EPA-650/4-75-024-H Environmental Monitoring Series GUIDELINI FOR QUALITY ASSURANCE PROGRAMS FOR MOBILE SOURCE EMISSIONS MEASUREMENT SYSTEMS: PHASE IV, HEAVY-DUTY GASOLINE ENGINES - TEST PROCEDURES U.S. Environmental Protection Agency Office of Research and Development Washington, 0. C. 20460 ------- GUIDELINE DISTRIBUTION RECORD EPA-650/4-75-024-h "Guidelines for Quality Assurance Programs for Mobile Source Emissions Measurements Systems: Phase IV, Hea'vy-Duty Gasoline Engines - Test Procedures" The series of documents, "Guidelines for Quality Assurance Programs for Mobile Source Emissions Measurement Systems," have been prepared and issued in a revisable document-controlled format so that any future revisions or additions may be distributed to the Guideline users. Individual copy numbers have been assigned to each volume of the series. These numbers appear on this record sheet and on the title page of each document. The user of these documents must complete the "Distribution Record Card" and return it in the pre-addressed envelope to the address shown below so that automatic distribution for future revisions may be made directly to the user. Also, notice of any reassignment of the documents by number and title to other individuals (by name, address, and copy number) should be sent to the same address. U.S. Environmental Protection Agency Office of Mobile Source Air Pollution Control 2565 Plymouth Road Ann Arbor, Michigan 48105 ATTN: Quality Assurance COPY No. (cut along dotted line) DISTRIBUTION RECORD CARD Guideline User Date Last Name First Middle Initial Title Address to Send Future Street Revisions 5treet and Additions City State Zip Code If address is a firm (fill in) Firm I have received copy No. of EPA-650/4-75-«024-h "Guidelines for Quality Assurance Programs for Mobile Source Emissions Measurement Systems: Phase IV, Heavy-Duty Gasoline Engines - Test Procedures" Please send me any revisions and additions of this volume. ------- EPA-650/4-75-024-h GUIDELINES FOR QUALITY ASSURANCE PROGRAMS FOR MOBILE SOURCE EMISSIONS MEASUREMENT SYSTEMS: PHASE IV, HEAVY-DUTY GASOLINE ENGINES - TEST PROCEDURES by Harold Wimette, Rod Pilkington, and Tom Kelly Olson Laboratories , Inc. 421 East Cerritos Avenue Anaheim, California 92805 401 Contract No. 68-02-1740 ROAP No. 26BGC Program Element No. 1HA327 EPA Project Officers: R. C. Rhodes Quality Assurance and Environmental Monitoring Laboratory Research Triangle Park, North Carolina 27711 and C. Don Paulsell Office of Program Management Ann Arbor, Michigan 48105 Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Mobile Source Air Pollution Control and Office of Research and Development Washington, D. C. 20460 June 1975 ------- EPA REVIEW NOTICE This volume has been prepared by Olson Laboratories, Incorporated consistent with the Environmental Protection Agency Quality Assurance principles and concepts and with the Environmental Protection Agency Mobile Source Testing Practices at Ann Arbor, Michigan. The guidelines and procedures are generally applicable to mobile source testing operations and are intended for use by those engaged in such measurement programs It is requested that recipients and users of this document submit any comments and suggestions to the Project Officers. Mention of trade names or commercial products does not constitute Environmental Protection Agency endorsement or recommendation for use. RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, U.S . Environ- mental Protection Agency, have been grouped into series. These broad categories were established to facilitate further development and applica- tion of environmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and maximum interface in related fields. These series are: ]. ENVIRONMENTAL HEALTH EFFECTS RESEARCH 2. ENVIRONMENTAL PROTECTION TECHNOLOGY 3. ECOLOGICAL RESEARCH 4. ENVIRONMENTAL MONITORING 5. SOCIOECONOMIC ENVIRONMENTAL STUDIES 6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS 9. MISCELLANEOUS This report has b«ysn assigned to the ENVIRONMENTAL MONITORING series. This series describes research conducted to develop new or improved methods and instrumentation for the identification and quanti- fication of environmental pollutants at the lowest conceivably significant concentrations. It also includes studies to determine the ambient concen- trations of pollutants in the environment and/or the variance of pollutants as a function of time or meteorological factors. This document is available to the public for sale through the National Technical Information Service, Springfield, Virginia 22161. Publication No. EPA-650/4-75-024-h 11 ------- INTRODUCTION The test procedures contained in this volume are a documen- tation of the 1975 heavy-duty gasoline emission measurement test require- ments presently in use at the Ann Arbor facility of the Environmental Protection Agency. These test procedures comply with Federal Regula- tions as stated in the Federal Register, (Subpart H). Refer to Section 3, of Volume I, for a listing of applicable Federal Register paragraphs. Section 5, Volume I, outlines the development of an Operations manual which may be used as a guideline for a Quality Assurance program. A typical format of a test procedures manual is described and offers a guide for implementing and interpreting the test procedures contained in Volume II. A user may accept the manual in its presented form, or may modify the format to suit specific contractual obligations, or delete certain procedures which may not be performed at that facility. The user will be required to make revisions as needed to assure that the manual complies with Federal Regulations. Revisions may be implemented manually, by computer updates or by magnetic card storage. For ease of use, the test procedures are separated into nine distinct sections, numbered 100-900. The table of contents shows the major heading of each section and the test procedures contained in each. To differentiate between the light-duty and heavy-duty testing which are both included in this contract, the test procedures are numbered to correspond to Light Duty, 101-149, 201-249, etc. and Heavy Duty, 150- 199, 250-299, etc. Heavy-duty diesel procedures modified for use with heavy-duty gasoline engines are suffixed with a -G, e.g.TP-750-G. Certain procedures developed for Phase I and II (Light-Duty Gasoline Vehicle and Heavy-Duty Diesel Engine) are equally applicable to Phase IV (Heavy-Duty Gasoline Engines) and have been included in this volume, utilizing the original Test Procedure reference number allocated for Phase I and II. To assist in defining the overall scope of the heavy-duty testing program, the tables from Section 3, Volume I, briefly outlining the test procedures, specifications, and quality provisions are included in the introduction to the test procedures manual. This document details test procedures for heavy-duty gasoline engines. The test procedures for light-duty diesel (Phase III) appear as a supplement to the light-duty gasoline vehicle procedures detailed in Phase I, Volume II. Heavy-Duty Diesel Engine Test Procedures appear in Volume II of the Report for Phase II. 111 ------- TABLE OF CONTENTS Page INTRODUCTION ill TEST PROCEDURE SUMMARY vii Effective Section Date(s) 100 GAS BLENDING, FUEL ANALYSIS AND INVENTORY 101 Preparation of Binary Gas Mixture .... 102 Calibration of Gas Mixtures 200 CALIBRATION 203 Gas Analyzer Calibration Curve Generation . . . 204 Chart Recorder Calibration 205 Temperature Recorder Calibration 206 Barometric Pressure Calibration and Correlation 250 Engine Dynamometer Calibration 300 VERIFICATION 304 CO /HO Interference Check. 400 CORRELATION 401 Analyzer Cross Check. 600 DAILY OPERATION . . . 601 Log Book Entries. . . 602 Drift/Noise/Gain/Tune 700 EMISSION TESTING , 750-G Receipt, Build-up and Installation of the Gasoline Test Engine , 757 Heavy Duty Gasoline Engine Dynamometer Test Cycle . . 758 Heavy Duty Gasoline Engine Exhaust Analysis Procedure, CO, CO , HC, and NO £* 800 DATA VALIDATION 850 Data Validation-Heavy Duty Testing. 900 PROGRAM PLANNING AND QUALITY AUDIT. ------- HEAVY DUTY GASOLINE ENGINE TEST PROCEDURE SUMMARY OR TASK 1 Engine, Receiving Inspection 2. Engine Installation 3. Englne/Dyno Check out 4. Engine precondi- tioning 5. Engine Test Cycle 6. Sampling System 7. Instrument Calibration 8. COj/HjO Response check 9. Sample Analysis 10. Data Reduction DRIEF DESCRIPTION Engine shipped to the EPA from the manufacturer 1s Inspected for damage and conformance to Installation The engine and preaHgned stand are Installed In the test cell and attached to the dynamometer The engine Is operated at Idle and load condi- tions to check for proper operation. Engine parameters are checked against nanu- facturer's specifications Start engine and pre- condition with one or more cycles, service accumulation or test cycle. Allow to soak prior to test An Initial 5 minute Idle, two Mrmup cycles, and two hot cycles constitute a complete Dyno Run Comprised basically of S NDIR Instruments. Sample pumps, refrigera- tion, flow controls and pressure and flow meters Calibration gases with concentrations varying across the Instrument range are used to Identify the Instrument curve for data reduction The Hydrocarbon instruments are checked monthly for Interference from water vapor and carbon dioxide A portion of the exhaust gases are analyzed con- tinuously from the first Idle thru four nine-mode cycles ending with the engine at Idle. Direct computer analysis of Instruments' output Is used to reduce the data to brake specific emis- sions (gms/hr.) rotr: EPA TP NO. FR. Vol. 40 2-27-75 85.774-29(a) TP 750-G 85.774-11 05.774-16(a)(l) TP-750-6 85.774-16(2) TP-750-6 B5.774-7.il, 16 TP-757 85.774-11,12.16 TP-757 35.775-13 TP-758 05.775-15 TP-203 TP-758 35.775-15 TP-304 05.775-1C, 17 TP-758 1)5. 775-16 TP-758 SPECIFIC*™ OR TOLERANCE-FEO. REG. Dynamometer capable of maintaining constant speed '100 RPN from full throttle to closed throttle motoring Adjustments on engine are limited to unscheduled mainte- nance listed In Ref. Para. Engine must reach normal operating conditions, soak time 1-2 hours temp., 60-86°F Arab. Temp. 68-86°F 2000 t 100 RPN Idle - Hfr. spec. Instrument ranges LHC 0-1000 pom Equlv. LHC 0-10.000 pjm Equlv. CO 0-101, C02 0-161 NO 0-4000 ppm Calibrated once every 30 days, Flowrate HHC, LHC, NO 10CFN, CO, CO, 5 CFH Concentration of gas should be known with- in ±2J of true value CUy loot - Response not to exceed 0.51 Sat. N» 75°F - LHC- 0.51 of full scale, HHC 0.5)1 of full scale. Chart Speed 6 1n./m1n. Min. 4-nlne mode cycles. 2 Idle roodes-before and after test Chart reading should be within 0.5J of full scale. Chart speed 3 In./ lilin. with marker to Indicate computed segments. SPECinCA-TTuTS SAE OR ENG PKACT MS WC Advisory Circular ;io. 22A Appendix A. 4-23-7J MSAPC Mo. 22A SAE J3166-Eiig1ne test code water/oil at equilibrium temp Sampling System tubing/ hardware/accessories must be made of Teflon, stainless steel or glass only Weekly checks, calibra- tion standards trace- able to NBS/knowri to ±11 of true value or better. Curve gene- rated must be within :2t uf all points. Visually i«n1tor Inst. Inlet pressure during sampling *1 In. H,0 Tol. * - IjUAUTV PROVISIONS Receiving Inspection check list Installation check list/Inspection by mfr. rep. Calibration of engine analyzer Speed/ torque/ t»ip. trace, soak time checked by Data Validation Data validation Q.A. audit Approval of system design and parts 11st, procure- ment control. Inspection of system by Q.C. prior to on-line operation Curve defined mathe- matically by least squares method. Curve approved by Data validation/ Audit. Monthly check Data validation, cal ibration check, Q.C. audit Data validation. Computer program verification, random audit of test data. i TUT INVALID Failure to comply will) specifications/ shipping damage Incompl ete/ Improper installation Incorrect Engine parameters Out of Hi.i1t soak time/ Temp/Cycle Deviation of 2 sec. CT node; 0.3 Inc. Hg. cru1se/PTO mode, 0.2 Inc. Hg. PTA/FL Mode last 10 sec. of Mode. 200 RPM first 4 sec./lOO RPH rest. System leak/compon- ent failure/Incor- rect sample flow or pressure/cal ibratlon overdue Overdue calibration, system leak during calibration. Excessive Inter- ference from C02/H20 Excessive hangup Instrument drift In excess of I", or other rial - function Incorrect cycle seg- ments used for con- puter analysis, recorder mal - function. CORRECTIVE ACTION Contact engine manu- facture for dis- position if the engine. Correct Discrepancy Adjust to mfr. specifications Repeat precondi- tioning Repeat precondi- tioning and Test Correct variance and repeat test Locate and correct problem, recali- brate. Recharge filter cell with CO, Replace de- lector. Clean sampling system, repair instrument, repeat test Manually reduce data/repeat test THAIS™™ SKILL LEVEL Knowledge of engine installation require- ments/Inspection procedures Mechanical skill and knowledge of engine/ dyno. Knowledge of dyno engine analyzer operation Knowledge of engine/ dyno operation As above Trained for operation of analytical systan. As above As above As above. Corrective action may require basic knowledge of electronic instru- ments. ------- 700 ------- EPA TEST PROCEDURE Number TP-750-G Page Of fi SUBJECT RECEIPT, BUILD-UP AND INSTALLATION OF THE HEAVY-DUTY GASOLINE TEST ENGINE Reference MSAPC ADVISORY CIRCULAR NO. 22A 4/3/73 Data Form No. Responsible Organization HEAVY-DUTY TEST OPERATIONS Computer Program NONE Test Witness HD - TEST SUPERVISOR Performance Interval EACH ENGINE Type of Test Report CHECK LIST Supersedes Report Distribution CERTIFICATION - TEST OPERATIONS - DATA FILE Superseded by REMARKS/COMMENTS ORIGINAL RELEASE APPKUVALb Office Section Signature Date Lab. Oper. Quality Assurance Test Oper. Chief HD Testing Supervisor Certification Heavy Duty Change Letter REVISIONS Description of Change Approval Date ------- REVISIONS: RECEIPT, BUILD-UP AND INSTALLATION OF HEAVY-DUTY GASOLINE TEST ENGINES TEST PROCEDURE PROCEDURE NO. rpD — *7cr\ /~* PAGE_2_OF £ 1.0 PURPOSE Outlines the proper procedure for receiving inspection and proper installation of engines received for emission testing. 2.0 TEST ARTICLE DESCRIPTION Heavy-duty gasoline engines are shipped to the EPA for certification or other emission tests. These engines are prepared for testing by the Manufacturer according to the prescribed procedure in MSAPC Advisory Circular No. 22A. 3.0 REFERENCES 3.1 MSAPC Advisory Circular No. 22A dated April 3, 1973. 3.2 Federal Register, paragraphs 85.744-12 and 85.974-12. 4.0 REQUIRED EQUIPMENT/CONDITIONS 4.1 Small tools and necessary plumbing, thermocouple connectors etc., necessary for installation. See Section 8.0 for more detail. 5.0 PRECAUTIONS 5.1 Care should be taken when unloading the engine to place the forks or other lifting device properly to prevent damage to engine or components. 5.2 Engine should not be lifted nor moved by any part of the engine except by those means provided by the manufacturer, such as bed plate pallet, engine mounts, etc. 5.3 Never start the engine without first checking all installation connections and alignment. 6.0 VISUAL INSPECTION 6.1 Receiving - Check engine for proper packaging and unloading require- ments. After unloading, check for proper shipping documents and markings. Check for any signs of damage to shipping container and engine. 6.2 Build-up - Check engine for specified temperature, cooling, fuel, drive shaft, and pressure connections. 6.3 Installation - Check for proper coolant and oil level, distance from centerline of shaft to bed plate, engine lag down bolts. 7.0 TEST ARTICLE DESCRIPTION See Sections 6.0 and 8.0 for preparation procedures. ------- REVISIONS: RECEIPT, BUILD-UP AND INSTALLATION OF HRAW-DIITY GASOT.TNR TEST RNCiTMR TEST PROCEDURE PROCEDURE NO. TP-750-G 8.0 TEST PROCEDURE Test Sequence Description Data Output 101 Unload from truck using fork lift. Verify Check Sheet shipping weight does not exceed forklift HD-750G-01 capacity. 102 Fill out HD-receipt form. Explain all Receiving deficiencies. List all parts, number of Inspection shipping containers, shipping markings, other Form No. identifying marks and pertinent information. HD-750G-02 103 Build-up and Install. Check Sheet HD-750G-01 o Thermocouple (s) o Water Hose (s) o Drive Shaft Check adapter plate bolts o Oil Pressure Line o Fuel Feed Line and Return Line o Fuel Pressure Line o Manifold Pressure Line 104 Check oil level (fill if required), distance Check Sheet from centerline of shaft to bed plate, engine HD-750G-01 lag down bolts. 105 Move engine to test cell and install on the Check Sheet test bed using the following sequence. HD-750G-01 o Prepare engine test bed to receive engine and pre-aligned stand o Lift engine onto bed with hoist and bolt it in place o Bolt coupling to dynamometer and engine shaft; connect fuel oil and coolant systems using hand tools (refer to appropriate manufacturer's requirements for specifications) o Check carburetor inlet air filter o Connect thermocouples pressure gauges, vacuum lines, ignition, accelerator activator o Check engine for completeness, engine mounting, and engine alignment, o Position engine cooling fan if required ------- REVISIONS^ RECEIPT, BUILD-UP AND INSTALLATION OF HEAVY-DUTY GASOLINE TEST ENGINES TEST PROCEDURE PROCEDURE NO. TP-750-G 8.0 TEST PROCEDURE (CONTINUED) Test Sequence Description Data Output 105 (cont'd) o Install exhaust system, making provisions for probe location o Verify compliance maintenance procedures. 106 Engine - Dynamometer check out. After careful inspection of the installation, the engine is run to make adjustments. o Using test cell dynamometer check list Check List confirm that all the necessary connections HD-750G-03 have been made, instruments and equipment properly installed, and all controls are properly set prior to engine start up o Check safety interlock system for proper installation o Check throttle positioning o Check oil and water for proper level o Check operation of system safety interlocks o Start engine and perform visual, audio, and functional inspection Listen for internal noises, such as piston slap, knocks, taps and gear noises that indicate irregularities in engine operation Check for fuel and lubricant leaks, check for exhaust and crankcase emission leaks o Bring engine to rated load and speed in gradual steps o Determine when engine conditions have stabilized and record BHP and fuel rate Dyno Log o Lug engine to peak torque speed and record torque and fuel rate o Check engine performance for compliance with manufacturer's specifications; if non- compliance is noted, contact supervisor o Shut down engine and dynamometer systems and record time and ambient temperature o Fill out request for repairs if necessary o All pretest functions should be completed with a minimum amount of engine running time 107 Preparation of test engine for return to Check List Manufacturer HD-750G-04 o Disconnect; o Drive Shaft - Dyno End, only ------- REVISIONS-- RECEIPT, BUILD-UP AND INSTALLATION OF HEAVY-DUTY GASOLINE TEST ENGINES TEST PROCEDURE PROCEDURE NO. TP-750-C; PAGE_5_OF £ 8.0 TEST PROCEDURE (CONTINUED) Test Sequence Description Data Output o Engine Stand Lag Down Bolts o Accessory Stands o Exhaust System at exhaust manifold only o All temperature thermocouple wires from Control Room assembly o All sample probe lines from engine only o All fuel, oil, vacuum, manifold, pressure and feed lines from Control Room assembly only o Oil coolant hoses from Coolant package o Move Engine and Exhaust System o Gasoline Engine (s) to Room 409 o Disconnect Remove and put in proper place o All thermocouples, wires and fitting (if installed by E.P.A.) o Water Hoses o Drive Shaft o All fuel, oil, vacuum, manifold, pressure and feed lines and fittings o Drain o Follow manufacturer's recommended procedure for draining coolant Drain oil if necessary o Re-Install NOTE: Exhaust System and all other engine parts and accessories received Check HD Receiving form to assure shipment is complete as received 108 Complete Shipping Order No. HD-750G-05 8 ------- REVISIONS: RECEIPT, BUILD-UP AND INSTALLATION OP HEAVY-DUTY GASOLINE TEST ENGINES TEST PROCEDURE 1 kW 1 1 l\VX%«b iX WI\C PROCEDURE NO. TP-7sn-p PAOF6,^<">F6 9.0 DATA INPUT 9.1 Check sheets validated by supervisor and place into test file. 10.0 DATA ANALYSIS None 11.0 DATA OUTPUT None 12.0 ACCEPTANCE CRITERIA 12.1 Engine as received must conform to specifications outlined in MSAPC Advisory Circular No. 22A (4-3-73). 12.2 Engine must conform to manufacturer's specifications. 12.3 Engine must not exhibit any malfunctions such as oil leaks, engine noise, erratic running or overheating. 13.0 QUALITY PROVISIONS 13.1 Engine returned to manufacturer if all specifications not met. 13.2 Engine installation approved by supervisor and certification engineer. 13.3 Data validation inspects check lists for discrepancies and completeness. 13.4 Discrepancies noted during receiving inspection reported to supervisor and quality assurance. ------- Check List - Receipt, Build-Up And Installation Gasoline Test Engine Description Unload from truck Visual Inspection; Build-up and Install; Check: Move to test cell: Connect: Oper. Init. Fill out HD-receipt form Explain all deficiencies List all parts (s) Temperature Thermocouple Water Hose (s) Drive Shaft (check adaptor plate bolts) Oil Pressure Line Fuel Feed Line Vacuum Line(s) Ignition Wiring Fuel Pressure Line Oil Level (fill if required) Distance C/L shaft to bed plate Engine Lag Down Bolts Center engine stand on bed plate and lag down Temperature Thermocouple (s) Water Hoses Drive Shaft Oil Pressure Line Fuel Feed Line Fuel Pressure Line Vacuum Line(s) Ignition Line Accelerator Actuator Exhaust System Exhaust Sample Probes Cooling Fan (if required) Form HD-750G-01 10 ------- Date Engine C.I.D. Test Type # Pieces Description Condition Received by Test Date HC CO NOV Manufacturer Engine I.D.# Cert.| ~{ Dura.| ~| Correl.f } Other Test # EPA EPA Accel. Lug Manufacturer's Rep. Signature Certification Rep. Signature Returned Date Form HD-750G-02 - Receiving Inspection Report 11 ------- Check List Test Cell 3 and 4 Gasoline Engine Dynamometer Operation Check: Water Cooler Package; Oper. Init. Water ON Expansion Tank - 2/3 to 3/4 full Booster Pump ON Air Pressure - ON Control Boom Assembly; Vacuum Line - Installed Fuel Line - Installed Fuel Pressure Line - Installed Oil Pressure Line - Installed Temperature Thermocouple (s) - Installed Ignition Wire - Connected Throttle Control - Connected Dynamometers; Drive Shaft - Connected Drive Shaft Guard - Connected Engine Water Hoses - Connected Exhaust Muffler etc: - Connected Exhaust Sample Probes - Connected Fuel Regulator - Correct Setting Cooler Fan {if used) - ON Console All Potentiometers in OFF position Power ON in M.G. Room M. G. set - ON- 10 min. warm-up min. Primary Power - ON Vacuum Manometer at zero Ignition - ON Rotation - CW - front side Temp. Recorder - ON CCW - rear side Inertia - Pos. position Wet Bulb thermo-filled Mode - Manual and power ON Strip chart recorder - ON Form HD-750G-03 12 ------- Check List - Preparation of Test Engine for Return to Mfr. Description Oper. Init. Disconnect; Drive Shaft - Dyno End, only. Engine Stand Lag Down Bolts. Accessory Stands. Water Hoses from Coolant package. Exhaust System at Exhaust manifold only. All Temp, thermocouple wires from Control Boom Assembly. All sample probe lines from engine only. All fuel, oil, vacuum, manifold, pressure, and feed lines from Control Boom Assembly only. Oil coolant hoses from Coolant package. Move Engine and Exhaust System Heavy-Duty Gasoline Engine(s) to Room 409. Disconnect, Remove and put in proper place: All Thermocouples, wires and fittings (if installed by E.P.A.) Water Hoses Drive Shaft All fuel, oil, vacuum, manifold, pressure and feed lines and fittings. Coolant complete; oil (if required). All pipe plugs, cap plugs and other fittings removed by E.P.A. Disassemble: Exhaust System and all other engine Pack in Box; parts and accessories received. Strap to Skid; Note: Check HD Rec. form to assure shipment is complete as received. Form HD-750G-04 13 ------- Environmental Protection Agency Office of Air S Water Programs 2565 Plymouth Road Ann Arbor, Michigan 48105 SHIPPING ORDER No. Date Ship To : Charge To: Address : Address : Attention: Attention: The following listed material/equipment/engine(s) now on consigment/loan to this facility is herewith returned per signature of your carrier (or, common carrier, if applicable.) Quantity Description Ser. No. The above items were received by (Signature) on (Date) Form HD-750G-05 14 ------- EPA TEST PROCEDURE NUmbTO-757 Page i of 6 SUBJECT HEAVY-DUTY GASOLINE ENGINE DYNAMOMETER TEST CYCLE Reference FEDERAL REGISTER VOL. 40 NO. 40 FEBRUARY 27, 1975 Responsible Organization TEST OPERATIONS Test Witness SUPERVISOR - HEAVY-DUTY TESTING Type of Test Report COMPUTER OUTPUT Report Distribution CSD/LAB. CHIEF/MFR. REP. /DATA FILE Data Form No. Computer Program Performance Interval EACH TEST Supersedes WRW Superseded by REMARKS/COMMENTS ORIGINAL RELEASE APPROVALS Office PROP RAM MPMT LAB. BRANCH LAB. BRANCH Change Letter Section Signature OT1AT TTV A^^TTPZXWn? CHIEF TEST OPERATIONS CHIEF Date REVISIONS Description of Change Approval Date 15 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE DYNAMOMETER TEST CYCLE TEST PROCEDURE PROCEDURE NO. TP-757 PAGE 2 OF 6 1.0 PURPOSE A prescribed sequence of engine operating conditions are conducted on an engine dynamometer to determine conformity with the standards stated in the Federal Register. 2.0 TEST ARTICLE DESCRIPTION Applicable to new gasoline heavy-duty engines beginning with the 1974 model year. A heavy-duty engine is defined as any engine which the engine manufacturer could reasonably expect to be used for motive power in a heavy-duty vehicle. 3.0 REFERENCES 3.1 Federal Register, Volume 40, Number 40, February 27, 1975. pp 8482 - 8495 4.0 REQUIRED EQUIPMENT/CONDITIONS 4.1 An engine dynamometer capable of maintaining constant speed +_ 100 RPM from full throttle to closed throttle motoring. 4.2 A chassis-type exhaust system or equivalent. 4.3 A radiator typical of that used with the engine in a vehicle or equivalent. 4.4 Auxiliary fixed speed cooling fan (if required.) 4.5 Tape recorder with prerecorded instructions for dynamometer operator. 4.6 Fuel shall be Indolene clear or Indolene HO if catalyst equipped. 5.0 PRECAUTIONS 5.1 Maintain ambient temperature of test cell between 60°F to 68°F during engine soak period and between 68°F to 86°F during test cycle. 5.2 Tolerances for time, speed and manifold vacuum must be followed during cycle in order to perform valid test. 5.3 Visual and audible observation of engine-dyno operation should be performed during test. Shut down engine-dyno if abnormalities are detected. ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE DYNAMOMETER TEST CYCLE TEST PROCEDURE PROCEDURE NO. TP-757 PAGE J OF .§ 6.0 VISUAL INSPECTION 6.1 Perform visual inspection of engine-dyno systems prior to start up. 6.2 Inspect fuel system for leaks before and after test. 7.0 TEST ARTICLE PREPARATION Refer to TP-750-G. 18 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE DYNAMOMETER TEST CYCLE TEST PROCEDURE PROCEDURE NO. TP-757 PAftP 4 r>P 6 8.0 TEST PROCEDURE An initial 5-minute idle, two warm-up cycles and two hot cycles constitute a complete dynamometer run. Idle modes may be run at the beginning and end of each test only, thus eliminating the need to change speed between cycles. Test Sequence Test Description Data Output 100 PRECONDITIONING 101 Start cooling system. 102 Start the engine and precondition it by operation Dyno over one or more cycles prescribed for service Log Book accumulation or dynamometer operation until the Water engine has reached normal operating conditions. Temp.°F 103 Shut down engine and cooling system and allow Record to stand for at least 1 hour but not more than Soak 2 hours. Time 200 TEST CYCLE 201 Start cooling system. 202 Start engine and operate within the manufacturer's RPM specifications for off-idle operation for 5 minutes. 203 Return the engine throttle control to the normal idle position. 204 Turn on prerecorded tape and run four nine mode Continuous cycles according to the following time, speed, Record load requirements. Of RPM, Manifold Vacuum vs. Time 19 ------- REVISIONS: HEAVY-DOTY GASOLINE ENGINE DYNAMOMETER TEST TEST PROCEDURE PROCEDURE NO. TP-757 Test Sequence Test Description Data Output SEQUENCE NO. MODE MANIFOLD TIME IN CUMULATIVE WEIGHTING VACUUM MODE-SECS. TIME-SECS. FACTORS 1 Idle 70 2 Cruise... 16" Hg... 23 <3 * • • •*•••••• f TA •••**» j-\J *-*^3 • • * 44 4 Cruise—16" Hg— 23 5 PTD 19" Hg... 17 6 Cruise 16" Hg... 23 7 FL 3" Hg... 34 8 Cruise... 16" Hg... 23 9 CT 43 70 93 137 160 177 200 234 257 300 0.232 .077 .147 .077 .057 .077 .113 .077 .143 The engine dynamometer shall be operated at a constant speed of 2,000 r.p.m. +100 r.p.m. (Speed deviations, not to exceed 200 r.p.m., will be allowed during the first four seconds of each mode.) The idle operating mode shall be carried out at the manufacturer's recommended engine speed. The CT operating mode shall be carried out at the same engine speed as above. If the specified manifold vacuum can not be reached during the PTD mode, the engine shall be operated at closed throttle during that mode. If the specified manifold vacuum can not be reached during the FL mode, the engine shall be operated at wide open throttle during that mode. 205 Record fuel flow and brake horsepower during each mode. 206 Shut down engine and cooling system after last idle period. Lbs/Hr Torque Record Engine Running Time 20 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE DYNAMOMETER TEST CYCLE TEST PROCEDURE 1 k «? 1 t I\X^ V»k \J V/IVb PROCEDURE NO. TP-757 PA«F 6 ni6 9.0 DATA INPUT 9.1 Test number/system tested/inst. oper./dyno oper./engine make/I.D. #/ mfr. data. 9.2 Engine date of manufacture/engine hours/CID/family/idle RPM/carb/BBl. 9.3 Date and time of day for each part of the test schedule. 9.4 Intake manifold vacuum and engine RPM continuously recorded on the same chart. 10.0 DATA ANALYSIS 10.1 Determine whether the cycle was run in accordance with Acceptance Criteria (12.0) by observing chart peaks, speed trace and manifold vacuum traces. 11.0 DATA OUTPUT 11.1 All data entries and chart records maintained in HD Test File. 12.0 ACCEPTANCE CRITERIA 12.1 The test will be invalidated if there is a deviation by more than: (a) two seconds from the specified time for the CT mode, or (b) 0.3 inch Hg during the cruise and PTD modes, or more than 0.2 inch Hg during the PTA and FL modes from the specified mode vacuums during the last ten seconds of a mode, or (c) 200 r.p.m. during the first four seconds of each mode, or 100 r.p.m. during the remainder of each mode. 13.0 QUALITY PROVISIONS 13.1 Dynamometer calibrated monthly according to TP-250. Weekly single point torque check. 13.2 Fuel flow meter calibrated using dead weight tester. 13.3 RPM/torque recorder output checked prior to each test. Recorder serviced and calibrated at 3 month intervals. 13.4 Driving tape checked monthly for proper timing and wear. 21 ------- EPA TEST PROCEDURE Number TP-758 Page i of SUBJECT HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO , HC AND NO FEDERAL REGISTER VOL. 40 NO. 40 FEBRUARY 27, 1975 Data Form No. Responsible Organization TEST OPERATIONS Test Witness SUPERVISOR - HEAVY-DUTY TESTING Computer Program SAQP: GAS Performance Interval EACH TEST Type of Test Report COMPUTER OUTPUT Report Distribution CSD/LAB. CHIEF/MFR. REP./DATA FILE Supersedes NEW Superseded by REMARKS/COMMENTS ORIGINAL RELEASE APPROVALS Office Section Signature Date PROGRAM MGNT QUALITY ASSURANCE LAB. BRANCH CHIEF LAB. BRANCH TEST OPERATIONS CHIEF Change Letter REVISIONS Description of Change Approval Date 23 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO,, HC AND NOy TEST PROCEDURE PROCEDURE NO. TP-758 PAGE_2_OF 7 1.0 PURPOSE Exhaust gases are analyzed continuously during a prescribed sequence of engine operating conditions to determine conformity with the standards specified in the Federal Register. 2.0 TEST ARTICLE DESCRIPTION Applicable to new heavy-duty engines beginning with the 1974 model year. A heavy-duty engine is defined as any engine which the engine manufacturer could reasonably expect to be used for motive power in a heavy-duty vehicle. 3.0 REFERENCES 3.1 Federal Register, Volume 40 Number 40 February 27, 1975. pp 8482-8495 4.0 REQUIRED EQUIPMENT/CONDITIONS 4.1 Exhaust gas sampling and analytical system conforming to schematic H774-1 (Attachment No. 1) with the following instruments: A. Nitric oxide NDIR analyzer, range 0-4000 PPM B. Carbon monoxide NDIR analyzer, range 0-10 percent C. Carbon dioxide NDIR analyzer, range 0-16 percent D. High-range hydrocarbon NDIR analyzer, range 0-10,000 PPM hexane equivalent (propane cone, x 0.52) E. Low-range hydrocarbon NDIR analyzer, range 0-1,000 PPM hexane equivalent. Sample lines, filter, valves, pumps, flowmeters and other components which are in contact with exhaust sample must be of stainless steel, teflon, viton or glass construction. 4.2 Zero grade air or nitrogen meeting the following maximum requirements of contamination level Carbon Response = 10 ppm CO Response = 10 ppm NO Response = 1 ppm CO2 Response = 400 ppm 25 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO,, HC AND NOX TEST PROCEDURE PROCEDURE NO. TP-758 PAOF.3 OF 7 4.3 Calibration gases with concentrations known to be within ±2 percent of true value as follows (N2 diluent): Low range High range NO ana- HC analyz- HC analyz- lyzer- er-Hexane er-Hexane NO equivalent^ equivalent CO and CO2 analyzers-Blend of CO and CO2 containing CO plus C02 p.p.m 100 200 300 400 600 800 1,000 p. p. in 600 1,000 1,500 2,500 4,000 6,000 8,000 10,000 p.p.m i 250 500 750 1,000 1,500 2,000 2,500. 3,000. ... 3,500 4,000 Mole percent 0.5 1.0 2.0 3.0 4.0 6.0 8.0 10.0 Mole percent 16.0 15.0 14.0 13.0 12.0 10.0 8.0 6.0 The hexane equivalent of propane when used as the normalizing gas for calibrating nondispersive infrared analyzer is prescribed to be 0.52 (propane concentra- tion x 0.52 = hexane equivalent concentration). Mini- mum storage temperature of the cylinders shall be 60OF; minimum use temperature shall be 68°F. NOTE: Concentration values should be traceable to EPA gravimetric standards. 4.4 Daily working gases (span gases) equivalent to 80 to 100 percent full scale response for each range. 4.5 Recorders (4 channels) for continuous record of analyzer output and calibration. 5.0 PRECAUTIONS 5.1 Safety precautions should be followed when handling compressed gases. NO and CO are toxic gases. 5.2 Insure gas cylingers have adequate pressure for testing ^200 psig.) 5.3 When calibrating/spanning/sampling the identical instrument inlet pressure must be used. Adjust flows to pressure reading rather than flowmeter. 26 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO2, HC AND NOX TEST PROCEDURE PROCEDURE NO. TP-758 PAGEJ OF I 5.4 Insure that flowrates are adequate to minimize response time. 5.5 Check the condition of the drier in the nitric oxide analyzer sampling line. Replace the drying agent if necessary. 5.6 Insure that the sample probe(s) is properly inserted 2 feet into tailpipe. 6.0 VISUAL INSPECTION 6.1 Inspect recorder connections and other electrical connections to insure they are secure. 6.2 Inspect pressure gauges and flowmeters for proper operation, stuck floats, pointers, etc. 6.3 Inspect system vent for proper connection. 7.0 TEST ARTICLE PREPARATION 7.1 Leak check exhaust gas sampling system by closing off valve at sample probe. All pressure gauges should drop to zero reading. 7.2 Calibrate exhaust emission analyzer system using zero and span gases. Adjust instrument gain and zero as required. Analyzers require a minimum of 2 hours warm-up, therefore they are usually never turned off, except for chopper motors, while they are in service. 7.3 The following inter-service checks are performed monthly. (5) Check response of hydrocarbon analyzer to 100 percent CO. If response is greater than 0.5 percent full scale, refill filter cells with 100 percent CO, and recheck. Note any remaining response on chart. If response still exceeds 0.5 percent, replace detector. (6) Check response of hydrocarbon analyzers to nitrogen saturated with water at ambient temperature. Record ambient temperature. If the low-range instrument response exceeds 5 percent of full scale with saturated nitrogen at 75°F., replace the detector. If the high- range response exceeds 0.5 percent of full scale, check detector on low-range instrument, then reject if response exceed 5 percent of full scale at 75°F. 7.4 Change filter papers and back flush water traps and sample line. 7.5 Turn-on sample pumps. 27 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO2, HC AND NOX TEST PROCEDURE PROCEDURE NO. TP-758 8.0 TEST PROCEDURE The exhaust sample is analyzed continuously during 4 nine-mode cycles. Test Sequence Test Description Data Output 101 Check zero, span, flow and pressure immediately prior to start of cycle. 102 Start sample flow and recorders when engine throttle control is returned to normal idle position from the initial off-idle position. Chart speed should be 6 inch per minute. 103 Sample and analyze exhaust gases for 4 nine-mode cycles (TP-757) including the final idle mode. 104 Purge sample line with nitrogen to establish a a constant hydrocarbon "hangup". 105 Recheck zero, span, flowmeter, pressure gauge readings. Recorder Defl. Recorder Defl. Continuous Trace, Computer Input HC Defl. vs. Time 28 ------- REVISIONS-- HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, COp, HC AND NOV TEST PROCEDURE PROCEDURE NO. TP-758 PAftP 6 ftF 7 9.0 DATA INPUT 9.1 The following steps are performed by direct computer analysis. (a) Time correlate the hydrocarbon, carbon monoxide, carbon dioxide, and nitric oxide charts. Determine the location on the chart of analyzer response corresponding to each mode. Determine and compensate for trace abnormalities. (b) Locate the last 3 seconds of the HC, CO, CO2, and NO traces obtained from the 3 inch, 10 inch, 16 inch, 19 inch and idle modes. Divide this portion of each trace into a minimum of three segments of equal length. Determine the chart reading at the end of each segment to within 0.5 percent of full scale. Convert these readings into concentration values. Determine the average of these values. (c) The values recorded for the initial idle mode are used for both warm-up cycles 1 and 2. The final idle mode values are applied to hot cycles 3 and 4. (d) Locate the HC, CO, CO2, and NO closed throttle mode traces. Divide each trace into a minimum of 43 segments of equal length. Determine the chart reading at the end of each segmentss within 0.5 percent of full scale. Convert these reading into concen- tration values. Determine the average of these values. 9.2 Fuel consumption in Ibs. per hour are determined for each mode including idle. 9.3 Record test number, instrument operators, all pertinent instrument information such as tuning-gain-serial numbers-detector number-range, barometric pressure, intake air temperature and humidity. 10.0 DATA ANALYSIS 10.1 Analysis of all recorded data performed by Data Validation for completeness, accuracy and conformance to specified procedure. 11.0 DATA OUTPUT 11.1 Concentration values are reduced by computer to brake specific values (gms/hr) for CO, HC and NOV using specified weighting and humidity li correction factors. 29 ------- REVISIONS: HEAVY-DUTY GASOLINE ENGINE EXHAUST ANALYSIS PROCEDURE, CO, CO2» HC AND NOX TEST PROCEDURE i tw 1 ri%N^v»t wi%c PROCEDURE NO. TP-758 PAOF_Z..<">F 7 12.0 ACCEPTANCE CRITERIA 12.1 Upon completion of the test, the hydrocarbon concentration (hangup) shall drop to 5 percent or less of full scale within 10 seconds and 3 percent or less of full scale within 3 minutes, while being purged with nitrogen at the specified flow rate, or the test is invalid. 12.2 A drift in excess of 2 percent of full scale in the calibration of any one or the exhaust emission analyzers invalidates the test. 13.0 QUALITY PROVISIONS 13.1 Analyzer calibrations and interference checks performed monthly while in service. 13.2 Calibration checks performed before and after each test. 13.3 Quality Assurance performs audit of procedure and test cell equipment on non-routine basis. 30 ------- TP-758 (Attachment No. 1) FLi V VIS FLOW SCHEMATIC OF EXHAUST GAS ANALYSIS SYSTEM EMPLOYED BY EPA ------- HEAVY DUTY GASOLINE ENGINE DATA SHEET ll ENGINE ID ENS FAKILY iiiiijiiiijiiiijmijiiiyiiiyiMyiiiijiiigrTTTFrTTji DATE BU/LT DISP. ! TEST s* ' o ^ 8 sgmrj EXH.SVJ. AIR IDLE . BACIJ. | Itaf T WHO MAX®. SOV'D, RPM SPEED' LUB. OIL RPrt n:rg. f-:.r. VMCW RPM FUEL H? RPM FUEL iTIMiNai RPM SPEED j LUB. OIL £Sl CARB KODEL . I . ' . Mlll|llllliMMlllllllnlM|lh. M|lilTlM!l{lTH'!illlllllllllj;HI|lla2|ll|-ll sF3 is M 25 jo jis«3« 235 3 3 w sso M4NWF. RESULTS CWDIT10HS IPPTO. t%; (PPM) , . -B5HC4 c>15.| i I IACCUM. MAX , KOWEJIUI , HC CO NO I BSHC B5CQ B^IOX BSNO* T^vs P^RQ TDBny/BjSUN. MRS CFM OJR IKIT ;3?l-.'M J03 NO. PA II11II11111| 11 ill111 I'M 1111111} I i 11 M I \\\ M IJ11 i I M «! 11 j 11 i 11 i 11 i 1114 5 10 1^ XT 25 id JS ft 45 3 55 64 « 10 20 7C 75 MM! ihiiic^nnn ••£ 7c' S W 111 M M 111 M 8! ! M I ;! t i M I M M M M M I i I i M ! I' nTT t 5 tf Js 20 25 30 % 53 45 . IDLE '.ST5. AIR 25 fM wrA !S5!W-,i®,ppM yf.ST* t -v* u^ f\f ^ EL Mil !i{iiii-MT; To Js & b <-4oo (?£sy:r^ ,R)|!3M. @. PPM FUEL |r->'«)S PPM J^ nn i» ?5!fC I BSCO iBSHC-1 30 35 40 -B 50 CONDITIONS A*C'IV i C1^1?. ^c TCST •^yl BARO ITPB ITWBI"-•:.'Hit£i ETnrnfs: 161 Aro. To 3 TEST COVPLgT Tl^Ei PAT£ mrm m ! •• i 1 30 35 50 (S 10 T5 .HC CO CO?. WO RP TORQUE 'ii JiZi co IC02 I MO NOXRPM I9R4£ 5UEL >i5 -tTTTT i 54/:/1 i! i ! 1 /r* 1>81i i: • ii L-ULLLLLU TTT22 i; i. i TnJ* \ ' ~i _i_L ILL r 36113' i 3'B'/!51 i r • i rus i I _L_L iMMiiiM 1 ! i M H ' ' • ' !'!!••: 11 5 to~~ is FORM NO. HD-758-01 i-U- i 25. I'"! I i 26' ! ; : i ! I i I i I : Z,7« I : M ; ! 23 : _i_t I i < . I I ! i : • • e.o ; . : • , i ' * ' 1 • ' ' : nt3ii~aiL-ii3t;iuiL:: ) 35 *0 45 50 55 60 I i' ^4!i ^Ul-l .* —1—*_« L_i_i_4 -*--1!- I * ' 1 • * yl_l . I I 30 35 *Q 45 ,5/28/73 32 ------- |