detroit diesel series 50 - 60 gas
TRANSCRIPT
Detroit DieselSeries 50G / 60GTraining Program
Leo BeattieLeo Beattie
Presenter\Name of PresentationRevised Date 4
Series 50G/60G Natural Gas Engine
Presenter\Name of PresentationRevised Date 5
Agenda
• Introduction / Background• Specifications, Ratings and Emissions • Glossary of Terms and Engine Sensors • Series 50G / 60G Engine Components
– Major Engine Control Systems– Other Unique Engine Systems– Vehicle Fuel System
• OEM Interfaces with Engine • Unique Requirements for Gas Engines• Summary
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Mission Statement
To Provide Proven Alternate Fueled Engines in Conjunction with Our Diesel Engines that Exceed Our Customers Expectations The First Time, Every Time
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DDC Milestones
• Alternative Fuel Engineering Started1970’s
• First Alternative Vehicle on Road 1983• The First Emission Certified Alternative
Fueled Engines (Methanol) 1991• Introduced Ethanol Engine 1992• Introduced LNG/Diesel Duel Fuel Engine 1992• Introduced Dedicated Natural Gas Engines 1994
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DDC Alternate Fuel Projects
• Methanol Fueled– Urban Buses– Heavy Duty Trucks– Generator Set
• Ethanol Fueled– Urban Buses– Heavy Duty Trucks
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DDC Alternate Fuel Projects
• Natural Gas Fueled– Urban Buses– School Buses– Medium and Heavy Duty Trucks– Refuse Packers– Street Sweepers
• Also Miscellaneous Projects on Bio Diesel
Water Emulsions & Propane
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Series 50G / 60G Development
• Series 50G Evolved from the 8.5 L Series 50 Diesel Engine
– Utilizes Similar Components and Design Criteria as the 8.5 Liter Diesel
– Utilizes Experience From Two-Cycle Alternative Fueled Engines Since the 1980’s
• Series 60G Evolved from the Series 50G
– Significant Experience Carryover
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Series 50G / 60G Release Dates
• Series 50G Coach (GFI Fuel System) Aug 94• Series 50G Genset (60Hz, Standby) 1995• Series 60G Genset (60Hz, Standby) 1996• Series 60G Genset (50Hz Standby) 1996• Series 50G Coach (DDC Fuel System) Jan 98• Series 50G / 60G Prime Power Aug. 98• Series 60G Coach Sept 98
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Commonality With Diesel
• Major Components That Are Shared– Block
– Cooling System
– Cylinder Kit Parts » Exception, Dome and Rings
– Flywheel
– Housings
– Gear Train and Front Cover
– Lubrication System
– External Accessories
Presenter\Name of PresentationRevised Date 13
DDC Natural Gas Engine Features
• Lean Burn Combustion Technology• High Energy Ignition System• DDEC Electronic Control of Spark Timing, Fuel Flow,
Throttle Position & Speed Governing• Closed Loop Feedback to Control Air/Fuel Ratio• Engine Knock Protection• Turbocharger With Integral Turbine Wastegate• Full DDEC Engine Protection System• Air-to-Air Charge Cooling• 10:1 Compression Ratio
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Specific Features of DDCNatural Gas Gensets
• Fuel Inlet Pressure Range 5"- 20" H2O
• Venturi Type Fuel System Design
• DDEC Control of Fuel, Air & Spark
• No-Maintenance Fuel Regulator
• Full DDEC System Diagnostics
• Excellent Transient Response
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Series 50G / 60G Coach Specifications
Engine Type
Displacement
Compression Ratio
Engine Control
Ignition
Aspiration
Fuel Control
Throttle
Rated Power
Peak Torque
Series 50G
4-Cycle (Dedicated Fuel)
8.5 Liters
10:1
DDEC IV, On-Engine
Electronic Spark
Turbocharged
DDC Closed Loop
60 mm Electronic
275 @ 2100 RPM
890 Ft-Lb @ 1200 RPM
Series 60G
4-Cycle (Dedicated Fuel)
12.7 Liters
10:1
DDEC IV, On-Engine
Electronic Spark
Turbocharged
DDC Closed Loop
68 mm Electronic
330 @ 2100 RPM
1400 Ft-Lb @ 1200 RPM
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Series 50G / 60G Genset Specifications
Engine Type
Displacement
Compression Ratio
Ignition
Aspiration
Fuel Control
Throttle
Ratings Engine Hp 60 Hz
Engine Hp 50 Hz
4-Cycle(Dedicated Fuel)
8.5 Liters
10:1
Electronic Spark
Turbocharged
DDC Low Pressure
60 mm Electronic
225 HP - 300 HP
N/A
4-Cycle(Dedicated Fuel)
12.7 Liters
10:1
Electronic Spark
Turbocharged
DDC Low Pressure
68 mm Electronic
340 HP - 450 HP
230 HP - 400 HP
Series 50G Series 60G
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DDC Series 50G / 60G Gas Engines
275 HP @ 2100 RPM890 FT-LB EPA / CARB
275 HP @ 2100 RPM890 FT-LB LEV / ULEV
225 - 300 HP @ 1800 RPM
330 HP @ 2100 RPM1400 FT-LB EPA / CARB
340 - 450 HP @ 1800 RPM
230 - 400 HP @ 1500 RPM
Transit Bus
Motor Coach
Gen SetStand-By
Now
2nd Quarter ‘99
3rd. Quarter ‘98
Now
Now
Series 50G
Series 60G
Rating Application Availability
Transit Bus
Gen SetStand-By
Gen SetStand-By
Now
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Series 50G Exhaust Emissions
Rating 275 HP - 890 FT-LB NOx
4.0
2.2
NMHC
1.2
0.5
CO
15.5
2.3
PM
.05
<.01
1998 CARB / EPA Standards
1998 Configuration*
G/HP-HR
*No Catalyst
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Series 50G ULEV Exhaust Emissions
Rating 275 HP - 890 FT-LB
ULEV CertificationNOX + NMHC CO
7.2
.01
PM
.05
<.01
1998 ULEV Standards
ULEV Program Goals *
G/HP-HR
*With Catalyst / No DF
2.5
1.7-2.0
HCHO
.025
.003
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Series 60G Exhaust Emissions
Rating 330 HP - 1400 FT-LB NOx
4.0
2.0
NMHC
1.2
0.6
CO
15.5
1.9
PM
.05
.02
1998 CARB / EPA Standards
1998 Configuration*
G/HP-HR
*No Catalyst
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Series 50G Transit Sites
Hamilton / KitchenerArea (58 Units)
Hamilton / KitchenerArea (58 Units)
Vancouver(50 Units)
Vancouver(50 Units)
Denver(5 Units)Denver
(5 Units)
Tucson(44 Units)Tucson
(44 Units)
Los Angeles / San DiegoArea (200 Units)
Los Angeles / San DiegoArea (200 Units)
Monterey / Sonoma(25 Units)
Monterey / Sonoma(25 Units)
NY / New JerseyArea (100 Units)NY / New JerseyArea (100 Units)
Pennsylvania(47 Units)
Pennsylvania(47 Units)
Orlando(11 Units)Orlando
(11 Units)
Atlanta(118 Units)
Atlanta(118 Units)
Springfield(7 Units)
Springfield(7 Units)
Oklahoma(3 Units)
Oklahoma(3 Units)
Cleveland(190 Units)Cleveland(190 Units)
El Paso(35 Units)El Paso
(35 Units)
Laredo(15 Units)Laredo
(15 Units)Indonesia(41 Units)Indonesia(41 Units)
Phoenix(9 Units)Phoenix(9 Units)
INEEL(6 Units)INEEL
(6 Units)
Houston(10 Units)Houston(10 Units)
Pinellas(3 Units)Pinellas(3 Units)
Natural Gas Compressed and Liquid
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Natural Gas
• Methane– Product of Decomposing Organic Material
» A By-Product of Decarbonization of Coal
• Odorless, Colorless, and Non-Toxic– Mercaptan is Added to Gas as an Odorant
• Fuel Composition– Composition is Controlled in Processing– Regional Changes Due to Different Suppliers– Seasonal Changes Due to Usage Demands
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CNG Fuel Composition
DDC SPECIFICATIONS Minimum Maximum
Methane 88 (%)
Ethane 0 6.0 (%)
Propane 0 1.7 (%)
Butane 0 0.3 (%)
CO2 + Nitrogen + Oxygen 0 4.5 (%)
Hydrogen 0 0.1 (%)
Motor Octane Number 115 Minimum
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LNG Fuel Composition
DDC SPECIFICATIONS Minimum Maximum
Methane 98 (%)
Ethane 0 0.5 (%)
Propane 0 0.0 (%)
Butane 0 0.0 (%)
Nitrogen 0 2.0 (%)
Hydrogen 0 0.0 (%)
Motor Octane Number 130 Minimum
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Comparisons
DIESEL GAS CNG LNG
1. BTU”s/ Gallon 140,000 136,000 28,000 91,000
2. Flame deg F 3,730 3,590 3,423 3,423
3. Octane 0 89 115 130
4. Auto Ignition deg F 540 428 1,150 1,150
NOTE: One Gallon of Diesel Fuel is Equal to 140 Cubic Feet of CNG 618 Cubic Feet of CNG is Equal to 1 Cubic Foot of LNG
Handling and Safety
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Safety Concerns
• Natural Gas is Lighter Than Air– Flammable Vapors Rise
» Reflective Shop Heaters
• CNG is Stored at High Pressures– Up to 4000 Psi in Tanks
» Tank Pressure Will Be Higher Immediately After Refueling Due to Compression During Fill
» Pressure Release Can Cause Bodily Harm» Ambient Temperature Effects Tank Pressure
• Follow all Safety Cautions and Warnings
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Safety Concerns
• Vapors formed from LNG– Above -160 F Vapors are Lighter Than Air– Below -160 F are Heavier Than Air
• LNG is Stored in Cryogenic State– Extremely Cold, and can Freeze Skin
• LNG Stored at Low Pressure– Maximum Storage Pressure
» Pressure Relief Device Releases at 235 psig
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Boiling Point of Liquids
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Ignition Limits
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Background
Glossary of Terms
Engine Sensors
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Glossary of Terms
• SING– Spark Ignited Natural Gas Engine– Relies on Spark Plugs to Ignite Air/Fuel Mixture
» Same Cycle as a Typical Car Engine
– Unlike Compression Ignition Engines (Diesel)– Dedicated Fuel (Only Burns Natural Gas)– DDC Utilizes Series 50G and 60G Engines Which are 4
Stroke (Cycle) Engines
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Four Stroke Cycle
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Glossary of Terms
• Absolute Pressure– Any Pressure Reading that Includes Atmosheric Pressure
» Standard Atmospheric Pressure is 14.7 psi» Units are Followed by a “A” (PSIA, KPAA, ect)
• Gage Pressure– Pressure Reading that does not Include Atmoshperic
Pressure» Units are Followed by an “G” (PSIG, KPAG, ect)
• Example: Tire Pressure Gage Reads 30 psi» Gage Pressure is 30 PSIG» Absolute Pressure is (30+14.7) 44.7 PSIA
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Glossary of Terms
• AFR – Air Fuel Ratio - % Air to Fuel Entering Engine– # 1 Parameter to Control on SI Engine
» Performance» Fuel Economy» Emissions
• Stoichiometric AFR– Optimum AFR That Yields Complete Combustion – For Natural Gas This Ratio is Typically 16.4
Parts Air to 1 Part Fuel (Gasoline is 14.7 to 1)
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Glossary of Terms
• Lean Burn – Engine Design That Operates Leaner Than
Stoichiometric AFR to Reduce Exhaust Emissions and Exhaust Temperatures
• Lambda– A Method of Expressing Air Fuel Ratio
» Greater Than 1 Indicates Leaner Than Stoichiometric AFR» Less Than 1 Indicates Richer Than Stoichiometric AFR
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Glossary of Terms
• Open Loop Fuel Control – No Feedback to Correct Engine Fueling
» Not Self Correcting » DDC / GFI Fuel System is Open Loop
• Closed Loop Fuel Control – Providing Feedback to the Open Loop Fuel System Based on
Real Time Measurements
– DDC Natural Gas Engines Utilize an Exhaust Oxygen Sensor to Provide this Feedback
» Measures Exhaust Oxygen Content » Adjusts Fuel Flow to Match Desired and Actual Air Fuel Ratio» System Goes From Open Loop to Closed Loop Control Depending on
Conditions
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Glossary of Terms
• Adaptive Learn – Ability of the Fuel Control System to “Remember” Air
Fuel Ratio Control Corrections. This “Learned” Information is Not Lost When the Engine is Shut Down
• Engine Knock– Undesirable Condition That Occurs in Spark Ignition
Engines that Leads to Increased Cylinder Pressures and Temperatures and Possible Component Damage
– Fuel Mixture Ignites Prematurely and Uncontrolled
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Glossary of Terms
– Generates High Frequency “Ringing” in Combustion Chamber
– Primarily Caused by Rich Air Fuel Ratio, Poor Fuel Quality or High Intake Manifold Temperatures
• Lean Misfire– Engine Miss Caused By Incomplete Combustion
» Ignition System Problems» Cold Intake Air Temperatures» Low Fuel Pressure / Restricted Fuel Flow
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Glossary of Terms
• BTU– British Thermal Unit
» Measurement Unit of Heat Energy• The Amount of Heat Needed to Raise The Temperature of One
Gallon of Water One Degree F in One Minute
• VSG– Variable Speed Governor
» Holds the engine at a requested constant speed regardless of load fluctuation
• Generator drive engines only
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Glossary of Terms
• Foot Throttle – Otherwise Known as Accelerator or Foot Pedal– Electronic Resistor to Input Foot Pedal Signal Into DDEC
System– Same Function Between Gas and Diesel
• Air System Throttle– Butterfly Valve in Gas Engine Air Intake– Controls Engine Speed– Indirectly Receives Input From Foot Pedal
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Engine Sensors
• Absolute Air Inlet Pressure Sensor– Similar to Turbo Boost Pressure on Diesel– Measures Intake Manifold Vacuum and Pressure– Direct Measure of Engine Power– Sensor Mounted on Intake Manifold
• Barometric Pressure Sensor– Measures Barometric Pressure– Sensor Mounted on Rear of Engine
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Engine Sensors
• Fuel Delivery Pressure Sensor– Fuel Pressure into Engine Low Pressure Regulator
» Normally 110 psig for CNG Applications» Sensor Mounted on Low Pressure Regulator Inlet
• Fuel Inlet Temperature Sensor– Gas Fuel Temperature into Engine– Sensor Mounted on Fuel Mixer
• Coolant Temperature Sensor– Same as Diesel– Mounted on Right Side of Cylinder Head
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Engine Sensors
• Oil Temperature Sensor– Same as Diesel Through 1997 Gas Engines– Not Used on 1998 + Gas Engines
• Exhaust Gas Temperature Sensor– Exhaust Gas Temperature After Turbocharger– Sensor Mounted on Exhaust Pipe After Turbocharger
• Intake Air Temperature Sensor– Same as Diesel– Sensor Mounted on Air Inlet Tube
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Engine Sensors
• Oxygen Sensor– Measures Oxygen Content in Exhaust– Mounted in Exhaust Pipe After Turbocharger
• SRS / TRS Sensors– Same as Diesel– Mounted in Front Gearcase
• Knock Sensor– Reacts to Engine Knock or “Ringing”– Sensor Mounted on Left Side Cylinder Block
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Gas Engine Unique MPSI Reader Parameters
• Gas Valve– Feedback Signal Indicating Gas Valve (PSV) Position
» Full Range 0-100%» Normally Around 40-70%
• TPS– Throttle Position Sensor
» Foot Pedal Position - Same as Diesel» Full Range 0 - 100%
• Throttle Plate– Air System Throttle Plate Position
» Ranges From 0 - 100%
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Gas Engine Unique MPSI Reader Parameters
• Fuel TMP– Fuel Temperature at Inlet to Fuel Mixer– Units are Degrees F
• Fuel PSR– Fuel Inlet Pressure at Inlet to Impco Regualtor – Units are PSIA
• Air Inlet PR– Pressure or Vacuum in Intake Manifold– Units are PSIA
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Gas Engine Unique MPSI Reader Parameters
• Baro PSR– Current Barometric Pressure – Units are PSIA
• Exhaust TMP– Exhasut Gas Temperature at Outlet of Turbocharger– Units are Degrees F
• Exhaust Gas AFR– Exhaust Gas Air Fuel Ratio Expressed as Lamda– Unit-less– Ranges from 1.0 (Rich) to 1.55 (Lean)
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Gas Engine Unique MPSI Reader Parameters
• Loop Status– Indicates if Control System is in Open or Closed Loop
Status» Due to Software Issues, Do Not Use at This Time
• Knock Volts– Indication of Knock Sensor Output to DDEC ECM
• Knock Control– Indication of Whether the Engine is Taking Preventative
Action in Response to Knock Sensor Input
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Engine Modules
• Igniter Module– Interface Between DDEC and Spark Plug Coils
• Oxygen Sensor Module– Interface Between DDEC and Oxygen Sensor
• SNEF Module– Interface Between DDEC and Knock Sensor
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Series 50G / 60G Engine Components
Presenter\Name of PresentationRevised Date 53
Series 50G Transit Bus Engine
Fuel Mixer
Coil Over PlugIgnition Coils
InsulatedExhaustManifold
Water CooledTurbocharger
Center Section
InsulatedTurbineHousing
Automatic Tensionerfor 50 DN
Alternator Belt
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Series 50G Transit Bus Engine
Oxygen SensorModule
Oxygen SensorModule
AdaptorlessAir Compressor
DDEC IVECM
Ignition SystemModule
PSV
Knock SignalProcessor
Low PressureRegulator Fuel Pressure
Sensor
OEM PigtailInterfaces
Basic Engine Unique Parts
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Series 50G / 60G Cylinder Kit
• Shorter Connecting Rod
• Unique Gas Engine Piston
• Plasma Coated Fire Ring
• Rectangular Style Compression Ring
• Top Liner Cooling
Cylinder Kit
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Series 50G /60G Connecting Rod
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Series 50G / 60G Liner Cooling
• Top Liner Cooling (TLC)
– Reduces Fire Ring Temperature
– Reduces Ring & Liner Wear
– Extends Ring Life
– Reduces Maintenance Costs
– Maximizes Life to Overhaul LINER COOLINGCHANNEL
COOLINGCHANNEL
INLET NOTCHIN BLOCK
COOLINGCHANNELEXIT HOLE
MAIN COOLANTSTREAM
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Series 50G / 60G Cylinder Head
Cylinder Head• Hardened Valve Seats
& Valve Stems• Optimized Valve Seat Angle• Improved Material Exhaust
Valves & Guides• Low Flow Valve Stem Seals• Stainless Steel Spark
Plug Adaptors
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Series 50G / 60G Camshaft
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Series 50G /60G Overhead
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Series 50 Balance Shaft
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Manifold Wrap
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Series 50G / 60G Engine Controller
• DDEC IV– Provides Control for Fuel,
Air & Spark Systems» Lower Emissions» Optimum Fuel Usage» Good Performance
– Acceleration– Driveability
– Knock Sensor » Reduces the Probability of
Costly Engine Damage
– Complete Diagnostics & Troubleshooting
» Easy to Diagnose Problems» Minimal Downtime» Low Maintenance Costs
Presenter\Name of PresentationRevised Date 65
Commonality With Diesel
• Major Components That are Shared– Block– Cooling System – Cylinder Kit Parts
» Exception, Dome and Rings
– Flywheel, Except Genset– Housings, Flywheel– Gear Train and Front Cover– Lubrication System
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Series 50G / 60G Fuel Control Systems
Coach Fuel Control System
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Series 50G / 60G Coach Fuel System
• Venturi Design to Provide Correct Air / FuelRatio Over All Speeds & Loads
• DDEC Bias to Alter Air / Fuel Ratio (Rich or Lean) Based on Transient Conditions
• Feedback via Engine Exhaust to MatchDesired and Actual Air / Fuel Ratios
• Components Divided into Three Areas– Open Loop, Closed Loop and Fuel Supply
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Series 50G / 60G Coach Fuel System
• Open Loop Components– Low Pressure Regulator– Pulse Width Stepper Valve (PSV)– Venturi / Mixer
• Closed Loop Components– Oxygen Sensor– Oxygen Sensor Interface Module
• Fuel Supply Components– Primary Regulator– Low Pressure Fuel Control Solenoid
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Series 50G / 60G Coach Fuel System
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Series 50G / 60G Coach Fuel System
Low Pressure Regulator• Engine Mounted Above
Intake Manifold• Referenced to Air Inlet
Depression• Coolant Heated• No Adjustment
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Series 50G / 60G Coach Fuel System
Electronic PSV• DDEC Interface
to Control Air / Fuel Ratio• Fully Electronic Fuel
Control Valve• Incorporates DDEC
Diagnostics• No Maintenance Required
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Series 50G / 60G Coach Fuel System
• Similar to a Carburetor
• Balanced To Provide Correct Air /Fuel Ratio
• No Moving Parts
• No Maintenance Required
Venturi / Mixer
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Series 50G / 60G Coach Fuel System
AirfromCAC
ThrottleMixer / Venturi Intake Elbow
FuelInlet
Fuel TransferTube
Fuel BalanceLine
Air / Fuelto Engine
Low Pressure Regulator
PSV
Presenter\Name of PresentationRevised Date 75
Series 50G / 60G Coach Fuel System
• Wide Range O2 Sensorto Monitor All Speeds & Loads
• No Calibration Required
• Minimal Drift
• Excellent Durability Results to Date
Oxygen Sensor
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Series 50G / 60G Coach Fuel System
• Converts O2 Sensor Output into DDEC Input
• Provides SensorHeater Control
• Self Contained - Engine Mounted
• No Maintenance Required
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Series 50G / 60G Coach Fuel System
• Manufactured by ITT Conoflow
• Designed for Heavy-Duty Applications
• Coolant Heated to Prevent Freeze-Up
• Built-In Pressure Relief Device (PRD)
• Supplied & Warranted by DDC
Primary Fuel Pressure Regulator
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Series 50G / 60G Coach Fuel System
• Manufactured byHoneywell-Skinner
• Provides Positive Fuel Shut-Off to Engine
• DDEC Digital Output Controlled
• 12 or 24 Volt Versions Available
• Supplied & Warranted by DDC
Low Pressure Fuel Control Solenoid
Presenter\Name of PresentationRevised Date 79
Series 50G / 60G Exhaust Temperature Sensor
• Monitors Turbine Outlet Temperature
• Triggers DDEC Engine Shutdown if Overtemperature is Detected
• Fast Response• No Maintenance Required
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Barometric Pressure Sensor
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Air and Fuel Temperature Sensor
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Series 50G / 60G Transit Bus Engine Closed Loop Fuel System
ChargeAir
Cooler
ChargeAir
Cooler
ENGINEENGINE
Exhaust
TurboCompressor
VenturiMixer
AirIntake
ThrottleActuator
Intake Pressure& Temperature
DDEC IVDDEC IV
ElectronicControl Valve
(PSV)
Input GasPressure
(70 - 120 PSIG)
InterfaceModule
Zero PressureRegulator
GasPressure
O2 Sensor
GasTemperature
Ga
s t
o E
ng
ine
Other DDEC EngineProtection Sensors & Signals
BaroSensor
DDECControlled
Solenoid Valve
ExhaustTemperature
Sensor
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Series 50G/ 60G Fuel Control System
Coach Fuel Control System
Troubleshooting
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Series 50G / 60G Fuel Control Systems
Generator Set Fuel Control System
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Series 50G / 60G Genset Specifications
Engine Type
Displacement
Compression Ratio
Ignition
Aspiration
Fuel Control
Throttle
Ratings Engine Hp 60 Hz
Engine Hp 50 Hz
4-Cycle(Dedicated Fuel)
8.5 Liters
10:1
Electronic Spark
Turbocharged
DDC Low Pressure
60 mm Electronic
225 HP - 300 HP
N/A
4-Cycle(Dedicated Fuel)
12.7 Liters
10:1
Electronic Spark
Turbocharged
DDC Low Pressure
68 mm Electronic
340 HP - 450 HP
230 HP - 400 HP
Series 50G Series 60G
Presenter\Name of PresentationRevised Date 87
Specific Features of DDCNatural Gas Gensets
• Fuel Inlet Pressure Range 5"- 20" H2O
• Venturi Type Fuel System Design
• DDEC Control of Fuel, Air & Spark
• No-Maintenance Fuel Regulator
• Full DDEC System Diagnostics
• Excellent Transient Response
Presenter\Name of PresentationRevised Date 88
Series 50G/60G Generator Set Fuel System
• Fuel is Introduced into the Air Upstream of Turbocharger
• Utilizes Similar Concept / Components as Coach Fuel System– DDEC Controlled– Venturi Mixer– PSV for DDEC Fuel Control
• Open Loop Design– No Oxygen or Barometric Sensor
Presenter\Name of PresentationRevised Date 89
Series 50/60G Genset Gas Engine
Insulated ExhaustManifold & Turbine
Housing
Water CooledTurbocharger
Center Housing
Fuel Mixer / Venturi
PSV Control Valve
Fuel Line
Fuel Regulator
Fuel / AirBalance
Lines
Air InletTube
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Mixer Inlet, GENSET
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Mixer & PSV, GENSET
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DDC Pulsewidth Stepper Valve
• DDEC Interfaceto Air / Fuel RatioControl
• DDEC Diagnostics
• No Maintenance Required
Electronic PSV
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Series 50G DDC Fuel System
• Mixer / Venturi
– Inherently Balancedto provide CorrectAir /Fuel Ratio
– No Moving Parts
– No Maintenance Required
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Series 50/60G Electronic Throttle
• Full Control by DDEC
– Idle & GovernorSpeed Control
– No Internal / External Adjustments
– Auto CalibrationDuring Startup
– Diagnostic Fault Protection
– Fail Safe “Closed” Feature
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Regulator, Low Pressure
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GENSET, Front
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GENSET, Right Bank
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GENSET, Left Bank
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Flywheel, GENSET
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MAP Sensor
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Air and Fuel Temperature Sensor
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Natural Gas Genset Fuel System
CHARGEAIR
COOLER
CHARGEAIR
COOLER
ENGINEENGINE
TURBOWASTEGATE
VALVE
TURBOWASTEGATE
VALVE
EXHAUST
TURBOCOMPRESSORVENTURI
MIXER
AIRINTAKE
THROTTLEACTUATOR
INTAKE PRESSURE& TEMPERATURE
DDECDDEC
OTHER DDECENGINE PROTECTIONSENSORS & SIGNALS
KNOCKSENSOR
IGNITIONCOILS
BOOSTPRESSURE
FUEL TEMP.SENSOR
ELECTRONICCONTROL VALVE
LOW PRESSUREREGULATOR
INPUT GASPRESSURE
5”- 20” H2O
Presenter\Name of PresentationRevised Date 103
Series 50G / 60G Fuel Control System
Generator Set Fuel Control System
Troubleshooting
Series 50G / 60GAir System
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Series 50G / 60G Electronic Throttle
• Full Control by DDEC
– Idle & GovernorSpeed Control
– No Internal / External Adjustments
– Auto CalibrationDuring Startup
– Diagnostic Fault Protection
– Fail Safe “Closed” Feature
Presenter\Name of PresentationRevised Date 106
Series 50G / 60G Turbocharger
• Water Cooled Center Section
• Insulated Turbine Housing
• Dual Poppet Wastegatewith Heavy-Duty Arm
• “Long Can” Wastegate Actuator
• Recirculation Valve
• Strengthened Compressor Backplate
• “V” Band Turbine Housing
Turbocharger
Presenter\Name of PresentationRevised Date 107
Wastegate Actuator
Presenter\Name of PresentationRevised Date 108
Wastegate Poppets
Presenter\Name of PresentationRevised Date 109
Wastegate Calibration
Presenter\Name of PresentationRevised Date 110
Turbocharger, GENSET
Presenter\Name of PresentationRevised Date 111
Air System
• Turbocharger Wastegate Settings– Series 50G SOP Through ‘96 Build
» Short Can 18.5 Psig @ .040”
– Series 50G ‘97 and 98 Production Build» Long Can 21.0 Psig @ .040”
– Series 60G Coach Engines» Long Can 24.0 Psig @ .040”
– Series 60G Truck Engines» Short Can 18.5 Psig @ .040”
– Series 50G Truck Engines» Short Can 18.5 Psig @ .040”
Presenter\Name of PresentationRevised Date 112
Series 50G / 60G Closed Breather
• “Dirty Air” is Routed from Rocker Cover Outlet
• Special Baffling Minimizes Oil Carryover
• Self ContainedCoalescing Filter
• Water Condensate is Drained• “Clean Air” is Routed
to Intake System
Presenter\Name of PresentationRevised Date 113
Series 50G / 60G Air Control System
Troubleshooting
Series 50G/ 60GIgnition System
Presenter\Name of PresentationRevised Date 115
Series 50G / 60G Coil Over Plug Ignition System
Presenter\Name of PresentationRevised Date 116
Series 50G / 60G Ignition System
• Coil Over Plug Ignition System
– Higher Voltage to Spark Plugs
– Electronically Controlled
– No Spark Plug Wires
– No Adjustments or Maintenance
– Long Spark Plug Life
Presenter\Name of PresentationRevised Date 117
Series 50/60G Ignition System
• Full Electronic Control by DDEC– Automatic Compensation
(Cold Start, Acceleration, Knock)
– No Adjustments or Maintenance
– No Moving Components
• Integral Ignition Coils– Individual Coils for Each Cylinder
– Mounted into Rocker Cover– No Secondary Spark Plug Wires
Presenter\Name of PresentationRevised Date 118
Series 50G / 60G Spark Igniter Module
Presenter\Name of PresentationRevised Date 119
Spark Plug Tube, Upper
Presenter\Name of PresentationRevised Date 120
Spark Plug Tube, Lower
Presenter\Name of PresentationRevised Date 121
Spark Plug
Presenter\Name of PresentationRevised Date 122
Series 50G 60G Ignition Control System
Troubleshooting
Presenter\Name of PresentationRevised Date 123
Cylinder Cut-Out
Series 50G / 60GOther Engine Systems
Presenter\Name of PresentationRevised Date 125
Knock Sensor
Presenter\Name of PresentationRevised Date 126
SNEF Module
Presenter\Name of PresentationRevised Date 127
Sensor Harness
Presenter\Name of PresentationRevised Date 128
DDEC System
Error Codes and Troubleshooting
Presenter\Name of PresentationRevised Date 129
DDR Reader
Presenter\Name of PresentationRevised Date 130
DDEC Tools
Presenter\Name of PresentationRevised Date 132
Vehicle Systems
• Fuel Supply– High Pressure Regualtor– High Pressure Fuel Solenoid– Filters
» Coalescing– Low Pressure Fuel Solenoid
– Fuel Lines– Vehicle Fuel Systems
Presenter\Name of PresentationRevised Date 133
Regulator, High Pressure Fuel
Presenter\Name of PresentationRevised Date 135
Typical High Pressure Fuel Control Solenoid
Presenter\Name of PresentationRevised Date 136
Low Pressure Fuel Solenoid
Presenter\Name of PresentationRevised Date 138
CNG Vent Lines
Presenter\Name of PresentationRevised Date 139
CNG Fuel System
Presenter\Name of PresentationRevised Date 140
LNG Fuel System
Presenter\Name of PresentationRevised Date 141
LNG Tank
Presenter\Name of PresentationRevised Date 142
LNG Vaporizer
Power Requirements
Presenter\Name of PresentationRevised Date 144
Throttle Power Supply
• Throttle Actuator Power Supply Recently Changed– SOP Thru ‘97 Build
» Power is Supplied by DDEC
– ‘98 Production» DDEC Controls a Solid State Relay From a 12V or 24V Source
Presenter\Name of PresentationRevised Date 145
Throttle Relay
Presenter\Name of PresentationRevised Date 146
Unique Requirements
Engine Oil and Coolant
Presenter\Name of PresentationRevised Date 147
Oil Requirements
• DDC Tested Engine Oils
– Mobil Super Geo SAE 15W - 40– Exxon Estor SAE 15W - 40
Note: Refer to Series 50G / 60G Engine Operator
Guides for More Information
Presenter\Name of PresentationRevised Date 148
Coolant Requirements
• Refer to DDC Bulletin 7SE 298– Coolant for Detroit Diesel Engines
• Coolant, Water and Antifreeze Specification– Inhibitor Requirements
» Especially the Phosphorous Content» Coolant Filters
– General Cooling System Recommendations» Important to Follow on the Series 50G/60G Engines
Presenter\Name of PresentationRevised Date 149
Series 50G Maintenance IntervalsUrban Coach Service
Component / Item Maintenance Required
Spark Plugs Replace Every 24,000 Miles
Spark Plug Boots Inspect Every 24,000 Miles
Throttle Body & Actuator Inspect Every 6,000 Miles
Turbocharger & WastegateCalibration
Inspect Every 36,000 Miles
Coalescing Fuel Filters Drain Daily & Replace ElementEvery 6,000 Miles
Valve Lash Inspect Every 36,000 Miles
Lubricating Oil & FilterReplace Every 6,000 Miles &Check Oil Level Daily
Presenter\Name of PresentationRevised Date 150
Summary and Wrap-Up
Presenter\Name of PresentationRevised Date 151
Series 50G/60G Natural Gas Engine