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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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TP-758 (Attachment No. 1)
FLi
V
VIS
FLOW SCHEMATIC OF EXHAUST GAS ANALYSIS SYSTEM EMPLOYED BY EPA
-------
HEAVY DUTY GASOLINE ENGINE DATA SHEET
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32
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