Presented by: Gil Garcia

Clean Air Power, Inc.

LEV Products
Dual-Fuel Training Course
Part 2
October 17, 2008
Dual-Fuel System
Diagnostics
Caterpillar ET Codes

Use the Caterpillar Electronic

Technician (ET) program to
look for faults in the Cat ECM
 Caterpillar ET Codes
❦ Any active code in the Cat ECM
can kick you out of mode and not
log a fault in Panels
Dual-Fuel specific Faults:

68-0 Unknown code (50% diesel fall-back)

64-11 No Pattern On Speed Sensor #2 (34)

 Caterpillar ET Codes
68-0 Unknown code (50% fall-
back)
 Unique feature with-in CARB flash files

 Reducesrated power by 50% when

operated out of mode for more than 10
hrs.

 Theneed for this file depends greatly on

regulations with-in the areas of intended
 Caterpillar ET Codes
Fall-back strategy:
 In mode: 100% of Dual-Fuel rated power

 Out of mode: 80% of diesel rated power for

10 hrs. – clock starts counting up

 Outof mode after 10 hrs: 50% of diesel rated

power (fault 68-0) – until repaired

 Back in mode: after 15 minutes fault resets

 Caterpillar ET Codes
68-0 Unknown code (50% fall-
back) What can cause a code 68?
 CAT system failure
 Dual-Fuel system failure

 Out of fuel (NG)

 NG tank shut off
 Caterpillar ET Codes
64-11 No Pattern On Speed Sensor #2 (34)

 Can be set by more than one action

 CAT: Sensor, wiring, connections, etc…

 Dual-Fuel:wiring, connections, timing

buffer, power and ground connections
through cab

 Power and grounds should be attached to a

 Caterpillar ET Codes
Always check ET for Active, Logged Faults and
Logged Events FIRST before assuming it is a
Dual-Fuel problem not allowing it to go into
mode

 Cat ECM is always in control even in gas mode

 Coolant temperature

 Engine timing
Caterpillar Flash files
 Caterpillar Flash Files
 Flashing the ADEM

 Parameters that must be set

 Maintenance Indicator for SC or FC

 How to identify older SC to newer FC

 Personality Module Code not programmed

 Factory passwords
Caterpillar Flash Files
Flashing the ADEM
Caterpillar Flash Files
Parameters that must be set

for the C-10 engine to

run D-F
set
Caterpillar ET
Snap Shots
 Snap Shots
 Useful tool for when faults have been
erased

 View Graphs

 ViewData through Groups with 9 sec.

Before and 4 sec. after fault was Logged
Factory Passwords
Caterpillar Flash Files
View Graph
Factory Passwords
Caterpillar Flash Files
View Data through
Groups
Factory Passwords
Factory Passwords
Dual-Fuel
Eagle ECU
 ECU Specifications
 8097 or 80C196 Intel main
processor (CPU), Clock frequency:
12 MHz
 Memory: 32kBytes EPROM and RAM
 8 analog inputs, 0 – 5 volts, 10 bit
resolution, A/D conversion time 22
μs
 ECU Specifications
3 high-speed digital inputs
 80C51 or 87C51 multiplexer
(MUX)
 8 solenoid drivers (4 A peak,1 A
holding)
 Supply Voltage: 8.0 – 16.0 V dc
Electronic Control Unit (ECU)

EEPROM

EPROM PROCESSOR

MUX
 MUX
Remover

EPROM
Remover

EPROM
Installer
 REMEMBER!
When replacing an EPROM
 Settings on Verification Screen:
 EPROM_CHECKSUM
 CALIBRATION LEVEL
 SAFR_INDEX
 HV_RATIO_INDEX
Verify
Numbers
Match
 Eagle ECU
Inputs from CAT (ADEM)
1. Requested RPM (RPMCMD) or
Requested Fuel (FUELCMD)
2. Error Messages (%)
3. Inject OK (ICONFIRM)
4. Position Indicator Pulse (PIP)
5. Diesel Fuel Temperature (FT)
 EAGLE ECU
Sensor Inputs
1. Natural Gas Pressure (CNGP)
2. Natural Gas Temperature
(CNGT)
3. Air Charge Temperature (ACT)
4. Manifold Absolute Pressure
(MAP)
5. Injector Circuit Voltage
 EAGLE ECU
Outputs
1. Shut Off Valve (SOV)
2. Injectors – Gas and Diesel
3. Turbo Air Bypass Valve (TAB)
4. Waste Gate Control
5. Mode Lamp
6. Keep Alive Power Relay (KAPWR)
7. Solenoid Power Relay (SOLPWR)
 BOB Test Points
ANALOG SENSOR INPUTS
1. Natural gas pressure (CNGP)
• 515 – 1050 kPa operating range
• 665 kPa to go into mode
2. Natural gas temperature (CNGT)
• > -15 degrees Celsius operating range
3. Air charge temperature (ACT)
• Dependant on external factors
4. Manifold absolute pressure (MAP)
5. Diesel Fuel Temperature (FT)
 PRESSURE
Generic Sensor TEMPERATURE

Variable Resistor Ground

5 volts

5 volts 0 volts

Signal out
 Sensors

CNGT
MAP

CNGP

ACT CNGP
Connector Problems
Connector
Corrosion
Connector
Corrosion
 CNG Pressure vs Voltage
Operating Range: 515 to 1068 kPa
Pressure => 765 kPa to go into mode
1600
225
1500
1400 200
1300
1200 175
1100
1000 150
900 125
kPa800
700
psi
100
600
500 75
400
50
300
200 25
100
0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Voltage +/- 0.22

 NG Temperature vs Voltage
Operating Range: -15 and up
120
110
100 210

Temperature F
Temperature C

90
80
70 160
60
50
40 110
30
20
60
10
0
-10 10
-20
-30
-40 -40
0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50

Voltage +/- 0.22

 Manifold Absolute Pressure vs Voltage
Typical Range: 90 - 225 kPa
350.0 50
325.0
300.0
275.0 40
250.0
225.0
200.0 30

kPa 175.0 psi

150.0
20
125.0
100.0
75.0 10
50.0
25.0
0.0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Voltage +/- 0.22

 Air Charge Temperature vs Voltage
120
110
100 210
90

Temperature F
Temperature C

80
70 160
60
50
40 110
30
20
60
10
0
-10 10
-20
-30
-40 -40
0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50

Voltage +/- 0.22

 BOB Test Points (others)

1. ECU Power (ECUPWR)

2. Solenoid Power (SOLPWR)
3. Inject OK (ICONFIRM)
4. Sensor Reference Voltage
(VREF)
5. Ground
 BOB Test Points
DIGITAL SIGNALS (PWM)

1. INJECT – Diesel Injector (out)

2. PIP – Position Indicator Pulse (in)
3. RPMCMD/FUELCMD (in)
4. TAB – Turbo Air Bypass (out)
 Inputs from CAT (ADEM)
RPMCMD/FUELCMD Frequency
 200 Hz = normal command
 166 Hz = No droop requested
 125 Hz = FUELCMD
 Inputs from CAT (ADEM)
RPMCMD/FUELCMD Circuit
Duty cycle Error Messages
 1.0% = No diesel pulses, FC: 65
 1.5% = Bad diesel pulse timing, FC: 66
 2.0% = Bad diesel pulse duration, FC: 67
 2.5% = Extra diesel pulses received, FC:
68
 3.0% = ADEM not ready
 5 – 95% = 500 – 2500 RPM
 Presented by: Gil Garcia
Clean Air Power, Inc.

LEV Products
Dual-Fuel Training
Course Part 2
October 17, 2008