John Deere Engines Dual Fuel 6076AFD Series 400 CTM93 EN Technical Manual PDF

# " !

Series 400 6076AFD Dual Fuel Engines

!"#$"%&%'('&!)%*!+,(#+%-+, Series 400 6076AFD Dual Fuel Engines

LITHO IN U.S.A.

ENGLISH

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Deere Power Systems Group CTM93 (26SEP94)

English

" # $ % & '

CTM93 (26SEP94)

Introduction FOREWORD This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

N

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies product-model/component type-model relationship.

See the machine technical manual for information on component removal and installation, and gaining access to the components.

This manual is divided in two parts: repair and operation and tests. Repair sections contain

necessary instructions to repair the component.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

DX,CTMIFC

CTM93 (26SEP94)

-19-22MAY92

6076AFD Dual Fuel Engines 180496

PN=3

ABOUT THIS MANUAL This component technical manual covers the recommended repair procedure for 6076, 7.6 L (466 cu. in.) dual fuel engines produced in Waterloo, Iowa.

Before beginning repair of an engine, clean the engine and mount on a repair stand. (See Group 03 Engine Mounting in CTM6.)

This manual contains the necessary instructions to diagnose the electrical and natural gas/diesel fuel portions of the Dual Fuel System.

Direction of engine crankshaft rotation in this manual is referenced from the flywheel end looking toward the front. Front of engine is fan drive end.

Use this information in conjunction with the following CTMs:

Read each module completely before performing any service.

• CTM6 — For general engine repair • CTM68 — For electronic fuel injection diagnostics and repair • CTM77 — For charging and starter systems diagnostics and repair

RG,CTM93,G0,1 -19-13SEP94

CTM93 (26SEP94)

6076AFD Dual Fuel Engines 180496

PN=4

CTM93 (26SEP94)

6076AFD Dual Fuel Engines 180496

PN=5

Contents Page

Page

00 Group 00—Safety General . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 Group 01—General Information Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . .

Metric Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . .

Engine Model Designation . . . . . . . . . .

Engine Serial Number Plate Information .

Function of System Components—Continued Auxiliary Magnetic Speed Sensor . . . . . . .

Transient Voltage Protection (TVP) Module System Operation Engine Start-up . . . . . . . . . . . . . . . . . .

Fuel Selection Modes . . . . . . . . . . . . . .

Engine Shut Down . . . . . . . . . . . . . . . .

Aftercooler System with External Heat Exchanger . . . . . . . . . . . . . . . . . . . .

Diagnostic Features Lamps and Connectors . . . . . . . . . . . . .

. . . . 01-1 . . . . 01-2 . . . . 01-3 . . . . 01-4

Group 10—Dual Fuel System Introduction About the Dual Fuel System . . . . . . . . . .

General Dual Fuel OEM Engine Specifications . . . . . . . . . . . . . . . . . . .

Natural Gas Recommendations . . . . . . . .

System Power Requirements . . . . . . . . . .

ECU Environmental Restrictions . . . . . . . .

Glossary of Terms . . . . . . . . . . . . . . . . .

Component Serial Number Location Electronic Control Unit . . . . . . . . . . . . .

NG Governor . . . . . . . . . . . . . . . . . . .

NG Rotary Actuator . . . . . . . . . . . . . . .

Link Controller . . . . . . . . . . . . . . . . . .

Group 20—Dual Fuel System Theory of Operation Function of System Components Major Components Used . . . . . . . . . .

Link Controller . . . . . . . . . . . . . . . . .

Engine Control Unit . . . . . . . . . . . . . .

NG Governor . . . . . . . . . . . . . . . . . .

NG Low Pressure Sensor . . . . . . . . . .

NG Pressure Regulator . . . . . . . . . . .

NG Metering Valve . . . . . . . . . . . . . .

NG Rotary Actuator . . . . . . . . . . . . . .

NG Shut-off Solenoid . . . . . . . . . . . . .

Intake Air Temperature Sensor . . . . . .

. . . . . . . . . .

Group 30—Dual Fuel System Diagnostics Before You Start Diagnostics . . . . . . . . . .

Dual Fuel System Schematic Wiring Diagram and Component Location Drawing Legend . . . . . . . . .

Functional Section Legend . . . . . . . . . .

Functional Schematic . . . . . . . . . . . . . .

Dual Fuel System Wiring Diagram Control Panel Harness (WD1) . . . . . . . .

Link Controller Harness (WD2) . . . . . . .

Pump Harness (WD3) . . . . . . . . . . . . .

Wiring Harness and Component Location Drawing . . . . . . . . . . . . . . .

Diagnose Malfunctions of Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . .

NG Governor Speed Setpoint Requirements . . . . . . . . . . . . . . . . . . .

ECU Torque Curve Chart . . . . . . . . . . . .

. . 10-1 . . . . .

. . . . .

10-1 10-2 10-2 10-2 10-3

. . . .

. . . .

10-6 10-6 10-6 10-7

. . . . . . . . . .

. . . . . . . . . .

20-1 20-1 20-2 20-2 20-3 20-4 20-4 20-5 20-5 20-6

Group 40—Dual Fuel System Repair Service Equipment and Tools . . . . . .

Other Material . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . .

Disconnect and Connect Natural Gas Supply . . . . . . . . . . . . . . . . . . .

Control Panel Replace Lamps . . . . . . . . . . . . .

Remove and Install Switches . . . .

. 20-6 . 20-7

01

. 20-8 . 20-9 20-11

10

20-12 20-14

. . 30-1

40

. . 30-6 . . 30-8 . . 30-9

50

. 30-10 . 30-11 . 30-27 . 30-28

. . . . . . 40-1 . . . . . . 40-1 . . . . . . 40-1 . . . . . . 40-2 . . . . . . 40-3 . . . . . . 40-3

Continued on next page

CTM93-19-26SEP94 COPYRIGHT© 1994 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION™ Manual

i

30

. . 30-2 . . 30-3 . . 30-4

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

CTM93 (26SEP94)

20

6076AFD Dual Fuel Engines 180496

PN=102

INDX

Contents Page

00 01 10 20 30 40 50 INDX

Engine Control Unit (ECU) Remove and Install . . . . . . . . . . . . . .

Natural Gas Governor Remove and Install . . . . . . . . . . . . . .

Link Controller Remove and Install . . . . . . . . . . . . . .

Transient Voltage Protector (TVP) Module Remove and Install . . . . . . . . . . . . . .

Natural Gas Replace Filter . . . . . . . . . . . . . . . . . .

Remove and Install Low Pressure Sensor . . . . . . . . . . . . . . . . . . . . .

Remove and Install Shut-off Solenoid Valve . . . . . . . . . . . . . . . . . . . . . .

Remove and Install Regulator . . . . . . .

Remove and Install Metering Valve . . .

Metering Valve Remove and Install Linkage . . . . . . . .

Remove and Install Actuator . . . . . . . .

Flywheel Speed Sensor Remove and Install . . . . . . . . . . . . . .

Remove and Install Charge Air Temperature Switch . . . . . .

Link Wire Harness Remove and Install . . . . . . . . . . . . . .

Operator’s Panel Wire Harness Remove and Install . . . . . . . . . . . . . .

Auxiliary Water Pump Remove and Install . . . . . . . . . . . . . .

External Heat Exchanger Orifice Vent Remove and Install . . . . . . . . . . . . . .

. . . 40-4 . . . 40-5 . . . 40-6 . . . 40-7 . . . 40-7 . . . 40-8 . . . 40-9 . . 40-10 . . 40-12 . . 40-13 . . 40-15 . . 40-16 . . 40-16 . . 40-17 . . 40-19 . . 40-20 . . 40-22

Group 50—Dual Fuel System Adjustments Service Equipment and Tools . . . . . . . . . . .

Adjust NG Governor Gain . . . . . . . . . . . . . . . .

NG Regulator Outlet Pressure . . . . . . . . .

NG Governor . . . . . . . . . . . . . . . . . . . .

. 50-1 . 50-1 . 50-2 . 50-5

Index

CTM93 (26SEP94)

ii

6076AFD Dual Fuel Engines 180496

PN=103

Group 00

Safety

HANDLE FLUIDS SAFELY—AVOID FIRES

00 1

When you work around fuel, do not smoke or work near heaters or other fire hazards.

-UN-23AUG88

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn spontaneously.

DX,FLAME

-19-04JUN90

HANDLE NATURAL GAS SAFELY

-UN-23AUG88

Handle natural gas with care: it is highly flammable. Do NOT smoke while working on or around natural gas equipment.

Natural gas fumes may cause sickness or death. Work in well ventilated area.

TS227

Shut off natural gas supply before servicing equipment.

Have a manual valve installed away from the engine to shut off gas supply in case of an emergency.

TS220

-UN-23AUG88

Prevent fires by keeping machine clean of accumulated trash, grease, and debris.

RG,NATGAS,SFTY -19-26FEB93

CTM93 (26SEP94)

00-1

6076AFD Dual Fuel Engines 180496

PN=6

Safety/General

PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

-UN-23AUG88

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm battery to 16˚C (60˚F).

DX,SPARKS

-19-03MAR93

DX,FIRE2

-19-03MAR93

PREPARE FOR EMERGENCIES Be prepared if a fire starts.

-UN-23AUG88

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291

00 2

CTM93 (26SEP94)

00-2

6076AFD Dual Fuel Engines 180496

PN=7

Safety/General

PREVENT ACID BURNS

00 3

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

TS203

-UN-23AUG88

If acid is swallowed: 1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

DX,POISON

CTM93 (26SEP94)

00-3

-19-21APR93

6076AFD Dual Fuel Engines 180496

PN=8

Safety/General

AVOID HIGH-PRESSURE FLUIDS

-UN-23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID

-19-03MAR93

DX,WEAR

-19-10SEP90

WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

-UN-23AUG88

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS206

00 4

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

CTM93 (26SEP94)

00-4

6076AFD Dual Fuel Engines 180496

PN=9

Safety/General

SERVICE MACHINES SAFELY

00 5 -UN-23AUG88

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

TS228

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

DX,LOOSE

-19-04JUN90

DX,AIR

-19-04JUN90

DX,CLEAN

-19-04JUN90

WORK IN VENTILATED AREA

-UN-23AUG88

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

TS220

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

WORK IN CLEAN AREA

T6642EJ

-UN-18OCT88

Before starting a job: • Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt shortcuts.

CTM93 (26SEP94)

00-5

6076AFD Dual Fuel Engines 180496

PN=10

Safety/General

Avoid potentially toxic fumes and dust.

-UN-23AUG88

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

TS220

Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

Remove paint before welding or heating: • If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

DX,PAINT

-19-03MAR93

DX,TORCH

-19-03MAR93

DX,LIGHT

-19-04JUN90

AVOID HEATING NEAR PRESSURIZED FLUID LINES

TS953

-UN-15MAY90

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

ILLUMINATE WORK AREA SAFELY

-UN-23AUG88

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

TS223

00 6

REMOVE PAINT BEFORE WELDING OR HEATING

CTM93 (26SEP94)

00-6

6076AFD Dual Fuel Engines 180496

PN=11

Safety/General

USE PROPER LIFTING EQUIPMENT

00 7

Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226

-UN-23AUG88

Follow recommended procedure for removal and installation of components in the manual.

DX,LIFT

-19-04JUN90

DX,SERV

-19-03MAR93

PRACTICE SAFE MAINTENANCE Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

TS218

-UN-23AUG88

Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

CTM93 (26SEP94)

00-7

6076AFD Dual Fuel Engines 180496

PN=12

Safety/General

USE PROPER TOOLS Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

-UN-08NOV89

Use power tools only to loosen threaded parts and fasteners.

TS779

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR

-19-04JUN90

DX,DRAIN

-19-03MAR93

DISPOSE OF WASTE PROPERLY

-UN-26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

TS1133

00 8

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

CTM93 (26SEP94)

00-8

6076AFD Dual Fuel Engines 180496

PN=13

Safety/General

LIVE WITH SAFETY

00 9

TS231

-19-07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE

CTM93 (26SEP94)

00-9

-19-25SEP92

6076AFD Dual Fuel Engines 180496

PN=14

Safety/General

00 10

CTM93 (26SEP94)

00-10

6076AFD Dual Fuel Engines 180496

PN=15

Group 01

General Information UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

TS1162

-19-04MAR91

01 1

Grade 2b

Grade 1 Size

Lubricateda

Drya

Lubricateda

Grade 5, 5.1, or 5.2 Dry a

Lubricateda

Grade 8 or 8.2

Dry a

Lubricateda

Dry a

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

1/4 5/16 3/8

3.7 7.7 14

2.8 5.5 10

4.7 10 17

3.5 7 13

6 12 22

4.5 9 16

7.5 15 27

5.5 11 20

9.5 20 35

7 15 26

12 25 44

9 18 33

13.5 28 50

10 21 36

17 35 63

12.5 26 46

7/16 1/2 9/16

22 33 48

16 25 36

28 42 60

20 31 45

35 53 75

26 39 56

44 67 95

32 50 70

55 85 125

41 63 90

70 110 155

52 80 115

80 120 175

58 90 130

100 150 225

75 115 160

5/8 3/4 7/8

67 120 190

50 87 140

85 150 240

62 110 175

105 190 190

78 140 140

135 240 240

100 175 175

170 300 490

125 225 360

215 375 625

160 280 450

240 425 700

175 310 500

300 550 875

225 400 650

1 1-1/8 1-1/4

290 400 570

210 300 425

360 510 725

270 375 530

290 400 570

210 300 425

360 510 725

270 375 530

725 900 1300

540 675 950

925 1150 1650

675 850 1200

1050 1450 2050

750 1075 1500

1300 1850 2600

975 1350 1950

1-3/8 1-1/2

750 1000

550 725

950 1250

700 925

750 990

550 725

950 1250

700 930

1700 2250

1250 1650

2150 2850

1550 2100

2700 3600

2000 2650

3400 4550

2550 3350

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.

b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.

CTM93 (26SEP94)

01-1

DX,TORQ1

-19-20JUL94

6076AFD Dual Fuel Engines 180496

PN=16

General Information/Metric Bolt and Cap Screw Torque Values

METRIC BOLT AND CAP SCREW TORQUE VALUES

TS1163

-19-04MAR91

01 2

Class 4.8 Size

Lubricateda

Class 8.8 or 9.8 Drya

Lubricateda

Class 10.9

Dry a

Lubricateda

Class 12.9 Dry a

Lubricateda

Dry a

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

N·m

lb-ft

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 255

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 1000 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

CTM93 (26SEP94)

01-2

DX,TORQ2

-19-20JUL94

6076AFD Dual Fuel Engines 180496

PN=17

General Information/Engine Model Designation

ENGINE MODEL DESIGNATION JOHN DEERE ENGINE MODEL—6076 John Deere engine model designation includes number of cylinders, displacement in liters, aspiration, user code, and application code. For example:

01 3

6076AFD00 Engine 6 ......

07.6 . . .

A ..

FD .

00

. . . .

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. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

Number of cylinders . Liter displacement . . . Aspiration code . . . . . . . User code . . Application code

Aspiration Code A . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled User Code FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM Dual Fuel Application Code 00 RG,CTM93,G1,1 -19-12SEP94

CTM93 (26SEP94)

01-3

6076AFD Dual Fuel Engines 180496

PN=18

General Information/Engine Serial Number Plate Information

ENGINE SERIAL NUMBER PLATE INFORMATION

-UN-13SEP94

1. Engine Serial Number

RG7235

01 4

IMPORTANT: The engine serial number plate can be easily destroyed. Remove the plate or record the information elsewhere, before “hot tank” cleaning the block.

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example: RG6076A000000 RG . . . . . . . . . . . . . . Factory code producing engine 6076A . . . . . . . . . . . Engine Model Designation 000000 . . . . . . Sequential Number Factory Code Producing Engine RG . . . . . . . . . . . . . . Waterloo Engine Works Engine Model Designation 6076A . . . . . . . . . . . . Definition explained previously.

(See ENGINE MODEL DESIGNATION.) Sequential Number 000000 . . . . . . . . . . . 6-digit sequential number.

The engine serial number plate is located either on the right-hand side of engine between the oil conditioning housing and fuel injection pump (viewed from flywheel end) or on the left-hand side of the block directly above the starting motor.

2. Engine Application Data The second line of information on the engine serial number plate identifies the engine OEM relationship.

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Group 10

Dual Fuel System Introduction ABOUT THE DUAL FUEL SYSTEM The Dual Fuel System utilizes the 6076AFD engine that is available at two power levels: 112 kW (150 hp) and 150 kW (200 hp) continuous rating at 2200 rpm. The system uses a natural gas regulator that is available in either a 4 psi or 20 psi model. This is to accommodate the range of line pressures supplied by the natural gas companies.

The difference between the 112 kW (150 hp) and 150 kW (200 hp) systems are: • Programming of Control Units • External Heat Exchanger and Auxiliary Water [Pump Used on 150 kW (200 hp) engines only]

10 1 RG,CTM93,G10,1 -19-12SEP94

GENERAL DUAL FUEL OEM ENGINE SPECIFICATIONS

Item

Unit Of Measure

6076AFD 112kW (150HP)

6076AFD 150kW (200HP)

Fast Idle Speed Min-Max/Electronic Governor

RPM

2450

2450

Rated Speed

RPM

2200

2200

kW (HP)

112 (150)

149 (200)

Normal Working Speed Range

RPM

1400—2200

1400—2200

Torque (max) @ RPM without fan

RPM N·m (lb-ft)

1956 547 (403)

1956 721 (537)

Natural Gas Supply Filter Size

micron

10

10

Natural Gas Supply Pressure 138 kPa (20 psi) system Minimum allowable regulator inlet Maximum allowable regulator inlet

kPa (psi) kPa (psi)

103 (15)* 207 (30)

103 (15)* 207 (30)

28 kPa (4 psi) system Minimum allowable regulator inlet Maximum allowable regulator inlet

kPa (psi) kPa (psi)

14 (2)** 41 (6)

14 (2)** 41 (6)

in. H2O

5

9.8

Industrial power rating @ rated speed without fan Continuous

Natural Gas Regulated Pressure (at metering valve)

* Operating pressure only. Must be 131 kPa (19 psi) or higher to change to dual fuel initially. ** Operating pressure only. Must be 24 kPa (4 psi) or higher to change to dual fuel initially.

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6076AFD Dual Fuel Engines 180496

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Dual Fuel System Introduction/ECU Environmental Restrictions

NATURAL GAS RECOMMENDATIONS NOTE: Dry natural gas is a mixture of methane, ethane, propane, and butane. Dry natural gas is also referred to as Commercial Pipeline Natural Gas.

10 2

Dry natural gas that meets or exceeds the following specifications is recommended for use in John Deere Dual Fuel engines: • Maximum Propane content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 percent • Maximum Butane content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 percent • Maximum Hydrogen Sulfide (H2S) content • Minimum Octane Rating

. . . . . . . . . . . . . . . . . . 10 ppm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

• Nominal Low Heat Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.72 kJ/L (905 BTU/cu ft)

RG,76AFD,FNG1 -19-12SEP94

SYSTEM POWER REQUIREMENTS Nominal System Voltage: 12V Operating Supply Voltage Range: 9—16V Supply Voltage Range During Starting: 6—16V Required current (including actuator solenoid and fuel shut-off solenoid): 17A maximum, 7A nominal

RG,CTM93,G10,2A-19-12SEP94

ENGINE CONTROLLER ENVIRONMENTAL RESTRICTIONS Operating Temperature Range -40 to +65˚C (-40˚F to +150˚F) Storage Temperature Range -50 to +100˚C (-58˚F to +212˚F) Operating Vibration Range -30m/sec2 max. from 0—2500 Hz

S55,2000,CP

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Dual Fuel System Introduction/Glossary of Terms

GLOSSARY OF TERMS Term

Description

ADS

Association of Diesel Specialists. Used throughout the manual to mean authorized repair facilities for injection systems.

A/D CONVERTER

Analog-to-Digital Converter. An integrated circuit within the Engine Controller which converts an analog voltage to an 8-bit number (1’s and 0’s) so the microcomputer can understand it.

ACTUATOR SOLENOID

The solenoid in the actuator housing on the back of injection pump which moves the control rack as commanded by Engine Controller.

ANALOG

Signal which has a continuous range of possible voltages. Usually represents a continuously variable physical value such as rack position, fuel temperature or throttle lever position.

AUXILIARY SPEED SENSOR

Engine speed sensor located on engine timing gear cover. Serves as back-up to primary engine speed sensor. (See Group 61 for further description.)

DIAGNOSTIC CODE

A number which represents a problem detected by Engine Controller. Diagnostic codes are transmitted for use by on-board displays of a diagnostic reader so the operator or technician is aware there is a problem and in what part of the fuel injection system the problem can be found.

DIAGNOSTIC READER

Any electronic module which is able to read the Diagnostic Codes Output signal, and possibly other diagnostic signals, and display diagnostic information to the operator or technician.

DIGITAL

A signal which consists of only two voltage levels, usually 0 volts and +5 volts. Examples of digital signals are: • Diagnostic Code Output • PWM Throttle Input • Auxiliary Speed Output • Fuel Flow/Throttle Output • Any ON/OFF type signals

ECU

Electronic Control Unit. General term for any electronic controller. When used in Diagnostic Procedures, ECU refers to the Engine Controller.

ELECTRONIC GOVERNOR

The computer program within the Engine Controller which determines the commanded fuel delivery based on throttle command, engine speed and fuel temperature. Replaces the function of a mechanical governor. The entire electronic fuel injection control system is sometimes referred to as the electronic governor.

ELECTRONIC MODULE

Any enclosure containing electronic components designed to operate in a specified manner.

10 3

Continued on next page RG,CTM93,G10,3 -19-12SEP94

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Dual Fuel System Introduction/Glossary of Terms GLOSSARY OF TERMS—Continued

10 4

Term

Description

ENGINE CONTROLLER

The electronic module which controls fuel delivery, diagnostic outputs, back-up operation and communications with other electronic modules.

LINK CONTROLLER

An electronic module that provides speed and throttle setpoints to the NG Governor and ECU.

NG

Natural Gas.

NG GOVERNOR

An electronic module that provides drive current to the NG Actuator in response to any differences between the desired engine speed signal, generated by the Link Controller, and actual engine speed measured by the Speed Pickup Sensor located at flywheel.

NG ROTARY ACTUATOR

A device that contains a spring loaded solenoid actuator and a potentiometer. The solenoid provides a means to open the NG Metering Valve while the spring closes the valve. The potentiometer provides feedback to indicate actuator position.

NG METERING VALVE

A rotary valve is used to throttle NG flow into the air intake.

PRIMARY SPEED SENSOR

Engine speed sensor located inside the actuator housing on the back of injection pump.

PTC HEATER

Positive Temperature Coefficient Heater. Used for extreme low temperature environments below -30˚C (-22˚F). It takes 10 minutes to heat up the governor area when ambient temperature is at -40˚C (-40˚F). This heater is offered as an option.

PWM

Pulse-Width-Modulation. A digital electronic signal which consists of pulses generated at a fixed frequency. The information transmitted by the signal is contained in the width of the pulse. The width of the pulse is changed (modulated) to indicate a corresponding change in the information being transmitted, such as throttle command.

TVP MODULE

Transient Voltage Protection Module. A electronic device which protects the Engine Controller electronics against high energy voltage transients such as alternator load dumps.

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Dual Fuel System Introduction/Glossary of Terms

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Dual Fuel System Introduction/Component Serial Number Location

COMPONENT SERIAL NUMBER LOCATION

RG,CTM93,G10,5 -19-12SEP94

ECU SERIAL NUMBER PLATE

RG6792

-UN-29JUN93

Located on the front side of ECU. (ECU is located in the control panel.)

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NG GOVERNOR SERIAL NUMBER PLATE

RG6793

-UN-29JUN93

Located on bottom side of governor. (NG Governor is located in the control panel.)

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NG ROTARY ACTUATOR SERIAL NUMBER PLATE

-UN-29JUN93

Located on the top side of actuator body.

RG6794

10 6

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Dual Fuel System Introduction/Component Serial Number Location

LINK CONTROLLER SERIAL NUMBER PLATE

RG6795

-UN-29JUN93

Located on left side (connector side) of controller. (Link Controller is located in the control panel.)

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Dual Fuel System Introduction/Component Serial Number Location

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Group 20

Dual Fuel System Theory of Operation MAJOR COMPONENTS USED The Dual Fuel System consists of the following major components: • Link Controller • Engine Control Unit (ECU) • NG Governor • NG Low Pressure Sensor • NG Pressure Regulator • NG Metering Valve • NG Rotary Actuator • NG Shut-off Solenoid • Intake Air Temperature Sensor [150 kW (200 hp) only] • Magnetic Speed Sensor • Transient Voltage Protection (TVP) Module

20 1

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LINK CONTROLLER

-UN-29JUN93

The Link Controller is an electronic module that functions as an intelligent interface between operator, ECU and NG governor. The link controller manages changeovers between diesel and dual fuel. It also monitors conditions to insure safe, reliable engine operation.

RG6795

The link controller is located in the control panel, behind the NG governor, directly below the ECU.

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Dual Fuel System Theory of Operation/Function of System Components

ENGINE CONTROL UNIT (ECU)

-UN-29JUN93

The ECU is a self-contained module which contains electronic circuitry and a computer program which performs governor and diagnostic functions.

Two versions are available: 112 kW (150 hp) and 150 kW (200 hp). The differences between the two versions are primarily torque curves. Diesel torque curves and the required diesel pilot quantities are programmed into the ECU memory.

The ECU is located in the control panel, above the link controller and NG governor.

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NG GOVERNOR

-UN-29JUN93

The NG governor provides a pulse width modulated (PWM) drive current to the NG rotary actuator in response to differences between the output speed signal from the link controller and actual speed signal from the magnetic speed pickup. The governor maintains speed stability in dual fuel mode and limits rotary actuator position in response to the external limit input voltage from link controller.

RG6796

20 2

RG6797

The ECU is configured as a MIN/MAX governor for dual fuel operation. It controls diesel fuel injection quantity in response to the throttle signal from the link controller while still governing idle speed and maximum speed.

The NG governor is located in the control panel, below the ECU.

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Dual Fuel System Theory of Operation/Function of System Components

NG LOW PRESSURE SENSOR

RG6798

-UN-29JUN93

The NG low pressure sensor senses when the line pressure (before the NG shut-off solenoid) drops below a specified pressure. It utilizes normally closed contacts that open when line pressure reaches nominal pressure.

When the sensor contacts close, a signal is sent to the link controller. The link controller will then put the system in “Diesel Mode” and/or prohibit a changeover to “Dual Fuel Mode”.

The sensor is located next to the NG Shut-Off Solenoid, mounted on the NG inlet line.

20 3

The sensor is available in two versions: • 28 kPa (0.28 bar) (4 psi) Version

Contacts open when rising pressure reaches 24 kPa (0.24 bar) (3.5 psi) ± 3.5 kPa (0.04 bar) (0.5 psi).

Contacts close when falling pressure reaches 10.3 kPa (0.10 bar) (1.5 psi) ± 3.5 kPa (0.04 bar) (0.5 psi).

• 138 kPa (1.38 bar) (20 psi) Version

Contacts open when rising pressure reaches 124 kPa (1.24 bar) (18 psi) ± 7.0 kPa (0.07 bar) (1 psi).

Contacts close when falling pressure reaches 89.6 kPa (0.90 bar) (13 psi) ± 7.0 kPa (0.07 bar) (1 psi).

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Dual Fuel System Theory of Operation/Function of System Components

NG PRESSURE REGULATOR

-UN-29JUN93

The NG pressure regulator senses pressure from the air intake by use of a “balance line”. The balance line connects the regulator to the air intake so as to reference the regulator NG output pressure with the air intake pressure. The result is a regulated NG supply to the NG metering valve.

RG6801

The regulator is located next to the NG Shut-Off Valve, mounted on the NG inlet line.

20 4

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NG METERING VALVE

-UN-29JUN93

The NG metering valve is a rotary valve used to throttle (meter) natural gas flow into the air intake. It is operated by the NG rotary actuator.

RG6802

The valve is attached to the NG rotary actuator. The NG rotary actuator/metering valve assembly is mounted on top of the air intake tube which is located between the air filter assembly and turbocharger.

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Dual Fuel System Theory of Operation/Function of System Components

NG ROTARY ACTUATOR

RG6803

-UN-29JUN93

The NG rotary actuator is a rotary solenoid that provides 60 degrees of rotation. The rotary movement is transferred to the NG metering valve through a pair of male/female slip linkages which change the 60 degrees movement of the actuator into 90 degrees. This provides the necessary movement required to open the NG metering valve. An internal spring returns the valve to the CLOSED position.

A potentiometer, located inside the actuator, is used for position feedback. The “feedback” signal, from the potentiometer, is sent to the link controller which monitors the actuator position.

20 5

The actuator is attached to the NG metering valve. The NG rotary actuator/metering valve assembly is mounted on top of the intake tube, located between the air filter assembly and turbocharger.

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NG SHUT-OFF SOLENOID

RG6804

-UN-29JUN93

The NG shut-off solenoid is a solenoid operated two-way valve that is normally closed. When in “Dual Fuel Mode”, current from the link controller activates the solenoid to open the valve, allowing natural gas to flow through the NG portion of the dual fuel system. When the system returns to “Diesel Mode”, the link controller stops current flow to the solenoid, causing the valve to close.

The solenoid is located between the NG low pressure sensor and NG pressure regulator, mounted in the NG inlet line.

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Dual Fuel System Theory of Operation/Function of System Components

INTAKE AIR TEMPERATURE SENSOR

RG6799

When the sensor contacts close, a signal is sent to the link controller. The link controller will then put the system into “Diesel Mode” and/or prohibit a changeover to “Dual Fuel Mode”. This is to prevent possible engine knock caused by the high intake air temperature.

The sensor is located in the bottom side of the aftercooler.

RG,CTM93,G20,10-19-12SEP94

AUXILIARY MAGNETIC SPEED SENSOR

-UN-29JUN93

The auxiliary magnetic speed sensor is an electro-magnetic device used to sense engine speed.

The sensor produces an electrical pulse whenever ferrous metal, such as a gear tooth, passes within close proximity to the sensor tip. The sensor utilizes the flywheel teeth to produce a continuous series of pulses which are analogous to the engine speed. The pulses, which vary with engine speed, are sent to the NG governor which processes the information.

RG6800

20 6

-UN-29JUN93

Used only on the 150kW (200 hp) engine, the intake air temperature sensor is a temperature sensitive switch that monitors charge air temperature. It utilizes normally open contacts that close when the charge air temperature increases to 53˚C (127˚F) and open when air temperature lowers to 48˚C (118˚F).

The speed sensor is located on the top of the flywheel housing.

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Dual Fuel System Theory of Operation/Function of System Components

TRANSIENT VOLTAGE PROTECTION (TVP) MODULE

-UN-09JAN90

The TVP Module limits “high energy” voltage transients to 40 volts. This protects the electronic circuitry in the ECU, link controller and NG governor from energy transients such as alternator load dumps.

RG5374

The module consists of a relay, a 20 amp circuit breaker, and a voltage suppressor. When the key switch is turned to the RUN or START positions, the internal relay is energized, closing the relay contacts. Current from the battery will then flow through the contacts, circuit breaker and voltage suppressor circuit inside the TVP, and onto the following components: • ECU • Link Controller • NG Governor • Fuel Rack Solenoid • NG Shut-off Solenoid • Indicator Lamps • Diagnostic Reader Connector

20 7

The module is mounted on the backside of the control panel door.

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Dual Fuel System Theory of Operation/System Operation

DUAL FUEL SYSTEM OPERATION The operation of the Dual Fuel System can be divided into four sub-systems: • Engine Startup • Fuel Selection Modes • Engine Shutdown • Aftercooler System With External Heat Exchanger [150 kW (200 hp) Engine Only]

20 8

RG,CTM93,G20,13-19-12SEP94

ENGINE STARTUP At power-up, the ECU momentarily illuminates the amber ECU Fault lamp, also the link controller illuminates the Diesel and Dual Fuel lamps for 5 seconds after which only the Diesel lamp remains on.

The link controller will ramp the % throttle signal sent to the ECU, at a fixed rate in response to the +/— speed inputs from the switch, accelerating and decelerating the engine.

Upon startup, the link controller defaults to diesel operation and the ECU manages the engine starting procedure as for a normal diesel engine. The link controller generates a % throttle signal of 0% to idle the engine. The NG supply solenoid remains off and the link controller provides a 0% speed setpoint and 100% Limit to the NG governor to ensure that the rotary actuator is closed (fully clockwise when viewed from front of engine).

Operator speed adjustments are possible only in diesel operation, and not during fuel changeovers or dual fuel operation. If the system is running on dual fuel, the link controller will automatically force a return to diesel operation in order to adjust the engine speed. When any speed adjustments are complete, the engine will be returned to dual fuel operation automatically if conditions permit.

NOTE: The engine must be operating under normal load conditions (load engaged) for proper adjustment of speed when operated on diesel.

The ECU operates as a fuel controller to ensure that the correct amount of pilot fuel is always given. The NG governor operates as a speed controller to ensure the engine will continue to run at the same speed in Dual Fuel Mode as it did in Diesel Mode.

After starting, the operator may change the engine speed via the speed switch on the operator’s panel.

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Dual Fuel System Theory of Operation/System Operation

FUEL SELECTION MODES Diesel to Dual Fuel: The operator selects dual fuel operation via the fuel select switch on the operator’s panel. If the present conditions are suitable for dual fuel operation, the link controller will initiate a changeover. If the operating conditions are not suitable for dual fuel operation, the link controller will continue to operate the engine on diesel. The dual fuel indicator lamp will flash on and off to indicate that the operator has selected dual fuel operation. When conditions are suitable for dual fuel operation, the link controller will automatically switch to dual fuel. This enables the NG system, changing the dual fuel indicator lamp from flashing to steady on and turns the diesel lamp off.

The link controller monitors the intake air temperature sensor and the low NG pressure sensor. It calculates engine rpm and % of engine load to determine if conditions permit the engine to be operated on dual fuel.

to approximate the torque curve of the diesel engine.

If the engine load is within safe operating limits, the % limit feature will not affect engine operation.

The changeover sequence from diesel to dual fuel is as follows: • The diesel lamp is turned OFF while the dual fuel lamp is turned ON. • The link controller monitors the engine speed and generates a % speed setpoint voltage for the NG governor representing the same speed. At the same time, the link controller opens the NG supply solenoid and enables the % limit voltage to the NG governor.

20 9

• The link controller implements a 5 second delay before ramping down the % throttle signal to the ECU. This is to allow the NG governor’s internal dynamics time to adjust to the % speed setpoint and % limit voltages and time for the NG regulator to stabilize the NG supply pressure to the rotary actuator.

The following conditions must exist before engine will change over to dual fuel operation: • Engine not in “shut-down” mode.

• Diesel/dual fuel selector in DUAL FUEL position.

• For 4 psi line pressure, NG supply pressure greater than 24 kPa (0.24 bar) (3.5 psi).

• For 20 psi line pressure, NG supply pressure greater than 124 kPa (1.2 bar) (18 psi).

• Engine speed greater than 1400 rpm.

• % of load greater than 40%.

• Intake air temperature less than 53˚C (127˚F).

[150 kW (200 hp) engine only.]

• The % throttle signal to the ECU is ramped down from the user-selected value to 25%. The % throttle signal is ramped down at a clock frequency of 12.5 Hz, which corresponds to a time of 15 seconds to ramp from 100% to 25% throttle. This slow ramping speed is required in order to avoid a large speed drop during changeover. At this point, the NG governor controller assumes control of the engine speed.

An internal “look-up” table, located in the link controller memory, contains % speed setpoint versus engine rpm information. The controller uses this information to generate a % speed signal. The % speed signal, which corresponds to the rpm at which the engine was running just prior to changeover, is sent to the NG governor during changeover from diesel to dual fuel operation.

• The link controller selects the derated torque curve programmed into the ECU representing the required diesel pilot quantity for dual fuel operation. This occurs when the link controller detects that the % throttle signal has reached 25%.

The link controller contains another “look-up” table which contains % limit versus engine rpm information.

The controller uses this information to generate a % limit signal. The % limit signal is sent to the NG governor to prevent overfueling during dual fuel operation at lower rpm. This allows the link controller

• Once the engine is operating on dual fuel, the operator can adjust the engine speed. The link controller detects a speed change and forces a return to diesel where the speed adjustment is made. Once any speed adjustments are complete, the link controller automatically returns to dual fuel mode, unless diesel was manually selected.

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Dual Fuel System Theory of Operation/System Operation Dual Fuel to Diesel:

20 10

Any of the following conditions will change dual fuel operation back to diesel: • Diesel/dual fuel selector in DIESEL position.

• For 4 psi line pressure, NG supply pressure less than 10.3 kPa (0.04 bar) (1.5 psi).

• For 20 psi line pressure, NG supply pressure less than 90 kPa (0.9 bar) (13 psi).

• Engine speed less than 1200 rpm.

• % load less than 30%.

• Intake air temperature greater than 53˚C (127˚F).

[150 kW (200 hp) engine only.]

The link controller diagnostic circuitry implements a 1.25 second time delay filter for detecting any changes in the fault status of the dual fuel engine.

This means that any fault must be absent or present for at least 1.25 seconds for it to be detected by the link controller. Because they are critical, the speed fault and the load fault will latch during dual fuel operation. This disallows any return to dual fuel operation without a power-down or system reset. A 0.75 second time delay filter is implemented in the detection of these faults.

The normal changeover sequence from dual fuel to diesel is as follows: • The dual fuel lamp is turned off while the diesel lamp is turned on.

• The link controller selects the normal torque curve in the ECU and closes the NG supply solenoid.

• The % throttle signal to the ECU is ramped up from 25% to the value last set by the operator in diesel mode. The % throttle is ramped up at a clock frequency of 800 Hz, which corresponds to a time of 255 milliseconds to ramp from 25% to 100% throttle. This fast ramping speed is required to avoid a large speed drop during changeover, as the NG supply is shut off. At this point, the ECU assumes control of the engine.

• The % speed setpoint to the NG governor is reset to 4 volts and the % limit signal is set to 100% limit (0 volts). This ensures that the rotary actuator is closed during diesel operation.

• If a diagnostic fault (eg. high intake air temperature or low NG pressure) forced a return to diesel, the dual fuel lamp will flash and the diesel lamp is turned on. If the detected fault later disappears, the link controller will return the engine to dual fuel operation. The lamps would then indicate dual fuel operation.

• If the user selected a return to diesel, the dual fuel lamp is extinguished and the diesel lamp is turned on.

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Dual Fuel System Theory of Operation/System Operation

ENGINE SHUTDOWN The ECU will immediately shut down the engine if there’s a loss of: • Both Primary and Auxiliary speed pickups.

• Rack solenoid power driver or position sensor.

return to diesel operation. The rpm will continue to drop. When low oil pressure is indicated, shutdown will be as described above.

When any of these faults occur, the diesel fuel rack is pulled back to zero fuel position, stopping the engine. The ECU will then illuminate the ECU fault lamp on the operator’s panel. The oil pressure switch/gage, located on the engine display panel, will sense low oil pressure and safely shut down the entire system.

If the engine runs out of diesel fuel, the rpm will drop.

As the rpm falls below 1200, the link controller will shut off the NG shut-off solenoid and attempt to

An operator-initiated shutdown will be the same as a low oil pressure or high coolant temperature shut down. No cool-down cycle is anticipated since this feature may be used as an emergency stop.

If additional shut-down features are required, they can be added to the engine display panel in parallel with the oil pressure and coolant temperature switch/gages. The additional shut-down switches must be normally-open type (contacts close to indicate a fault).

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Dual Fuel System Theory of Operation/System Operation

AFTERCOOLER SYSTEM WITH EXTERNAL HEAT EXCHANGER

RG6827

-UN-23SEP93

20 12

A—Aftercooler B—Intake Air Temperature Switch C—Aftercooler System Orifice

D—Aftercooler Outlet E—Auxiliary Water Pump F—Fill Port Connected To Engine

G—Pump Inlet H—12˚F Temperature Differential

J—External Heat Exchanger K—Well Water

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Dual Fuel System Theory of Operation/System Operation The aftercooler system, for the 150 kW (200 hp) engine, consists of four major components: • • • •

temperature. (Lowering the intake are temperature helps prevent engine knock, thus, more power can be produced.)

Aftercooler Orifice Fitting External Heat Exchanger Auxiliary Water Pump

Due to the requirement for lower intake air temperature, the 150 kW (200 hp) engine requires an external heat exchanger (J) to cool the charged intake air. The external heat exchanger is connected in series with the engine aftercooler and uses an auxiliary water pump (E) to circulate engine coolant between heat exchanger and aftercooler. The engine coolant is used as a medium to remove heat from the charge intake air and transfer it to an external source via the external heat exchanger.

The external source, usually well water (K), removes heat from the coolant as the coolant circulates through the external heat exchanger. The auxiliary water pump draws the lower temperature coolant from the heat exchanger and forces it through the engine aftercooler. As the coolant circulates through the aftercooler, heat from the compressed intake air is transferred to the coolant, lowering the intake air

After the coolant circulates through the aftercooler, the now heated coolant flows to orifice (C) and then back to the heat exchanger. The orifice is used to isolate the aftercooler system from the engine cooling system because of the temperature differential between the two systems. The passage in the orifice, along with fill port (F), allows a small amount of coolant to flow between the two systems. This prevents air lock, provides a means for coolant makeup in the aftercooler system and allows the need of only one expansion tank.

EXTERNAL HEAT EXCHANGER SPECIFICATIONS Pressure Drop

. . . . . . . . . . . . . 35 kPa (0.4 bar) @ 34 L/min (f) (5 psi @ 9 gpm)

Coolant Flow . . . . . . . . . . . . . . . . . . 34 L/min (f) @ 1760 rpm (9 gpm @ 1760 rpm) Heat Rejection . . . . . . . . . . . . 13.4 kW @ 1760 rpm—Full Load (760 Btu/min @ 1760 rpm—Full Load) Max Coolant Temperature Out . . . . . . . . . . . 29˚C @ 34 L/min (f) (External Heat Exchanger) (85˚F @ 9 gpm)

RG,CTM93,G20,25-19-12SEP94

CTM93 (26SEP94)

20-13

6076AFD Dual Fuel Engines 180496

PN=40

20 13

Dual Fuel System Theory of Operation/Diagnostic Features

DIAGNOSTIC FEATURES—LAMPS AND CONNECTORS LAMPS: Amber Diesel Malfunction Lamp (A) — Controlled by the ECU and is illuminated to indicate the presence of an ECU fault.

-UN-06JAN92

Fuel-Select Switch (C) — A momentary contact switch used to select either diesel or dual fuel operation.

Speed-Set Switch (E) — A momentary contact switch used to increase or decrease the engine speed.

RG6030

20 14

Clear Diesel Lamp (B) and Green Dual Fuel Lamp (D) — Controlled by the link controller and are illuminated in the combinations described below to indicate the various modes of operation.

DIESEL LAMP (clear)

DUAL FUEL LAMP (green)

OPERATING CONDITION

ON

OFF

Operating in diesel mode.

OFF

ON

Operating in dual fuel mode.

ON

FLASHING

Dual fuel selected, but change-over to dual fuel is disabled.

-ORSpeed adjustment being made while running dual fuel.

-ORFault has forced return to diesel mode.

RG,CTM93,G20,19-19-12SEP94

CTM93 (26SEP94)

20-14

6076AFD Dual Fuel Engines 180496

PN=41

RG5401

-UN-13JAN89

Dual Fuel System Theory of Operation/Diagnostic Features

Connector (X1):

20 15 -UN-09JAN90

Connector X1 connects the ECU to the rest of the system. The connector is rectangular with 35 pins total; one row of 18 pins and one row of 17 pins. The pin numbers are not labeled on the connector. Therefore, the connector figure, shown above, must be used during troubleshooting to identify pin numbers.

RG5418

The connector is disconnected by releasing the spring latch beneath the wire exit end of the connector and pivoting the wire end of the connector away from the controller. This will allow the tip of the other end of the connector to be released from under the locking pin of the controller housing. Mating the connector is done by reversing these steps. The tip of the connector is inserted beneath the locking pin of the controller housing. Then the connector is pivoted toward the controller until the spring latch locks the wire end of the connector in place.

IMPORTANT: Care should be used during diagnostic procedures to avoid damaging the pins of the ECU connector. Probes should not be poked into the pins or damage will result. Probes should only be touched against the pins to make measurements.

RG,CTM93,G20,20-19-12SEP94

CTM93 (26SEP94)

20-15

6076AFD Dual Fuel Engines 180496

PN=42

Dual Fuel System Theory of Operation/Diagnostic Features CONNECTOR X1—Continued The following is a list of each connector pin, signal on that pin and description of the signal for the X1 connector.

Pin

20 16

Functional Description

1

+ 12 Volt Input: This pin provides power to the ECU and is common with Pin 34.

2

+ 5 Volt Analog Throttle: +5 Volt supply for the analog throttle sensor. (Sent to the link controller.)

3

Not used.

4

Not used.

5

Not used.

6

Analog Throttle Input: 0 to 5 volt D.C. analog input from link controller. Used by the analog throttle to input throttle position.

7

Start Signal Input: A high voltage (greater than 3 volts) on this input causes the ECU to enter the start sequence if conditions allow.

8

This signal must be open circuit or less than 0.5 volts to allow the system to operate normally.

(Used for ECU diagnostics.)

9

Rack Position Sensor Common: One of three pins which connect to the rack position sensor. This pin provides for return current and ground reference for the rack position sensor.

10

Primary Engine Speed: This input receives the signal on the “minus” lead from the pump-mounted engine speed sensor.

11

Auxiliary Speed Input: Input which receives an A.C. signal whose frequency is proportional to engine speed. In the event of a primary engine speed sensor failure, the ECU will shut-down the engine.

12

This input should be left open circuit for normal operation. (Used for ECU diagnostics.)

13

Output which drives the ECU fault lamp during failure conditions. The output flashes at a one flash per second rate when activated.

14

Clear Stored Codes Input: Used to clear the stored diagnostic codes from ECU memory when shorted to ground with pin 16 also active.

15

Fuel Shut-Off Solenoid Output: Current-sourcing output which turns on the fuel shut-off valve.

During certain fault conditions this output turns off the fuel shut-off valve to force zero fuel delivery.

16

Transmit Stored Codes Input: When shorted to ground, this input causes stored diagnostic codes to be transmitted via the Diagnostic Codes Output (Pin 31) rather than the current diagnostic codes.

When this input and Pin 14 are simultaneously selected, the stored diagnostic codes are cleared.

17

Actuator Solenoid Output: Current-sinking output which drives the solenoid coil of the injection pump rack actuator. Pin 17 is common with Pin 18.

RG,CTM93,G20,21-19-12SEP94

CTM93 (26SEP94)

20-16

6076AFD Dual Fuel Engines 180496

PN=43

Dual Fuel System Theory of Operation/Diagnostic Features CONNECTOR X1—Continued Pin

Functional Description

18

Actuator Solenoid Output: See Pin 17.

19

Code Storage + 12V Input: Provides +12V continuous power for code storage memory. Must remain at +12V even when key switch is off.

20

Signal Ground: This pin is used to provide a ground reference for the electronic signals within the controller.

21

+5V supply output for the rack position sensor.

22

Sensor Common: This pin is used to provide a reference voltage for the fuel temperature sensor and for the link controller.

23

Fuel Temperature Input: Analog input which is connected to a Nippondenso resistive sensor that is pump mounted. The input has a pull-up resistor (5000 ohms) to +5 volts.

24

Fuel Limit Select Input: Three-state input which selects between three optional torque curves.

Selection is made by connecting input to ground, by connecting input to ground through a 2000 ohms resistor, or by leaving input open. Input controlled by the link controller.

25

Not used.

26

Not used.

27

Rack Position Voltage: D.C. voltage from the rack position sensor which is proportional to pump rack position. The relationship is as follows: RACK VOLTAGE (volts) = 3.00 volts + [RACK POSITION (mm) x -0.1]

28

Primary Speed + Input: This input receives the signal on the “plus” lead from the Nippondenso pump-mounted sensor which monitors engine speed. The sensor provides six pulses per engine revolution.

29

Auxiliary Speed Output: This output provides a buffered output of the auxiliary speed input. It supplies one pulse for each pulse received on the auxiliary input. The signal is sent to the link controller.

30

Not used.

31

Diagnostic Codes Input: Signal which sends diagnostic codes to a service tool or on-board code reader.

32

Fuel Flow/Throttle Output: Output control signal which contains percent of rated fuel flow and throttle position information to be used by a diagnostic reader. The throttle position value represents the analog throttle input value received on Pin 6.

33

Power Ground Input: This pin supplies a high current ground connection to the ECU. It is common with Pin 35. Only Pins 33 and 35 should be used as high current connections.

34

+12 Volt Input: See Pin 1.

35

Power Ground Input: See Pin 33.

20 17

RG,CTM93,G20,22-19-12SEP94

CTM93 (26SEP94)

20-17

6076AFD Dual Fuel Engines 180496

PN=44

Dual Fuel System Theory of Operation/Diagnostic Features Diagnostic Reader Connector P2 (X4):

N

A B C D E F

+12V input Transmit stored codes input Clear stored codes input Diagnostic Codes output Fuel flow/throttle output Signal Ground

RG5390

Function

CAUTION: DO NOT short pin “A” to pin “F”.

This will short battery voltage to ground which may blow a circuit breaker or fuse. Sparks may be produced as a result of the short circuit.

Checking the governor system supply voltage can be done by measuring the voltage between pin “A” (+) and pin “F” (—). This provides a test to see if the supply voltage is reaching the pump harness and if the voltage level is adequate to allow system function (greater than 9 volts).

RG,CTM93,G20,23-19-12SEP94

Test Connector P3 (X20):

Pin

Function

A B C D E F

Signal Ground % Throttle to ECU % Speed to NG Governor % Limit to NG Governor PGA Done Not Used

-UN-14DEC88

Test connector P3 (X20) is provided to assist in troubleshooting the link controller. It provides the following voltages to assist in troubleshooting:

RG5390

20 18

Pin

-UN-14DEC88

The diagnostic reader connector (P2) is used to connect to the electronic governor tester during service work.

However, when the electronic governor tester is disconnected, this connector can be used to measure the governor system +12V supply voltage.

RG,CTM93,G20,24-19-12SEP94

CTM93 (26SEP94)

20-18

6076AFD Dual Fuel Engines 180496

PN=45

Group 30

Dual Fuel System Diagnostics BEFORE YOU START DIAGNOSTICS Found in this group is the Functional Schematic, Wiring Diagrams and Diagnostic Table for troubleshooting the Dual Fuel System. Refer to Basic Infomation in Group 20 of CTM67 manual for information on how to troubleshoot electrical systems.

RG,CTM93,G30,1 -19-12SEP94

The following test equipment is necessary for troubleshooting the Dual Fuel Electrical System.

30 1 -UN-12DEC88

• JT05791 Digital Multimeter or equivalent

RW11274

• JT05829 JD Electronic Governor Tester (Diagnostic Reader)

RG5351

-UN-09JAN90

JT05791 DMM

JT05829 JD Electronic Gov Tester

RG,CTM93,G30,2 -19-12SEP94

CTM93 (26SEP94)

30-1

6076AFD Dual Fuel Engines 180496

PN=46

Dual Fuel System Diagnostics/Dual Fuel System Schematic

DUAL FUEL SYSTEM SCHEMATIC, WIRING DIAGRAM AND COMPONENT LOCATION DRAWING LEGEND

30 2

A1—ECU (SE2) A2—Link Controller (SE4) A3—TVP (SE5) A4—NG Governor (SE5) B1—Speed/Rack Sensors (SE1, WD3) B2—Fuel Temperature Sensor (SE2, WD3) B3—Auxiliary Speed Pickup (SE2, WD3) B4—NG Pressure Switch (SE3, WD2) B5—Air Temperature Switch (SE3, WD2) B6—Flywheel Speed Sensor (SE3, WD2) H1—ECU Fault Indicator Light (SE5, WD1) H2—Diesel Mode Indicator Light (SE5, WD1) H3—Dual Fuel Mode Indicator Light (SE6, WD1) K1—Safety Switch (SE4, WD3) K2—Starter Relay

P1—X4 Diagnostic Reader Connector (SE1, WD3) P2—X5 ECU Diagnostic Connector (SE1, WD1) P3—X20 Test Connector (SE6, WD1) P6—Ammeter (WD2) S1—Key Switch (SE4, WD2) S2—Dual Fuel/Diesel Switch (SE6, WD1) S3—± Speed Switch (SE6, WD1) W1—Frame Ground (WD2) W2—Ground to Control Panel Box (WD1) W3—ground to Control Panel Door (WD1) X1—ECU Connector (WD1) X3—ECU Throttle Connector (WD1) X3M—ECU Throttle Connector (WD1) X7—Rack Solenoid Connector (WD3) X8—Fuel Temperature Connector (WD3)

X9—Speed/Rack Sensors Connector (WD3) X10—Fuel Solenoid Connector (WD3) X11—NG Actuator Connector (WD2) X12—Air Temperature Connector (WD2) X13—NG Pressure Switch Connector (WD2) X14—NG Shut-off Solenoid Connector (WD2) X15—Flywheel Speed Connector (WD2) X16—Link Harness Connector (WD2) X17—Pump Harness Connector (WD3) X18—Link Connector (WD1) X19—TVP Connector (WD1) X21—NG Governor Connector (WD1) X22—NG Governor Connector (WD1) X23—NG Governor Connector (WD1)

X24—Splice (WD1) X25—Splice (WD1) X26—Splice (WD1) X27—Splice (WD1) X28—Splice (WD1) X29—Splice (WD1) X30—Splice (WD1) X31—Splice (WD1) X32—Splice (WD1) X33—Splice (WD1) X34—Splice (WD1) X35—Splice (WD1) X36—Splice (WD1) X37—Splice (WD1) X38—Splice (WD1) X39—Splice (WD1) X40—Splice (WD2) Y1—Rack Solenoid (SE2, WD2) Y2—Diesel Fuel Solenoid (SE2, WD2) Y3—NG Shut-off Solenoid (SE2, WD3) Y4—NG Actuator (SE3, WD3)

NOTE: All splices inside harness.

RG,CTM93,G30,3 -19-12SEP94

CTM93 (26SEP94)

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6076AFD Dual Fuel Engines 180496

PN=47

Dual Fuel System Diagnostics/Dual Fuel System Wiring Diagram

DUAL FUEL SYSTEM PUMP HARNESS (WD3) WIRING DIAGRAM

RG6824

-19-28SEP93

30 9

RG,CTM93,G30,10-19-12SEP94

CTM93 (26SEP94)

30-9

6076AFD Dual Fuel Engines 180496

PN=54

Dual Fuel System Diagnostics/Dual Fuel System Wiring Diagram

DUAL FUEL SYSTEM WIRING HARNESSES AND COMPONENT LOCATION DRAWING

RG6791

-UN-23SEP93

30 10

RG,CTM93,G30,11-19-12SEP94

CTM93 (26SEP94)

30-10

6076AFD Dual Fuel Engines 180496

PN=55

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

DIAGNOSE MALFUNCTIONS OF DUAL FUEL SYSTEM Symptom

Problem

Solution

Engine does not crank.

Dead or discharged battery

Check battery and connections.

Starter malfunction

Check starter and solenoid.

Switch malfunction

Check key switch at engine display panel. (Refer to Group 21 in CTM67 manual.)

Wiring fault

Check for battery voltage at “+” terminal of ammeter at engine display panel. If not present, check wiring to battery.

Engine cranks but does not start.

Blown fuse

Check for battery voltage at “BATT” terminal of key switch at display panel. If not present, check fuse.

Replace fuse if required. (Refer to Group 21 in CTM67 manual.)

No diesel fuel

Turn fuel valve on.

Refill tank.

Prime injection pump.

No power—Indicators do not illuminate

Disconnect X19 located at TVP. Check for battery voltage between pins “A” (+) and “F” (—) on harness side of connector while cranking engine.

No power—magnetic safety switch pushbutton not fully depressed during cranking

Depress safety reset pushbutton fully during and after cranking until oil pressure reaches nominal pressure.

Overfuelling—NG solenoid and NG metering valve open

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST) while cranking engine. Voltage should be 5 VDC ± 0.25 volt. Replace link controller if voltage does not meet specification.

Disconnect X14 (NG solenoid). Turn key switch to “OFF” position and measure resistance (ohms) between pin “2” and engine ground. Confirm resistance is greater than 1000 ohms. If not, disconnect X16 at operator’s panel and repeat test. If resistance is ok, there may be a short in the operator panel harness.

Continued on next page

CTM93 (26SEP94)

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6076AFD Dual Fuel Engines 180496

PN=56

30 11

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine will not start or stalls: All three indicators on operator’s panel do not turn on for approximately 5 seconds when key turned to RUN position and magnetic safety switch button fully depressed.

No power

Disconnect X19 located at TVP. Check for battery voltage between pins “A” (+) and “F” (—) on harness side of connector while cranking engine.

No power—TVP module faulty

Replace transient voltage protection module.

Wiring fault

Check wiring and connectors.

Lamp burned out

Check indicator bulbs. Replace as required.

No power—faulty magnetic safety switch or starter switch

Test safety switch. (Refer to Group 21 in CTM67 manual.)

Engine will not start or stalls after starting: Amber ECU indicator stays on for longer than 5 seconds or flashes.

ECU fault

Attempt restart and repeat test.

Check fault code using Diagnostic Reader and make appropriate corrections.

Engine will not start or stalls after starting: Green dual fuel indicator on longer than 5 seconds.

Low battery voltage

Check battery voltage. Voltage must be greater than 6 volts when cranking and 13.3 volts during engine operation.

Wiring fault

Check wiring at dual fuel lamp located on operator panel door.

Link controller fault

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST) while cranking engine. Voltage should be 5 VDC ± 0.25 volt. Replace link controller if voltage does not meet specifications.

Bulb burned out

Check indicator bulbs. Replace as required.

Wiring fault

Check wiring at diesel lamp inside operator panel door.

30 12

Engine will not start or stalls after starting: White diesel indicator goes off after 5 seconds.

Continued on next page

CTM93 (26SEP94)

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6076AFD Dual Fuel Engines 180496

PN=57

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Engine starts but stalls when safety switch button is released.

Problem

Solution

Link controller fault

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST) while cranking engine. Voltage should be 5 VDC ± 0.25 volt. Replace link if voltage does not meet specifications.

Safety switch button not fully depressed during cranking

Switch button must be depressed fully during and after cranking until oil pressure reaches nominal pressure.

Pushbutton of Magnetic Safety Switch pops out when released after engine starts.

Check battery voltage. Voltage must be greater than 6 volts when cranking and 13.3 volts when operating.

Check all sensors connected to safety switch. Sensor circuits must be open (not completing a path to ground) once engine starts.

Low oil pressure

Check oil level on level gage.

Add oil if required.

Engine may idle roughly or not start: White or green indicators do not come on. Amber indicator comes on or flashes.

Incorrect link controller hardware installed in operator’s panel

Determine version of engine and make sure appropriate hardware is installed.

Engine will not change speed when in diesel mode: White indicator off or flashing, green indicator on.

Link controller fault Engine not in diesel mode

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST) while cranking engine. Voltage should be 5 VDC ± 0.25 volt replace link controller if voltage does not meet specification.

Engine will not change speed when in diesel mode: Cannot decrease speed.

Speed select switch malfunction

Replace switch in operator panel door.

Wiring fault

Check wiring and connectors at speed select switch Check wiring and connections at X3 and X3M (ECU throttle)

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage should decrease slowly while Speed Select Switch is held down. Voltage will not decrease below 0.5 VDC. Replace link controller if signal does not change.

Continued on next page

CTM93 (26SEP94)

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30 13

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine will not change speed when in diesel mode: Cannot increase speed under load.

Engine operating at maximum power

Check injection pump power requirements and compare to available engine torque. Engine and pump may be mis-matched.

Speed select switch malfunction

Replace speed select switch in operator’s panel.

Wiring fault

Check wiring and connectors at speed select switch.

Check wiring and connections at X3 and X3M (ECU throttle).

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage should increase slowly while speed select switch is held in up position. Voltage will not increase above 4.5 VDC. Replace link controller if signal does not change.

30 14

Connect Diagnostic Reader to X4.

Monitor % fuel while holding speed select switch in up position. If maximum reading is less than 40%, the wrong torque curve has been selected in the ECU. See ECU Torque Curve Chart in this group.

Engine speed drifts during diesel operation: Speed drifts over a period of several minutes or hours. This results in a permanent speed offset which must be manually corrected.

Load drifting

Normal operation Diesel engine governing is min/max.

Throttle setting sets fuel quantity, therefore, load changes affect speed directly.

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage must be between 0.5 and 4.5 VDC and stable. Replace link controller if voltage not within specifications.

Continued on next page

CTM93 (26SEP94)

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6076AFD Dual Fuel Engines 180496

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Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine speed unstable during diesel operation.

Load unstable

Normal operation.

Diesel engine governing is min/max.

Throttle setting sets fuel quantity, therefore, load changes affect speed directly.

Wiring fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage must be between 0.5 and 4.5 VDC and stable. If not check for loose connection at X18 (LINK) Monitor fault codes using Diagnostic Reader connected to X4.

ECU fault

Monitor fault codes using Diagnostic Reader connected to X4.

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage must be between 0.5 and 4.5 VDC and stable. Replace link controller if voltage not within specification.

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST).

Voltage should be 5 VDC ± 0.25 volt. Replace link controller if voltage does not meet specification.

Dual Fuel Mode selected: Both white and green indicators not lit.

Actuator moves towards open position (CW (clockwise) rotation viewed from front of engine).

Speed changes momentarily then stabilizes within 2% of engine speed when on diesel.

Low battery voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

Normal dual fuel operation

Check indicator bulbs located in control panel door.

Continued on next page

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30 15

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

30 16

Symptom

Problem

Solution

Engine will not change over to dual fuel when Dual Fuel Mode is selected: White indicator remains on, green indicator off (not flashing).

Wiring fault

Check wiring and connectors at fuel select switch.

Switch malfunction

Replace fuel select switch

Link controller fault

Check voltage between pin “E” (+) and “A” (—) at X20 (TEST). Voltage should be 5 VDC ± 0.25 volt.

Replace link controller if voltage is not within specifications.

Normal operation—Conditions not suitable for dual fuel operation

Check the following conditions:

Engine will not changeover to dual fuel when Dual Fuel Mode is selected: NG actuator does not move during changeover attempt— White indicator remains on, green indicator flashing.

• Using the Diagnostic Reader connected at X4, monitor % throttle.

—150 kW (200 hp) engine: % throttle must be greater than 43%.

—112 kW engine (150 hp): % throttle must be greater than 45% • Engine speed must be greater than 1400 rpm.

• NG supply pressure must be greater than 18 psi.

• 150 kW (200 hp) engine only: Intake air temp must be less than 53˚C (128F).

NG pressure switch fault

Disconnect X13 to test switch.

Intake air temperature switch fault —150 kW (200 hp) engine only

Disconnect X12 to test switch.

A critical fault may have occurred earlier when operating on dual fuel causing the system to return to diesel Example—NG valve position more than 30% —Engine speed less than 1200 rpm

Investigate cause of critical fault.

Check NG outlet pressure. (Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

Check pump for normal operation.

Stop engine and restart to clear fault.

Wiring fault

Check wiring and connectors at fuel select switch.

Switch malfunction

Replace fuel select switch.

Continued on next page

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Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Engine will not changeover to dual fuel when Dual Fuel Mode is selected: NG actuator does not move during changeover attempt— White indicator goes off, green indicator comes on then flashes, and white indicator comes back on.

Engine will not changeover to dual fuel when Dual Fuel Mode is selected: NG actuator does not move during changeover attempt— White indicator goes off, green indicator comes on then flashes, and white indicator comes back on.

Problem

Solution

Link controller fault—Controller does not detect fuel selector switch input

Replace link controller.

Critical fault detected during changeover: Example—NG valve position greater than 30%

Check NG regulator adjustment.

Check inlet and outlet pressure.

(Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

Link controller fault—Pilot diesel fuel curve not selected

Replace link controller.

NG actuator wiring faulty

Check wiring connections at X11 (NG Actuator)

NG actuator faulty

Disconnect X11 and measure actuator coil resistance between pins “E” and “F”. Resistance should be 1.8 to 2.8 ohms. Replace actuator if resistance is not within specifications.

No speed signal at NG governor

Measure AC voltage between pins “10” and “11” at the NG governor.

Voltage must be greater than 2.5 VAC when the engine is operating at 1200 rpm or higher. If not, check speed pickup at flywheel housing.

To check speed pickup, disconnect X15 (speed pickup) at the engine flywheel and measure the voltage between pins “A” and “B”. Voltage must be greater than 2.5 VAC when the engine is operating at 1200 rpm or higher. If not, stop engine and check coil resistance between pins “A” and “B” of X15. Resistance should be between 2600 and 3400 ohms.

Replace sensor if resistance is not within specifications. If in range, check sensor installation and wiring between sensor and NG governor.

Continued on next page

CTM93 (26SEP94)

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6076AFD Dual Fuel Engines 180496

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30 17

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

30 18

Engine will not changeover to dual fuel when Dual Fuel Mode is selected: NG actuator moves towards open position (CW rotation viewed from front of engine) during changeover attempt— White indicator goes off, green indicator comes on then flashes, and white indicator comes back on.

Problem

Solution

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

NG supply line too small—Regulator Check regulator inlet and outlet inlet pressure drops below 13 psi pressure. (Refer to Adjust NG under load Regulator Outlet Pressure in Group 50 of this manual.) Ensure 3/4 inch minimum supply line is used at regulator inlet.

NG metering valve linkage setup incorrect

Stop engine and check follower arm setup angle. Angle should be 45 degrees from horizontal reference when actuator in OFF position.

If angle greater than 45 degrees, adjust driver arm or replace NG Metering assembly.

NG actuator wiring faulty

Check wiring connections at X11 (NG actuator)

NG actuator faulty—Incorrect valve position feedback signal

Disconnect X11 and measure resistance: • Resistance between pins “A” and “C” should be 5000 ohms ± 250 ohms.

• Resistance between pins “A” and “B” with actuator in OFF position (fully CW) should be 2000 ohms ± 100 ohms • Resistance between pins “A” and “B” with actuator in ON position (fully CCW) should be 3000 ohms ± 100 ohms. If any of these requirements are not met, replace the actuator.

Continued on next page

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PN=63

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine stalls when dual fuel operation attempted: Actuator does not move when changeover attempted. RPM drops and engine switches back to diesel before stalling—White lamp on, green flashing.

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

NG actuator wiring faulty

Check wiring connections at X11 (NG actuator).

No speed signal at NG governor

Measure AC voltage between pins “10” and “11” at the NG governor.

Voltage must be greater than 2.5 VAC when the engine is operating at 1200 rpm or higher. If not, check speed pickup at flywheel housing.

To check speed pickup, disconnect X15 (speed pickup) at the engine flywheel and measure the voltage between pins “A” and “B”. Voltage must be greater than 2.5 VAC when the engine is operating at 1200 rpm or higher. If not, stop engine and check coil resistance between pins “A” and “B” of X15. Resistance should be between 2600 and 3400 ohms.

Replace sensor if resistance is not within specifications. If in range, check sensor installation and check wiring between sensor and NG governor.

Link controller fault

Measure % speed voltage between pins “C” (+) and “A” (—) at X20 (TEST) during changeover attempt.

Voltage should be approximately 4 VDC before changeover and increase within 5 seconds of start of changeover.

Measure % limit voltage between pins “D” (+) and “A” (—) at X20 (TEST) during changeover attempt.

Voltage should be approximately 0.5 VDC before changeover and increase within 5 seconds of start of changeover.

Continued on next page

CTM93 (26SEP94)

30-19

6076AFD Dual Fuel Engines 180496

PN=64

30 19

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine stalls when dual fuel operation attempted: Actuator opens fully (CCW (counterclockwise) rotation viewed from front of engine).

Engine switches back to diesel before stalling—white lamp on, green flashing.

NG solenoid not opening

Disconnect X14 (NG solenoid). With engine running in Diesel mode, check for battery voltage between pins “2” (+) and ground (—) on the harness side of connector. If voltage not found, check harness for breaks.

Measure solenoid coil resistance between pins “1” and “2”.

Resistance should be 9 ohms ± 2 ohms. Replace if coil does not meet specifications.

30 20

NG supply inadequate—Pressure drops when dual fuel operation attempted

Check regulator adjustment cap and inlet and outlet pressure.

(Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

Low battery voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

Engine speed will not change in Dual Fuel Mode: Engine changes back to Diesel Mode (white indicator on, green flashing) after 1.25 second delay when speed select switch toggle lever is moved up or down.

Normal operation

Hold speed select toggle lever up or down to adjust speed. If speed does not change, go to next step.

Engine speed will not change in Dual Fuel Mode: Engine does not change back to diesel when speed change is attempted, but switches to diesel when fuel select switch used.

Once in diesel mode, (white indicator on, green indicator off) speed cannot be adjusted up or down

Speed select switch malfunction

Replace speed select switch located in operator panel door.

Wiring fault

Check wiring and connectors at speed select switch.

Continued on next page

CTM93 (26SEP94)

30-20

6076AFD Dual Fuel Engines 180496

PN=65

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine speed will not change in Dual Fuel Mode: Engine returns to Diesel Mode (white indicator on, green flashing) when speed switch toggle lever is held in the UP position but speed does not increase.

Engine operating at maximum power

Check pump power requirements and compare to available engine torque. Engine and pump may be mis-matched.

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage should increase slowly while speed select switch toggle lever is held in the UP position.

Replace link controller if signal does not change.

Engine speed will not change in Dual Fuel Mode: Engine returns to Diesel Mode (white indicator on, green flashing) when speed switch toggle lever is held in the DOWN position but speed does not decrease.

Link controller fault

Measure % throttle voltage at pins “B” (+) and “A” (—) at X20 (TEST).

Voltage should decrease slowly while speed select switch toggle lever is held in the DOWN position.

Voltage will not decrease below 0.5 VDC. Replace link controller if signal does not change.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

Continued on next page

CTM93 (26SEP94)

30-21

6076AFD Dual Fuel Engines 180496

PN=66

30 21

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine speed drifts during dual fuel operation: Speed drifts over a period of several minutes or hours. This results in a permanent speed offset which must be manually corrected.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

Engine operating at maximum power, NG limiting controlling valve position. Changes in load affect speed directly

Check pump power requirements and compare to available engine torque. Engine and pump may be mis-matched.

NG regulator pressure drifting outside of operating range

Check NG regulator outlet pressure.

(Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

NG governor fault

Measure % speed voltage at pins “C” (+) and “A” (—) at X20 (TEST). If voltage is stable and speed drift still observed, governor may be faulty. Replace NG governor.

Link controller fault

Measure % speed voltage at pins “C” (+) and “A” (—) at X20 (TEST). Voltage must be stable, otherwise, replace controller.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

30 22

Engine speed drifts during dual fuel operation: Speed drifts over a short period of time (several seconds or minutes) but NG actuator attempts correction.

Continued on next page

CTM93 (26SEP94)

30-22

6076AFD Dual Fuel Engines 180496

PN=67

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

NG supply pressure inadequate and/or changing

Measure NG supply pressure at regulator inlet when under load.

Pressure must be within range specified in field adjustment procedure for NG regulators. If not, make appropriate adjustments or modifications to regulators. (Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

Inspect hoses and reference lines for cracks. Replace equipment as required.

Engine speed drifts during dual fuel operation: Speed drifts over a period of seconds but actuator does not move. Speed cannot be increased manually.

Engine speed drifts during dual fuel operation: Speed unstable—Slow, regular oscillations.

Engine operating on varying BTU NG supply

Check NG supply composition and consistency. Decrease engine load to prevent operation near maximum power.

Linkage between actuator and metering valve may be worn or fouled with debris

Stop engine and check for smooth operation of linkages. Replace parts or clean as required.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

Engine operating at maximum power. Link controller, NG limiting circuit, controls metering valve position

Check pump power requirements and compare to available engine torque. Engine and pump may be mis-matched.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

NG governor gain settings incorrect

Reset to factory specification. (Refer to Adjust NG Governor Gain in Group 50 of this manual.)

NG regulator outlet pressure high

Check regulator adjustment cap safety wire and inlet and outlet pressure. (Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

Continued on next page

CTM93 (26SEP94)

30-23

6076AFD Dual Fuel Engines 180496

PN=68

30 23

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine speed drifts during dual fuel operation: Speed unstable—Fast, irregular oscillations.

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

NG governor gain settings incorrect

Reset to factory specification. (Refer to Adjust NG Governor Gain in Group 50 of this manual.)

Wiring harness fault

Check wiring and connectors at actuator.

NG governor fault

Measure % speed voltage at pins “C” (+) and “A” (—) at X20 (TEST).

If voltage is stable and speed drift still observed, governor may be faulty. Replace NG governor.

Link controller fault

Measure % speed voltage at pins “C” (+) and “A” (—) at X20 (TEST).

Voltage must be stable, otherwise, replace controller.

Speed incorrect on dual fuel: Speed is stable on dual fuel and within ± 2% of speed when in Diesel Mode.

Normal operation—Up to 2% speed variation allowed

Fine tune speed using speed select switch

Speed incorrect on dual fuel: Speed is stable on dual fuel, but is more than 2% higher than when in Diesel Mode.

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

NG governor fault

Check lacquer on “SPEED IN” potentiometer on NG governor. If seal broken, pot may have been adjusted by unauthorized persons.

Carefully adjust potentiometer or replace controller.

Link controller fault

Measure % speed voltage at pins “C” (+) and “A” (—) at X20 (TEST).

Also measure and record voltages at terminals “6” and “7” on NG governor with respect to terminal “10”. Calculate the % speed using the formula:

30 24

Continued on next page

CTM93 (26SEP94)

30-24

6076AFD Dual Fuel Engines 180496

PN=69

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

V(%SPEED)—V(Term. “7”) -------------------------------------X100 V(Term. “7”)—V(Term “6”) Compare result to specifications shown on speed set point chart.

(Refer to NG Governor Speed Setpoint Requirements in this group.) Replace link controller if not within specifications.

Speed incorrect on dual fuel: Speed is stable on dual fuel, but is more than 2% lower than when in Diesel Mode.

Engine operating at maximum power. Link controller, NG limiting circuit, controls metering valve position

Load may have increased since dual fuel selected. Check pump power requirements and compare to available engine torque. Engine and pump may be mis-matched.

Linkage connecting rotary actuator to NG metering valve may be misaligned, causing improper power limiting

Realign to factory specification.

Stop engine and check follower arm setup angle. Angle should be 45 degrees from horizontal reference when actuator in OFF position.

If angle greater than 45 degrees, adjust driver arm or replace NG metering assembly.

NG regulator malfunction—Outlet pressure too low

Check regulator adjustment cap and inlet and outlet pressure. (Refer to Adjust NG Regulator Outlet Pressure in Group 50 of this manual.)

NG actuator, metering valve or linkages binding

Stop engine and check for smooth operation of actuator, valve and linkages. Replace parts as required.

NG governor fault

Check lacquer on “SPEED IN” potentiometer on NG governor. If seal broken, pot may have been adjusted by unauthorized persons.

Carefully adjust potentiometer or replace controller.

Continued on next page

CTM93 (26SEP94)

30-25

6076AFD Dual Fuel Engines 180496

PN=70

30 25

Dual Fuel System Diagnostics/Diagnose Malfunctions of Dual Fuel System

Symptom

Problem

Solution

Engine knocks on dual fuel

High BTU NG supply (High propane and ethane content) Max. power output may be too high for some NG compositions. (Engine development performed with 80% methane, 7.5% ethane, 5.0% propane.)

Check NG composition.

Reduce engine load.

NG overfuelling—Linkage connecting rotary actuator to NG metering valve may be misaligned

Realign to factory specification.

Stop engine and check follower arm setup angle. Angle should be 45 degrees from horizontal reference when actuator in off position.

If angle greater than 45 degrees, adjust driver arm or replace NG metering assembly.

High engine operating temperature

Check coolant level.

Check thermostat.

Intake air temperature greater than 53˚C (128˚F)—Faulty intake air temperature switch [150 kW (200 hp) Engine only]

Check operation of air temperature switch: Switch is normally open, closes at 53˚C ± 2˚C (128˚F ± 3˚F) Once closed, does not open until 48˚C ± 2˚C (118˚F ± 3˚F) Replace switch if faulty.

Injection timing advanced

Check static injection timing and adjust to factory specification.

Both green and white indicators off when Diesel Mode selected.

Rotary actuator fully CW viewed from front of engine. Engine speed ok.

Engine operating normally.

Diesel indicator bulb burned out

Check indicator bulb. Replace as necessary.

Cannot select diesel operation: Green indicator remains on, white indicator off.

Fuel select switch malfunction

Replace fuel select switch

Low battery/charging voltage

Check battery voltage. Voltage must be greater than 13.3 volts during engine operation.

Wiring fault

Check wiring and connectors at fuel select switch.

30 26

Continued on next page

CTM93 (26SEP94)

30-26

6076AFD Dual Fuel Engines 180496

PN=71

Dual Fuel System Diagnostics/NG Governor Speed Setpoint Requirements

Symptom

Cannot select diesel operation: White indicator flashes, green indicator remains on.

Problem

Solution

Link controller fault—Link controller does not sense switch input

Replace link controller.

Internal link controller fault

Replace link controller.

RG,CTM93,G30,12-19-13SEP94

NG GOVERNOR SPEED SETPOINT REQUIREMENTS

RG6942

-19-30SEP93

30 27

RG,CTM93,G30,13-19-12SEP94

CTM93 (26SEP94)

30-27

6076AFD Dual Fuel Engines 180496

PN=72

Dual Fuel System Diagnostics/ECU Torque Curve Chart

ECU TORQUE CURVE CHART Engine Version Torque Curve

A B C

Signal

Open Ground 2 Kohm

112 kW (150 hp)

150 kW (200 hp)

Diesel Hi Pilot Lo Pilot

Hi Pilot Diesel Lo Pilot

RG,CTM93,G30,14-19-12SEP94

30 28

CTM93 (26SEP94)

30-28

6076AFD Dual Fuel Engines 180496

PN=73

Group 40

Dual Fuel System Repair SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

Name

Use

JDG529 Belt Tension Gauge

To adjust belt tension of auxiliary water pump.

RG,CTM93,G40,23-19-12SEP94

OTHER MATERIAL Number

Name

Use

LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. TY9375/TY9480/592

Pipe Sealant with TEFLON®

40 1

To seal pipe threads on air temperature sensor and gas lines and coolant system fittings.

LOCTITE is a trademark of the Loctite Corporation.

TEFLON is a trademark of the DuPont Co.

RG,CTM93,G40,24-19-12SEP94

SPECIFICATIONS Item

Measurement

Specification

Flywheel Speed Sensor

Clearance between sensor and flywheel teeth

0.76 mm (0.030 in.)

Auxiliary Water Pump Belt

Tension New Belt

178 N (40 lb force)

Used Belt Mounting Bracket Cap Screws External Heat Exchanger Vent Orifice

89—178 N (20—40 lb force)

Torque

102 N·m (75 lb-ft)

Diameter

1.59 mm (0.063 in.)

RG,CTM93,G40,25-19-12SEP94

CTM93 (26SEP94)

40-1

6076AFD Dual Fuel Engines 180496

PN=74

Dual Fuel System Repair/Disconnect and Connect Natural Gas Supply

DISCONNECT AND CONNECT NATURAL GAS SUPPLY CAUTION: Natural gas is highly flammable. DO NOT smoke while working on or around natural gas equipment. Shut off natural gas supply before servicing equipment.

-UN-23AUG88

N

TS220

Natural gas fumes may cause sickness or death. Work in well ventilated area and shut off natural gas supply before servicing equipment.

DISCONNECT: 1. Close manual natural gas supply valve before loosening supply line connections.

3. Disconnect supply line. Install a cap or plug to close openings, preventing debris from entering lines.

RG6025

40 2

-UN-06JAN92

2. Loosen supply line fitting and allow natural gas pressure to bleed off.

CONNECT:

NOTE: A natural gas filter (not shown) must be installed in the supply line between the manual shutoff valve (not shown) and the natural gas supply pressure sensor.

IMPORTANT: DO NOT use Teflon tape to seal threads on natural gas lines as tape may form debris in the line. Debris may cause the valve and regulator to malfunction.

1. Apply pipe sealant to supply line threads.

2. Connect supply line to pressure sensor end of regulator assembly and tighten.

3. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair.

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

RG,CTM93,G40,1 -19-12SEP94

CTM93 (26SEP94)

40-2

6076AFD Dual Fuel Engines 180496

PN=75

Dual Fuel System Repair/Control Panel

REPLACE CONTROL PANEL LAMPS 1. Turn lens (A, B or C) counterclockwise to remove lens.

2. Push bulb in and turn counterclockwise to remove bulb.

3. Inspect lens O-ring for damage; replace if necessary.

4. Install new bulb.

5. Install lens.

RG6805

-UN-29JUN93

A—Diesel Malfunction Lamp—Amber Lens B—Diesel Lamp—Clear (White) Lens C—Duel Fuel Lamp—Green Lens

RG,CTM93,G40,2 -19-12SEP94

REMOVE AND INSTALL CONTROL PANEL SWITCHES 1. Remove large nut to remove weather-proof cover from switch (A or B).

2. Open panel door. Tag and disconnect wires from switch.

3. Remove small retaining nut from front of panel door to remove switch.

4. Install switch and retaining nut.

5. Connect wires and close panel door.

6. Install weather-proof cover.

RG6806

-UN-29JUN93

A—Fuel-Select Switch B—Speed-Set Switch

RG,CTM93,G40,3 -19-12SEP94

CTM93 (26SEP94)

40-3

6076AFD Dual Fuel Engines 180496

PN=76

40 3

Dual Fuel System Repair/Engine Control Unit (ECU)

REMOVE AND INSTALL ENGINE CONTROL UNIT (ECU) 1. Disconnect negative (—) battery cable.

-UN-29JUN93

2. Open control panel door. Remove four nuts (A) and washers to remove ECU from panel.

RG6807

3. Push down on retaining clip (B) and pull up to remove connector from ECU. IMPORTANT: If ECU is replaced, be sure to replace unit with properly programmed ECU. If the wrong ECU is used, misleading diagnostic messages, poor performance or engine damage can occur.

4. Connect harness connector to ECU, making sure retaining clip engages.

40 4

5. Install ECU in panel and fasten using washers and nuts.

6. Connect negative (—) battery ground cable.

RG,CTM93,G40,4 -19-12SEP94

CTM93 (26SEP94)

40-4

6076AFD Dual Fuel Engines 180496

PN=77

Dual Fuel System Repair/Natural Gas Governor

REMOVE AND INSTALL NATURAL GAS GOVERNOR 1. Disconnect negative (—) battery cable.

-UN-29JUN93

2. Disconnect three wiring connectors (A).

RG6810

3. Remove four nuts and washers (B) to remove NG governor.

4. If necessary, remove connector harnesses one at a time and install harnesses on replacement NG governor.

5. Install NG governor in panel and fasten using washers and nuts.

6. Connect governor wiring connectors.

7. Connect negative (—) battery ground cable.

40 5

8. Adjust NG governor. (See procedures in Group 50.)

RG,CTM93,G40,5 -19-12SEP94

CTM93 (26SEP94)

40-5

6076AFD Dual Fuel Engines 180496

PN=78

Dual Fuel System Repair/Link Controller

REMOVE AND INSTALL LINK CONTROLLER 1. Disconnect negative (—) battery cable.

-UN-29JUN93

IMPORTANT: Support mounting plate assembly to prevent stressing or breaking harness wires or connectors.

RG6808

NOTE: It is not necessary to disconnect governor harness to remove link controller.

2. Remove four nuts and washers (A) to remove mounting plate (B) with NG governor attached.

3. Remove four nuts and washers (C).

5. Connect harness connector to controller and fasten with hex nut on connector.

6. Install controller and fasten with washers and nuts.

RG6809

40 6

-UN-29JUN93

4. Loosen hex nut on connector (D) to remove connector. Remove controller from panel.

7. Install NG governor with mounting plate. Fasten with washers and nuts.

8. Connect negative (—) battery cable.

A—Nut and Washer (4 used) B—NG Governor and Mounting Plate C—Nut and Washer (4 used) D—Connector

RG,CTM93,G40,6 -19-12SEP94

CTM93 (26SEP94)

40-6

6076AFD Dual Fuel Engines 180496

PN=79

Dual Fuel System Repair/Natural Gas

REMOVE AND INSTALL TRANSIENT VOLTAGE PROTECTOR (TVP) MODULE 1. Disconnect negative (—) battery cable.

-UN-29JUN93

2. Disconnect wiring connector (A).

RG6811

3. Remove two nuts and washers to remove TVP module.

4. Install TVP module and fasten with washers and nuts.

5. Connect TVP module wiring connector.

6. Connect negative (—) battery ground cable.

RG,CTM93,G40,7 -19-12SEP94

40 7

REPLACE NATURAL GAS FILTER CAUTION: Natural gas is highly flammable. DO NOT smoke while working on or around natural gas equipment. Shut off natural gas supply before servicing equipment.

-UN-23AUG88

N

TS220

Natural gas fumes may cause sickness or death. Work in well ventilated area and shut off natural gas supply before servicing equipment.

1. Shut off gas supply at manual shut-off valve.

2. Loosen natural gas filter outlet fitting (A).

3. Remove filter element (C) and gasket (B).

4. Install new filter element and gasket in housing.

5. Tighten fitting securely.

-UN-22FEB93

6. Check filter assembly for leaks.

RG6655

A—Filter Outlet Fitting B—Gasket C—Filter Element

RG,CTM93,G40,8 -19-12SEP94

CTM93 (26SEP94)

40-7

6076AFD Dual Fuel Engines 180496

PN=80

Dual Fuel System Repair/Natural Gas

REMOVE AND INSTALL NATURAL GAS LOW PRESSURE SENSOR CAUTION: Natural gas is highly flammable. DO NOT smoke while working on or around natural gas equipment. Shut off natural gas supply before servicing equipment.

-UN-23AUG88

N

TS220

Natural gas fumes may cause sickness or death. Work in well ventilated area and shut off natural gas supply before servicing equipment.

1. Close manual natural gas supply valve.

2. Disconnect pressure sensor wiring connector (A).

IMPORTANT: DO NOT use Teflon tape to seal threads on natural gas pressure sensor as tape may form debris in the gas lines. Debris may cause the sensor and other components to malfunction.

RG6818

40 8

-UN-29JUN93

3. Remove pressure sensor (B). Close all openings using caps and plugs.

4. Apply pipe sealant to threads of pressure sensor.

Install and tighten pressure sensor.

5. Connect sensor wiring connector.

6. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair leak.

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

RG,CTM93,G40,9 -19-12SEP94

CTM93 (26SEP94)

40-8

6076AFD Dual Fuel Engines 180496

PN=81

Dual Fuel System Repair/Natural Gas

REMOVE AND INSTALL NATURAL GAS SHUT-OFF SOLENOID VALVE 1. Disconnect natural gas supply. (See procedure in this group.)

2. Disconnect sensor wiring connector (B). Remove nut and washer to remove solenoid coil (C) from shutoff valve.

3. Remove tie bands securing harness to lower, horizontal part of supply line.

4. Remove three cap screws (D) securing pipe clamps to engine frame.

-UN-29JUN93

5. Move supply line from engine frame. Remove sensor and pipe from shutoff valve. Close all openings using caps and plugs.

6. Remove solenoid shutoff valve from supply line.

Do not over-tighten fittings, valve housing can be damaged.

RG6812

IMPORTANT: DO NOT use Teflon tape to seal threads on natural gas lines as tape may form debris in the line. Debris may cause the valve and regulator to malfunction.

A—Balance Hose B—Natural Gas Pressure Sensor Connector C—Natural Gas Shut-off Solenoid Coil D—Mounting Cap Screws (3 used) E—Natural Gas Regulator

7. Apply pipe sealant to all supply line male threads.

Install shutoff valve and sensor with section of supply line.

8. Move supply line assembly into position and install three pipe clamp cap screws and washers. Adjust pipe clamp position if necessary.

9. Connect pressure sensor wiring connector. Install solenoid coil, nut and washer on valve.

10. Install tie bands to secure harness to lower, horizontal part of supply line.

11. Connect natural gas supply. (See procedure in this group.)

12. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair leak.

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

RG,CTM93,G40,10-19-12SEP94

CTM93 (26SEP94)

40-9

6076AFD Dual Fuel Engines 180496

PN=82

40 9

Dual Fuel System Repair/Natural Gas

REMOVE AND INSTALL NATURAL GAS REGULATOR 1. Disconnect natural gas supply. (See procedure in this group.)

2. Disconnect balance hose (A) from regulator.

3. Disconnect sensor wiring connector (B). Remove nut and washer to remove solenoid coil (C) from valve.

4. Remove tie bands securing harness to lower, horizontal part of supply line.

5. Remove three cap screws (D) securing pipe clamps to engine frame.

7. Remove NG regulator (E).

A—Balance Hose B—NG Pressure Sensor Connector C—NG Shutoff Solenoid Coil D—Mounting Cap Screws (3 used) E—Natural Gas Regulator

RG6812

40 10

-UN-29JUN93

6. Move supply line from engine frame. Remove sensor and valve part of supply line from regulator.

RG,CTM93,G40,11-19-12SEP94

CTM93 (26SEP94)

40-10

6076AFD Dual Fuel Engines 180496

PN=83

Dual Fuel System Repair/Natural Gas IMPORTANT: DO NOT use Teflon tape to seal threads on natural gas lines as tape may form debris in the line. Debris may cause the valve and regulator to malfunction.

11. Install tie bands to secure harness to lower, horizontal part of supply line.

12. Connect balance hose to regulator.

13. Connect natural gas supply. (See procedure in this group.)

Do not over-tighten fittings, regulator housing can be damaged.

14. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair leak.

8. Apply pipe sealant to all supply line male threads.

Install NG regulator and sensor and valve section of supply line.

9. Move supply line assembly into position and install three pipe clamp cap screws and washers. Adjust pipe clamp position if necessary.

10. Connect pressure sensor wiring connector. Install solenoid coil, nut and washer on valve.

15. Adjust NG pressure regulator. (See procedure in Group 50.)

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

40 11

RG,CTM93,G40,26-19-13SEP94

CTM93 (26SEP94)

40-11

6076AFD Dual Fuel Engines 180496

PN=84

Dual Fuel System Repair/Natural Gas

REMOVE AND INSTALL NATURAL GAS METERING VALVE CAUTION: Natural gas is highly flammable. DO NOT smoke while working on or around natural gas equipment. Shut off natural gas supply before servicing equipment.

-UN-23AUG88

N

TS220

Natural gas fumes may cause sickness or death. Work in well ventilated area and shut off natural gas supply before servicing equipment.

1. Close manual natural gas supply valve.

2. Disconnect supply hose (A).

4. Move lever of the valve until valve is in the closed position. Scribe a mark on the valve body to indicate lever position.

RG6813

40 12

-UN-29JUN93

3. Remove four socket head screws (B) to remove metering valve and gasket. Inspect gasket and replace if necessary.

5. Install gasket, metering valve and socket head screws.

Make sure pin of actuator lever fits into slot of metering valve lever. Linkage must not bind or stick.

Replace linkage if excessive play or wear exists between pin and slot. (See procedure in this group.)

A—Supply Hose B—Socket Head Screw (4 used) C—Socket Head Screw

6. Adjust linkage for proper valve operation: •Loosen socket head screw (C) so actuator shaft can turn freely.

•Move valve lever until lever is aligned with scribe mark (closed position).

•Tighten socket head screw.

•Check linkage for free movement.

7. Connect supply hose.

8. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair leak.

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

RG,CTM93,G40,12-19-12SEP94

CTM93 (26SEP94)

40-12

6076AFD Dual Fuel Engines 180496

PN=85

Dual Fuel System Repair/Metering Valve

REMOVE AND INSTALL METERING VALVE LINKAGE CAUTION: Natural gas is highly flammable. DO NOT smoke while working on or around natural gas equipment. Shut off natural gas supply before servicing equipment.

-UN-23AUG88

N

TS220

Natural gas fumes may cause sickness or death. Work in well ventilated area and shut off natural gas supply before servicing equipment.

1. Close manual natural gas supply valve.

2. Disconnect supply hose (A).

-UN-29JUN93

3. Remove four socket head screws (B) to remove metering valve and gasket. (See procedure in this group.)

RG6814

IMPORTANT: Support metering valve shaft when removing and installing roll pin, otherwise shaft may be damaged and bent. A bent shaft can cause gas leaks or binding linkage.

4. Remove roll pin (C) to remove metering valve lever.

5. Install metering valve lever and roll pin. When looking at the end of the shaft and the valve closed, lever must be towards the upper left.

A—Supply Hose B—Socket Head Screw (4 used) C—Roll Pin D—Socket Head Screw

6. Move lever of the valve until valve is in the closed position. Scribe a mark on the valve body to indicate lever position.

7. Loosen socket head screw (D) to remove actuator lever. Install new lever but do not tighten screw at this time.

8. Install gasket, metering valve and socket head screws.

Make sure pin of actuator lever fits into slot of metering valve lever. Linkage must not bind or stick.

Replace linkage if excessive play or wear exists between pin and slot.

RG,CTM93,G40,13-19-12SEP94

CTM93 (26SEP94)

40-13

6076AFD Dual Fuel Engines 180496

PN=86

40 13

Dual Fuel System Repair/Metering Valve 9. Adjust linkage for proper valve operation:

-UN-29JUN93

•Loosen socket head screw (D) so actuator shaft can turn freely.

•Move valve lever until lever is aligned with scribe mark (closed position).

•Tighten socket head screw.

•Check linkage for free movement.

RG6814

10. Connect supply hose.

11. Open manual natural gas supply valve. Use soapy water or a leak detecting substance to check each connection for leaks. If leaks are found, close manual supply valve and repair leak.

NOTE: Keep manual natural gas supply valve closed when engine is not operating.

40 14

RG,CTM93,G40,27-19-12SEP94

CTM93 (26SEP94)

40-14

6076AFD Dual Fuel Engines 180496

PN=87

Dual Fuel System Repair/Metering Valve

REMOVE AND INSTALL METERING VALVE ACTUATOR 1. Disconnect actuator wiring connector (A).

-UN-29JUN93

2. Remove four countersunk socket hex screws (C) to remove actuator.

RG6815

3. Loosen socket head screw (B) to remove actuator lever.

4. Install lever and screw but do not tighten screw at this time.

5. Install actuator and countersunk socket head screws.

Make sure pin of actuator lever fits into slot of metering valve lever. Linkage must not bind or stick.

Replace linkage if excessive play or wear exists between pin and slot. (See procedure in this group.)

40 15

6. Adjust linkage for proper valve operation: •Loosen socket head screw (B) so actuator shaft can turn freely.

•Move valve lever until valve is in closed position (fully counterclockwise).

•Tighten socket head screw.

•Check linkage for free movement.

7. Connect actuator wiring connector.

RG,CTM93,G40,14-19-13SEP94

CTM93 (26SEP94)

40-15

6076AFD Dual Fuel Engines 180496

PN=88

Dual Fuel System Repair/Remove and Install

REMOVE AND INSTALL FLYWHEEL SPEED SENSOR 1. Disconnect speed sensor wiring connector (A).

-UN-29JUN93

2. Loosen lock nut (B). Turn sensor counterclockwise to remove sensor.

RG6816

3. Install sensor in flywheel housing until tip just contacts a tooth on the ring gear. Turn sensor out (counterclockwise) 1/2 turn. This will provide approximately 0.76 mm (0.030 in.) clearance between flywheel and sensor tip.

4. Slowly rotate flywheel to make sure ring gear does not contact sensor.

5. Connect speed sensor wiring connector.

40 16

RG,CTM93,G40,15-19-12SEP94

REMOVE AND INSTALL CHARGE AIR TEMPERATURE SWITCH

-UN-29JUN93

NOTE: Charge air temperature switch is used on 150 kW (200 hp), 6076AFD engines only.

1. Disconnect temperature sensor wiring connector (A).

RG6817

2. Remove temperature sensor (B).

3. Apply pipe sealant to threads of sensor. Install sensor and tighten to 13.5 N·m (120 lb-in.).

4. Connect temperature sensor wiring connector.

RG,CTM93,G40,16-19-13SEP94

CTM93 (26SEP94)

40-16

6076AFD Dual Fuel Engines 180496

PN=89

Dual Fuel System Repair/Link Wire Harness

REMOVE AND INSTALL LINK WIRE HARNESS

-UN-11NOV93

1. Disconnect negative (—) battery cable.

2. Disconnect connectors (A—F) and wires (G—J).

RG6944

3. Remove tie bands to remove wire harness from engine. Note routing position of harness for installation.

4. Install wire harness. Connect connectors and wires.

5. Install tie bands on harness to prevent damage.

6. Connect negative (—) battery cable.

A—Operator Panel Connector B—Low NG Pressure Sensor Connector C—NG Shutoff Solenoid Connector D—Air Temperature Switch Connector E—NG Actuator Connector F—Speed Sensor Connector G—Red Wire to Ammeter Positive (+) Terminal H—Red/White Wire to Safety Switch Terminal C I—Brown/White Wire to Starter Relay Coil Terminal J—Black Ground Wire (3 used)

RG6820

-UN-29JUN93

40 17

RG,CTM93,G40,17-19-12SEP94

CTM93 (26SEP94)

40-17

6076AFD Dual Fuel Engines 180496

PN=90

Dual Fuel System Repair/Link Wire Harness

REMOVE AND INSTALL INJECTION PUMP WIRE HARNESS

-UN-11NOV93

1. Disconnect negative (—) battery cable.

2. Disconnect connectors (A—E) and wires (F and G).

RG6945

3. Remove tie bands to remove wire harness from engine. Note routing position of harness for installation.

4. Install wire harness. Connect connectors and wires.

5. Install tie bands on harness to prevent damage.

6. Connect negative (—) battery cable.

-UN-29JUN93 RG6821

40 18

A—Operator Panel Connector B—Fuel Shutoff Solenoid Connector C—Speed/Rack Sensors Connector D—Fuel Temperature Sensor Connector E—Rack Actuator Solenoid Connector F—Purple/Black Wire to Tachometer GN (Ground) Terminal G—Orange Wire to Tachometer SIG (Signal) Terminal

RG,CTM93,G40,18-19-12SEP94

CTM93 (26SEP94)

40-18

6076AFD Dual Fuel Engines 180496

PN=91

Dual Fuel System Repair/Operator’s Panel Wire Harness

REMOVE AND INSTALL OPERATOR PANEL WIRE HARNESS 1. Disconnect negative (—) battery cable.

-UN-29JUN93

NOTE: Engine Control Unit (ECU) must be removed to disconnect connector (A).

RG6819

2. Remove ECU. (See procedure in this group.)

3. Tag and disconnect wiring connectors (A—G and I) and wires (H and J—N).

4. Remove tie bands and clamps to remove wire harness from engine. Note routing position of harness for installation.

5. Install wire harness. Connect wiring connectors and wires.

6. Install ECU. 7. Install clamps and tie bands on harness to prevent damage.

8. Connect negative (—) battery cable.

A—ECU Connector B—Injection Pump Harness Connector C—Link Harness Connector D—Link Controller Connector E—6-Pin NG Governor Connector F—4-Pin NG Governor Connector G—6-Pin NG Governor Connector H—Control Panel Ground Wire (2 places) I—Transient Voltage Protector Connector J—Amber ECU Fault Lamp Wires K—White Diesel Lamp Wires L—Fuel Select Switch Wires M—Green Dual Fuel Lamp Wires N—Speed Select Switch Wires

40 19

RG,CTM93,G40,19-19-12SEP94

CTM93 (26SEP94)

40-19

6076AFD Dual Fuel Engines 180496

PN=92

Dual Fuel System Repair/Auxiliary Water Pump

REMOVE AND INSTALL AUXILIARY WATER PUMP NOTE: Auxiliary water pump is used with 150 kW (200 hp) 6076AFD engines only.

1. Disconnect negative (—) battery cable.

2. Drain engine coolant.

3. If engines use remote radiator, remove belt guards (A—C) as necessary. Do not loose spacers between guard and engine.

-UN-11NOV93

A—Remove Radiator Belt Guard B—Auxiliary Pump Belt Guard C—Without Auxiliary Pump Plate

RG6839

40 20

RG,CTM93,G40,20-19-12SEP94

CTM93 (26SEP94)

40-20

6076AFD Dual Fuel Engines 180496

PN=93

Dual Fuel System Repair/Auxiliary Water Pump 4. Remove drain plug (A) to drain coolant from aftercooler circuit.

NOTE: Hose to port (D), not shown.

-UN-29JUN93

5. Disconnect hoses.

RG6822

6. Loosen cap screws (E) to release belt tension.

Remove belt from water pump.

7. Remove cap screws (F) to remove water pump.

8. Install water pump and two cap screws.

9. Install belt on water pump pulley. Adjust belt tension: — Use a JDG529 Belt Tension Gauge or an equivalent on the longest straight length of the belt.

• Apply outward pressure on pump until belt tension is within specification.

A—Drain Plug B—Outlet Hose C—Makeup Hose D—Inlet Hose Port E—Bracket Mounting Cap Screw (2 used) F—Pump Mounting Cap Screw (2 used)

40 21

Auxiliary Water Pump Belt Tension Used Belt* . . . . . . . . . . . . . . . . . . . . . 89—178 N (20—40 lb force) New Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 N (40 lb force) *Belts are considered used after 10 minutes of operation.

• Tighten cap screws (E) to 102 N·m (75 lb-ft).

10. Connect hoses.

11. Install belt guards if used.

12. Install pump plug and close all other coolant drains.

Fill radiator with coolant.

13. Connect negative (—) battery cable. Start engine and add coolant until coolant system is filled.

IMPORTANT: Do not tighten or loosen belts while belts are hot. An inaccurate adjustment can be made.

14. Check belt tension again. If not within specification, adjust tension using step 9.

RG,CTM93,G40,21-19-13SEP94

CTM93 (26SEP94)

40-21

6076AFD Dual Fuel Engines 180496

PN=94

Dual Fuel System Repair/External Heat Exchanger Orifice Vent

REMOVE AND INSTALL EXTERNAL HEAT EXCHANGER ORIFICE VENT

-UN-14DEC92

NOTE: Orifice vent is used with 150 kW (200 hp) 6076AFD engines only.

1. Disconnect negative (—) battery cable.

RG6546

2. Drain engine coolant until coolant level is below orifice fitting.

3. Disconnect aftercooler outlet hose and heat exchanger inlet hose from orifice fitting.

4. Remove orifice fitting to inspect orifice (A). Clean any obstruction from orifice. Orifice diameter is 1.59 mm (0.063 in.).

40 22

5. Apply pipe sealant to male threads of fitting. Install fitting.

6. Connect hoses and close all drains.

7. Connect negative (—) battery cable. Start engine and add coolant until coolant system is filled.

RG,CTM93,G40,22-19-12SEP94

CTM93 (26SEP94)

40-22

6076AFD Dual Fuel Engines 180496

PN=95

Group 50

Dual Fuel System Adjustments SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

Name

Use

Water Manometer (0.1 in. Resolution)

For measuring N.G. regulator outlet pressure

JDG108 Pressure Gauge 0—207 kPa (0—2.1 bar) (0—30 psi)

For reading N.G. supply pressure

RG,CTM93,G50,1 -19-12SEP94

ADJUST NATURAL GAS GOVERNOR GAIN

50 1

IMPORTANT: DO NOT turn “GAIN” dial (A) beyond the “6:30 o’clock” position (minimum) or beyond the “9:00 o’clock” position (maximum). Adjustment past these limits will affect changeover performance.

-UN-23SEP93

NOTE: Adjustment of the N.G. governor will not affect diesel operation.

RG6832

The “GAIN” dial is factory set between the 8:15 and 8:30 o’clock position. The dial will be hard to turn initially due to sealer on the dial.

If engine speed is unstable during Dual Fuel operation: 1. Start engine and operate on Dual Fuel.

2. Using a plastic screwdriver, slowly turn “GAIN” dial counterclockwise while listening to the engine. Stop turning dial when engine stabilizes.

3. If stability is not achieved, turn “GAIN” dial slowly clockwise until engine stabilizes.

4. If stability cannot be achieved, return dial to original position and refer to Adjust NG Regulator Outlet Pressure in this group.

RG,CTM93,G50,2 -19-12SEP94

CTM93 (26SEP94)

50-1

6076AFD Dual Fuel Engines 180496

PN=96

Dual Fuel System Adjustments/Adjust

ADJUST NG REGULATOR OUTLET PRESSURE The engine should match any load and speed in Dual Fuel Mode that can be achieved in Diesel Mode. If full power cannot be achieved initially on dual fuel (engine speed slows after changeover to dual fuel), the regulated N.G. pressure may be too low. If engine achieves full power on dual fuel, but is unstable, regulated N.G. pressure may be too high.

-UN-23SEP93

NOTE: Do not adjust pressure regulator if engine operation is stable and desired operating speed can be achieved when in the Dual Fuel Mode.

50 2

RG6833

Before adjusting the pressure regulator, check the low power situation by switching to Dual Fuel Mode at a reduced speed and load condition. If the lower speed and load can be maintained on dual fuel, but not at high speed and load, then either the regulated N.G. pressure may need adjusting or N.G. supply pressure may be to low.

1. Stop engine and close the N.G. supply manual shut-off valve.

2. Install a flex hose fitting with pressure tap (A) in the 1 in. regulated N.G. supply line. Install a “T” fitting (B) in pressure balance line at intake tube.

3. Connect a 0.1 in. resolution water manometer (C) to the pressure taps in the supply and balance lines.

Manometer must be equipped with shutoff valves or line clamps on each tube to avoid sucking water from manometer when starting engine.

RG,CTM93,G50,3 -19-13SEP94

CTM93 (26SEP94)

50-2

6076AFD Dual Fuel Engines 180496

PN=97

Dual Fuel System Adjustments/Adjust 4. If not equipped, install a N.G. pressure gage (B) between manual shutoff valve (A) and the natural gas shutoff solenoid (C).

-UN-23SEP93

5. Check all connections and turn natural gas supply on.

Close valves or clamps on manometer tubes.

RG6836

6. Start engine and engage load. Bring engine up to desired speed in Diesel Mode.

7. Record engine rpm from the tachometer. Switch the engine to dual fuel operation and allow the engine to stabilize at the desired operating speed.

8. Record the natural gas supply pressure. The supply pressure must be within the range specified for regulator type used.

Natural Gas Supply Pressure Specifications

Regulator Model Fisher S402 Equimeter 122-6

Range 19—21 3.5—4.5

Supply Pressure (psi) Maximum 30 6

Minimum* 15 2

50 3

9. Determine the required regulator outlet pressure in inches of water (In. W.C.): Natural Gas Regulator Outlet Pressure Specifications In Inches of Water (In. W.C.)

Regulator Model Fisher S402 Equipment 122-6

Engine Configuration 112 kW (150 hp) 150 kW (200 hp) 5 In. W.C. 9.8 In. W.C. 5 In. W.C. 9.8 In. W.C.

10. Open valves or clamps on manometer tubes.

Measure and record the N.G. regulator outlet pressure on the manometer. If actual pressure is different than the required pressure by more than ± 0.2 In. W.C., adjustment of pressure regulator is required.

11. Close the valves or clamps on the manometer tubes, and return system to Diesel Mode.

* Operating pressure only. Must be range pressure or higher to switch to dual fuel initially.

CTM93 (26SEP94)

50-3

RG,CTM93,G50,4 -19-12SEP94

6076AFD Dual Fuel Engines 180496

PN=98

RG6883

-UN-23SEP93

Dual Fuel System Adjustments/Adjust

50 4

12. If no adjustment is required, go to step 18. If adjustment is required, remove the sealed safety wire (A) from the cap (B) on the regulator. Remove the cap.

NOTE: 1/2 turn of the adjusting screw is approximately 0.15—0.25 In. W.C. 13. Adjust the outlet pressure setting. Turn adjusting screw (C) clockwise to increase pressure; counterclockwise to decrease pressure.

IMPORTANT: For proper operation of pressure regulator, cap (B) must be installed before operating engine in Dual Fuel mode.

17. Measure and record the natural gas outlet pressure on the manometer. If actual setting is within ± 0.2 In. W.C. of the required setting from step 9, and engine is operating at the desired speed, adjustment is complete.

Repeat the adjustment procedure if necessary, but adjust regulator only enough to achieve proper dual fuel operation. If too much pressure is supplied, unstable dual fuel operation may occur.

18. Operate engine on dual fuel for several minutes and note anything unusual.

19. Record the supply pressure, outlet pressure, and operating rpm. Keep this information for your records.

14. Install cap on regulator.

20. Return to Diesel Mode and stop engine.

15. Start engine. Switch to dual fuel operation and open the valves or clamps on the manometer tubes.

21. Install new safety wire and seal on the regulator cap.

16. Allow the engine to stabilize at the desired operating speed.

22. Remove manometer and all pressure taps from natural gas supply and balance lines.

RG,CTM93,G50,5 -19-12SEP94

CTM93 (26SEP94)

50-4

6076AFD Dual Fuel Engines 180496

PN=99

Dual Fuel System Adjustments/Adjust

ADJUST NG GOVERNOR This procedure is to be used only if regulator outlet pressure and “GAIN” adjustments will not eliminate engine surging.

-UN-23SEP93

IMPORTANT: DO NOT adjust “DROOP” or “LIM” dials. Any change from factory settings will cause a speed offset when operating in Dual Fuel Mode.

The potentiometers on the natural gas governor are factory adjusted to the settings as follows:

Potentiometer Identification ACT (F) GAIN (D) DER (C) INT (B) LIM (A) DROOP (E)

RG6884

Initial Factory Potentiometer Settings Initial Setting (o’clock) 2:30 8:30 9:00 9:00 10:30 (do not adjust) 7:00 (do not adjust)

A—LIM B—INT C—DER D—GAIN E—DROOP F—ACT

50 5 RG,CTM93,G50,6 -19-12SEP94

CTM93 (26SEP94)

50-5

6076AFD Dual Fuel Engines 180496

PN=100

Dual Fuel System Adjustments/Adjust 1. Start engine and increase speed and load to the desired operating level. Switch to dual fuel operation.

6. Upset governor by tapping on actuator lever.

Engine should return quickly to the commanded speed without hunting.

2. Adjust the “ACT” dial slowly clockwise until the actuator lever oscillates (jiggles) rapidly.

7. Turn “DER” dial clockwise until actuator lever begins to hunt. It may be necessary to upset governor by tapping actuator lever.

3. Turn the “ACT” dial slowly counterclockwise until the rapid oscillation just stops.

8. Turn “DER” dial slowly counterclockwise until engine is stable.

4. Upset governor by tapping actuator lever. If the actuator lever oscillates rapidly, turn the “ACT” dial slowly counterclockwise until the rapid oscillation just stops.

9. After “ACT”, “GAIN”, and “DER” dials have been adjusted, momentarily reduce engine speed by tapping actuator lever. Watch and/or listen to engine speed.

NOTE: If actuator lever is moving and engine speed is constant, the unit is governing and not hunting. If engine speed is oscillating with actuator lever, the unit is hunting.

10. If engine speed overshoots the desired operating speed, set earlier, turn “INT” dial a small amount counterclockwise. Reduce engine speed again by tapping actuator lever. Observe engine speed. Repeat this step until engine no longer overshoots the commanded speed.

5. If governor is unstable (hunting), turn “GAIN” dial slowly counterclockwise until it is stable.

50 6

If governor is stable, turn “GAIN” dial slowly clockwise until governor starts to hunt. Then turn “GAIN” dial slowly counterclockwise until governor is stable.

RG,CTM93,G50,7 -19-12SEP94

CTM93 (26SEP94)

50-6

6076AFD Dual Fuel Engines 180496

PN=101

Index Page

A Air intake temperature sensor Remove and install . . . . . . . . . . . . . . . . 40-16 Auxiliary water pump Remove and install . . . . . . . . . . . . . . . . 40-20

Dual Fuel System—Continued NG regulator outlet pres, adjust . . .

NG regulator, replace . . . . . . . . .

NG shut-off solenoid valve, replace Operator panel harness, replace . .

Pump harness wiring diagram . . . .

Theory of operation . . . . . . . . . . .

TVP module, remove and install . .

C Component location drawing Dual Fuel System . . . . . .

Connector Engine Controller (X1) . . .

Control panel lamps Replace . . . . . . . . . . . . .

Control panel switches Remove and install . . . . .

Controller Engine Connector (X1) . . .

Page

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. 50-2 40-10 . 40-9 40-19 . 30-9 . 20-1 . 40-7

E . . . . . . . . . . . 30-10 . . . . . . . . . . . 20-15 . . . . . . . . . . . . 40-3 . . . . . . . . . . . . 40-3 . . . . . . . . . . . 20-15

ECU torque curve chart . . . . . . . . .

Engine Serial number plate . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . .

Engine cont. environmental restrictions Engine control unit (ECU) Remove and install . . . . . . . . . . .

Environmental restrictions . . . . . . . .

External heat exchanger Orifice vent, replace . . . . . . . . . .

Remove and install . . . . . . . . . . .

. . . . . 30-28 . . . . . . 01-4 . . . . . . 10-1 . . . . . 10-2 . . . . . . 40-4 . . . . . . 10-2 . . . . . 40-22 . . . . . 40-22

D Dual Fuel System Actuator linkage, replace . . . . . . .

Actuator, replace . . . . . . . . . . . . .

Air intake temp sensor, replace . . .

Auxiliary water pump, remove & inst Component location drawing . . . . .

Control panel lamps, replace . . . . .

Control panel switches, replace . . .

Control panel wiring diagram . . . . .

Diagnostic features . . . . . . . . . . .

Disconnect/Connect Gas Supply . .

ECU torque curve chart . . . . . . . .

Electrical system legend . . . . . . . .

Engine control unit (ECU), replace .

Functional schematic . . . . . . . . . .

Injection pump harness, replace . .

Link controller, remove and install .

Link harness wiring diagram . . . . .

Link harness, remove and install . .

NG filter, replace . . . . . . . . . . . .

NG governor gain, adjust . . . . . . .

NG governor speed setpoint chart .

NG governor, adjust . . . . . . . . . .

NG governor, remove and install . .

NG metering valve, replace . . . . .

NG pressure sensor, replace . . . .

F . . . . . 40-13 40-15, 40-16 . . . . . 40-16 . . . . 40-20 . . . . . 30-10 . . . . . . 40-3 . . . . . . 40-3 . . . . . . 30-6 . . . . . 20-14 . . . . . . 40-2 . . . . . 30-28 . . . . . . 30-2 . . . . . . 40-4 . . . . . . 30-4 . . . . . 40-18 . . . . . . 40-6 . . . . . . 30-8 . . . . . 40-17 . . . . . . 40-7 . . . . . . 50-1 . . . . . 30-27 . . . . . . 50-5 . . . . . . 40-5 . . . . . 40-12 . . . . . . 40-8

Fuel Natural gas specifications . . . . . . . . . . . . . 10-2

INDX 1

G Governor speed setpoint chart . . . . . . . . . . 30-27 Governor, NG Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5 Gain, adjust . . . . . . . . . . . . . . . . . . . . . . 50-1

I Inch torque values . . . . . . . . . . . . . . . . . . . 01-1

L Link controller Remove and install . . . . . . . . . . . . . . . . . 40-6

M Metering valve actuator Remove and install . . . . . . . . . . . 40-15, 40-16

Index-1

180496

PN=104

Index Page

Metering valve actuator linkage Remove and install . . . . . . . . . . . . . . . . 40-13 Metric torque values . . . . . . . . . . . . . . . . . . 01-2

N Natural Gas Specifications . . . . . . . . . . . . .

Natural gas filter Replace . . . . . . . . . . . . . . . . .

Natural gas governor Remove and install . . . . . . . . .

Natural gas metering valve Remove and install . . . . . . . . .

Natural gas pressure sensor Remove and install . . . . . . . . .

Natural gas regulator Remove and install . . . . . . . . .

Natural gas shut-off solenoid valve Remove and install . . . . . . . . .

Natural Gas Supply Disconnect and Connect . . . . .

. . . . . . . . 10-2 . . . . . . . . 40-7

Page

W Wire harness Injection pump, remove and install Link, remove and install . . . . . . .

Operator panel, remove and install Wiring Diagrams—Dual Fuel System Control panel . . . . . . . . . . . . . .

Legend . . . . . . . . . . . . . . . . . .

Link harness . . . . . . . . . . . . . .

Pump harness . . . . . . . . . . . . .

. . . . . . 40-18 . . . . . . 40-17 . . . . . . 40-19 . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

30-6 30-2 30-8 30-9

. . . . . . . . 40-5 . . . . . . . 40-12 . . . . . . . . 40-8 . . . . . . . 40-10 . . . . . . . . 40-9 . . . . . . . . 40-2

R

INDX 2

Regulator, NG Outlet pressure, adjust . . . . . . . . . . . . . . . 50-2

S Schematic Dual Fuel System . . . . .

Schematic legend Dual Fuel System . . . . .

Serial Number Plate . . . . .

Specifications Engine . . . . . . . . . . . .

Natural gas . . . . . . . . .

System power requirements

. . . . . . . . . . . . . 30-4 . . . . . . . . . . . . . 30-2 . . . . . . . . . . . . . 01-4 . . . . . . . . . . . . . 10-1 . . . . . . . . . . . . . 10-2 . . . . . . . . . . . . . 10-2

T Torque values Inch . . . . . . . . . . . . .

Metric . . . . . . . . . . . .

Transient voltage protector Remove and install . . .

. . . . . . . . . . . . . . 01-1 . . . . . . . . . . . . . . 01-2 module . . . . . . . . . . . . . . 40-7

Index-2

180496

PN=105