Detroit Diesel Series 50G / 60G Training Program

Leo Beattie

Series 50G/60G Natural Gas Engine

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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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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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DDC Milestones
Alternative Fuel Engineering Started First Alternative Vehicle on Road The First Emission Certified Alternative Fueled Engines (Methanol) Introduced Ethanol Engine Introduced LNG/Diesel Duel Fuel Engine Introduced Dedicated Natural Gas Engines 1970s 1983 1991 1992 1992 1994

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DDC Alternate Fuel Projects

Methanol Fueled
Urban Buses Heavy Duty Trucks Generator Set

Ethanol Fueled
Urban Buses Heavy Duty Trucks

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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

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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 1980s

Series 60G Evolved from the Series 50G

Significant Experience Carryover

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Series 50G / 60G Release Dates

Series 50G Coach (GFI Fuel System) Series 50G Genset (60Hz, Standby) Series 60G Genset (60Hz, Standby) Series 60G Genset (50Hz Standby) Series 50G Coach (DDC Fuel System) Series 50G / 60G Prime Power Series 60G Coach Aug 94 1995 1996 1996 Jan 98 Aug. 98 Sept 98

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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
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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
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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

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Series 50G / 60G Coach Specifications

Series 50G Engine Type 4-Cycle (Dedicated Fuel) Series 60G 4-Cycle (Dedicated Fuel)

Displacement
Compression Ratio Engine Control Ignition Aspiration Fuel Control Throttle

8.5 Liters
10:1 DDEC IV, On-Engine Electronic Spark Turbocharged DDC Closed Loop 60 mm Electronic

12.7 Liters
10:1 DDEC IV, On-Engine Electronic Spark Turbocharged DDC Closed Loop 68 mm Electronic

Rated Power
Peak Torque
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275 @ 2100 RPM

890 Ft-Lb @ 1200 RPM

330 @ 2100 RPM

1400 Ft-Lb @ 1200 RPM
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Series 50G / 60G Genset Specifications

Series 50G
Engine Type
Displacement Compression Ratio

Series 60G
4-Cycle (Dedicated Fuel)
12.7 Liters 10:1

4-Cycle (Dedicated Fuel)

8.5 Liters 10:1

Ignition
Aspiration Fuel Control Throttle Ratings Engine Hp Engine Hp 60 Hz 50 Hz

Electronic Spark
Turbocharged DDC Low Pressure 60 mm Electronic 225 HP - 300 HP N/A

Electronic Spark
Turbocharged DDC Low Pressure 68 mm Electronic 340 HP - 450 HP 230 HP - 400 HP

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DDC Series 50G / 60G Gas Engines

Rating Application
Transit Bus

Availability Now

Series 50G

275 HP @ 2100 RPM 890 FT-LB EPA / CARB 275 HP @ 2100 RPM 890 FT-LB LEV / ULEV 225 - 300 HP @ 1800 RPM

Transit Bus Gen Set Stand-By

2nd Quarter 99 Now 3rd. Quarter 98 Now Now

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Series 60G

330 HP @ 2100 RPM 1400 FT-LB EPA / CARB 340 - 450 HP @ 1800 RPM 230 - 400 HP @ 1500 RPM

Motor Coach
Gen Set Stand-By Gen Set Stand-By

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Series 50G Exhaust Emissions

Rating 275 HP - 890 FT-LB

1998 CARB / EPA Standards

G/HP-HR NOx NMHC CO

4.0 1.2 15.5

PM
.05

1998 Configuration*

2.2

0.5

2.3

<.01

*No Catalyst
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Series 50G ULEV Exhaust Emissions

Rating 275 HP - 890 FT-LB ULEV Certification 1998 ULEV Standards ULEV Program Goals *

G/HP-HR NOX + NMHC HCHO CO

PM .05 <.01

2.5
1.7-2.0

.025
.003

7.2 .01

*With Catalyst / No DF
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Series 60G Exhaust Emissions

Rating 330 HP - 1400 FT-LB

1998 CARB / EPA Standards

G/HP-HR NOx NMHC CO

4.0 1.2 15.5

PM
.05

1998 Configuration*

2.0

0.6

1.9

.02

*No Catalyst
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Series 50G Transit Sites

Vancouver (50 Units)

INEEL (6 Units) Monterey / Sonoma (25 Units)

Hamilton / Kitchener Area (58 Units) Pennsylvania NY / New Jersey (47 Units) Area (100 Units) Springfield Cleveland (7 Units) (190 Units)

Denver (5 Units)

Los Angeles / San Diego Area (200 Units) Phoenix (9 Units)

El Paso (35 Units) Tucson (44 Units) Indonesia (41 Units)

Oklahoma (3 Units)

Atlanta (118 Units)

Houston Laredo (10 Units) (15 Units)

Orlando (11 Units) Pinellas (3 Units)

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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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CNG Fuel Composition

DDC SPECIFICATIONS Minimum Maximum

Methane
Ethane Propane

88 (%)
0 0 6.0 (%) 1.7 (%)

Butane
CO2 + Nitrogen + Oxygen Hydrogen

0
0 0

0.3 (%)
4.5 (%) 0.1 (%)

Motor Octane Number

115 Minimum

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LNG Fuel Composition

DDC SPECIFICATIONS Minimum Maximum

Methane
Ethane Propane

98 (%)
0 0 0.5 (%) 0.0 (%)

Butane
Nitrogen Hydrogen

0
0 0

0.0 (%)
2.0 (%) 0.0 (%)

Motor Octane Number

130 Minimum

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Comparisons
DIESEL GAS CNG LNG

1. BTUs/ Gallon

140,000

136,000

28,000

91,000

2. Flame deg F

3,730

3,590

3,423

3,423

3. Octane

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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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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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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Boiling Point of Liquids

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Ignition Limits

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Background

Glossary of Terms Engine Sensors

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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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Four Stroke Cycle

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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
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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)

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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

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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 Presenter\Name of Presentation Depending on Conditions Revised Date

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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

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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

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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

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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

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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

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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
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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

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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

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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%
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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

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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)
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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

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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

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Series 50G / 60G Engine Components

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Series 50G Transit Bus Engine

Coil Over Plug Ignition Coils

Insulated Exhaust Manifold Fuel Mixer

Water Cooled Turbocharger Center Section Insulated Turbine Housing

Automatic Tensioner for 50 DN Alternator Belt

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Series 50G Transit Bus Engine

Low Pressure Regulator PSV Fuel Pressure Sensor Oxygen Sensor Module

Ignition System Module Adaptorless Air Compressor Knock Signal Processor DDEC IV ECM OEM Pigtail Interfaces
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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
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Series 50G /60G Connecting Rod

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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

COOLING CHANNEL INLET NOTCH IN BLOCK

LINER COOLING CHANNEL

COOLING CHANNEL EXIT HOLE MAIN COOLANT STREAM

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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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Series 50G / 60G Camshaft

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Series 50G /60G Overhead

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Series 50 Balance Shaft

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Manifold Wrap

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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
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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

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Series 50G / 60G Fuel Control Systems

Coach Fuel Control System

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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

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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
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Series 50G / 60G Coach Fuel System

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Series 50G / 60G Coach Fuel System

Low Pressure Regulator Engine Mounted Above Intake Manifold Referenced to Air Inlet Depression Coolant Heated No Adjustment

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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

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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

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Series 50G / 60G Coach Fuel System

Throttle Mixer / Venturi Air from CAC PSV Fuel Inlet Fuel Balance Line Air / Fuel to Engine Intake Elbow

Fuel Transfer Tube

Low Pressure Regulator

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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
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Series 50G / 60G Coach Fuel System

Converts O2 Sensor Output into DDEC Input

Provides Sensor Heater Control

Self Contained Engine Mounted No Maintenance Required
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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
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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

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Series 50G / 60G Exhaust Temperature Sensor

Monitors Turbine Outlet Temperature Triggers DDEC Engine Shutdown if Overtemperature is Detected Fast Response No Maintenance Required

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Barometric Pressure Sensor

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Air and Fuel Temperature Sensor

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Series 50G / 60G Transit Bus Engine

Closed Loop Fuel System
Other DDEC Engine Protection Sensors & Signals Interface Module

Baro Sensor

DDEC IV
Charge Air Cooler Gas Temperature Intake Pressure & Temperature

Turbo Compressor Air Intake

Venturi Mixer Electronic Control Valve (PSV) Gas to Engine Throttle Actuator

ENGINE
Exhaust
Gas Pressure DDEC Controlled Solenoid Valve O2 Sensor Input Gas Exhaust Pressure Temperature (70 - 120 PSIG) Sensor

Zero Pressure Regulator

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Series 50G/ 60G Fuel Control System

Coach Fuel Control System

Troubleshooting

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Series 50G / 60G Fuel Control Systems

Generator Set Fuel Control System

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Series 50G / 60G Genset Specifications

Series 50G
Engine Type
Displacement Compression Ratio

Series 60G
4-Cycle (Dedicated Fuel)
12.7 Liters 10:1

4-Cycle (Dedicated Fuel)

8.5 Liters 10:1

Ignition
Aspiration Fuel Control Throttle Ratings Engine Hp Engine Hp 60 Hz 50 Hz

Electronic Spark
Turbocharged DDC Low Pressure 60 mm Electronic 225 HP - 300 HP N/A

Electronic Spark
Turbocharged DDC Low Pressure 68 mm Electronic 340 HP - 450 HP 230 HP - 400 HP

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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

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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

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Series 50/60G Genset Gas Engine

Insulated Exhaust Manifold & Turbine Housing Air Inlet Tube Water Cooled Turbocharger Center Housing Fuel Mixer / Venturi PSV Control Valve Fuel Line Fuel / Air Balance Lines
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Fuel Regulator

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Mixer Inlet, GENSET

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Mixer & PSV, GENSET

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DDC Pulsewidth Stepper Valve

Electronic PSV

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

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Series 50G DDC Fuel System

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

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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

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Regulator, Low Pressure

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GENSET, Front

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GENSET, Right Bank

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GENSET, Left Bank

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Flywheel, GENSET

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MAP Sensor

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Air and Fuel Temperature Sensor

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Natural Gas Genset Fuel System

OTHER DDEC ENGINE PROTECTION SENSORS & SIGNALS INTAKE PRESSURE & TEMPERATURE

DDEC
FUEL TEMP. SENSOR VENTURI MIXER AIR INTAKE TURBO COMPRESSOR CHARGE AIR COOLER

KNOCK SENSOR IGNITION COILS

ELECTRONIC CONTROL VALVE

BOOST PRESSURE

THROTTLE ACTUATOR LOW PRESSURE REGULATOR INPUT GAS PRESSURE 5- 20 H2O

ENGINE
EXHAUST

TURBO WASTEGATE VALVE

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Series 50G / 60G Fuel Control System

Generator Set Fuel Control System

Troubleshooting

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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

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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

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Wastegate Actuator

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Wastegate Poppets

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Wastegate Calibration

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Turbocharger, GENSET

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Air System
Turbocharger Wastegate Settings
Series 50G SOP Through 96 Build
Short Can Long Can 18.5 Psig @ .040 21.0 Psig @ .040 24.0 Psig @ .040 18.5 Psig @ .040 18.5 Psig @ .040

Series 50G 97 and 98 Production Build

Series 60G Coach Engines

Long Can

Series 60G Truck Engines

Short Can

Series 50G Truck Engines

Short Can
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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

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Series 50G / 60G Air Control System

Troubleshooting

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Series 50G/ 60G Ignition System

Series 50G / 60G

Coil Over Plug Ignition System

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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

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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

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Series 50G / 60G Spark Igniter Module

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Spark Plug Tube, Upper

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Spark Plug Tube, Lower

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Spark Plug

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Series 50G 60G Ignition Control System

Troubleshooting

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Cylinder Cut-Out

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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 Exxon Estor SAE 15W - 40 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 Lubricating Oil & Filter Coalescing Fuel Filters Throttle Body & Actuator Spark Plugs Spark Plug Boots Turbocharger & Wastegate Calibration Valve Lash
Presenter\Name of Presentation Revised Date

Maintenance Required Replace Every 6,000 Miles & Check Oil Level Daily Drain Daily & Replace Element Every 6,000 Miles Inspect Every 6,000 Miles Replace Every 24,000 Miles Inspect Every 24,000 Miles Inspect Every 36,000 Miles Inspect Every 36,000 Miles

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