Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on October 6, 1992.
As of Tuesday, December 18th, 2018 this Executive Order has not been overturned or superceeded.

Approved Parts

ModelsModification
1992 model year Ford Motor Company vehicles powered by a 7.3L Navistar International heavy-duty diesel engine.Modifications to the OEM emission-related parts due to the installation of the turbocharger kit include replacement of the OEM exhaust systems with a 3-1/2" diameter exhaust system.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-175-4
  • Executive Order 175-4 / D175-4
  • ARB # D-175-4
  • Executive Order No: D-175-4
  • C.A.R.B. No. D-175-4
  • Resolution D-175-4
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-175-4 PDF

D-175-4 Document:



                                                                (Page 1 of 2)

                               State of California
                               AIR RESOURCES BOARD

                            EXECUTIVE ORDER D—175—4 _
                   Relating to Exemptions Under Section 27156
                              of the Vehicle Code


                           HYPERMAX ENGINEERING, INC.
                                TURBOCHARGER KIT

 Pursuant to the authority vested in the Air Resources Board by Section 27156
 of the Vehicle Code; and

‘rpursuant to the authority vested in the undersigned by Sections 39515 and
 39516 of the Health and Safety Code and Executive Order G—45—5;

 IT IS ORDERED AND RESOLVED:    That the installation of the add—on
 turbocharger kit manufactured by Hypermax Engineering, Inc. of 25§ E. Route
 72, Gilberts, Illinois, 60136, has been found not to reduce the
 effectiveness of required motor vehicle pollution control devices and
 complies with the forty (40) percent snap idle smoke opacity standard in
 Title 13, California Code of Regulations, Section 2180—2187, and therefore
 is exempt from the prohibitions of Section 27156 of the Vehicle Code for the
 1992 model—year Ford Motor Company heavy—duty vehicles powered by a 7.3L
 Navistar International heavy—duty diesel engine.  Hypermax‘s aneroid (puff
 limiter) is included as part of the turbocharger kit for the 1992 model year
 Ford Motor Company vehicles powered by a 7.3L Navistar International heavy—
 duty diesel engine.

 This Executive Order is valid for the Hypermax Engineering, Inc.‘s
 turbocharger kit which uses one of the following turbochargers:

      1.   AiReaearch model 409900—2 with area ratio (A/R) of 0.96;
      2.   AiResearch model 465124~5004 with A/R of 1.15;
      3.   Holset Engineering model H2A76§80E/FAOIOCAZ with A/R of 1.08;
      4.   Warner—Ishi model RHB7—97OOVP28NFBRLSS2A with A/R of 1.10

 Modifications to the OEM emission—related parts due to the installation of
 the turbocharger kit include replacement of the OEM exhaust system with a 3—
 1/2" diameter exhaust system.

 This Executive Order is valid provided that installation instructions for
 this device will not recommend tuning the vehicle to specifications
 different from those submitted by the vehicle manufacturer.

 Changes made to the design or operating conditions of the device, as
 exempted by the Air Resources Board, that adversely affect the performance
 of a vehicle‘s pollution control system shall invalidate this Executive
 Order.

 No claim of any kind, such as "Approved by Air Resources Board" may be made
 with respect to the action taken herein in any advertising or other oral or
 written communication.


HYPERMAX ENGINEERING, INC.                            EXECUTIVE ORDER D—175—4
TURBOCHARGER KIT                                     (Page 2 of 2)


Marketing of this device using an identification other than that shown in
this Executive Order does not constitute any opinion as to the effect that
the use of this device may have on any warranty either expressed or implied
by the vehicle manufacturer.

THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATIO®, ACCREDITATION,
APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESOURCES BOARD OF ANY
CLAIMS OF THE APPLICANT CONCERNING ANTI—POLLUTION BENEFITS OR ANY ALLECED
BENEFITS OF HYPERMAX ENGINEERING, INC.‘S TURBOCHARGER KIT FOR INSTALLATION
ON THE 1992 FORD MOTOR COMPANY VEHICLES POWERED BY A 7.3L NAVISTAR
INTERNATIONAL HEAVY—DUTY DIESEL ENGINE.

Section 17500 of the Business and Professions Code makes untrue or
misleading advertising unlawful, and Section 17534 makes violation
punishable as a misdemeanor.


Section 43644 of the Health and Safety Code provides as follows:

     "43644. (a) No person shall install, sell, offer for sale, or
     advertise, or except in an application to the state board for
     certification of a device, represent, any device as a motor vehicle
     pollution control device for use on any used motor vehicle unless that
     device has been certified by the state board.  No person shall sell,
     offer for sale, advertise, or represent any motor vehicle pollution
     control device as a certified device which, in fact, is not a certified
     device.  Any violation of this subdivision is a misdemeanor."

Any apparent violation of the conditions of this Executive Order will be
submitted to the Attorney General of California for such action as he deems
advisable.


Executed at El Monte,   California,   this      da     October,   1992.




                                               Summerfield
                                         Assistant Division Chief
                                         Mobile Source Division


                  State of California
                  AIR RESOURCES BOARD




EVALUATION OF HYPERMAX ENCINEERING, INC‘S TURBOCHARCGER KIT
    FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE
SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF
            THE CALIFORNIA CODE OF REGULATIONS




                           October 1992




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                                              State of California
                                              AIR RESOURCES BOARD




                            EVALUATION OF HYPERMAX ENGINEERING, INC‘S TURBOCHARCGER KIT
                                FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE
                          SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                                          CALIFORNIA CODE OF REGULATIONS




                                                        by

                                              Mobile Source Division
                                               State of California
                                               Air Resources Board
                                               9528 Telstar Avenue
                                             El Monte, CA    91731—2990




                   (This report has been reviewed by the staff of the California Air Resources
                   Board and approved for publication.  Approval does not signify that the
                   contents necessarily reflect the views and policies of the Air Resources
                   Board, nor does mention of trade names or commercial products constitute
                   endorsement or recommendation for use.)




seemmmeniniis os


                                      SUMMARY




       Hypermax Engineering,   Inc.   (Hypermax) of 255 E. Route 72, Gilberts,

Illinois 60136 has requested an update to Executive Order (E.0.) D—175—2,

which exempts their Turbocharger Kit from the préhibitions in Vehicle Code

Section 27156, to include the 1992 model year Ford Motor Company vehicles

powered by a 7.3L Navistar International heavy—duty diesel engine.

       Since the 1992 model year 7.3L Navistar International heavy—duty diesel

engine is carried over from the 1989 model year for which an exemption has been

granged and the snap idle test results indicate that smoke opacity of the

modified vehicles was less than the 40 percent standard,     staff believes that

the add—on turbocharger kit will have no adverse effect on exhaust emissions

from the engine for which the exemption update is requested.      Hypermax is

currently undergoing snap—idle tests to determine the smoke opacity levels of

the 1990 to 1991 models installed with their turbocharger kit.

       The staff recommends that Hypermax be granted an exemption as requested

and that Executive Order D—175—4 be issued.


                                              TABLE_ O R. CONTENTS




                                                                                 Page Number




SUMMARY

CONTENT S                                                                             i1

I.        INTRODUCTION

II.       CONCLUSION

III.      RECOMMENDATION

IV.       TURBOCHARGER KIT DESCRIPTION

          TURBOCHARGER KIT DISCUSSION

          APPENDIX — ANEROID INSTALLATION INSTRUCTIONS AND DIAGRAMS                    5




                                                             ii




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         EVALUATION OF HYPERMAX ENGINEERING, INC.‘S ADD—ON TURBOCHARGER
             KIT FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE
         SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                        CALIFORNIA CODE OF REGULATIONS




I.      INTRODUCTION

        Hypermax Engineering, Inc.   (Hypermax) of 255 E. Route 72, Gilberts,

Illinois 60136 has requested an update to Executive Order (E.0.) D—175—2 to

include the 1992 model year Ford Motor Company vehicles powered by a 7.3L

Navistar International heavy—duty diesel engine only.     The E.O. D—175—2

currently exempts Hypermax‘s Turbocharger Kit from the prohibitions of Vehicle

Code (VC) Section 27156 for the 1988—1989 model year Ford Motor Company

vehicles powered by a 7.3L Navistar International heavy—duty diesel engine.

Hypermax is currently undergoing snap—idle tests to determine the smoke opacity

levels of the 1990 to 1991 models installed with their turbocharger kit.

II.    _ concrustons
        Since the 1992 model year 7.3L Navistar International heavy—duty

diesel engine is carried over from the 1989 model year for which an exemption

has been granted and the snap idle test results indicate that smoke opacity of

the modified vehicle was less than the‘40 percent standard, the staff believes

that the add—on turbocharger system will have no adverse effect on exhaust

emissions from the engine for which the exemption update is requested.




III.    RECOMMENDATION

        The staff recommends that Hypermax be granted exemption for the add—on

turbocharger kit for the 1992 model year Ford Motor Company vehicles powered by

a 7.3L Navistar International heavy—duty diesel engine and that Executive Order

D—175—4 be issued.


Iv.           TURBOCHARGER KIT DESCRIPTION


               The purpose of the Hypermax turbocharger kit is to increase the power

output of the engine by compressing the intake charge to pressures above that

of the atmosphere.                 This increased pressure allows a greater charge density to

enter the combustion chamber and increase the volumetric efficiency.                            The

maximum fuel delivery is slightly increased in o?der to maintain proper air—

fuel ratios when the turbocharger is providing positive manifold pressure

(boost}.                The injection pump timing is retarded by two degrees from the

original equipment manufacturer (OEM) specifications.

               Hypermax offers four turbochargers with their system as follows:

               1.         AiResearch model 409900—2 with an area ratio (A/R) of 0.96;

               2.        AiResearch model 465124—5004 with an A/R of 1.15;

               3.        Holset Engineering model H2ZA7680E/FAOI9CAZ with an A/R of 1.08;

               4.        Warner—Ishi model RHBT7—9700VP28NFBRLS§S2A with an A/R of 1.10.

               The major components of the kit include a turbocharger, custom intake

adaptérs,               3—1/2" exhaust tubing, brackets, hoses and the hardware necessary to

complete the installation.

               Maximum positive manifold pressure is limited to 10 psig by the size of

the turbine and the compressor.                     The maximum engine speed is regulated by the

OEM fuel injection governor which is not modified by the installation of the

kit.          Therefore, by controlling maximum engine speed, maximum turbine speed and

corresponding boost pressures are also controlled.

               No OEM emission controls are removed or disconnected when the

turbocharger kit is installed.                     Positive Crankcase Ventilation (PCV)       system is

re—routed to the compressor inlet.                      To meet the newly implemented opacity

stapdard of 40 percent, Hypermax has developed an aneroid (Puff Limiter) for

installation on the 1992 model—year Ford Motor Company heavy—duty vehicles

powered by a 7.3L Navistar International heavy—duty diesel engine.                            Previous

model year applications do not include the installation of the aneroid because

such vehicle applications are not required to meet the 40 percent smoke

cpacity standards.




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                 v.         TURBOCHARGER KIT DISCUSSION

                            The applicant is making the add—on turbocharger kit available for the

                 1992 model year Ford Motor Company vehicles powered by a 7.3L Navistar

                ‘International heavy—duty diesel engine.          Certification documents show that the

                 1992 model year 7.3L Navistar International heavy—duty diesel engine is carried

                 over from the 1989 model year for which the fiurbficharger kit has been exempted.

                 Previous testing of the turbocharger showed no adverse affect on exhaust

               _emissions.          However, starting with the 1992 model year heavy—duty diesel

                 vehicles, snap—idle smoke opacity testing was required pursuant to California

                 Code of Regulations (CCR) Section 2182, Heavy—Duty Diesel Vehicle Smoke Opacity

                 Test Procedure.        The overall smoke opacity could not exceed 40 percent as

                 required by the CCR Section 2182        (c).   Turbochargers do not kick—in immediately

                 upon engine start up.         Thus, during transient periods, air is momentarily

                 restricted even though fuel is increased, causing an increase in peak smoke.

                 To meet the 40 percent opacity standard, Hypermax developed an aneroid which

                 reduces the response time (boost to fuel) of the turbocharger.             This has a

                 favorable impact on particulate emissions as well as meeting the 40 percent

                 opacity standard.         During periods of low manifold pressures, such as during

                 rapid acceleration, the aneroid reduces the fuel charge to each cylinder by

                 lowering the fuel rail pressure.         As the turbocharger increases the intake

                 manifold pressure, the fuel pressure increases to rated pump calibration volume

                 and pressure.         According to the manufacturer, the system, if properly adjusted,

                 reduces the smoke opacity while not affecting performance and no other

                 modifications to the system are necessary for installation on the 1992 model

                 year applicable vehicles.

                            Smoke opacity testing performed in accordance with California Code of

                 Regulations ({CCR) Section 2182 et seq. was conducted at the Hypermax facilities

                 on a 1992 Ford Motor Company F—250 pick—up truck powered by a 7.3L Navistar




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       International heavy—duty diesel engine.     Smoke opacity tests were conducted

      with the aneroid installed, and adjusted to the optimum level.

               Results are as follows:




                                Run Number        Percent Opacity

                                    1                  38.4

                                    2                  39.0

                                    3                  38.4

                                    4                  35.9




      The snap—idle test results indicate that the smoke opacity of the modified

      vehicle was less than 40 percent.      This demonstrates that the addition of the

      Hypermax Engineering, Inc. turbocharger kit will not have an adverse effect on

      emissions for the 1992 Ford Motor Company vehicles powered by a 7.3L Navistar

      Interhational heavy—duty diesel engine for which the exemption was requested.

               Hypermax has submitted all the required information and fulfilled the

      requirements for an exemption.




reccmmtenmse


APPENDIX .


                     ANEROID INSTALLATION INSTRUCTIONS


Background:

           The state of California limits 1992 aftermarket
           turbocharger equlpped diesel engines to a 40% maximunm snap
           idle smoke opacity.  Briefly, California‘s roadside testing
           requlres a vehicle‘s engine to be rapidly accelerated from
           low idle to high idle at no load.   The peak exhaust smoke
           opacity is measured and recorded.> 1992 and later vehicles
           must not exceed 40% opacity.

           The Hypermax Englneerlng Fuel Injection Pump Aneroid, or
           "Puff Limiter", limits the O.E.M. Stanadyne In]ectlon
           Pump‘s fuel dellvery to the naturally aspirated setting
           until sufficient turbocharger boost or intake manifold
           pressure is available for an acceptable smoke level during
           acceleration.

           It is strongly recommended that the user seek the ¢erv1ces
           of an authorized diesel fuel injection shop to equip his
           injection pump with the Hypermax Engineering 6.9/7.3L
           Aneroid.


Injection Pump Cover Removal:
     (Note:To avoid a fire, be certain top of, engine is cool to the
     touch if the aneroid is being installed without the injection
     pump being removed from the engine.)
           Disconnect electrical connections       (2).
          Disconnect fuel return line.
          Remove 3 cover screws and remove cover from housing.
          Remove return fuel valve assembly and "O" ring.
          Remove terminal nut/washer assembly (two sets)          from the top
           front of the cover and remove the electric shut—off
           solenoid from the cover including the small plastic
          insulating washers.
     6)   Remove the side terminal nuts    (one set)       and remove the cold
           advance solenoid.   Again, be sure to remove the insulating
          washers.                             n

Equipping New Cover:

     1)    Install cold advance solenoid and secure with terminal
          nut/washer assembly.    Install nuts and washers the same way
          they were removed from the old cover.           Tighten nuts to 12
          inch—lbs.  Do not overtighten.
     2) Install electric shut—off solenoid and install with
           terminal nut/washer assemblies.
     3)    Grease return valve "0" ring and 1nstall valve and fitting
           into cover.  If the return flttlng requires reallgnment
           hold the return valve assembly with a wrench to avoid
           stripping the threads in the cover.


                                  Page 1
06—12—92


    4) Grease aneroid "O" ring and install aneroid assembly into
          machined bore of new cover.  Install set screw and locate
          screw into the groove on the aneroid housing.  The screw
           should sit flush in the cover when it is correctly
           installed in the groove machined for it.   Place the aneroid
           plate into the cover, angled side inboard.   Screw the plate
           onto the shaft until the shaft protrudes about 4".
     5) Install rectangular section seal ring into cover groove.

New Cover Installation:

     1) Place a clean screwdriver into the pump housing at the left
           front corner (drive end) and push the governor linkage
           towards the rear of the pump. While doing this, install
           the cover fitted with the anercid making sure the aneroid
           "plate" is between the throttle shaft and the tab of the
           governor linkage as illustrated on the installation
           drawing.                   —
     2) wWhen you are certain the aneroid plate is between the shaft
           and linkage tab slide the front of the cover around and
           onto the injection pump, removing the screwdriver at the
           last instant.   (Note: Be certain the aneroid/coverassembly
           is in the correct location to avoid an engine runaway upon
           start—upl!!)
     3) The cover should now be about 4" forward, and slightly
           raised in front, of its final placement. Slide cover
           rearward and downward to allow installation of 3 cover
           screws. Tighten screws to 40 inch—lbs.
     4)    Reattach return line and electrical connections.  (Note: If
           the return fitting requires realignment, hold return valve
           assembly with wrench to avoid stripping threads in cover.)

Setting    cut Back Fuel Quantity:
           If, per our recommendation, the aneroid is being set up on
           a fuel injection pump flow bench, charge the aneroid air
           fitting with 5 PSI air pressure and set the injection pump
           per Stanadyne factory set—up sheets, but for turbocharged
           fuel d?livery (see Hypermax Engineering Pump Setting Fuel
           Curves}.
           After the fuel injection pump is set, remove the 5 PSI air
           source and set the aneroid cut back fuel delivery to 60cc
           at 1200 pump RPM.  This is done by loosening the aneroid to
           cover set screw and turning the aneroid assembly
           counterclockwise   (less fuel).   Lock the set screw and lock
           seal it to the cover boss with a dab of silicone sealer.


           If the services of an authorized diesel fuel injection shop
           are not available, the following procedure may be used to
           set the fuel cut back:

                                   Page 2
06—12—92


                                Before starting the engine, remove the air filter assembly
                                to gain access to the turbocharger air inlet.  Fold up a
                                heavy towel to use to block the air flow through the
                                turbocharger to the engine should an engine runaway occur
                                as a result of improper aneroid cover installation.
                                Have a helper start the engine while you are poised over
                                the turbocharge inlet.  (Note: Stand to the side, not the
                                front, of the engine to avoid contact with the fan blade.)
                                If the engine starts and begins to accelerate without any
                                throttle application, quickly cover the inlet with the
                                towel.  This will starve the engine for air and shut it
                                down.     Allow the engine to cool and remove the aneroid
                                cover and install it correctly per the instructions.
                                With the engine idling, check for any fuel leaks.        Allow
                                the engine to warm up until the coolant temperature reaches
                                normal.     With the engine—idling, loosen the aneroid to
                                cover set screw and rotate the aneroid assembly clockwise
                                until the low idle is effected ({lowered) then turn the
                                aneroid assembly counterclockwise 4 turns.       Lock the set
                                screw and seal it with a dab of silicone sealer.

                     Final Connections:

                          1) Connect the aneroid air fitting to the intake manifold
                                turbocharger air housing with the push on hose provided.
                                The air fitting on the intake manifold air housing shares a
                                tee fitting with the vehicle‘s boost pressure gauge line
                                {intake manifold pressure).

                          2)    If possible, have the snap idle acceleration smoke opacity
                                checked at a diesel engine repair facility or a California
                                inspection station.  Should a minor adjustment be
                                necessary, loosen the aneroid to cover set screw and rotate
                                the aneroid assembly clockwise to reduce the exhaust smoke
                                opacity.  The adjustment: is extremely sensitive: 1/8 of a
                                turn will lower the opacity 10%.   If no change in opacity
                                is noted at 1/4 of a turn,      do not attempt further
                                adjustment without professional assistance.




                                Hypermax Engineering, Inc.
                                255 E.   Rt.   72
                                Gilberts,      IL   60136
                                (708)}428—5655



                                                            Page 3
                     06—12—92




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Document Created: 2005-09-01 12:44:59
Document Modified: 2005-09-01 12:44:59

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