detroit diesel series 50 - 60 gas

Detroit DieselSeries 50G / 60GTraining Program

Leo BeattieLeo Beattie

Presenter\Name of PresentationRevised Date 4

Series 50G/60G Natural Gas Engine


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


Mission Statement

To Provide Proven Alternate Fueled Engines in Conjunction with Our Diesel Engines that Exceed Our Customers Expectations The First Time, Every Time


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


DDC Alternate Fuel Projects

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

• Ethanol Fueled– Urban Buses– Heavy Duty Trucks


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


Boiling Point of Liquids


Ignition Limits


Background

Glossary of Terms

Engine Sensors


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


Four Stroke Cycle


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


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)


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


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


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


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


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


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


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


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


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


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


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%



• 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



• 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)



• 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


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


Series 50G / 60G Engine Components


Series 50G Transit Bus Engine

Fuel Mixer

Coil Over PlugIgnition Coils

InsulatedExhaustManifold

Water CooledTurbocharger

Center Section

InsulatedTurbineHousing

Automatic Tensionerfor 50 DN

Alternator Belt


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


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


Series 50G /60G Connecting Rod


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


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


Series 50G / 60G Camshaft


Series 50G /60G Overhead


Series 50 Balance Shaft


Manifold Wrap


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


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


Series 50G / 60G Fuel Control Systems

Coach Fuel Control System


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



• 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



Low Pressure Regulator• Engine Mounted Above

Intake Manifold• Referenced to Air Inlet

Depression• Coolant Heated• No Adjustment



Electronic PSV• DDEC Interface

to Control Air / Fuel Ratio• Fully Electronic Fuel

Control Valve• Incorporates DDEC

Diagnostics• No Maintenance Required



• Similar to a Carburetor

• Balanced To Provide Correct Air /Fuel Ratio

• No Moving Parts

• No Maintenance Required

Venturi / Mixer



AirfromCAC

ThrottleMixer / Venturi Intake Elbow

FuelInlet

Fuel TransferTube

Fuel BalanceLine

Air / Fuelto Engine

Low Pressure Regulator

PSV



• Wide Range O2 Sensorto Monitor All Speeds & Loads

• No Calibration Required

• Minimal Drift

• Excellent Durability Results to Date

Oxygen Sensor



• Converts O2 Sensor Output into DDEC Input

• Provides SensorHeater Control

• Self Contained - Engine Mounted




• 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



• 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


Series 50G / 60G Exhaust Temperature Sensor

• Monitors Turbine Outlet Temperature

• Triggers DDEC Engine Shutdown if Overtemperature is Detected

• Fast Response• No Maintenance Required


Barometric Pressure Sensor


Air and Fuel Temperature Sensor


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


Series 50G/ 60G Fuel Control System

Coach Fuel Control System

Troubleshooting


Series 50G / 60G Fuel Control Systems

Generator Set Fuel Control System


Series 50G / 60G Genset Specifications

Engine Type

Displacement

Compression Ratio

Ignition

Aspiration

Fuel Control

Throttle

Ratings Engine Hp 60 Hz

Engine Hp 50 Hz


8.5 Liters

10:1

Electronic Spark

Turbocharged

DDC Low Pressure

60 mm Electronic

225 HP - 300 HP

N/A


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


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


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


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


Mixer Inlet, GENSET


Mixer & PSV, GENSET


DDC Pulsewidth Stepper Valve

• DDEC Interfaceto Air / Fuel RatioControl

• DDEC Diagnostics


Electronic PSV


Series 50G DDC Fuel System

• Mixer / Venturi

– Inherently Balancedto provide CorrectAir /Fuel Ratio

– No Moving Parts

– No Maintenance Required


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


Regulator, Low Pressure


GENSET, Front


GENSET, Right Bank


GENSET, Left Bank


Flywheel, GENSET


MAP Sensor


Air and Fuel Temperature Sensor


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


Series 50G / 60G Fuel Control System

Generator Set Fuel Control System

Troubleshooting

Series 50G / 60GAir System


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


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


Wastegate Actuator


Wastegate Poppets


Wastegate Calibration


Turbocharger, GENSET


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”


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


Series 50G / 60G Air Control System

Troubleshooting

Series 50G/ 60GIgnition System


Series 50G / 60G Coil Over Plug Ignition System


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


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


Series 50G / 60G Spark Igniter Module


Spark Plug Tube, Upper


Spark Plug Tube, Lower


Spark Plug


Series 50G 60G Ignition Control System

Troubleshooting


Cylinder Cut-Out

Series 50G / 60GOther Engine Systems


Knock Sensor


SNEF Module


Sensor Harness


DDEC System

Error Codes and Troubleshooting


DDR Reader


DDEC Tools


Vehicle Systems

• Fuel Supply– High Pressure Regualtor– High Pressure Fuel Solenoid– Filters

» Coalescing– Low Pressure Fuel Solenoid

– Fuel Lines– Vehicle Fuel Systems


Regulator, High Pressure Fuel


Typical High Pressure Fuel Control Solenoid


Low Pressure Fuel Solenoid


CNG Vent Lines


CNG Fuel System


LNG Fuel System


LNG Tank


LNG Vaporizer

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


Throttle Relay


Unique Requirements

Engine Oil and Coolant


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


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


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


Summary and Wrap-Up


Series 50G/60G Natural Gas Engine

detroit diesel series 50 - 60 gas

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