Series 50-60 Training

Detroit Diesel
Series 50G / 60G

Training Program
Leo Beattie
Series 50G/60G Natural Gas Engine
Presenter\Name of Presentation
Revised Date 4
Agenda
Introduction / Background
Specifications, Ratings and Emissions
Glossary of Terms and Engine Sensors
Series 50G / 60G Engine Components
Major Engine Control Systems
Other Unique Engine Systems
Vehicle Fuel System
OEM Interfaces with Engine
Unique Requirements for Gas Engines
Summary
Revised Date 5
Mission Statement
To Provide Proven Alternate Fueled Engines in

Conjunction with Our Diesel Engines that Exceed
Our Customers Expectations The First Time, Every
Time
Revised Date 6
DDC Milestones
Alternative Fuel Engineering Started 1970s

First Alternative Vehicle on Road 1983
The First Emission Certified Alternative
Fueled Engines (Methanol) 1991
Introduced Ethanol Engine 1992
Introduced LNG/Diesel Duel Fuel Engine 1992
Introduced Dedicated Natural Gas Engines 1994
Revised Date 7
DDC Alternate Fuel Projects
Methanol Fueled
Urban Buses
Heavy Duty Trucks
Generator Set
Ethanol Fueled
Urban Buses
Heavy Duty Trucks
Revised Date 8
DDC Alternate Fuel Projects
Natural Gas Fueled

Urban Buses
School Buses
Medium and Heavy Duty Trucks
Refuse Packers
Street Sweepers
Also Miscellaneous Projects on Bio Diesel
Water Emulsions & Propane
Revised Date 9
Series 50G / 60G Development
Series 50G Evolved from the 8.5 L Series 50 Diesel

Engine
Utilizes Similar Components and Design Criteria as the
8.5 Liter Diesel
Utilizes Experience From Two-Cycle Alternative
Fueled Engines Since the 1980s
Series 60G Evolved from the Series 50G
Significant Experience Carryover
Revised Date 10
Series 50G / 60G Release Dates
Series 50G Coach (GFI Fuel System) Aug 94

Series 50G Genset (60Hz, Standby) 1995
Series 60G Genset (60Hz, Standby) 1996
Series 60G Genset (50Hz Standby) 1996
Series 50G Coach (DDC Fuel System) Jan 98
Series 50G / 60G Prime Power Aug. 98
Series 60G Coach Sept 98
Revised Date 11
Commonality With Diesel
Major Components That Are Shared

Block
Cooling System
Cylinder Kit Parts
Exception, Dome and Rings
Flywheel
Housings
Gear Train and Front Cover
Lubrication System
External Accessories
Revised Date 12
DDC Natural Gas Engine Features
Lean Burn Combustion Technology
High Energy Ignition System
DDEC Electronic Control of Spark Timing, Fuel Flow,
Throttle Position & Speed Governing
Closed Loop Feedback to Control Air/Fuel Ratio
Engine Knock Protection
Turbocharger With Integral Turbine Wastegate
Full DDEC Engine Protection System
Air-to-Air Charge Cooling
10:1 Compression Ratio
Revised Date 13
Specific Features of DDC
Natural Gas Gensets
Fuel Inlet Pressure Range 5"- 20" H2O
Venturi Type Fuel System Design
DDEC Control of Fuel, Air & Spark
No-Maintenance Fuel Regulator
Full DDEC System Diagnostics
Excellent Transient Response
Revised Date 14
Series 50G / 60G Coach Specifications
Series 50G Series 60G
Engine Type 4-Cycle (Dedicated Fuel) 4-Cycle (Dedicated Fuel)
Displacement 8.5 Liters 12.7 Liters
Compression Ratio 10:1 10:1
Engine Control DDEC IV, On-Engine DDEC IV, On-Engine
Ignition Electronic Spark Electronic Spark
Aspiration Turbocharged Turbocharged
Fuel Control DDC Closed Loop DDC Closed Loop
Throttle 60 mm Electronic 68 mm Electronic
Rated Power 275 @ 2100 RPM 330 @ 2100 RPM
Peak Torque 890 Ft-Lb @ 1200 RPM 1400 Ft-Lb @ 1200 RPM
Revised Date 15
Series 50G / 60G Genset Specifications

Engine Type 4-Cycle 4-Cycle
(Dedicated Fuel) (Dedicated Fuel)
Fuel Control DDC Low Pressure DDC Low Pressure
Ratings Engine Hp 60 Hz 225 HP - 300 HP 340 HP - 450 HP
Engine Hp 50 Hz N/A 230 HP - 400 HP
Revised Date 16
DDC Series 50G / 60G Gas Engines
Rating Application Availability
Series 50G 275 HP @ 2100 RPM Transit Bus No

890 FT-LB EPA / CARB w
275 HP @ 2100 RPM

Transit Bus 2nd Quarter 99
890 FT-LB LEV / ULEV
225 - 300 HP @ 1800 RPM Gen Set Now

Stand-By
Series 60G 330 HP @ 2100 RPM Motor Coach 3rd. Quarter 98
1400 FT-LB EPA / CARB
340 - 450 HP @ 1800 RPM Gen Set Now

Stand-By
230 - 400 HP @ 1500 RPM Gen Set No

Stand-By w
Revised Date 17
Series 50G Exhaust Emissions
G/HP-HR
NOx NMHC CO PM
Rating 275 HP - 890 FT-LB
4.0 1.2 15.5 .05
1998 CARB / EPA Standards
2.2 0.5 2.3 <.01
1998 Configuration*
*No Catalyst
Revised Date 18
Series 50G ULEV Exhaust Emissions
Rating 275 HP - 890 FT-LB NOX + NMHC G/HP-HR CO PM

ULEV Certification HCHO
7.2 .05
1998 ULEV Standards 2.5 .025
.01 <.01
ULEV Program Goals * 1.7-2.0 .003
*With Catalyst / No DF
Revised Date 19
Series 60G Exhaust Emissions
G/HP-HR
NOx NMHC CO PM
Rating 330 HP - 1400 FT-LB
4.0 1.2 15.5 .05
1998 CARB / EPA Standards
2.0 0.6 1.9 .02
1998 Configuration*
*No Catalyst
Revised Date 20
Series 50G Transit Sites
Vancouver
(50 Units)
Hamilton / Kitchener
INEEL Area (58 Units)
(6 Units)
Pennsylvania
(47 Units) NY / New Jersey
Monterey / Sonoma Area (100 Units)
Denver Springfield Cleveland
(25 Units) (7 Units) (190 Units)
(5 Units)
Los Angeles / San Diego

Oklahoma
Area (200 Units)
Phoenix (3 Units) Atlanta
(9 Units) (118 Units)
El Paso
Tucson (35 Units)
(44 Units) Houston Orlando
Indonesia Laredo (10 Units) (11 Units)
(41 Units) (15 Units)
Pinellas
(3 Units)
Revised Date 21
Natural Gas
Compressed and Liquid
Natural Gas
Methane
Product of Decomposing Organic Material
A By-Product of Decarbonization of Coal
Odorless, Colorless, and Non-Toxic
Mercaptan is Added to Gas as an Odorant
Fuel Composition
Composition is Controlled in Processing
Regional Changes Due to Different Suppliers
Seasonal Changes Due to Usage Demands
Revised Date 23
CNG Fuel Composition
DDC SPECIFICATIONS Minimum Maximum
Methane 88 (%)
Ethane 0 6.0 (%)
Propane 0 1.7 (%)
Butane 0 0.3 (%)
CO2 + Nitrogen + Oxygen 0 4.5 (%)
Hydrogen 0 0.1 (%)
Motor Octane Number 115 Minimum
Revised Date 24
LNG Fuel Composition
DDC SPECIFICATIONS Minimum Maximum
Methane 98 (%)
Ethane 0 0.5 (%)
Propane 0 0.0 (%)
Butane 0 0.0 (%)
Nitrogen 0 2.0 (%)
Hydrogen 0 0.0 (%)
Motor Octane Number 130 Minimum
Revised Date 25
Comparisons
DIESEL GAS CNG LNG
1. BTUs/ Gallon 140,000 136,000 28,000 91,000
2. Flame deg F 3,730 3,590 3,423 3,423
3. Octane 0 89 115 130
4. Auto Ignition deg F 540 428 1,150 1,150
NOTE: One Gallon of Diesel Fuel is Equal to 140 Cubic Feet of CNG
618 Cubic Feet of CNG is Equal to 1 Cubic Foot of LNG
Revised Date 26
Handling and Safety
Safety Concerns
Natural Gas is Lighter Than Air

Flammable Vapors Rise
Reflective Shop Heaters
CNG is Stored at High Pressures
Up to 4000 Psi in Tanks
Tank Pressure Will Be Higher Immediately After Refueling Due to
Compression During Fill
Pressure Release Can Cause Bodily Harm
Ambient Temperature Effects Tank Pressure
Follow all Safety Cautions and Warnings
Revised Date 28
Safety Concerns
Vapors formed from LNG

Above -160 F Vapors are Lighter Than Air
Below -160 F are Heavier Than Air
LNG is Stored in Cryogenic State
Extremely Cold, and can Freeze Skin
LNG Stored at Low Pressure
Maximum Storage Pressure
Pressure Relief Device Releases at 235 psig
Revised Date 29
Boiling Point of Liquids
Revised Date 30
Ignition Limits
Revised Date 31
Background
Glossary of Terms
Engine Sensors
Revised Date 32
Glossary of Terms
SING
Spark Ignited Natural Gas Engine
Relies on Spark Plugs to Ignite Air/Fuel Mixture
Same Cycle as a Typical Car Engine
Unlike Compression Ignition Engines (Diesel)
Dedicated Fuel (Only Burns Natural Gas)
DDC Utilizes Series 50G and 60G Engines Which are 4
Stroke (Cycle) Engines
Revised Date 33
Four Stroke Cycle
Revised Date 34
Glossary of Terms
Absolute Pressure
Any Pressure Reading that Includes Atmosheric Pressure
Standard Atmospheric Pressure is 14.7 psi
Units are Followed by a A (PSIA, KPAA, ect)
Gage Pressure
Pressure Reading that does not Include Atmoshperic
Pressure
Units are Followed by an G (PSIG, KPAG, ect)
Example: Tire Pressure Gage Reads 30 psi
Gage Pressure is 30 PSIG
Absolute Pressure is (30+14.7) 44.7 PSIA
Revised Date 35
Glossary of Terms
AFR
Air Fuel Ratio - % Air to Fuel Entering Engine
# 1 Parameter to Control on SI Engine
Performance
Fuel Economy
Emissions
Stoichiometric AFR
Optimum AFR That Yields Complete Combustion
For Natural Gas This Ratio is Typically 16.4
Parts Air to 1 Part Fuel (Gasoline is 14.7 to 1)
Revised Date 36
Glossary of Terms
Lean Burn
Engine Design That Operates Leaner Than
Stoichiometric AFR to Reduce Exhaust Emissions and
Exhaust Temperatures
Lambda
A Method of Expressing Air Fuel Ratio
Greater Than 1 Indicates Leaner Than Stoichiometric AFR
Less Than 1 Indicates Richer Than Stoichiometric AFR
Revised Date 37
Glossary of Terms
Open Loop Fuel Control
No Feedback to Correct Engine Fueling
Not Self Correcting
DDC / GFI Fuel System is Open Loop
Closed Loop Fuel Control
Providing Feedback to the Open Loop Fuel System Based on Real
Time Measurements
DDC Natural Gas Engines Utilize an Exhaust Oxygen Sensor to
Provide this Feedback
Measures Exhaust Oxygen Content
Adjusts Fuel Flow to Match Desired and Actual Air Fuel Ratio
System Goes From Open Loop to Closed Loop Control Depending on
Conditions
Revised Date 38
Glossary of Terms
Adaptive Learn
Ability of the Fuel Control System to Remember Air
Fuel Ratio Control Corrections. This Learned
Information is Not Lost When the Engine is Shut Down
Engine Knock
Undesirable Condition That Occurs in Spark Ignition
Engines that Leads to Increased Cylinder Pressures and
Temperatures and Possible Component Damage
Fuel Mixture Ignites Prematurely and Uncontrolled
Revised Date 39
Glossary of Terms
Generates High Frequency Ringing in Combustion
Chamber
Primarily Caused by Rich Air Fuel Ratio, Poor Fuel
Quality or High Intake Manifold Temperatures
Lean Misfire
Engine Miss Caused By Incomplete Combustion
Ignition System Problems
Cold Intake Air Temperatures
Low Fuel Pressure / Restricted Fuel Flow
Revised Date 40
Glossary of Terms
BTU
British Thermal Unit
Measurement Unit of Heat Energy
The Amount of Heat Needed to Raise The Temperature of One Gallon
of Water One Degree F in One Minute
VSG
Variable Speed Governor
Holds the engine at a requested constant speed regardless of load
fluctuation
Generator drive engines only
Revised Date 41
Glossary of Terms
Foot Throttle
Otherwise Known as Accelerator or Foot Pedal
Electronic Resistor to Input Foot Pedal Signal Into DDEC
System
Same Function Between Gas and Diesel
Air System Throttle
Butterfly Valve in Gas Engine Air Intake
Controls Engine Speed
Indirectly Receives Input From Foot Pedal
Revised Date 42
Engine Sensors
Absolute Air Inlet Pressure Sensor

Similar to Turbo Boost Pressure on Diesel
Measures Intake Manifold Vacuum and Pressure
Direct Measure of Engine Power
Sensor Mounted on Intake Manifold
Barometric Pressure Sensor
Measures Barometric Pressure
Sensor Mounted on Rear of Engine
Revised Date 43
Engine Sensors
Fuel Delivery Pressure Sensor

Fuel Pressure into Engine Low Pressure Regulator
Normally 110 psig for CNG Applications
Sensor Mounted on Low Pressure Regulator Inlet
Fuel Inlet Temperature Sensor
Gas Fuel Temperature into Engine
Sensor Mounted on Fuel Mixer
Coolant Temperature Sensor
Same as Diesel
Mounted on Right Side of Cylinder Head
Revised Date 44
Engine Sensors
Oil Temperature Sensor

Same as Diesel Through 1997 Gas Engines
Not Used on 1998 + Gas Engines
Exhaust Gas Temperature Sensor
Exhaust Gas Temperature After Turbocharger
Sensor Mounted on Exhaust Pipe After Turbocharger
Intake Air Temperature Sensor
Same as Diesel
Sensor Mounted on Air Inlet Tube
Revised Date 45
Engine Sensors
Oxygen Sensor
Measures Oxygen Content in Exhaust
Mounted in Exhaust Pipe After Turbocharger
SRS / TRS Sensors
Same as Diesel
Mounted in Front Gearcase
Knock Sensor
Reacts to Engine Knock or Ringing
Sensor Mounted on Left Side Cylinder Block
Revised Date 46
Gas Engine Unique MPSI Reader
Parameters
Gas Valve
Feedback Signal Indicating Gas Valve (PSV) Position
Full Range 0-100%
Normally Around 40-70%
TPS
Throttle Position Sensor
Foot Pedal Position - Same as Diesel
Full Range 0 - 100%
Throttle Plate
Air System Throttle Plate Position
Ranges From 0 - 100%
Revised Date 47
Parameters
Fuel TMP
Fuel Temperature at Inlet to Fuel Mixer
Units are Degrees F
Fuel PSR
Fuel Inlet Pressure at Inlet to Impco Regualtor
Units are PSIA
Air Inlet PR
Pressure or Vacuum in Intake Manifold
Units are PSIA
Revised Date 48
Parameters
Baro PSR
Current Barometric Pressure
Units are PSIA
Exhaust TMP
Exhasut Gas Temperature at Outlet of Turbocharger
Units are Degrees F
Exhaust Gas AFR
Exhaust Gas Air Fuel Ratio Expressed as Lamda
Unit-less
Ranges from 1.0 (Rich) to 1.55 (Lean)
Revised Date 49
Parameters
Loop Status
Indicates if Control System is in Open or Closed Loop
Status
Due to Software Issues, Do Not Use at This Time
Knock Volts
Indication of Knock Sensor Output to DDEC ECM
Knock Control
Indication of Whether the Engine is Taking Preventative
Action in Response to Knock Sensor Input
Revised Date 50
Engine Modules
Igniter Module
Interface Between DDEC and Spark Plug Coils
Oxygen Sensor Module
Interface Between DDEC and Oxygen Sensor
SNEF Module
Interface Between DDEC and Knock Sensor
Revised Date 51
Series 50G / 60G Engine Components
Revised Date 52
Series 50G Transit Bus Engine
Coil Over Plug
Ignition Coils
Insulated
Exhaust
Manifold
Fuel Mixer
Water Cooled Automatic Tensioner

Turbocharger for 50 DN
Center Section Alternator Belt
Insulated
Turbine
Housing
Revised Date 53
Series 50G Transit Bus Engine
Low Pressure Fuel Pressure
Regulator Sensor
PSV
Oxygen Sensor
Module
Ignition System
Module
Adaptorless
Air Compressor
DDEC IV
ECM
Knock Signal
Processor
OEM Pigtail
Interfaces
Revised Date 54
Basic Engine Unique Parts
Series 50G / 60G Cylinder Kit
Cylinder Kit
Shorter Connecting Rod
Unique Gas Engine Piston
Plasma Coated Fire Ring
Rectangular Style Compression Ring
Top Liner Cooling
Revised Date 56
Series 50G /60G Connecting Rod
Revised Date 57
Series 50G / 60G Liner Cooling
Top Liner Cooling (TLC)

Reduces Fire Ring
Temperature
Reduces Ring & Liner Wear
Extends Ring Life
Reduces Maintenance Costs
Maximizes Life to Overhaul LINER COOLING
CHANNEL
COOLING
CHANNEL
INLET NOTCH COOLING
IN BLOCK CHANNEL
EXIT HOLE
MAIN COOLANT
STREAM
Revised Date 58
Series 50G / 60G Cylinder Head
Cylinder Head
Hardened Valve Seats
& Valve Stems
Optimized Valve Seat Angle
Improved Material Exhaust
Valves & Guides
Low Flow Valve Stem Seals
Stainless Steel Spark
Plug Adaptors
Revised Date 59
Series 50G / 60G Camshaft
Revised Date 60
Series 50G /60G Overhead
Revised Date 61
Series 50 Balance Shaft
Revised Date 62
Manifold Wrap
Revised Date 63
Series 50G / 60G Engine Controller
DDEC IV
Provides Control for Fuel,
Air & Spark Systems
Lower Emissions
Optimum Fuel Usage
Good Performance
Acceleration
Driveability
Knock Sensor
Reduces the Probability of
Costly Engine Damage
Complete Diagnostics &
Troubleshooting
Easy to Diagnose Problems
Minimal Downtime
Low Maintenance Costs
Revised Date 64
Commonality With Diesel
Major Components That are Shared

Block
Cooling System
Cylinder Kit Parts
Exception, Dome and Rings
Flywheel, Except Genset
Housings, Flywheel
Gear Train and Front Cover
Lubrication System
Revised Date 65
Series 50G / 60G Fuel Control Systems
Coach Fuel Control System
Revised Date 66
Series 50G / 60G Coach Fuel System
Venturi Design to Provide Correct Air / Fuel

Ratio Over All Speeds & Loads
DDEC Bias to Alter Air / Fuel Ratio (Rich or Lean)
Based on Transient Conditions
Feedback via Engine Exhaust to Match
Desired and Actual Air / Fuel Ratios
Components Divided into Three Areas
Open Loop, Closed Loop and Fuel Supply
Revised Date 67
Open Loop Components
Low Pressure Regulator
Pulse Width Stepper Valve (PSV)
Venturi / Mixer
Closed Loop Components
Oxygen Sensor
Oxygen Sensor Interface Module
Fuel Supply Components
Primary Regulator
Low Pressure Fuel Control Solenoid
Revised Date 68
Revised Date 69
Engine Mounted Above
Intake Manifold
Referenced to Air Inlet
Depression
Coolant Heated
No Adjustment
Revised Date 70
Electronic PSV
DDEC Interface
to Control Air / Fuel Ratio
Fully Electronic Fuel
Control Valve
Incorporates DDEC
Diagnostics
No Maintenance Required
Revised Date 72
Venturi / Mixer
Similar to a Carburetor
Balanced To Provide Correct
Air /Fuel Ratio
No Moving Parts
Revised Date 73
Throttle
Intake Elbow
Mixer / Venturi
Air
from
CAC
PSV
Fuel
Inlet
Fuel Balance
Line
Air / Fuel
Fuel Transfer to Engine
Tube

Revised Date 74
Oxygen Sensor
Wide Range O2 Sensor
to Monitor All Speeds &
Loads
No Calibration Required
Minimal Drift
Excellent Durability
Results to Date
Revised Date 75
Converts O2 Sensor
Output into DDEC Input
Provides Sensor
Heater Control
Self Contained - Engine
Mounted
Revised Date 76
Primary Fuel Pressure Regulator

Manufactured by ITT Conoflow
Designed for Heavy-Duty
Applications
Coolant Heated to Prevent
Freeze-Up
Built-In Pressure Relief Device
(PRD)
Supplied & Warranted by DDC
Revised Date 77
Low Pressure Fuel Control Solenoid

Manufactured by
Honeywell-Skinner
Provides Positive Fuel Shut-Off
to Engine
DDEC Digital Output Controlled
12 or 24 Volt Versions Available
Supplied & Warranted by DDC
Revised Date 78
Series 50G / 60G Exhaust Temperature
Sensor
Monitors Turbine Outlet
Temperature
Triggers DDEC Engine
Shutdown if
Overtemperature is
Detected
Fast Response
Revised Date 79
Barometric Pressure Sensor
Revised Date 81
Air and Fuel Temperature Sensor
Revised Date 82
Series 50G / 60G Transit Bus Engine
Closed Loop Fuel System
Other DDEC Engine
Protection Sensors & Signals
Interface
Module
Baro
Sensor DDEC IV
Charge Intake Pressure
Air Gas & Temperature
Cooler Temperature
Turbo
Compressor
Air
Intake
Venturi
Mixer ENGINE
ENGINE
Electronic
Control Valve Throttle
(PSV) Actuator
Gas to Engine
Exhaust
O2 Sensor
Gas
Pressure
Input Gas Exhaust
Pressure Temperature
DDEC (70 - 120 PSIG) Sensor
Zero Pressure Controlled
Regulator Solenoid Valve
Revised Date 83
Series 50G/ 60G Fuel Control System
Coach Fuel Control System
Troubleshooting
Revised Date 84
Series 50G / 60G Fuel Control Systems
Generator Set Fuel Control System
Revised Date 85
Series 50G / 60G Genset Specifications

Engine Type 4-Cycle 4-Cycle
(Dedicated Fuel) (Dedicated Fuel)
Fuel Control DDC Low Pressure DDC Low Pressure
Ratings Engine Hp 60 Hz 225 HP - 300 HP 340 HP - 450 HP
Engine Hp 50 Hz N/A 230 HP - 400 HP
Revised Date 86
Specific Features of DDC
Natural Gas Gensets
Fuel Inlet Pressure Range 5"- 20" H2O
Venturi Type Fuel System Design
DDEC Control of Fuel, Air & Spark
No-Maintenance Fuel Regulator
Full DDEC System Diagnostics
Excellent Transient Response
Revised Date 87
Series 50G/60G Generator
Set Fuel System
Fuel is Introduced into the Air Upstream of
Turbocharger
Utilizes Similar Concept / Components as Coach
Fuel System
DDEC Controlled
Venturi Mixer
PSV for DDEC Fuel Control
Open Loop Design
No Oxygen or Barometric Sensor
Revised Date 88
Series 50/60G Genset Gas Engine
Insulated Exhaust
Manifold & Turbine
Housing
Air Inlet Water Cooled

Tube Turbocharger
Center Housing
Fuel Mixer / Venturi
PSV Control Valve

Fuel Line
Fuel / Air
Balance Fuel Regulator
Lines
Revised Date 89
Mixer Inlet, GENSET
Revised Date 90
Mixer & PSV, GENSET
Revised Date 91
DDC Pulsewidth Stepper Valve
Electronic PSV
DDEC Interface
to Air / Fuel Ratio
Control
DDEC Diagnostics
Revised Date 92
Series 50G DDC Fuel System
Mixer / Venturi
Inherently Balanced
to provide Correct
Air /Fuel Ratio
No Moving Parts
Revised Date 93
Series 50/60G Electronic Throttle
Full Control by DDEC

Idle & Governor
Speed Control
No Internal / External
Adjustments
Auto Calibration
During Startup
Diagnostic Fault Protection
Fail Safe Closed Feature
Revised Date 94
Regulator, Low Pressure
Revised Date 95
GENSET, Front
Revised Date 96
GENSET, Right Bank
Revised Date 97
GENSET, Left Bank
Revised Date 98
Flywheel, GENSET
Revised Date 99
MAP Sensor
Revised Date 100
Air and Fuel Temperature Sensor
Revised Date 101
Natural Gas Genset Fuel System
OTHER DDEC
ENGINE PROTECTION
SENSORS & SIGNALS
INTAKE PRESSURE
& TEMPERATURE
DDEC KNOCK
FUEL TEMP. CHARGE
CHARGE SENSOR
SENSOR AIR
AIR IGNITION
COOLER COILS
TURBO
VENTURI COMPRESSOR
MIXER
AIR
INTAKE
THROTTLE
ENGINE
ENGINE
BOOST ACTUATOR
PRESSURE LOW PRESSURE
ELECTRONIC REGULATOR
CONTROL VALVE EXHAUST
INPUT GAS
PRESSURE
5- 20 H2O
TURBO
TURBO
WASTEGATE
WASTEGATE
VALVE
VALVE
Revised Date 102
Series 50G / 60G Fuel Control System
Generator Set Fuel Control System
Troubleshooting
Revised Date 103
Series 50G / 60G
Air System
Series 50G / 60G Electronic Throttle
Full Control by DDEC

Idle & Governor
Speed Control
No Internal / External
Adjustments
Auto Calibration
During Startup
Diagnostic Fault Protection
Fail Safe Closed Feature
Revised Date 105
Series 50G / 60G Turbocharger
Turbocharger
Water Cooled Center Section
Insulated Turbine Housing
Dual Poppet Wastegate
with Heavy-Duty Arm
Long Can Wastegate Actuator
Recirculation Valve
Strengthened Compressor Backplate
V Band Turbine Housing
Revised Date 106
Wastegate Actuator
Revised Date 107
Wastegate Poppets
Revised Date 108
Wastegate Calibration
Revised Date 109
Turbocharger, GENSET
Revised Date 110
Air System
Turbocharger Wastegate Settings

Series 50G SOP Through 96 Build
Short Can 18.5 Psig @ .040
Series 50G 97 and 98 Production Build
Long Can 21.0 Psig @ .040
Series 60G Coach Engines
Long Can 24.0 Psig @ .040
Series 60G Truck Engines
Series 50G Truck Engines
Revised Date 111
Series 50G / 60G Closed Breather
Dirty Air is Routed from

Rocker Cover Outlet
Special Baffling Minimizes
Oil Carryover
Self Contained
Coalescing Filter
Water Condensate is Drained
Clean Air is Routed
to Intake System
Revised Date 112
Series 50G / 60G Air Control System
Troubleshooting
Revised Date 113
Series 50G/ 60G
Ignition System
Series 50G / 60G
Coil Over Plug Ignition System
Revised Date 115
Series 50G / 60G Ignition System
Coil Over Plug Ignition

System
Higher Voltage to Spark
Plugs
Electronically Controlled
No Spark Plug Wires
No Adjustments or
Maintenance
Long Spark Plug Life
Revised Date 116
Series 50/60G Ignition System
Full Electronic Control by DDEC

Automatic Compensation
(Cold Start, Acceleration, Knock)
No Adjustments or Maintenance
No Moving Components
Integral Ignition Coils
Individual Coils for Each Cylinder
Mounted into Rocker Cover
No Secondary Spark Plug Wires
Revised Date 117
Series 50G / 60G Spark Igniter Module
Revised Date 118
Spark Plug Tube, Upper
Revised Date 119
Spark Plug Tube, Lower
Revised Date 120
Spark Plug
Revised Date 121
Series 50G 60G Ignition Control System
Troubleshooting
Revised Date 122
Cylinder Cut-Out
Revised Date 123
Series 50G / 60G
Other Engine Systems
Knock Sensor
Revised Date 125
SNEF Module
Revised Date 126
Sensor Harness
Revised Date 127
DDEC System
Error Codes and Troubleshooting
Revised Date 128
DDR Reader
Revised Date 129
DDEC Tools
Revised Date 130
Vehicle Systems
Fuel Supply
High Pressure Regualtor
High Pressure Fuel Solenoid
Filters
Coalescing
Low Pressure Fuel Solenoid
Fuel Lines
Vehicle Fuel Systems
Revised Date 132
Regulator, High Pressure Fuel
Revised Date 133
Typical High Pressure Fuel Control
Solenoid
Revised Date 135
Low Pressure Fuel Solenoid
Revised Date 136
CNG Vent Lines
Revised Date 138
CNG Fuel System
Revised Date 139
LNG Fuel System
Revised Date 140
LNG Tank
Revised Date 141
LNG Vaporizer
Revised Date 142
Power Requirements
Throttle Power Supply
Throttle Actuator Power Supply Recently Changed

SOP Thru 97 Build
Power is Supplied by DDEC
98 Production
DDEC Controls a Solid State Relay From a 12V or 24V Source
Revised Date 144
Throttle Relay
Revised Date 145
Unique Requirements
Engine Oil and Coolant
Revised Date 146
Oil Requirements
DDC Tested Engine Oils
Mobil Super Geo SAE 15W - 40

Exxon Estor SAE 15W - 40
Note: Refer to Series 50G / 60G Engine Operator

Guides for More Information
Revised Date 147
Coolant Requirements
Refer to DDC Bulletin 7SE 298

Coolant for Detroit Diesel Engines
Coolant, Water and Antifreeze Specification
Inhibitor Requirements
Especially the Phosphorous Content
Coolant Filters
General Cooling System Recommendations
Important to Follow on the Series 50G/60G Engines
Revised Date 148
Series 50G Maintenance Intervals
Urban Coach Service
Component / Item Maintenance Required
Replace Every 6,000 Miles &
Lubricating Oil & Filter
Check Oil Level Daily
Drain Daily & Replace Element
Coalescing Fuel Filters
Every 6,000 Miles
Throttle Body & Actuator Inspect Every 6,000 Miles
Spark Plugs Replace Every 24,000 Miles
Spark Plug Boots Inspect Every 24,000 Miles
Turbocharger & Wastegate

Inspect Every 36,000 Miles
Calibration
Valve Lash Inspect Every 36,000 Miles
Revised Date 149
Summary and Wrap-Up
Revised Date 150
Series 50G/60G Natural Gas Engine
Revised Date 151

Series 50-60 Training

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Series 50-60 Training

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Detroit Diesel

Series 50G / 60G

To Provide Proven Alternate Fueled Engines in

Alternative Fuel Engineering Started 1970s

Natural Gas Fueled

Series 50G Evolved from the 8.5 L Series 50 Diesel

Series 50G Coach (GFI Fuel System) Aug 94

Major Components That Are Shared

Venturi Type Fuel System Design

DDEC Control of Fuel, Air & Spark

No-Maintenance Fuel Regulator

Full DDEC System Diagnostics

Excellent Transient Response

Series 50G Series 60G

Series 50G 275 HP @ 2100 RPM Transit Bus No

275 HP @ 2100 RPM

225 - 300 HP @ 1800 RPM Gen Set Now

340 - 450 HP @ 1800 RPM Gen Set Now

230 - 400 HP @ 1500 RPM Gen Set No

Rating 275 HP - 890 FT-LB NOX + NMHC G/HP-HR CO PM

Los Angeles / San Diego

DDC SPECIFICATIONS Minimum Maximum

Ethane 0 6.0 (%)

Propane 0 1.7 (%)

Butane 0 0.3 (%)

CO2 + Nitrogen + Oxygen 0 4.5 (%)

Hydrogen 0 0.1 (%)

Motor Octane Number 115 Minimum

DDC SPECIFICATIONS Minimum Maximum

Ethane 0 0.5 (%)

Propane 0 0.0 (%)

Butane 0 0.0 (%)

Nitrogen 0 2.0 (%)

Hydrogen 0 0.0 (%)

Motor Octane Number 130 Minimum

1. BTUs/ Gallon 140,000 136,000 28,000 91,000

2. Flame deg F 3,730 3,590 3,423 3,423

3. Octane 0 89 115 130

4. Auto Ignition deg F 540 428 1,150 1,150

Natural Gas is Lighter Than Air

Vapors formed from LNG

Absolute Air Inlet Pressure Sensor

Fuel Delivery Pressure Sensor

Oil Temperature Sensor

Water Cooled Automatic Tensioner

Unique Gas Engine Piston

Plasma Coated Fire Ring

Rectangular Style Compression Ring

Top Liner Cooling

Top Liner Cooling (TLC)

Major Components That are Shared

Coach Fuel Control System

Venturi Design to Provide Correct Air / Fuel

Low Pressure Regulator

Primary Fuel Pressure Regulator

Low Pressure Fuel Control Solenoid

Coach Fuel Control System

Generator Set Fuel Control System

Series 50G Series 60G

Venturi Type Fuel System Design

DDEC Control of Fuel, Air & Spark

No-Maintenance Fuel Regulator

Full DDEC System Diagnostics

Excellent Transient Response