City Of La Training 3
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- Pages: 47
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 3 October 17, 2008
Engine Dual-Fuel Diagnostics
“Diesel” “Diesel” light flashes codes
Series of two-digit codes
Uses 607416 fault clearing plug
PC diagnostic system
Uses the Panels program
Requires 607119-1 serial interface cable
Diagnostics
Cat requirements for Dual-Fuel mode
Engine must be out of start mode
Coolant must be warm 150º F (65º C)
Engine cannot be in timing calibration mode
No active faults on the Cat ECM
Diagnostics
Eagle requirements for Dual-Fuel mode
Diesel fuel must be 5º C below the fuel temperature limit (78º C)
The ACT Must be 5º C below the limit (65º C)
Natural gas pressure (to the manifold) must be within limits (515 kPa to 1050
Dual-Fuel Requirements
Eagle requirements for Dual-Fuel
Natural gas temperature must be above the minimum allowable (5º F or -15º C)
Desired RPM from the Cat ECM must be within acceptable limits (500-3,000 RPM)
Intake MAP must be within limits (50 to 300kPa)
Dual-Fuel Requirements
Eagle requirements for Dual-Fuel The
confirm line from the Cat ECM
must be Low (changes from abt 860 to abt 50) The
EEPROM verification code must
pass the validity test
Not Verified
Verified
Dual-Fuel Requirements
Once all the requirements are met The NG
gas shut off valve is tested
injector leakage test is performed
Checks
for low DC voltage (<11.5 VDC
for 10 seconds) Goes
into gas mode
• Green diesel light goes out
Dual-Fuel Requirements Methods
of retrieving fault codes
Flashes codes (green light) • Ignition on, engine not running
Use computer and Panels software • Requires serial interface cable • Ignition on, engine not running
Dual-Fuel Relay Diagnostics
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR
K1 – ECUPWR Relay To Mode and KA Power Relays To ECU P1, Pin F1 Ground (12 v Neg)
30
86
Un-Switched Power
87 K1
85
Switched Power Diode
Energizes from ignition circuit
Sends power to Mode relay
Sends power to KAPWR relay
Sends power to ECU connector P1, pin F1
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode
K2 – Mode Relay Switched Power Mode Light To ECU P1, Pin G3 Ground (12 v Neg)
86
87A K2
85
Power from ECUPWR Relay
Controls Mode light
30
Light gets constant ground (negative) from NC contacts
Relay receives power from ECUPWR relay
Opens ground (negative) to Mode light when energized
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode • K3 – KAPWR
K3 – KAPWR Relay Power from ECUPWR Relay Diode 30 To ECU P1, Pin A1
86
87 K3
85
Switched Power
Diode
Power from ECUPWR relay
Energizes - ground (neg) from ECU P1, A1
Latches itself in once energized Keeps power to Eagle a few seconds after key off to write data from EPROM to EEPROM
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode • K3 – KAPWR • K4 – SOLPWR
K4 – SOLPWR Relay Power to ECU (P1, J2), SOV, waste gate, TAB, and 7.5 amp fuse To ECU P1, Pin A1. Same neg as KAPWR
30
86
Un-Switched Power
87
K4
85
Switched Power Diode
Gets power from ignition circuit Energizes with ground (negative) from ECU
Sends power to SOV, WG, TAB, injector fuse
Sends power to ECU connector P1, pin J2
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • •
K1 K2 K3 K4 K5
– ECUPWR – Mode – KAPWR – SOLPWR - Waste Gate Relay
K5 – Waste Gate Relay Wastegate Sol A
Power from K4 - SOLPWR relay
B
30 86
87 85 K5
Ground (12v Neg) To ECU P1, Pin D3
Gets power from SOLPWR relay (K4) Energizes with ground (negative) from ECU
Sends ground (12v neg) to Wastegate solenoid
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • • •
K1 – ECUPWR K2 – Mode K3 – KAPWR K4 – SOLPWR K5 – Waste gate relay Mode light
Mode Light Mode Light To ECU P1, Pin G3 Ground (12 v Neg)
Switched Power
30
K2
87A
Mode light gets 12v from ignition
Mode light gets negative from NC K2 contacts Once
Mode relay is energized
Mode light then gets negative from the ECU (P1, G3)
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • • • •
K1 – ECUPWR K2 – Mode K3 – KAPWR K4 – SOLPWR K5 – Waste gate relay Mode light Diagnostic connector
Diagnostic Connector
Connects to Serial Interface cable or extension to bulkhead connector
Natural Gas Injector Testing
Injector Leak Test • Vacuum Tester
Injector Testing • “Click” Test
The Panels Program
To use Panels:
Requires serial interface (607119-1)
The Panels Program
To use Panels:
Requires serial interface IBM PC computer with Com 1 port
Operating system
• DOS • Win 95/98/ME/XP • Customer and full versions
ECU Diag Operation
Pull-down menus, Hotkeys, help screen Configuration Fault codes (Active, logged) Erasing codes Fuel & Hours used Verification, Password Refuse flag, SAFR/HV-Ratio Indexes Saving Data
ECU Diag Program
C10 refuse setting
Refuse Setting
ECU Diag Operation Troubleshooting/Diagnostics Poll
Gas
Data
injectors
Click
test Vacuum test
System Installation
Use ECU Diag to:
Set Verification – new passwords
Write Down
SAFR_Index HV_Ratio_Index EUI_Gain
Injector Flow Compensation Check_Code Hour_Count
Input New Password
Send Changed Data
Panels Program
Turn ignition off
Wait 15 seconds
Then turn ignition back on
Receive data to verify change
SAFR and HV_Ratio
Numbers used to compensate for gas quality variations
Calculated from gas analysis
Clean Air Partners will calculate numbers
Numbers vary by location and type of fuel (LNG or CNG)
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 3 October 17, 2008
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 3 October 17, 2008
Engine Dual-Fuel Diagnostics
“Diesel” “Diesel” light flashes codes
Series of two-digit codes
Uses 607416 fault clearing plug
PC diagnostic system
Uses the Panels program
Requires 607119-1 serial interface cable
Diagnostics
Cat requirements for Dual-Fuel mode
Engine must be out of start mode
Coolant must be warm 150º F (65º C)
Engine cannot be in timing calibration mode
No active faults on the Cat ECM
Diagnostics
Eagle requirements for Dual-Fuel mode
Diesel fuel must be 5º C below the fuel temperature limit (78º C)
The ACT Must be 5º C below the limit (65º C)
Natural gas pressure (to the manifold) must be within limits (515 kPa to 1050
Dual-Fuel Requirements
Eagle requirements for Dual-Fuel
Natural gas temperature must be above the minimum allowable (5º F or -15º C)
Desired RPM from the Cat ECM must be within acceptable limits (500-3,000 RPM)
Intake MAP must be within limits (50 to 300kPa)
Dual-Fuel Requirements
Eagle requirements for Dual-Fuel The
confirm line from the Cat ECM
must be Low (changes from abt 860 to abt 50) The
EEPROM verification code must
pass the validity test
Not Verified
Verified
Dual-Fuel Requirements
Once all the requirements are met The NG
gas shut off valve is tested
injector leakage test is performed
Checks
for low DC voltage (<11.5 VDC
for 10 seconds) Goes
into gas mode
• Green diesel light goes out
Dual-Fuel Requirements Methods
of retrieving fault codes
Flashes codes (green light) • Ignition on, engine not running
Use computer and Panels software • Requires serial interface cable • Ignition on, engine not running
Dual-Fuel Relay Diagnostics
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR
K1 – ECUPWR Relay To Mode and KA Power Relays To ECU P1, Pin F1 Ground (12 v Neg)
30
86
Un-Switched Power
87 K1
85
Switched Power Diode
Energizes from ignition circuit
Sends power to Mode relay
Sends power to KAPWR relay
Sends power to ECU connector P1, pin F1
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode
K2 – Mode Relay Switched Power Mode Light To ECU P1, Pin G3 Ground (12 v Neg)
86
87A K2
85
Power from ECUPWR Relay
Controls Mode light
30
Light gets constant ground (negative) from NC contacts
Relay receives power from ECUPWR relay
Opens ground (negative) to Mode light when energized
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode • K3 – KAPWR
K3 – KAPWR Relay Power from ECUPWR Relay Diode 30 To ECU P1, Pin A1
86
87 K3
85
Switched Power
Diode
Power from ECUPWR relay
Energizes - ground (neg) from ECU P1, A1
Latches itself in once energized Keeps power to Eagle a few seconds after key off to write data from EPROM to EEPROM
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • K1 – ECUPWR • K2 – Mode • K3 – KAPWR • K4 – SOLPWR
K4 – SOLPWR Relay Power to ECU (P1, J2), SOV, waste gate, TAB, and 7.5 amp fuse To ECU P1, Pin A1. Same neg as KAPWR
30
86
Un-Switched Power
87
K4
85
Switched Power Diode
Gets power from ignition circuit Energizes with ground (negative) from ECU
Sends power to SOV, WG, TAB, injector fuse
Sends power to ECU connector P1, pin J2
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • •
K1 K2 K3 K4 K5
– ECUPWR – Mode – KAPWR – SOLPWR - Waste Gate Relay
K5 – Waste Gate Relay Wastegate Sol A
Power from K4 - SOLPWR relay
B
30 86
87 85 K5
Ground (12v Neg) To ECU P1, Pin D3
Gets power from SOLPWR relay (K4) Energizes with ground (negative) from ECU
Sends ground (12v neg) to Wastegate solenoid
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • • •
K1 – ECUPWR K2 – Mode K3 – KAPWR K4 – SOLPWR K5 – Waste gate relay Mode light
Mode Light Mode Light To ECU P1, Pin G3 Ground (12 v Neg)
Switched Power
30
K2
87A
Mode light gets 12v from ignition
Mode light gets negative from NC K2 contacts Once
Mode relay is energized
Mode light then gets negative from the ECU (P1, G3)
Relay Diagnostics
Relay harness
Five relays (Non-waste gate 4 relays) • • • • • • •
K1 – ECUPWR K2 – Mode K3 – KAPWR K4 – SOLPWR K5 – Waste gate relay Mode light Diagnostic connector
Diagnostic Connector
Connects to Serial Interface cable or extension to bulkhead connector
Natural Gas Injector Testing
Injector Leak Test • Vacuum Tester
Injector Testing • “Click” Test
The Panels Program
To use Panels:
Requires serial interface (607119-1)
The Panels Program
To use Panels:
Requires serial interface IBM PC computer with Com 1 port
Operating system
• DOS • Win 95/98/ME/XP • Customer and full versions
ECU Diag Operation
Pull-down menus, Hotkeys, help screen Configuration Fault codes (Active, logged) Erasing codes Fuel & Hours used Verification, Password Refuse flag, SAFR/HV-Ratio Indexes Saving Data
ECU Diag Program
C10 refuse setting
Refuse Setting
ECU Diag Operation Troubleshooting/Diagnostics Poll
Gas
Data
injectors
Click
test Vacuum test
System Installation
Use ECU Diag to:
Set Verification – new passwords
Write Down
SAFR_Index HV_Ratio_Index EUI_Gain
Injector Flow Compensation Check_Code Hour_Count
Input New Password
Send Changed Data
Panels Program
Turn ignition off
Wait 15 seconds
Then turn ignition back on
Receive data to verify change
SAFR and HV_Ratio
Numbers used to compensate for gas quality variations
Calculated from gas analysis
Clean Air Partners will calculate numbers
Numbers vary by location and type of fuel (LNG or CNG)
Presented by: Gil Garcia
Clean Air Power, Inc.
LEV Products Dual-Fuel Training Course Part 3 October 17, 2008
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