City Of La Training 2
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- Pages: 54
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 2 October 17, 2008
Dual-Fuel System Diagnostics
Caterpillar ET Codes Use the Caterpillar Electronic Technician (ET) program to look for faults in the Cat ECM
Caterpillar ET Codes ❦
Any active code in the Cat ECM can kick you out of mode and not log a fault in Panels
Dual-Fuel specific Faults: 68-0 Unknown code (50% diesel fall-back) 64-11 No Pattern On Speed Sensor #2 (34)
Caterpillar ET Codes 68-0 Unknown code (50% fallback) Unique
feature with-in CARB flash files
Reduces
rated power by 50% when operated out of mode for more than 10 hrs.
The
need for this file depends greatly on regulations with-in the areas of intended
Caterpillar ET Codes Fall-back strategy: In
mode: 100% of Dual-Fuel rated power
Out
of mode: 80% of diesel rated power for 10 hrs. – clock starts counting up
Out
of mode after 10 hrs: 50% of diesel rated power (fault 68-0) – until repaired
Back
in mode: after 15 minutes fault resets
Caterpillar ET Codes 68-0 Unknown code (50% fallback) What can cause a code 68?
CAT system failure
Dual-Fuel system failure
Out of fuel (NG)
NG tank shut off
Caterpillar ET Codes 64-11 No Pattern On Speed Sensor #2 (34) Can
be set by more than one action
CAT:
Sensor, wiring, connections, etc…
Dual-Fuel:
wiring, connections, timing buffer, power and ground connections through cab
Power
and grounds should be attached to a
Caterpillar ET Codes Always check ET for Active, Logged Faults and Logged Events FIRST before assuming it is a Dual-Fuel problem not allowing it to go into mode Cat
ECM is always in control even in gas mode
Coolant Engine
temperature
timing
Caterpillar Flash files
Caterpillar Flash Files Flashing
the ADEM
Parameters
that must be set
Maintenance How
Indicator for SC or FC
to identify older SC to newer FC
Personality Factory
Module Code not programmed
passwords
Caterpillar Flash Files Flashing the ADEM
Caterpillar Flash Files Parameters that must be set for the C-10 engine to run D-F
set
Caterpillar ET Snap Shots
Snap Shots Useful
tool for when faults have been
erased View View
Graphs
Data through Groups with 9 sec. Before and 4 sec. after fault was Logged
Factory Passwords
Caterpillar Flash Files View Graph
Factory Passwords
Caterpillar Flash Files View Data through Groups
Factory Passwords
Factory Passwords
Dual-Fuel Eagle ECU
ECU Specifications 8097
or 80C196 Intel main processor (CPU), Clock frequency: 12 MHz Memory: 32kBytes EPROM and RAM 8 analog inputs, 0 – 5 volts, 10 bit resolution, A/D conversion time 22 μs
ECU Specifications 3
high-speed digital inputs 80C51 or 87C51 multiplexer (MUX) 8 solenoid drivers (4 A peak,1 A holding) Supply Voltage: 8.0 – 16.0 V dc
Electronic Control Unit (ECU) EEPROM EPROM
PROCESSOR
MUX
MUX Remover EPROM Remover
EPROM Installer
REMEMBER! When replacing an EPROM
Settings on Verification Screen: EPROM_CHECKSUM CALIBRATION LEVEL SAFR_INDEX HV_RATIO_INDEX
Verify Numbers Match
Eagle ECU Inputs from CAT (ADEM) 1. Requested RPM (RPMCMD) or Requested Fuel (FUELCMD) 2. Error Messages (%) 3. Inject OK (ICONFIRM) 4. Position Indicator Pulse (PIP) 5. Diesel Fuel Temperature (FT)
EAGLE ECU Sensor Inputs 1. Natural Gas Pressure (CNGP) 2. Natural Gas Temperature (CNGT) 3. Air Charge Temperature (ACT) 4. Manifold Absolute Pressure (MAP) 5. Injector Circuit Voltage
EAGLE ECU Outputs 1. 2. 3. 4. 5. 6. 7.
Shut Off Valve (SOV) Injectors – Gas and Diesel Turbo Air Bypass Valve (TAB) Waste Gate Control Mode Lamp Keep Alive Power Relay (KAPWR) Solenoid Power Relay (SOLPWR)
BOB Test Points ANALOG SENSOR INPUTS
1. Natural gas pressure (CNGP) • 515 – 1050 kPa operating range • 665 kPa to go into mode
2. Natural gas temperature (CNGT) • > -15 degrees Celsius operating range
3. Air charge temperature (ACT) • Dependant on external factors
4. Manifold absolute pressure (MAP) 5. Diesel Fuel Temperature (FT)
PRESSURE
Generic Sensor Variable Resistor
5 volts
5 volts
Ground
0 volts
Signal out
TEMPERATURE
Sensors MAP
CNGT
CNGP
ACT
CNGP
Connector Problems
Connector Corrosion
Connector Corrosion
CNG Pressure vs Voltage Operating Range: 515 to 1068 kPa Pressure => 765 kPa to go into mode 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
225 200 175 150 125
kPa
100 75 50 25 0 0.0
0.5
1.0
1.5
2.0
2.5
Voltage +/- 0.22
3.0
3.5
4.0
psi
120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 0.50
210 160 110 60 10
1.00
1.50
2.00
2.50
3.00
Voltage +/- 0.22
3.50
4.00
-40 4.50
Temperature F
Temperature C
NG Temperature vs Voltage Operating Range: -15 and up
Manifold Absolute Pressure vs Voltage Typical Range: 90 - 225 kPa
kPa
350.0 325.0 300.0 275.0 250.0 225.0 200.0 175.0 150.0 125.0 100.0 75.0 50.0 25.0 0.0
50
40
30
psi 20
10
0 0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Voltage +/- 0.22
4.0
4.5
5.0
120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 0.50
210 160 110 60 10
1.00
1.50
2.00
2.50
3.00
Voltage +/- 0.22
3.50
4.00
-40 4.50
Temperature F
Temperature C
Air Charge Temperature vs Voltage
BOB Test Points (others) 1. 2. 3. 4.
ECU Power (ECUPWR) Solenoid Power (SOLPWR) Inject OK (ICONFIRM) Sensor Reference Voltage (VREF) 5. Ground
BOB Test Points DIGITAL SIGNALS (PWM) 1. INJECT – Diesel Injector (out) 2. PIP – Position Indicator Pulse (in) 3. RPMCMD/FUELCMD (in) 4. TAB – Turbo Air Bypass (out)
Inputs from CAT (ADEM) RPMCMD/FUELCMD Frequency 200
Hz 166 Hz 125 Hz
= = =
normal command No droop requested FUELCMD
Inputs from CAT (ADEM) RPMCMD/FUELCMD Circuit Duty cycle Error Messages 1.0%
= No diesel pulses, FC: 65 1.5% = Bad diesel pulse timing, FC: 66 2.0% = Bad diesel pulse duration, FC: 67 2.5% = Extra diesel pulses received, FC: 68 3.0% = ADEM not ready 5 – 95% = 500 – 2500 RPM
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 2 October 17, 2008
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 2 October 17, 2008
Dual-Fuel System Diagnostics
Caterpillar ET Codes Use the Caterpillar Electronic Technician (ET) program to look for faults in the Cat ECM
Caterpillar ET Codes ❦
Any active code in the Cat ECM can kick you out of mode and not log a fault in Panels
Dual-Fuel specific Faults: 68-0 Unknown code (50% diesel fall-back) 64-11 No Pattern On Speed Sensor #2 (34)
Caterpillar ET Codes 68-0 Unknown code (50% fallback) Unique
feature with-in CARB flash files
Reduces
rated power by 50% when operated out of mode for more than 10 hrs.
The
need for this file depends greatly on regulations with-in the areas of intended
Caterpillar ET Codes Fall-back strategy: In
mode: 100% of Dual-Fuel rated power
Out
of mode: 80% of diesel rated power for 10 hrs. – clock starts counting up
Out
of mode after 10 hrs: 50% of diesel rated power (fault 68-0) – until repaired
Back
in mode: after 15 minutes fault resets
Caterpillar ET Codes 68-0 Unknown code (50% fallback) What can cause a code 68?
CAT system failure
Dual-Fuel system failure
Out of fuel (NG)
NG tank shut off
Caterpillar ET Codes 64-11 No Pattern On Speed Sensor #2 (34) Can
be set by more than one action
CAT:
Sensor, wiring, connections, etc…
Dual-Fuel:
wiring, connections, timing buffer, power and ground connections through cab
Power
and grounds should be attached to a
Caterpillar ET Codes Always check ET for Active, Logged Faults and Logged Events FIRST before assuming it is a Dual-Fuel problem not allowing it to go into mode Cat
ECM is always in control even in gas mode
Coolant Engine
temperature
timing
Caterpillar Flash files
Caterpillar Flash Files Flashing
the ADEM
Parameters
that must be set
Maintenance How
Indicator for SC or FC
to identify older SC to newer FC
Personality Factory
Module Code not programmed
passwords
Caterpillar Flash Files Flashing the ADEM
Caterpillar Flash Files Parameters that must be set for the C-10 engine to run D-F
set
Caterpillar ET Snap Shots
Snap Shots Useful
tool for when faults have been
erased View View
Graphs
Data through Groups with 9 sec. Before and 4 sec. after fault was Logged
Factory Passwords
Caterpillar Flash Files View Graph
Factory Passwords
Caterpillar Flash Files View Data through Groups
Factory Passwords
Factory Passwords
Dual-Fuel Eagle ECU
ECU Specifications 8097
or 80C196 Intel main processor (CPU), Clock frequency: 12 MHz Memory: 32kBytes EPROM and RAM 8 analog inputs, 0 – 5 volts, 10 bit resolution, A/D conversion time 22 μs
ECU Specifications 3
high-speed digital inputs 80C51 or 87C51 multiplexer (MUX) 8 solenoid drivers (4 A peak,1 A holding) Supply Voltage: 8.0 – 16.0 V dc
Electronic Control Unit (ECU) EEPROM EPROM
PROCESSOR
MUX
MUX Remover EPROM Remover
EPROM Installer
REMEMBER! When replacing an EPROM
Settings on Verification Screen: EPROM_CHECKSUM CALIBRATION LEVEL SAFR_INDEX HV_RATIO_INDEX
Verify Numbers Match
Eagle ECU Inputs from CAT (ADEM) 1. Requested RPM (RPMCMD) or Requested Fuel (FUELCMD) 2. Error Messages (%) 3. Inject OK (ICONFIRM) 4. Position Indicator Pulse (PIP) 5. Diesel Fuel Temperature (FT)
EAGLE ECU Sensor Inputs 1. Natural Gas Pressure (CNGP) 2. Natural Gas Temperature (CNGT) 3. Air Charge Temperature (ACT) 4. Manifold Absolute Pressure (MAP) 5. Injector Circuit Voltage
EAGLE ECU Outputs 1. 2. 3. 4. 5. 6. 7.
Shut Off Valve (SOV) Injectors – Gas and Diesel Turbo Air Bypass Valve (TAB) Waste Gate Control Mode Lamp Keep Alive Power Relay (KAPWR) Solenoid Power Relay (SOLPWR)
BOB Test Points ANALOG SENSOR INPUTS
1. Natural gas pressure (CNGP) • 515 – 1050 kPa operating range • 665 kPa to go into mode
2. Natural gas temperature (CNGT) • > -15 degrees Celsius operating range
3. Air charge temperature (ACT) • Dependant on external factors
4. Manifold absolute pressure (MAP) 5. Diesel Fuel Temperature (FT)
PRESSURE
Generic Sensor Variable Resistor
5 volts
5 volts
Ground
0 volts
Signal out
TEMPERATURE
Sensors MAP
CNGT
CNGP
ACT
CNGP
Connector Problems
Connector Corrosion
Connector Corrosion
CNG Pressure vs Voltage Operating Range: 515 to 1068 kPa Pressure => 765 kPa to go into mode 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
225 200 175 150 125
kPa
100 75 50 25 0 0.0
0.5
1.0
1.5
2.0
2.5
Voltage +/- 0.22
3.0
3.5
4.0
psi
120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 0.50
210 160 110 60 10
1.00
1.50
2.00
2.50
3.00
Voltage +/- 0.22
3.50
4.00
-40 4.50
Temperature F
Temperature C
NG Temperature vs Voltage Operating Range: -15 and up
Manifold Absolute Pressure vs Voltage Typical Range: 90 - 225 kPa
kPa
350.0 325.0 300.0 275.0 250.0 225.0 200.0 175.0 150.0 125.0 100.0 75.0 50.0 25.0 0.0
50
40
30
psi 20
10
0 0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Voltage +/- 0.22
4.0
4.5
5.0
120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 0.50
210 160 110 60 10
1.00
1.50
2.00
2.50
3.00
Voltage +/- 0.22
3.50
4.00
-40 4.50
Temperature F
Temperature C
Air Charge Temperature vs Voltage
BOB Test Points (others) 1. 2. 3. 4.
ECU Power (ECUPWR) Solenoid Power (SOLPWR) Inject OK (ICONFIRM) Sensor Reference Voltage (VREF) 5. Ground
BOB Test Points DIGITAL SIGNALS (PWM) 1. INJECT – Diesel Injector (out) 2. PIP – Position Indicator Pulse (in) 3. RPMCMD/FUELCMD (in) 4. TAB – Turbo Air Bypass (out)
Inputs from CAT (ADEM) RPMCMD/FUELCMD Frequency 200
Hz 166 Hz 125 Hz
= = =
normal command No droop requested FUELCMD
Inputs from CAT (ADEM) RPMCMD/FUELCMD Circuit Duty cycle Error Messages 1.0%
= No diesel pulses, FC: 65 1.5% = Bad diesel pulse timing, FC: 66 2.0% = Bad diesel pulse duration, FC: 67 2.5% = Extra diesel pulses received, FC: 68 3.0% = ADEM not ready 5 – 95% = 500 – 2500 RPM
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 2 October 17, 2008
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