City Of La Training 1
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- Pages: 76
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 1 October 17, 2008
Dual-Fuel System Overview
What is Dual-Fuel?
Engine runs on natural gas
Uses diesel for pilot ignition
Intake Stroke Intake Air
Intake Stroke - Gas Injection NG Injector
Natural Gas
Intake Stroke – Gas/Air Mixture
Natural Gas & Air
Compression Stroke
Natural Gas & Air
Power Stroke – Diesel Pilot Diesel Injector
Diesel Pilot
Power Stroke
Combustion
Power Stroke
Combustion
Exhaust Stroke
Exhaust gasses
Exhaust Stroke
Exhaust gasses
What is Dual-Fuel?
Engine runs on natural gas with diesel pilot ignition
Uses a standard Caterpillar electronic diesel engine
Maintains electronic control of both gas and diesel injection
Advantages of Dual-Fuel
Advantages of Dual-Fuel
90% - 100% of diesel efficiency
Same compression ratio
No throttle body (carburetor)
Similar performance to diesel
Same heat rejection as diesel
Operates with exhaust (Jake) brake
Advantages of Dual-Fuel
Retains diesel back-up
Economical operation
Longer engine life
Lower maintenance
Reduced emissions
Dual-Fuel System Components
Dual-Fuel System Installation
System Installation
R & I Intake manifold assembly
Includes 6 natural gas injectors
MAP sensor
ACT sensor
NG temperature sensor
NG fuel pressure sensor
NG shutoff solenoid valve (SOV)
C-10 Dual-Fuel Intake Manifold MAP Sensor NG Temp Sensor
NG Inlet
ACT Sensor
SOV
NG Press Sensor
Gas Injectors
System Installation
Install Eagle Dual-Fuel ECM
Uses diesel fuel for cooling
Eagle Dual-Fuel Computer Fuel Line
P1 Connector
EPROM Chip P2 Connector
Fuel Line
Eagle Dual-Fuel Computer
Dual-Fuel Computer
System Installation
Install Engine Wiring Harness
Wires to both ADEM 70 pin connectors
Dual-Fuel Engine Harness Eagle Connectors TAB Valve Connectors
Fuse
Wastegate Connector 9-pin Connector Ground Lead Speed Timing Connector
System Installation
Grounding and Power Connections
Requires 12 VDC system
Connects to engine ground (12 v)
12 volt power to unswitched
12 volt ignition power to switched
System Installation
Install Speed Buffer Box and connect to ADEM 70-pin connector
Speed Buffer Box Wires to Cat Engine Harness
To RPM Circuit
Speed Buffer Box Speed Buffer
System Installation
Install Turbo Air Bypass (TAB) valve
Turbo Air Bypass (TAB) Valve TAB Valve
System Installation
Install TAB Driver Box
TAB Valve Driver Box TAB Driver Box
Air Tube Modification TAB valve inlet
Air Tube Modification
Air Compressor Inlet
TAB valve outlet
TAB Valve Installation
TAB Valve Installation
System Installation
Install relay wire harness in cab
Includes 5 relays (12 V) and breaker • Non-waste gated engine has 4 relays
Wire to green “diesel” light
Provides diagnostic connection
Connects through 9-pin connector to engine wiring harness
5-Relay Wire Harness Waste Gate Connector
Output to Diesel LED
Relays 9-pin Connector Breaker
Serial Connector Power Leads
Cab Installed Components
Diesel Label Diesel LED
Cab Installed Components
LNG Fuel Gauge
Cab Installed Components
Methane Detector
Cab Installed Components Methane Detector Sensor
Diagnostic Connectors Cat Diagnostic Connector
Dual-Fuel Diagnostic Connector
How Does the System Work
Normal Operation of Dual-Fuel
Normal Operation
Runs on 100% diesel until engine coolant reaches 150º F (65º C)
Green “diesel” light goes out when temperature reaches 150º F (65º C)
Unit runs on 100% diesel at low loads
Green diesel light stays off
Normal Operation
Gas mode uses 15% to 20% diesel
Gas mode uses 80% to 85% gas
Dual-Fuel system uses two computers
Drops back to diesel mode on failure
Green Diesel light turns on (logs a fault)
Normal Operation
Drops back to diesel when out of NG
Logs a fault
Failure codes 23, 25 & 81 can be “normal”
Other “Normal” fault codes
Code 93
Code 97, 98 or 99
Normal Operation
Runs on diesel if NG is not available
Maintains about the same power as a diesel engine
Torque requires higher RPM than diesel
Controls turbo boost pressure under load
Low boost does not mean low power
Normal Operation Turbo air bypass valve details
Dumps from the cold side of the turbo
Dumps boost for richer mixture
Improves emissions
Improves fuel efficiency
Allows higher % of gas at higher loads
Normal Operation
Drives differently than when it is in diesel mode
Drivers need to be trained Requires higher RPM
Uses skipfire technology
Skipfire - Features
Controls diesel and gas to each cylinder Alternates “active” & “skipping” cylinders Adjusts number of “active” cylinders
Based on load demand
Skips from 1 to 3 cylinders when driving
Runs on 1.5 cylinders at idle
Skipfire - Benefits
Effectively utilizes gas and diesel at light load
No adverse effect on performance or longevity of engine
Improves emission levels
Improves fuel efficiency
Skipfire - Operator Problems
Don’t understand the normal operation of skipfire
May feel the engine is not running properly
Skipfire - Operation
When can it happen?
Only in Dual-Fuel mode
Only when actually burning gas
Any time all 6 cylinders are not needed
At idle for C-10 refuse truck
Skipfire Theory Text Figure 1 1- –Without Skipfire Figure Without Skipfire
Figure 22– -With Skipfire Figure With Skipfire
Skipfire - Operation
When can it happen?
Only in Dual-Fuel mode
Only when burning gas
Any time all 6 cylinders are not needed
At idle for C-10 refuse truck
Under what circumstances?
Cruising on the highway
When accelerating through the gears
Skipfire Chart Typical skipfire on a Dual-Fuel engine Percent Torque (%)
100 90 80
6-cylinder gas
70 60
5-cylinder gas
50 40 30
4-cylinder gas
3-cylinder gas
20 10
6-cylinder diesel
0
Idle
Engine Speed (RPM)
Max Engine Speed
What Dual-Fuel Won’t Do
Drive exactly like a diesel engine
Again, drivers need to be trained
Run without diesel fuel
No diesel fuel means no ignition source
Dual-Fuel Maintenance
Maintenance Intervals
Oil and filter changes
Follow standard Caterpillar Maintenance intervals for your application including oil type and filters
Use Any
oil analysis (Cat SOS)
deviation of service intervals could result in voided warranties
LNG Primary Filter & Regulator
Filter Drain
Maintenance Intervals Extremely important for fuel systems Every
250 hours
Replace primary (coalescing) filter
As
per Manufactures Spec. and TSB 1031
Possibility
of extending only after conducting a CAP field evaluation test program
Primary (Coalescing) Filter
.01 Micron Filter
Nut
Primary (Coalescing) Filter Arrows up Molded End Seals
Down
Primary (Coalescing) Filter Centering Locator
Maintenance - Dual-Fuel
Every 500 hours
Clean secondary (last chance) filter
Secondary Filter
Inserts Into Supply Hose
Maintenance - Dual-Fuel
Every 250 hours
Inspect natural gas connections for leaks • CNG has gas odor • LNG has NO gas odor
Maintenance Intervals
Every 1,000 hours 250 hour service items, plus: Replace secondary (last chance) filter
Every 2,000 hours Clean and inspect natural gas injectors Replace injector seals Replace primary (coalescing ) filter Clean secondary (last chance) filter Inspect natural gas connections for
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products
Dual-Fuel Training Course Part 1 October 17, 2008
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 1 October 17, 2008
Dual-Fuel System Overview
What is Dual-Fuel?
Engine runs on natural gas
Uses diesel for pilot ignition
Intake Stroke Intake Air
Intake Stroke - Gas Injection NG Injector
Natural Gas
Intake Stroke – Gas/Air Mixture
Natural Gas & Air
Compression Stroke
Natural Gas & Air
Power Stroke – Diesel Pilot Diesel Injector
Diesel Pilot
Power Stroke
Combustion
Power Stroke
Combustion
Exhaust Stroke
Exhaust gasses
Exhaust Stroke
Exhaust gasses
What is Dual-Fuel?
Engine runs on natural gas with diesel pilot ignition
Uses a standard Caterpillar electronic diesel engine
Maintains electronic control of both gas and diesel injection
Advantages of Dual-Fuel
Advantages of Dual-Fuel
90% - 100% of diesel efficiency
Same compression ratio
No throttle body (carburetor)
Similar performance to diesel
Same heat rejection as diesel
Operates with exhaust (Jake) brake
Advantages of Dual-Fuel
Retains diesel back-up
Economical operation
Longer engine life
Lower maintenance
Reduced emissions
Dual-Fuel System Components
Dual-Fuel System Installation
System Installation
R & I Intake manifold assembly
Includes 6 natural gas injectors
MAP sensor
ACT sensor
NG temperature sensor
NG fuel pressure sensor
NG shutoff solenoid valve (SOV)
C-10 Dual-Fuel Intake Manifold MAP Sensor NG Temp Sensor
NG Inlet
ACT Sensor
SOV
NG Press Sensor
Gas Injectors
System Installation
Install Eagle Dual-Fuel ECM
Uses diesel fuel for cooling
Eagle Dual-Fuel Computer Fuel Line
P1 Connector
EPROM Chip P2 Connector
Fuel Line
Eagle Dual-Fuel Computer
Dual-Fuel Computer
System Installation
Install Engine Wiring Harness
Wires to both ADEM 70 pin connectors
Dual-Fuel Engine Harness Eagle Connectors TAB Valve Connectors
Fuse
Wastegate Connector 9-pin Connector Ground Lead Speed Timing Connector
System Installation
Grounding and Power Connections
Requires 12 VDC system
Connects to engine ground (12 v)
12 volt power to unswitched
12 volt ignition power to switched
System Installation
Install Speed Buffer Box and connect to ADEM 70-pin connector
Speed Buffer Box Wires to Cat Engine Harness
To RPM Circuit
Speed Buffer Box Speed Buffer
System Installation
Install Turbo Air Bypass (TAB) valve
Turbo Air Bypass (TAB) Valve TAB Valve
System Installation
Install TAB Driver Box
TAB Valve Driver Box TAB Driver Box
Air Tube Modification TAB valve inlet
Air Tube Modification
Air Compressor Inlet
TAB valve outlet
TAB Valve Installation
TAB Valve Installation
System Installation
Install relay wire harness in cab
Includes 5 relays (12 V) and breaker • Non-waste gated engine has 4 relays
Wire to green “diesel” light
Provides diagnostic connection
Connects through 9-pin connector to engine wiring harness
5-Relay Wire Harness Waste Gate Connector
Output to Diesel LED
Relays 9-pin Connector Breaker
Serial Connector Power Leads
Cab Installed Components
Diesel Label Diesel LED
Cab Installed Components
LNG Fuel Gauge
Cab Installed Components
Methane Detector
Cab Installed Components Methane Detector Sensor
Diagnostic Connectors Cat Diagnostic Connector
Dual-Fuel Diagnostic Connector
How Does the System Work
Normal Operation of Dual-Fuel
Normal Operation
Runs on 100% diesel until engine coolant reaches 150º F (65º C)
Green “diesel” light goes out when temperature reaches 150º F (65º C)
Unit runs on 100% diesel at low loads
Green diesel light stays off
Normal Operation
Gas mode uses 15% to 20% diesel
Gas mode uses 80% to 85% gas
Dual-Fuel system uses two computers
Drops back to diesel mode on failure
Green Diesel light turns on (logs a fault)
Normal Operation
Drops back to diesel when out of NG
Logs a fault
Failure codes 23, 25 & 81 can be “normal”
Other “Normal” fault codes
Code 93
Code 97, 98 or 99
Normal Operation
Runs on diesel if NG is not available
Maintains about the same power as a diesel engine
Torque requires higher RPM than diesel
Controls turbo boost pressure under load
Low boost does not mean low power
Normal Operation Turbo air bypass valve details
Dumps from the cold side of the turbo
Dumps boost for richer mixture
Improves emissions
Improves fuel efficiency
Allows higher % of gas at higher loads
Normal Operation
Drives differently than when it is in diesel mode
Drivers need to be trained Requires higher RPM
Uses skipfire technology
Skipfire - Features
Controls diesel and gas to each cylinder Alternates “active” & “skipping” cylinders Adjusts number of “active” cylinders
Based on load demand
Skips from 1 to 3 cylinders when driving
Runs on 1.5 cylinders at idle
Skipfire - Benefits
Effectively utilizes gas and diesel at light load
No adverse effect on performance or longevity of engine
Improves emission levels
Improves fuel efficiency
Skipfire - Operator Problems
Don’t understand the normal operation of skipfire
May feel the engine is not running properly
Skipfire - Operation
When can it happen?
Only in Dual-Fuel mode
Only when actually burning gas
Any time all 6 cylinders are not needed
At idle for C-10 refuse truck
Skipfire Theory Text Figure 1 1- –Without Skipfire Figure Without Skipfire
Figure 22– -With Skipfire Figure With Skipfire
Skipfire - Operation
When can it happen?
Only in Dual-Fuel mode
Only when burning gas
Any time all 6 cylinders are not needed
At idle for C-10 refuse truck
Under what circumstances?
Cruising on the highway
When accelerating through the gears
Skipfire Chart Typical skipfire on a Dual-Fuel engine Percent Torque (%)
100 90 80
6-cylinder gas
70 60
5-cylinder gas
50 40 30
4-cylinder gas
3-cylinder gas
20 10
6-cylinder diesel
0
Idle
Engine Speed (RPM)
Max Engine Speed
What Dual-Fuel Won’t Do
Drive exactly like a diesel engine
Again, drivers need to be trained
Run without diesel fuel
No diesel fuel means no ignition source
Dual-Fuel Maintenance
Maintenance Intervals
Oil and filter changes
Follow standard Caterpillar Maintenance intervals for your application including oil type and filters
Use Any
oil analysis (Cat SOS)
deviation of service intervals could result in voided warranties
LNG Primary Filter & Regulator
Filter Drain
Maintenance Intervals Extremely important for fuel systems Every
250 hours
Replace primary (coalescing) filter
As
per Manufactures Spec. and TSB 1031
Possibility
of extending only after conducting a CAP field evaluation test program
Primary (Coalescing) Filter
.01 Micron Filter
Nut
Primary (Coalescing) Filter Arrows up Molded End Seals
Down
Primary (Coalescing) Filter Centering Locator
Maintenance - Dual-Fuel
Every 500 hours
Clean secondary (last chance) filter
Secondary Filter
Inserts Into Supply Hose
Maintenance - Dual-Fuel
Every 250 hours
Inspect natural gas connections for leaks • CNG has gas odor • LNG has NO gas odor
Maintenance Intervals
Every 1,000 hours 250 hour service items, plus: Replace secondary (last chance) filter
Every 2,000 hours Clean and inspect natural gas injectors Replace injector seals Replace primary (coalescing ) filter Clean secondary (last chance) filter Inspect natural gas connections for
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products
Dual-Fuel Training Course Part 1 October 17, 2008
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