ANNEX IVSupplementary provisions
ANNEX IV Test type III requirements: emissions of crankcase gases 1. Introduction This Annex describes the procedure for type III testing, as referred to in Part A of Annex V to Regulation (EU) No 168/2013. 2. General provisions 2.1. The manufacturer shall provide the approval authority with technical details and drawings to prove that the engine is or engines are so constructed as to prevent any fuel, lubrication oil or crankcase gases from escaping to the atmosphere from the crankcase gas ventilation system. 2.2. Only in the following cases shall the technical service and approval authority require the manufacturer to carry out the type III test: 2.2.1. for new vehicle types with regard to environmental performance equipped with a new design of the crankcase gas ventilation system, in which case a parent vehicle, with a crankcase gas ventilation concept representative of that approved, may be selected if the manufacturer so chooses to demonstrate to the satisfaction of the technical service and approval authority that the type III test has been passed; 2.2.2. if there is any doubt that any fuel, lubrication oil or crankcase gases might escape to the atmosphere from the crankcase gas ventilation system, the technical service and the approval authority may require the manufacturer to conduct the type III test in accordance with point 4.1 or 4.2 (as chosen by the manufacturer). 2.3. In all other cases, the type III test shall be waived. 2.4. L-category vehicles equipped with a two-stroke engine containing a scavenging port between the crank case and the cylinder(s) may be exempted from the type III test requirements at the request of the manufacturer. 2.5. The manufacturer shall attach a copy of the test report on the parent vehicle with the positive result from the type III test to the information folder provided for in Article 27 of Regulation (EU) No 168/2013. 3. Test conditions 3.1. The type III test shall be carried out on a test vehicle which has been subjected to the type I testing in Annex II and the type II testing in Annex III. 3.2. The vehicle tested shall have a leak-proof engine or leak-proof engines of a type other than those so designed that even a slight leak may cause unacceptable operating faults. The test vehicle shall be properly maintained and used. 4. Test methods 4.1. The type III test shall be conducted according to the following test procedure: 4.1.1. Idling shall be regulated in conformity with the manufacturer’s recommendations. 4.1.2. Measurements shall be taken in the following sets of conditions of engine operation: Table 3-1 Idle operation or steady state vehicle test speeds and power absorbed by the chassis dynamometer during the type III test Condition number Vehicle speed (km/h) 1 Idling 2 Highest of: (a) 50 ±2 (in 3rd gear or ‘drive’) or (b) if (a) not achievable, 50 % of max. design vehicle speed. 3 Condition number Power absorbed by the brake 1 Nil 2 That corresponding to the setting for type I test at 50 km/h or if not achievable type I test at 50 % of max. design vehicle speed. 3 As for condition 2, multiplied by a factor of 1,7 4.1.3. For all operation conditions listed in point 4.1.2., the reliable functioning of the crankcase ventilation system shall be checked. 4.1.4. Method of verification of the crankcase ventilation system 4.1.4.1. The engine’s apertures shall be left as found. 4.1.4.2. The pressure in the crankcase shall be measured at an appropriate location. It may be measured at the dip-stick hole with an inclined-tube manometer. 4.1.4.3. The vehicle shall be deemed satisfactory if, in every condition of measurement defined in point 4.1.2., the pressure measured in the crankcase does not exceed the atmospheric pressure prevailing at the time of measurement. 4.1.5. For the test method described in points 4.1.4.1. to 4.1.4.3., the pressure in the intake manifold shall be measured to within ±1 kPa. 4.1.6. The vehicle speed as indicated at the dynamometer shall be measured to within ± 2 km/h. 4.1.7. The pressures measured in the crankcase and the ambient pressure shall be measured to within ± 0,1 kPa and shall be sampled with a frequency ≥ 1 Hz within a time period of ≥ 60 s when the conditions in point 4.1.2. are continuously operated and stabilised. 4.2. If, in one or more of the conditions of measurement in point 4.1.2., the highest pressure value measured in the crankcase within the time period in point 4.1.7. exceeds the atmospheric pressure, an additional test as defined in point 4.2.1. or 4.2.3. (as chosen by the manufacturer) shall be performed to the satisfaction of the approval authority. 4.2.1. Additional type III test method (No 1) 4.2.1.1. The engine’s apertures shall be left as found. 4.2.1.2. A flexible bag impervious to crankcase gases and having a capacity of approximately five litres shall be connected to the dipstick hole. The bag shall be empty before each measurement. 4.2.1.3. The bag shall be closed before each measurement. It shall be opened to the crankcase for five minutes for each condition of measurement prescribed in point 4.1.2. 4.2.1.4. The vehicle shall be deemed satisfactory if, in every condition of measurement defined in points 4.1.2. and 4.2.1.3., no visible inflation of the bag occurs. 4.2.2. If the structural layout of the engine is such that the test cannot be performed by the methods described in point 4.2.1., the measurements shall be effected by that method modified as follows: 4.2.2.1. Before the test, all apertures other than that required for the recovery of the gases shall be closed; 4.2.2.2. The bag shall be placed on a suitable take-off which does not introduce any additional loss of pressure and is installed on the recycling circuit of the device directly at the engine-connection aperture. 4.2.2.3. Figure 3-1 Various test set-ups for type III test method No 1 Text of image See detail (i) See detail (i) (a) Direct recycling at slight vacuum (b) Indirect recycling at slight vacuum (i) Connection of take-off bag See detail (i) (c) Double-circuit direct recycling (d) Venting of crankcase with control valve (the bag must be connected to the vent) 4.2.3. Alternative additional type III test method (No 2) 4.2.3.1. The manufacturer shall prove to the approval authority that the crankcase ventilation system of the engine is leak-tight by performing a leak check with compressed air inducing an overpressure in the crankcase ventilation system. 4.2.3.2. The engine of the vehicle may be installed on a test rig and the intake and exhaust manifolds may be removed and replaced with plugs that hermetically seal the air intake and exhaust evacuation openings of the engine. Alternatively, the intake and exhaust systems may be plugged on a representative test vehicle on locations chosen by the manufacturer and to the satisfaction of the technical service and approval authority. 4.2.3.3. The crankshaft may be rotated to optimise the position of the pistons, minimising pressure loss to the combustion chamber(s). 4.2.3.4. The pressure in the crankcase system shall be measured at an appropriate location other than the opening to the crankcase system used to pressurise the crankcase. When present, the oil fill cap, drain plug, level check port and dipstick cap may be modified to facilitate the pressurisation and pressure measurement; however, all seals between the screw-thread, gaskets, O-rings and other (pressure) seals of the engine shall remain intact and representative of the engine type. Ambient temperature and pressure shall remain constant throughout the test. 4.2.3.5. The crankcase system shall be pressurised with compressed air to the maximum recorded peak pressure as monitored during the three test conditions specified in point 4.1.2. and at least to a pressure of 5 kPa over ambient pressure or to a higher pressure at the choice of the manufacturer. The minimum pressure of 5 kPa shall be allowed only if it can be demonstrated by means of traceable calibration that test equipment has accurate resolution for testing at that pressure. A higher test pressure shall be used otherwise, according to the equipment’s calibrated resolution. 4.2.3.5. The compressed air source inducing the overpressure shall be closed and the pressure in the crankcase shall be monitored for 300 seconds. The test pass condition shall be: crankcase pressure ≥ 0,95 times the initial overpressure for 300 seconds after closure of the compressed air source.