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 NG Press
ACT Sensor
Sensor Sensor

NG Inlet SOV 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 Fuse
Connectors

TAB Valve
Connectors 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
To RPM
Wires to Circuit
Cat Engine
Harness
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
Output to
Waste Diesel LED
Gate
Connector

Relays
9-pin
Connector Serial
Connector

Breaker 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
Figure Skipfire
Without Skipfire

Figure
Figure 22– -With
With Skipfire
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
100
Percent Torque (%)

90

80 6-cylinder gas

70

60 5-cylinder gas

50

4-cylinder gas
40

30
3-cylinder gas
20

10 6-cylinder diesel

0
Idle Max Engine Speed
Engine Speed (RPM)
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 oil analysis (Cat SOS)
 Any 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