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Detroit Diesel

Series 50G / 60G


Training Program

Leo Beattie
Series 50G/60G Natural Gas Engine

Presenter\Name of Presentation
Revised Date 4
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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Revised Date 5
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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Revised Date 6
DDC Milestones

• Alternative Fuel Engineering Started 1970‟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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Revised Date 7
DDC Alternate Fuel Projects

• Methanol Fueled
– Urban Buses
– Heavy Duty Trucks
– Generator Set
• Ethanol Fueled
– Urban Buses
– Heavy Duty Trucks

Presenter\Name of Presentation
Revised Date 8
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

Presenter\Name of Presentation
Revised Date 9
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

Presenter\Name of Presentation
Revised Date 10
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

Presenter\Name of Presentation
Revised Date 11
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 Presentation
Revised Date 12
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

Presenter\Name of Presentation
Revised Date 13
Specific Features of DDC
Natural 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 Presentation
Revised Date 14
Series 50G / 60G Coach Specifications
Series 50G Series 60G
Engine Type 4-Cycle (Dedicated Fuel) 4-Cycle (Dedicated Fuel)
Displacement 8.5 Liters 12.7 Liters
Compression Ratio 10:1 10:1
Engine Control DDEC IV, On-Engine DDEC IV, On-Engine
Ignition Electronic Spark Electronic Spark
Aspiration Turbocharged Turbocharged
Fuel Control DDC Closed Loop DDC Closed Loop
Throttle 60 mm Electronic 68 mm Electronic
Rated Power 275 @ 2100 RPM 330 @ 2100 RPM
Peak Torque 890 Ft-Lb @ 1200 RPM 1400 Ft-Lb @ 1200 RPM
Presenter\Name of Presentation
Revised Date 15
Series 50G / 60G Genset Specifications

Series 50G Series 60G


Engine Type 4-Cycle 4-Cycle
(Dedicated Fuel) (Dedicated Fuel)
Displacement 8.5 Liters 12.7 Liters
Compression Ratio 10:1 10:1
Ignition Electronic Spark Electronic Spark
Aspiration Turbocharged Turbocharged
Fuel Control DDC Low Pressure DDC Low Pressure
Throttle 60 mm Electronic 68 mm Electronic
Ratings Engine Hp 60 Hz 225 HP - 300 HP 340 HP - 450 HP
Engine Hp 50 Hz N/A 230 HP - 400 HP

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Revised Date 16
DDC Series 50G / 60G Gas Engines
Rating Application Availability
Series 50G 275 HP @ 2100 RPM Transit Bus Now
890 FT-LB EPA / CARB

275 HP @ 2100 RPM


Transit Bus 2nd Quarter „99
890 FT-LB LEV / ULEV
Gen Set Now
225 - 300 HP @ 1800 RPM Stand-By

Series 60G 330 HP @ 2100 RPM Motor Coach 3rd. Quarter „98
1400 FT-LB EPA / CARB
Gen Set
340 - 450 HP @ 1800 RPM Stand-By Now
Gen Set Now
230 - 400 HP @ 1500 RPM Stand-By
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Revised Date 17
Series 50G Exhaust Emissions

G/HP-HR
Rating 275 HP - 890 FT-LB NOx NMHC CO PM

1998 CARB / EPA Standards 4.0 1.2 15.5 .05

1998 Configuration* 2.2 0.5 2.3 <.01

*No Catalyst
Presenter\Name of Presentation
Revised Date 18
Series 50G ULEV Exhaust Emissions

Rating 275 HP - 890 FT-LB G/HP-HR


ULEV Certification NOX + NMHC HCHO CO PM

1998 ULEV Standards 2.5 .025 7.2 .05

ULEV Program Goals * 1.7-2.0 .003 .01 <.01

*With Catalyst / No DF
Presenter\Name of Presentation
Revised Date 19
Series 60G Exhaust Emissions

G/HP-HR
Rating 330 HP - 1400 FT-LB NOx NMHC CO PM

1998 CARB / EPA Standards 4.0 1.2 15.5 .05

1998 Configuration* 2.0 0.6 1.9 .02

*No Catalyst
Presenter\Name of Presentation
Revised Date 20
Series 50G Transit Sites
Vancouver
(50 Units)

Hamilton / Kitchener
INEEL Area (58 Units)
(6 Units)
Pennsylvania
(47 Units) NY / New Jersey
Monterey / Sonoma Springfield Cleveland Area (100 Units)
Denver
(25 Units) (7 Units) (190 Units)
(5 Units)

Los Angeles / San Diego


Oklahoma
Area (200 Units)
Phoenix (3 Units) Atlanta
(9 Units) (118 Units)

El Paso
Tucson (35 Units)
(44 Units) Houston Orlando
Indonesia Laredo (10 Units) (11 Units)
(41 Units) (15 Units)
Pinellas
(3 Units)

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Revised Date 21
Natural Gas
Compressed and Liquid
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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Revised Date 23
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

Presenter\Name of Presentation
Revised Date 24
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

Presenter\Name of Presentation
Revised Date 25
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

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Revised Date 26
Handling and Safety
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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Revised Date 28
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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Revised Date 29
Boiling Point of Liquids

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Revised Date 30
Ignition Limits

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Revised Date 31
Background

Glossary of Terms
Engine Sensors

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Revised Date 32
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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Revised Date 33
Four Stroke Cycle

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Revised Date 34
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

Presenter\Name of Presentation
Revised Date 35
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)

Presenter\Name of Presentation
Revised Date 36
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

Presenter\Name of Presentation
Revised Date 37
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
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Revised Date
Depending on Conditions 38
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

Presenter\Name of Presentation
Revised Date 39
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

Presenter\Name of Presentation
Revised Date 40
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

Presenter\Name of Presentation
Revised Date 41
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

Presenter\Name of Presentation
Revised Date 42
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

Presenter\Name of Presentation
Revised Date 43
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

Presenter\Name of Presentation
Revised Date 44
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

Presenter\Name of Presentation
Revised Date 45
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

Presenter\Name of Presentation
Revised Date 46
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%

Presenter\Name of Presentation
Revised Date 47
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

Presenter\Name of Presentation
Revised Date 48
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)
Presenter\Name of Presentation
Revised Date 49
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

Presenter\Name of Presentation
Revised Date 50
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

Presenter\Name of Presentation
Revised Date 51
Series 50G / 60G Engine Components

Presenter\Name of Presentation
Revised Date 52
Series 50G Transit Bus Engine
Coil Over Plug
Ignition Coils

Insulated
Exhaust
Manifold

Fuel Mixer

Water Cooled Automatic Tensioner


Turbocharger for 50 DN
Center Section Alternator Belt

Insulated
Turbine
Housing

Presenter\Name of Presentation
Revised Date 53
Series 50G Transit Bus Engine
Low Pressure Fuel Pressure
Regulator Sensor
PSV
Oxygen Sensor
Module

Ignition System
Module

Adaptorless
Air Compressor
DDEC IV
ECM
Knock Signal
Processor
OEM Pigtail
Interfaces
Presenter\Name of Presentation
Revised Date 54
Basic Engine Unique Parts
Series 50G / 60G Cylinder Kit

Cylinder Kit
• Shorter Connecting Rod

• Unique Gas Engine Piston

• Plasma Coated Fire Ring

• Rectangular Style Compression Ring

• Top Liner Cooling


Presenter\Name of Presentation
Revised Date 56
Series 50G /60G Connecting Rod

Presenter\Name of Presentation
Revised Date 57
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 COOLING
CHANNEL

COOLING
CHANNEL
INLET NOTCH COOLING
IN BLOCK CHANNEL
EXIT HOLE

MAIN COOLANT
STREAM

Presenter\Name of Presentation
Revised Date 58
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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Revised Date 59
Series 50G / 60G Camshaft

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Revised Date 60
Series 50G /60G Overhead

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Revised Date 61
Series 50 Balance Shaft

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Revised Date 62
Manifold Wrap

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Revised Date 63
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 Presentation
Revised Date 64
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

Presenter\Name of Presentation
Revised Date 65
Series 50G / 60G Fuel Control Systems

Coach Fuel Control System

Presenter\Name of Presentation
Revised Date 66
Series 50G / 60G Coach Fuel System

• Venturi Design to Provide Correct Air / Fuel


Ratio Over All Speeds & Loads
• DDEC Bias to Alter Air / Fuel Ratio (Rich or Lean)
Based on Transient Conditions
• Feedback via Engine Exhaust to Match
Desired and Actual Air / Fuel Ratios
• Components Divided into Three Areas
– Open Loop, Closed Loop and Fuel Supply

Presenter\Name of Presentation
Revised Date 67
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
Presenter\Name of Presentation
Revised Date 68
Series 50G / 60G Coach Fuel System

Presenter\Name of Presentation
Revised Date 69
Series 50G / 60G Coach Fuel System

Low Pressure Regulator


• Engine Mounted Above
Intake Manifold
• Referenced to Air Inlet
Depression
• Coolant Heated
• No Adjustment

Presenter\Name of Presentation
Revised Date 70
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

Presenter\Name of Presentation
Revised Date 72
Series 50G / 60G Coach Fuel System

Venturi / Mixer
• Similar to a Carburetor
• Balanced To Provide
Correct Air /Fuel Ratio
• No Moving Parts
• No Maintenance Required

Presenter\Name of Presentation
Revised Date 73
Series 50G / 60G Coach Fuel System
Throttle
Intake Elbow
Mixer / Venturi

Air
from
CAC
PSV

Fuel
Inlet

Fuel Balance
Line

Air / Fuel
Fuel Transfer to Engine
Tube

Low Pressure Regulator


Presenter\Name of Presentation
Revised Date 74
Series 50G / 60G Coach Fuel System

Oxygen Sensor
• Wide Range O2 Sensor
to Monitor All Speeds
& Loads
• No Calibration
Required
• Minimal Drift
• Excellent Durability
Results to Date

Presenter\Name of Presentation
Revised Date 75
Series 50G / 60G Coach Fuel System

• Converts O2 Sensor
Output into DDEC
Input
• Provides Sensor
Heater Control
• Self Contained -
Engine Mounted
• No Maintenance
Required

Presenter\Name of Presentation
Revised Date 76
Series 50G / 60G Coach Fuel System

Primary Fuel Pressure Regulator


• 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

Presenter\Name of Presentation
Revised Date 77
Series 50G / 60G Coach Fuel System

Low Pressure Fuel Control Solenoid


• Manufactured by
Honeywell-Skinner
• Provides Positive Fuel Shut-Off
to Engine
• DDEC Digital Output Controlled
• 12 or 24 Volt Versions Available
• Supplied & Warranted by DDC

Presenter\Name of Presentation
Revised Date 78
Series 50G / 60G Exhaust Temperature
Sensor
• Monitors Turbine Outlet
Temperature
• Triggers DDEC Engine
Shutdown if
Overtemperature is
Detected
• Fast Response
• No Maintenance Required

Presenter\Name of Presentation
Revised Date 79
Barometric Pressure Sensor

Presenter\Name of Presentation
Revised Date 81
Air and Fuel Temperature Sensor

Presenter\Name of Presentation
Revised Date 82
Series 50G / 60G Transit Bus Engine
Closed Loop Fuel System
Other DDEC Engine
Protection Sensors & Signals
Interface
Module
Baro
Sensor
DDEC IV
Charge Intake Pressure
Air Gas & Temperature
Cooler Temperature
Turbo
Compressor

Venturi
Air
Intake Mixer ENGINE
Electronic
Control Valve Throttle
(PSV) Actuator
Gas to Engine
Exhaust

Gas O2 Sensor
Pressure
Input Gas Exhaust
Pressure Temperature
DDEC (70 - 120 PSIG) Sensor
Zero Pressure Controlled
Regulator Solenoid Valve
Presenter\Name of Presentation
Revised Date 83
Series 50G/ 60G Fuel Control System

Coach Fuel Control System

Troubleshooting

Presenter\Name of Presentation
Revised Date 84
Series 50G / 60G Fuel Control Systems

Generator Set Fuel Control System

Presenter\Name of Presentation
Revised Date 85
Series 50G / 60G Genset Specifications

Series 50G Series 60G


Engine Type 4-Cycle 4-Cycle
(Dedicated Fuel) (Dedicated Fuel)
Displacement 8.5 Liters 12.7 Liters
Compression Ratio 10:1 10:1
Ignition Electronic Spark Electronic Spark
Aspiration Turbocharged Turbocharged
Fuel Control DDC Low Pressure DDC Low Pressure
Throttle 60 mm Electronic 68 mm Electronic
Ratings Engine Hp 60 Hz 225 HP - 300 HP 340 HP - 450 HP
Engine Hp 50 Hz N/A 230 HP - 400 HP

Presenter\Name of Presentation
Revised Date 86
Specific Features of DDC
Natural 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 Presentation
Revised Date 87
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 Presentation
Revised Date 88
Series 50/60G Genset Gas Engine

Insulated Exhaust
Manifold & Turbine
Housing

Air Inlet Water Cooled


Tube Turbocharger
Center Housing

Fuel Mixer / Venturi

PSV Control Valve


Fuel Line
Fuel / Air
Balance Fuel Regulator
Lines

Presenter\Name of Presentation
Revised Date 89
Mixer Inlet, GENSET

Presenter\Name of Presentation
Revised Date 90
Mixer & PSV, GENSET

Presenter\Name of Presentation
Revised Date 91
DDC Pulsewidth Stepper Valve

Electronic PSV
• DDEC Interface
to Air / Fuel Ratio
Control
• DDEC Diagnostics
• No Maintenance Required

Presenter\Name of Presentation
Revised Date 92
Series 50G DDC Fuel System

• Mixer / Venturi
– Inherently Balanced
to provide Correct
Air /Fuel Ratio
– No Moving Parts
– No Maintenance Required

Presenter\Name of Presentation
Revised Date 93
Series 50/60G Electronic Throttle
• Full Control by DDEC
– Idle & Governor
Speed Control
– No Internal / External
Adjustments
– Auto Calibration
During Startup
– Diagnostic Fault
Protection
– Fail Safe “Closed”
Feature
Presenter\Name of Presentation
Revised Date 94
Regulator, Low Pressure

Presenter\Name of Presentation
Revised Date 95
GENSET, Front

Presenter\Name of Presentation
Revised Date 96
GENSET, Right Bank

Presenter\Name of Presentation
Revised Date 97
GENSET, Left Bank

Presenter\Name of Presentation
Revised Date 98
Flywheel, GENSET

Presenter\Name of Presentation
Revised Date 99
MAP Sensor

Presenter\Name of Presentation
Revised Date 100
Air and Fuel Temperature Sensor

Presenter\Name of Presentation
Revised Date 101
Natural Gas Genset Fuel System
OTHER DDEC
ENGINE PROTECTION
SENSORS & SIGNALS
INTAKE PRESSURE
& TEMPERATURE

DDEC KNOCK
FUEL TEMP. CHARGE SENSOR
SENSOR AIR IGNITION
COOLER COILS
TURBO
VENTURI COMPRESSOR
MIXER

AIR
INTAKE

THROTTLE
ENGINE
BOOST ACTUATOR
PRESSURE LOW PRESSURE
ELECTRONIC REGULATOR
CONTROL VALVE EXHAUST
INPUT GAS
PRESSURE
5”- 20” H2O
TURBO
WASTEGATE
VALVE

Presenter\Name of Presentation
Revised Date 102
Series 50G / 60G Fuel Control System

Generator Set Fuel Control System

Troubleshooting

Presenter\Name of Presentation
Revised Date 103
Series 50G / 60G
Air System
Series 50G / 60G Electronic Throttle
• Full Control by DDEC
– Idle & Governor
Speed Control
– No Internal / External
Adjustments
– Auto Calibration
During Startup
– Diagnostic Fault
Protection
– Fail Safe “Closed”
Feature
Presenter\Name of Presentation
Revised Date 105
Series 50G / 60G Turbocharger

Turbocharger
• Water Cooled Center Section
• Insulated Turbine Housing
• Dual Poppet Wastegate
with Heavy-Duty Arm
• “Long Can” Wastegate Actuator
• Recirculation Valve
• Strengthened Compressor Backplate
• “V” Band Turbine Housing

Presenter\Name of Presentation
Revised Date 106
Wastegate Actuator

Presenter\Name of Presentation
Revised Date 107
Wastegate Poppets

Presenter\Name of Presentation
Revised Date 108
Wastegate Calibration

Presenter\Name of Presentation
Revised Date 109
Turbocharger, GENSET

Presenter\Name of Presentation
Revised Date 110
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 Presentation
Revised Date 111
Series 50G / 60G Closed Breather

• “Dirty Air” is Routed from


Rocker Cover Outlet
• Special Baffling Minimizes
Oil Carryover
• Self Contained
Coalescing Filter
• Water Condensate is Drained
• “Clean Air” is Routed
to Intake System

Presenter\Name of Presentation
Revised Date 112
Series 50G / 60G Air Control System

Troubleshooting

Presenter\Name of Presentation
Revised Date 113
Series 50G/ 60G
Ignition System
Series 50G / 60G
Coil Over Plug Ignition System

Presenter\Name of Presentation
Revised Date 115
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 Presentation
Revised Date 116
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 Presentation
Revised Date 117
Series 50G / 60G Spark Igniter Module

Presenter\Name of Presentation
Revised Date 118
Spark Plug Tube, Upper

Presenter\Name of Presentation
Revised Date 119
Spark Plug Tube, Lower

Presenter\Name of Presentation
Revised Date 120
Spark Plug

Presenter\Name of Presentation
Revised Date 121
Series 50G 60G Ignition Control System

Troubleshooting

Presenter\Name of Presentation
Revised Date 122
Cylinder Cut-Out

Presenter\Name of Presentation
Revised Date 123
Series 50G / 60G
Other Engine Systems
Knock Sensor

Presenter\Name of Presentation
Revised Date 125
SNEF Module

Presenter\Name of Presentation
Revised Date 126
Sensor Harness

Presenter\Name of Presentation
Revised Date 127
DDEC System

Error Codes and Troubleshooting

Presenter\Name of Presentation
Revised Date 128
DDR Reader

Presenter\Name of Presentation
Revised Date 129
DDEC Tools

Presenter\Name of Presentation
Revised Date 130
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 Presentation
Revised Date 132
Regulator, High Pressure Fuel

Presenter\Name of Presentation
Revised Date 133
Typical High Pressure Fuel Control
Solenoid

Presenter\Name of Presentation
Revised Date 135
Low Pressure Fuel Solenoid

Presenter\Name of Presentation
Revised Date 136
CNG Vent Lines

Presenter\Name of Presentation
Revised Date 138
CNG Fuel System

Presenter\Name of Presentation
Revised Date 139
LNG Fuel System

Presenter\Name of Presentation
Revised Date 140
LNG Tank

Presenter\Name of Presentation
Revised Date 141
LNG Vaporizer

Presenter\Name of Presentation
Revised Date 142
Power Requirements
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 Presentation
Revised Date 144
Throttle Relay

Presenter\Name of Presentation
Revised Date 145
Unique Requirements

Engine Oil and Coolant

Presenter\Name of Presentation
Revised Date 146
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 Presentation
Revised Date 147
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 Presentation
Revised Date 148
Series 50G Maintenance Intervals
Urban Coach Service
Component / Item Maintenance Required
Replace Every 6,000 Miles &
Lubricating Oil & Filter
Check Oil Level Daily
Drain Daily & Replace Element
Coalescing Fuel Filters
Every 6,000 Miles
Throttle Body & Actuator Inspect Every 6,000 Miles

Spark Plugs Replace Every 24,000 Miles

Spark Plug Boots Inspect Every 24,000 Miles

Turbocharger & Wastegate


Inspect Every 36,000 Miles
Calibration

Valve Lash Inspect Every 36,000 Miles

Presenter\Name of Presentation
Revised Date 149
Summary and Wrap-Up

Presenter\Name of Presentation
Revised Date 150
Series 50G/60G Natural Gas Engine

Presenter\Name of Presentation
Revised Date 151