o Horiba FID-2A Flame Ionization Analyzer using
40% H2 - 60% N2 fuel with the following full-
scale ranges:
0-100 ppm Carbon
0-300 ppm Carbon
o Beckman 108A Flame Ionization Analyzer using
40% H2 - 60% N2 fuel with the following full-
scale ranges:
0 - 1000 ppm Carbon
0 - 3000 ppm Carbon
o Horiba AIA-21 NDIR carbon monoxide analyzer
with a full scale range of 0-750 ppm.
3-
-------
o Horiba AIA-2 NDIR Analyzers with the fol-
lowing full-scale ranges:
Carbon Monoxide 0 - 0.3%
Carbon Monoxide 0-3%
Carbon Monoxide 0-5%
Carbon Dioxide 0 - 10%
Carbon Dioxide 0 - 15%
o TECO NO Analyzer of the chemiluminescence
type. This analyzer incorporates a thermal
converter for the conversion of nitrogen
dioxide (NO2) to nitric oxide (NO). The NO
analyzer full-scale ranges are as follows:
0 - 100 ppm NO
0-250 ppm NO
0 - 1000 ppm NO
0 - 2500 ppm NO
The operating ranges specified for the above
sampling conditions and analytical system(s) were expected
to cover the concentrations encountered in the performance
of this program. In some cases, the undiluted continuous
trace data for NO exceeded 2500 ppm.
Since no higher range existed, a common value of
100 plus 0.5 deflections was used to signify a 100-plus
trace reading. For vehicles 1-50, that number was 2442;
and for vehicles 51 and above, that number was 2444 due to
recalibrat ion.
A 0-10,000 ppm NO range was added for the tests
occurring after 22 January. Test results exceeding the
0-2500 ppm range were switched to the higher range to
obtain actual values.
The Constant Volume Sampler (CVS) conforms to the
specifications listed in 37 Federal Register 221 (Section
3-2
-------
85.073-20).
The Laminar Flow Element (Meriam Model 50 MC 2-4)
was used for calibration of the CVS.
The instrument used for measurement of undiluted
HC and CO emissions is a Horiba Instruments, GSM 300. This
portable, repair-garage-type instrument is capable of mea-
suring hydrocarbons in ranges of 0-400 ppm and 0 - 2000 ppm
Carbon and carbon monoxide in concentration ranges of 0 to
2 percent and 0 to 10 percent.
The dynamometer used is a Clayton Variable Inertia
Flywheel Dynamometer with 250-pound increment inertia load-
ing weights (below 3000 pounds inertia weight) and road-
loading characteristics. This dynamometer is suitable for
use in emission testing up to 5500 pounds inertia weight.
Continuous trace data were collected for HC, CO,
CO-, and NO. The recorders used were Honeywell Electronik
194, two-pen recorders. The following chart speeds were
used:
6 inches per minute for all volumetric meas-
urements, including continuous FTP traces for
vehicles 4101 to 4150
3 inches per minute for FTP mass measurements
from the bag samples and for continuous FTP
traces for vehicles 4151 to 4170
6 inches per minute for Federal Short-Cycle and
Composite NJ/NY mass measurements for vehicles
4101 to 4170
3-3
-------
3.2 CALIBRATION
Analyzers, constant volume sampler, dynamometer
calibration gases, and capabilities of personnel were
qualified to the satisfaction of the Project Officer prior
to the start of the vehicle testing. Calibration curves for
the exhaust analyzers, were checked on a monthly basis with
zero and span checks made prior to the analysis of each
sample. A NO converter efficiency check was made weekly.
J\
The CVS was checked daily utilizing the Propane Injection
Test. The dynamometer calibration was checked monthly.
Calibration gases used in the performance of this
contract were delivered to the EPA Laboratories in Ann Arbor,
Michigan, within two weeks after contract award date. EPA
provided some of the gases through the Propulsion Systems
Division of the U.S. Army Tank-Automotive Command and
performed the actual analysis on all gases. Olson provided
the remainder of the gases as well as providing for their
shipment to and from the EPA facilities. These named gases
were received by Olson on August 26.
Not all of the required ranges were shipped; and
some of the Army gases, not named by EPA due to time con-
straints prior to shipment to Olson, had a range of
concentration values identified instead of a specific value.
These unnamed gases were not used. For hydrocarbon cali-
bration, propane concentration rather than methane equivalent
concentration resulted in a shortage of low-concentration
named gases.
It was found in the course of calibrating the
instruments that several of the required gases were appar-
ently either not named correctly or were blended in an
unstable mixture. Renaming the gases against a valid curve
did not provide the value given on the bottle within a
reasonable error. These gases were not used. With the
3-4
-------
concurrence of the Project Officer, a combination of the
latest EPA named gases and previously EPA named (October
1973) laboratory standard gases (2 percent) were used to
enable completion of the calibrations.
The HC, CO, CO-, and NO instruments were cali-
2. X
brated against these gaseous standards. Each CO and CO-
instrument was calibrated with at least five (5) points
spread somewhat evenly across each range.
Calibration of the FID and the CL analyzer was
with at least three (3) points across each range.
Calibration was within one percent of full-scale
or five percent of measured value, whichever was smaller.
Two exceptions, both accepted by the Project Officer, were:
Analyzer Range Deflection Error
CO 0-750 ppm 20.0 5.440%
CO 0-3.0% 11.3 5.077%
The initial calibrations were completed on September 8.
Samples of data forms used for analyzer curve
generation, CVS and mass bench propane injection tests, and
daily start-up check sheets for mass and volumetric benches
are give in Figures 3-1 to 3-4 respectively.
A calibration check was performed on October 7,
1974, on the analyzers and ranges used in the previous
month. The 0 to 15 percent CO~ was found to deviate more
than 5 percent from its previously calibrated values in the
lower half of the curve. This portion had not been used to
date, so a new curve was not generated. The data for this
pollutant and range is not specifically reported, but is
recorded on a continupus trace for volumetric tests. The
dynamometer calibration was checked. Recalibration of the
CVS was not found to be necessary.
3-5
-------
ANALYZER CURVE GENERATION DATA
DEPT. NO.
ANALYZER_
PURPOSE
TRAIN
DATE
PIC
RANGE
MAKE
MODEL
DETECTOR NO,
CELL LENGTH
J5ERIAL NO-
RANGE SELECT
ANALYSER DATA: TUNE
GAIN
ZERO
FLOW RATES (Sample, By-pass, etc) .
OTHER PARAMETERS (Sample, Oxygen, Air, Fuel-pressure)
CURVE DATA: Deflection = [Recorder / /
[DVM / /
Zero Gas = [Zero Air / /
[Nitrogen / /
Cylinder Type
Zero Gas
-
Concentration
0.00
Deflecti on
0 . 0
Comp . Wo .
0
Computer Information: Data Tables Changed Y N / Curve Fit
Method_
Strip, Charts Attached /__/ Data Tables Attached / /
Comments:
Figure 3-1
3-6
-------
PROPANE INJECTION TEST
Date: CVS Frame # PIP
AM
Train # Dept. # Time PM
I. Calculation of V . (Total Volume of Mixture)
A. P = Barom. Pres. = In. Hg x 25.4 = mm Hg
B. PT = Pump Inlet Dpr = In. H-O x 1.868 = mm Hg
X ^
C. P = Pump Inlet Pres. = Pfi - P_ = mm Hg
D. PQ = Pump Outlet Pres. = In. H20 A? = In. H20
E. T = Pump Inlet Temp. = °F + 460°F = °P
G. N = Pump Revs = Time = min; RPM =
H. VQ = Pump Vol. per Rev = ft 3/rev
I. V . = £p x N x Vrt x .69474 = ft3
mix =« 0
P
II. A. Weight Exp. B. Bag Analysis
Cylinder (gms) Bag Deflection Range Concentration (ppm)
Before = Sample
After = Bkgd
/\ = Cone =
:il. Mass Calculation (Mass = V . x 17.3 x Cone x 10 )
liH^t
Mass = gms
Error = A"**as5 x 100 = %L
COMMENTS:
QC Use
Approved,
Rejected_
By
Figure 3-2
3-7
-------
OLSON LABORATORIES. IMC.
MASS START-UP CHECK SHEET
DEPT NO.
SHIFT
TRAIN
DATE
P. I.C.
WEEKLY
DAILY
CALIBRATION
^ - HIGH
X*
CO
FIA
"°X
co2
ZERO
RNG
0.3
3.0
500
IK
4K
250
IK
4.0
//
GAIN
»
XXX^
ZERO
^^
CYL NO.
RECORDER
CHART SP
ZERO
GAIN
DVM CORR
CONC
DEFL
^^
PRESS.
^
TUNE
x^
x^^
^^
^^
^^
^^
^^
^^
INTERMEDIATE
GAIN
^^
ZERO
^^
PRESSURE
^^
FIA
no%
SAMPLE
FUEL
^^
AIR
^^
OZONE
^^
^^
CYL NO.
BYPASS
FLOW RT
CONC
CONV
IND TEMP
°C
OEFL
REACTOR
OPR PRESS.
MM
PRESS.
MFGRS MODEL NO.
LEAK CHECK
^ FIA CO CO2 NOX
FL MTR OBS
MAG OBS
IQ
n>
Vjk)
oo
CVS
1 MIN. COUNT
IN. PRESS.
OUT. PRESS.
T.P. PRESS.
VOL/REV
FLEX
ADAP
BAGS
LIGHTS
PUMPS
SWITCHES
TEMP CONTROL
COMMENTS
FC
-------
4 £1 OLSON LABORATORIES. :?'&.
' .-. - '.-*. r ,, ;, [' i... .- ' t.r
TESTING SERVICES DIVISION
7-MODE START-UP CHECK SHEET
DEPT NO.
"SWIFT
TRAIN
DATE
P. I.C.
WEEKLY
DAILY
CALIBRATION
_ - HIGH
x^
CO
FIA
"°X
co2
ZERO
RNG
0.3
10
IK
3K
IK
2.5K
15
//
GAIN
.
^^
ZERO
^^
CYL NO.
RECORDER
CHART SP
ZERO
GAIN
DVM CORR
CONC
OEFL
^^
PRESS.
^
TUNE
^^
^^
^^
^^
^^
^^
^^
^^
INTERMEDIATE
GAIN
^^
ZERO
^
PRESSURE
^^
FIA
H°*
SAMPLE
FUEL
^
AIR
^
OZONE
^^
^^
CYL NO.
BYPASS
FLOW RT
CONC
CONV
IND TEMP
°C
maf l
DEFL
REACTOR
OPR PRESS.
MM
PRESS.
MFGRS MODEL NO.
LEAK CHECK
^^^-**^' FIA CO CO2 NQ^
FL MTR OBS
MAG OBS
10
c
-\
(t)
VjJ
COMMENTS
FORMQC02 1FE572 WHITE/SITE FILE CANARY/QUALITY CONTROL PINK/REGIONAL MANAGER
-------
Recalibration of all instruments and ranges
initially calibrated was completed by November 8, with the
exception of the GSM 300 which was checked on November 26.
The 0 to 4 percent CO2 instrument was found to
have drifted, with the major drift on the lower end of the
scale. Checking the day-to-day lab data showed that the
instrument problem occurred subsequent to November 1 and
therefore did not affect any of the tests for this project.
All other curves (excepting the 0 to 15 percent CO- pre-
viously noted) were found to be acceptable, including the
dynamometer and CVS.
The appropriate calibration gases were prepared
for return to the Army, but a hold was put on the shipment
until disposition of the five catalyst vehicles stored at
Olson is resolved.
Prior to testing the ten additional vehicles
requested by the Project Officer in December, the following
instruments and ranges were recalibrated.
Analyzer
Range
New Curve
Mass Bench
HC
CO
co2
NO
NO
x
Volumetric Bench
0-100 ppm
0-750 ppm
0-4%
0-100 ppm
0-250 ppm
Yes
Yes
Yes
Yes
No
HC
CO
CO,
NO
0-1000 ppm
0-3000 ppm
0-15%
0-2500 ppm
No
No
Yes
Yes
3-10
-------
The dynamometer had been recalibrated on November
25, so this new curve was used. The CVS calibration was
checked and found to be satisfactory.
All instruments were calibrated prior to commencing
the group of tests initiated in January. A new mass bench
had been installed in the interim between the December and
January tests requiring complete calibration. In addition,
the EPA/Army calibration gases used in earlier calibrations
had been prepared for return to the Army so new calibration
gases were utilized. The gases used were "Golden Standard"
gases obtained from the EPA/Olson surveillance test program
at Levittown, PA. The dynamometer was recalibrated on
January 13 and on February 8. A new CVS calibration was
performed on February 12.
Analyzer calibration curve points, CVS calibration
and dynamometer calibration curve point tables are presented
-*
in Appendices C, D and E respectively.
3-11
-------
Section 4
DATA PREPARATION
Test data were entered on punched, interpreted
cards (except driver traces) in a format approved by the
Project Officer shortly after contract award. Maintenance
data were obtained from Ford Motor Company for summarization
and presentation to EPA.
4.1 TEST DATA
Vehicle information consists of basic parameters
such as vehicle program identification number, make, model
year, accummulated mileage, date(s) of test(s), engine
displacement, carburetion, transmission type, emission
control systems on the vehicle, inertia weight, horsepower
settings, license number, owner identification, VIN, engine
parameter settings and identification of control systems
either inoperative or functioning improperly- (See Fig-
ure 2-1.)
Exhaust emission test results include ambient
temperature, barometric pressure, humidity, mass emissions
in each bag from the FTP and each CVS sampled short test, and
concentration emissions from each mode for all other short
tests. (See Figures 2-2 and 2-3.) NO is reported as N09
X ^
both as measured and corrected for relative humidity. The
humidity correction factor was calculated from a method
provided by EPA dated March 8, 1974.
-------
Grams-per-mile emissions for the FTP were cal-
uclated per the Federal Register, Volume 37, Number 221,
Section 85.075-26.
Mass emissions for the Federal Short Cycle test
were computed by the following formula:
m = Vdc/a
where:
m = mass emissions in grams per mile
V = total CVS flow = Volume per revolution
times revolution count
d = density of the exhaust component
c = measured concentration in the bag less
the background concentration
a = cycle length in miles (0.7536)
Running two tests back-to-back for vehicles 4151-
4170 resulted in twice the revolution count for twice the
cycle length. These factors of two cancel in the equation.
Measured concentration values for the composite
NJ/NY test are reported, but mass emissions were not com-
puted .
Fuel usage, in miles per gallon, was calculated
from bag data according to the carbon balance technique and
reported for each FTP on each vehicle.
All data were transmitted to EPA for statistical
analysis upon completion of an error screening process and
computer run. This submittal was made on the Friday of the
week following actual testing. Each submittal included all
emissions strip charts, the driver's trace, CVS temperature
k-2
-------
trace, computer summary printout for all tests for that week,
and the test data on punched 80-column computer cards.
4.2 REPORTS
Weekly Reports - Data were reported on punched,
interpreted and verified cards. Cards, strip charts and
computer printouts covering each week's work were sent to
the Task Project Officer by the Friday of the following
week.
Weekly progress reports were made by telephone to
the Task Project Officer or his representative during the
morning of the last day of the business week (normally
Friday).
Monthly Reports - Olson furnished letter-type
monthly reports to the Task Project Officer and one copy to
the Contracting Officer by the fifteenth of the month fol-
lowing the month being reported on. These reports outlined
the progress made, together with slippages and procedures
for correction, manpower expenditures (including names of
personnel and their classification, e.g., John Doe, Driver)
and costs for the month and the total contract on milestone
charts. In conjunction with the letter reports, one copy of
EPA Form 1900-11 was submitted to the Contracting Office and
one copy to the Task Project Officer.
4.3 VEHICLE USE AND MAINTENANCE HISTORY
A use-and-maintenance history was obtained from
Ford Motor Company records for each of the first 60 vehicles
tested. It was not always possible to identify who actually
performed the maintenance. Reasonable assumptions were
made based upon the total information in each maintenance
4-3
-------
package and the area of vehicle usage.
Maintenance histories were not available for all
of the vehicles tested in January and February (but see
page 1-3) due to transfer of the catalyst Task Force to
Dearborn, Mich igan.
4.3.1 Vehicle Use
The primary usage areas for the tested vehicles
(all in California) were:
Location Total Number
of Vehicles
Fresno 2
Goldstone (Barstow) 16+1 San Diego
Sacramento 27
San Diego 9
San Francisco 3
San Luis Obispo 3
60"
The following paragraphs describe the general type
of use to which the vehicles assigned to each of these
locations were subjected.
Fresno - These vehicles were used by State of
California personnel from a limited pool. They were driven
over all types of roads with many trips to other districts,
especially Sacramento. One vehicle was assigned to a specific
person.
Goldstone (Barstow) - These vehicles are used by
NASA personnel for transport from Barstow to the Goldstone
Tracking Facility. The distance is approximately 53 miles
each way over dry desert at very high speeds. A small
4-4
-------
amount of stop-and-go driving was involved to pick up or
drop off five passengers (about seven miles). One vehicle
was used in San Diego and then at Goldstone.
Sacramento - State and Federal employees used
these which were drown from a motor pool. Many different
drivers and all types od driving conditions were involved,
especially stop-and-go. One vehicle was used in Bishop.
San Diego - These vehicles had limited use by
State employees from a pool and were used mostly for local
driving. Two vehicles were each assigned to specific per-
sons. One vehicle was later transferred to Goldstone.
San Francisco - These vehicles were part of a
central motor pool and were used for all types of driving;
mostly by VIPs.
San Luis Obispo - State employees had use of these
vehicles from a limited pool for driving over all types of
roads with many trips to other districts, including Sacramento,
4.3.2 Vehicle Maintenance
Control vehicles that were included in the sample
were maintained primarily at 12,000 mile intervals by Ford
at Pico Rivera when emissions tests were scheduled. Oil
change and non-emissions related maintenance was mostly per-
formed by Ford dealers or by motor pool personnel.
Non-control vehicles were maintained by motor pool
personnel at Goldstone and by Ford dealers at other loca-
tions following procedures established and monitored by Ford
Motor Company. Particularly difficult problems were handled
by Ford at Pico Rivera.
Table 4-1 presents a list of the required main-
tenance actions for all catalyst fleet vehicles. Table 4-2
is a summary of the required actions performed on the 60 vehi-
cles acquired by Olson. A complete tabulation of scheduled
and unscheduled emissions related maintenance performed on
each tested vehicle, with mileage and dates performed, is
included in Appendix F.
4-5
-------
Table 4-1 REQUIRED SERVICE INTERVALS
1,000 Miles or Months, Whichever Occurs First
. Check coolant strength and inspect cooling
system. If the coolant is dirty and rusty
in appearance, the system should be cleaned
and flushed. Clean the radiator cap.
. Inspect the cooling system hoses for deterioration,
leaks, and/or loose hose clamps. Repair or replace
as required.
. Drain and flush the cooling system. Replace
coolant mixture.
. Check distributor cap and rotor.
. Inspect evaporative emission control canister
and purge hose.
. Test engine compression - all cylinders. Repair
any cylinder below specification (mileage basis
only) .
When checking compression, take the highest com-
pression reading and compare it to the lowest
reading. The lowest reading must be within 75%
of the highest.
4/4
8/8
12/12
X
16/16
20/20
24/24
X
X
X
X
X
28/28
32/32
36/36
X
X
40/40
(Time
44/44
. Basis
48/48
X
X
5 Only)
X
X
-------
Table 4-1 (cont.) REQUIRED SEIVCE INTERVALS
1,000 Miles or Months, Whichever Occurs First
. .
. Clean crankcase breather cap.
. Replace spark plugs and set gap.
. Check and adjust initial ignition timing 12° B.T.D.C
. Check distributor points and set gap. Inspect
condenser for loose terminals and/or ground
connections.
. Replace distributor points. Dwell 24° - 30°.
. Check secondary ignition wires resistance; inspect
wires for cuts, burns, abrasions, or punctures.
. Inspect all spark control system vacuum hoses and
electrical leads for damage, deterioration and firm
connections to proper points.
. Check for correct spark control system advance.
, Check for distributor spark advance and adjust if
necessary.
, Replace spark delay valves
. Check for correct component assembly and functioning
of air cleaner intake temperature control system.
. Replace PCV valve, clean emission system hoses,
tubes. Replace if deteriorated.
4/4
8/8
12/12
X
X
X
X
X
X
X
X
X
X
16/16
20/20
24/24
X
X
X
X '
X
X
X
X
X
X
X
28/28
32/32
36/36
X
X
X
X
X
X
X
X
X
X
40/40
44/44
48/48
X
X
X
X
X
X
X
X
X
X
X
-------
Table 41 (cont.) REQUIRED SERIVCE INTERVALS
1,000 Miles or Months, Whichever Occurs First
"
Change engine oil.
(Must meet Ford Specification ESE-M2C101-C/SE)
. Change engine oil filter.
(Must meet Ford Specification C8AF-6714-A or C)
. Check and adjust carburetor , curb idle speed, fast
idle speed, and throttle solenoid off-speed.
. Torque intake manifold bolts to specification.
. Replace crankcase emission filter in air cleaner.
. Replace carburetor air cleaner filter element.
. Inspect fuel evaporative emission control system
for restrictions or damage to filler cap, fuel vapor
line and fuel tank. Repair or replace as required.
. Check Operation of carburetor throttle and choke
linkage, and air valve, dashpot, and throttle
solenoid. Lubricate, adjust, or repair as required.
Curb idle, 650 RPM -- fast idle, 1500 RPM.
. Replace fuel system filter and check fuel lines
and connections for leaks.
. Check the EGR system for function. Inspect and
clean the EGR valve and system. Clean the exhaust
passages in the carburetor spacer and intake
manifold (8 cylinders). Repair or replace as
required.
. Check accessory drive belts for tension and wear
and adjust or replace as required.
4/4
X
X
8/8
X
X
12/12
X
X
X
X
X
X
X
X
X
16/16
X
X
20/20
X
X
24/24
X
X
X
X
X
X
X
X
X
X
28/28
X
X
32/32
X
X
36/36
X
X
X
X
X
X
X
X
X
40/40
X
X
44/4^
X
X
48/48
X
X
X
X
X
X
X
X
X
X
-------
Table 4-2 SCHEDULED MAINTENANCE ACTIONS
Vehicle
No.
T0284101
T1894102
T2433103
T0484104
T0234105
T2044106
T2714107 .
T2754108-
T3304109
T3104110
T1064111
i T0974112
^° T1764113
T1274114
T3044115
T1714116
T2194117
T0264118
T3494119
T3434120 '
T3414121
T1644122
T3234123
T3124124
T2774125
T2894126
T2984127
T2974128
T2574129
T2674130
Mileage
As Received
15,168
6,655
15,199
6,987
17,596
18,978
15,156
14,139
24,063
21,623
17,261
21,754
11,240
21,848
18,571
20,917
10,258
8,740
18,320
16,566
19,869
19,761
18,614
17,257
22,697
16,701
12,649
9,228
10,154
9,204
Location
Sacramento
San Francisco
Sacramento
San Francisco
Goldstone
Goldstone
Sacramento
Sacramento
Fresno
San Luis Obispo
Goldstone
Goldstone
Sacramento
Goldstone
San Diego
Sacramento
Sacramento
San Francisco
San Diego
San Diego
San Diego
Goldstone
San Diego
San Diego
Goldstone
Sacramento
Sacramento
Sacramento
Sacramento
Sacramento
4K
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Scheduled Maintenance Intervals
8K 12K 16K 20K 24K 28K 32K 36K
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X
X
XX X
XXX X
X
XXX
X X
X
XXX
X
X
X
X X
X
X
X XX
X X
-------
Table 4-2. SCHEDULED MAINTENANCE ACTIONS (cont.)
Vehicle
No.
T3294131
T1814132
T2804133
T0654134
T2464135
T1004136
T0564137
T1624138
T0994139
T2844140
T2544141
T2364142
-F- T2494143
L T1614144
o T2624145
T3394146
T0914147
T3004148 '
T1754149
T2104150
T0534151 '
T3784152
T1194153
T3734154
T3364155
T1204156
T1234157
T3244158
T3594159
T3074160
Mileage
As Received
20,019
20,615
9,401
18,104
15,660
20,644
20,583
16,074
20,981
16,264
Untested
9,857
14,646
25,005
10,975
14,078
17,071
7,538 #
Untested
23,172
35,388
33,209
34,689
35,615
36,025
34,310
34,274
32,743
35,875
33,509
Location
San Diego
Goldstone
Sacramento
Goldstone
Sacramento
Goldstone
Goldstone
Sacramento
Goldstone
Sacramento
Sacramento
Sacramento
Sacramento
Sacramento
Sacramento
San Diego
Goldstone
Sacramento
Sacramento
Sacramento
San Diego and
Goldstone
Fresno
Goldstone
Sacramento and
Bishop
Sacramento
Goldstone
Goldstone
San Luis Obispo
Sacramento
San Luis Obispo
4K
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Scheduled Maintenance Intervals
8K 12K 16K 20K 24K 28K 32K 36K
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XXX
X X
X
X X
X X
X
X
X X
X
XXX
X
X
X X
XXX
X
XXX
X
X
XXX
XXX
XXX
X
XXX
X
X X X X
X X
X X X X
X X
X X
X X X X
XX X
X XX
X X
X XX
* Tested with January group.
-------
4.3.3 Component Retrofit
Three ignition items were retrofitted on nearly
every car tested. These retrofits were performed at various
mileage points in the life of each vehicle. The specific
item replaced, date and mileage are included in the com-
plete maintenance listing given in Appendix F. The installer
completing each retrofit is also identified whenever pos-
sible.
Ignition Points - The original equipment point
sets were replaced on all but one tested vehicle with a
new design. The rubbing block on the original design showed
some susceptibility to breakage.
Cold Wire - The original primary coil wire was
replaced on most vehicles with a design that allowed easy
attachment of a tachometer for periodic engine parameter
inspection. The previous design tended to break after
repeated removal to allow tachometer connection.
Spark Plug Wires - The wire set was replaced on a
number of vehicles with a set of solid wire cables instead
of the carbon impregnated type which were found to break
down quite often. Sixteen out of the 60 vehicles experienced
failure of one or more plug wires, reguiring replacement.
A coolant recovery system was also retrofitted on
many of the vehicles to ensure that overheating did not
occur due to loss of radiator coolant. These recovery kits
were installed on any of the vehicles that showed any ten-
dency to overheat. Twenty-six of the vehicles were retro-
fitted and are noted in Appendix F.
4.3.4 Additives and Misfuels
Table 4-3 lists the vehicles that were misfueled
with leaded gas and that received gasoline or oil additives
4-11
-------
Table 4-3 MISFUELS AND ADDITIVES
Vehicle
No.
T0284101
T0234105
T2714107
T3304109
T3104110
T2984127
T2464135
T2544141
T2494143
T1614144
T0534151
T1194153
T3364155
T3244158
T3584159
T3074160
Mileage
5,800
1,317
7,000
4,000
8,169
-
7,986
20,453
4,625
7,753
13,565
8,170
11,828
4,083
4,127
1,307
8,806
1,813
16,245
11,991
15,632
11,762
Date
10/29/73
8/21/73
11/23/73
8/10/73
9/01/73
2/27/74
9/24/73
5/10/74
7/31/73
11/09/73
3/14/74
3/13/74
3/26/74
9/05/73
9/14/73
7/25/73
10/05/73
5/23/74
1/09/74
11/20/73
3/18/74
11/14/74
Mis fuel
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Gas Oil
Additive Additive
X
X
X
X
X
X
4-12
-------
during, their mileage accumulation. Vehicles that were acci-
dentally misfueled were generally not driven prior to drain-
ing and flushing the tank with unleaded fuel.
Several of the vehicles were retrofitted after
July 1974 with the small gas tank filler neck provided on
1975 vehicles to guard against misfueling.
4-13
-------
TECHNICAL REPORT DATA
(Please read Instruction* on the reverse before completing)
r REPORT NO. 2.
EPA-460/3-75-003-3
4. TITLE AND SUBTITLE
FTP/Short Cycle Correlation Testing for 207 (b)
Implementation - Catalyst Equipped Vehicles
Volume I
1. AUTHOR(S)
J. A. Gunderson
1. PERFORMING ORGANIZATION NAME AND ADDRESS
Olson Laboratories, Inc.
421 East Cerritos Avenue
Anaheim, California 92805
12. SPONSORING AGENCY NAME AND ADDRESS
Environmental Protection Agency
Office of Air & Waste Management
OMSAPC, ECTO
Ann Arbor, Michigan 48105
15. SUPPLEMENTARY NOTES
3. RECIPIENT'S ACCESSIOWNO.
5- Up?!1 f T9T7E5
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
Contract No. 68-03-0452 '
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
rr 1 1 i- ^» ^^ /o ^ o
16. ABSTRACT
Report contains emission data collected by the Federal Test Procedure and five
short tests. The vehicles tested were catalyst equipped prototype cars loaned to
EPA by the Ford Motor Company.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS b.lDENTIFI
Vehicle Testing
207 (b)
Emissions
18. DISTRIBUTION STATEMENT 19. SECUNV
' Unr.las
, ' 20. SECURI'
RELEASE UNLIMITED
ERS/OPEN ENDED TERMS C. COSATI Field/Group
-
rV CLASS (This Report) 21 . NO. OF PAGES
ei'f'tAH
rY CLASS (This page) 22. PRICE
EPA Form 2V30-1 (t-73)
4-14
------- |