Property of American Airlines

Size: px

Start display at page:

Download "Property of American Airlines"

Darrell Young
5 years ago
Views:

1 Emission-Related Installation Instructions EDI FORD 2.5L (MSG425) Failure to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40 CFR (b)), and is subject to fines or other penalties as described in the Clean Air Act. "These instructions are intended to give the installer of the engine all of the information that is necessary to properly install the engine and related components into the equipment chassis. The United States Environmental Protection Agency (EPA) requires that the manufacturer of the engine provide installation instructions to the equipment manufacturers as defined in the Code of Federal Regulations (40CFR )." "The EPA and CARB require every certified industrial engine to have a closed crankcase and no crankcase emissions may be vented to the atmosphere as described in the Code of Federal Regulations (40CFR )." The following instructions must be strictly adhered to when assembling a Ford MSG-425 engine. Table of Contents Section Page # Bill of Material (BOM) 2 Gasoline Fuel System 3 PCV System 6 Heated Oxygen Sensor 6 Catalyst Muffler 8 Catalyst Monitor Sensor 9 Gaseous Fuel Systems 10 Intake Depression / Exhaust Backpressure 14 GCP, Fuse Box, Harness 16 Malfunction Indicator Light (MIL) 17 Emission Control Information 17 Part # Originator: KL Page 1 of 16 Date Issued:

2 Bill of Material (BOM): Description Part # FUEL PUMP FUEL BLOCK FILTER ASSY-FUEL 9A011 TUBE - FUEL SUPPLY 9K541 ADAPTER-FUEL PUMP 9416 CLAMP - FUEL TUBE 9C334 MODULE - GCP HARNESS - ENGINE SENSORs - HEGO (Pre and Post Catalyst) PLUG - M18-1.5x12 (CATALYST MUFFLER OUTLET) W CATALYST - MUFFLER ASY INSERT - BUNG 9J467 DEPR DEPR Fuel Inlet (LP) DEPR Fuel Inlet (NG) MIXER MIXER ADAPTER Originator: KL Page 2 of 16 Date Issued:

3 EPA Gasoline Fuel System Requirements: System must be operated with gasoline fuel meeting 87 A.K.I. specifications. Equipment using this certified engine is subject to fuel line permeation evaporative emissions requirements. Only metal or nonmetallic fuel lines that meet the Category 1 specifications for permeation in SAE J2260 may be used. Equipment using this certified engine is subject to fuel tank permeation requirements. Only metal fuel tanks or coextruded high-density polyethylene fuel tanks with a continuous ethylene vinyl alcohol barrier layer (with not more than 40 molar percent ethylene) making up at least 2 percent of the fuel tank's overall wall thickness may be used. All fuel tanks must use a tethered or self-closing gas cap on a fuel tank that stays sealed up to a positive pressure of 24.5 kpa (3.5 psig); however, they may contain air inlets that open when there is a vacuum pressure inside the tank. All fuel tanks must use only the following: 1. Nonmetal gaskets with fuel caps made from low-permeability materials 2. Nonmetal gaskets and fuel caps that are not made from low-permeability materials with a total exposed surface area less than 0.25 percent of the total inside surface area of the fuel tank 3. Fuel caps directly mounted to the fuel tank with the surface area of the fuel cap less than 3.0 percent of the total inside surface area of the fuel tank. Use the smallest inside cross-sectional area of the opening on which the cap is mounted as the fuel cap's surface area. Equipment using this certified engine is subject to running loss evaporative emissions requirements. Position the fuel tank away from heat sources like the engine, cooling system, and catalyst and exhaust system. Liquid fuel in the fuel tank may not reach boiling during continuous engine operation an all equipment using this certified engine at an ambient temperature of 30 C. Note that gasoline with a Reid vapor pressure of 62 kpa (9 psi) begins to boil at about 53 C at atmospheric pressure. Please follow these notes while assembling this gasoline fuel system: 1) All fuel lines incorporated into equipment must either be metallic or must conform to the Category 1 specifications in SAE J2260 for nonmetallic fuel lines. Existing users of high-pressure hose (9K541) will be able to continue with the use of this line for the entire system. Cut high-pressure hose -9K541- to suit from the bulk hose provided. Minimum bend radius for high pressure hose is 3.0 inches. If exceeded the hose will kink and must be removed and replaced with new hose. Warning: if hose is not removed failure will occur in service. Two additional clamps are provided in case of Originator: KL Page 3 of 16 Date Issued:

4 misbuild. High pressure hose routing must be clear and not rub or chafe on any obstructions (Minimum clearance 0.62 inches.) 2) Clamps (9C334) on high pressure hose (9K541) must be crimped with Oetiker pincers, model 1098i or model 1099i. Clamps must be positioned properly, after clamp is crimped, a gap should be seen in the ear of the clamp, some spring back is normal. Check each clamp after crimping. Pinchers are available from Oetiker, inc. (248) , or through Grainger (Item #4E607 or #4E608). 3) All fuel line fittings must be automotive grade. Typically accepted automotive grade fuel line fittings incorporate quick connections with a rubber o-ring at the orifice. 4) A tethered or self-closing gas cap must be used. The fuel cap should incorporate a purge valve that stays seated up to a positive pressure of 24.5 kpa (3.5 psig) and a vacuum pressure of 0.7 kpa (0.1 psig). Install adapters and clamps -9C334- (see notes above) to the appropriate lengths of high pressure fuel hose -9K541- Figure 1: Clamped fuel line. Install fuel filter before the fuel pump Pay attention to the filter's flow direction. Install an adapter and clamp (9C334) to an appropriate length of high-pressure hose. This hose will be the systems return hose from the fuel sensor block to the tank. Warning: Do not use low-pressure rubber hose for any part of the gasoline system. Mount pump as close as possible to tank, away from external heat sources, in a horizontal plane, or if mounted on an angle, the outlet must be above the inlet. Suction specification is 4.35 PSI or 120 " of H 2 0. Pump should not be mounted in high temperature environments to prevent cavitation vapor lock conditions. Outlet end is where the electrical connectors are located. Mount fuel block inches from the fuel pump. Block should be mounted on a secure surface with the sensor side of the block on the top, 0 degrees is preferred, can be angled up to 15 degrees. Refer to figure 2 below for the orientation of the fuel block in relation to the other components. Originator: KL Page 4 of 16 Date Issued:

5 Fuel Block To Engine Filter Pump Fuel Supply From Tank Can be angled no more than 15 Return to Tank Return Inlet Figure 2: Fuel component layout. Outlet Check for leaks at start-up with a soapy water solution. If leaks occur replace the affected circuit. Install the electrical connections to the fuel pump The negative terminal of the pump needs to be connected to pin 18 and the positive terminal needs to be connected to Pin 5 of the 42-pin body side harness. It must be installed this way as it is controlled via the ECM with Pulse Width Modulation. The fuel sensor block is wired to the main engine harness via jumper harness The supplied fuel fittings and hoses are electrically conductive components. They ensure a path to ground and the dissipation of any static electric charge. Any deviation from these components must be approved by Engine Distributors Inc. engineering and must duplicate the continuous path to electrical ground. Without this conductive feature, pinhole leaks may form in the fuel line/hose, as the buildup electrical charge seeks ground through the wall of the fuel line/hose to nearby objects Originator: KL Page 5 of 16 Date Issued:

6 PCV System: The PCV valve should already be installed on your engine. There should be a line connecting the PCV valve with the upper intake manifold. The valve cover must be vented to filtered air. Adapter 4S4Z 9E499 AA can be utilized to reduce the size of the ventilation line. Heated Oxygen Sensor Location: The Heated Exhaust Gas Oxygen Sensor (HO2S) is an important part in controlling the air-to-fuel ratio of the engine. The HO2S measures the oxygen content in the exhaust gas and relays that information to the engine control module. If the HO2S interprets that there is excess oxygen in the exhaust, a lean reading, the control module will richen the air-fuel mixture. Similarly, if a low oxygen level is sensed, the engine running rich, the control module will lean out the air-fuel mixture. The HO2S location is extremely important. NOTE: Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates federal law and subjects the installer to fines or other penalties as described in the Clean Air Act. The H02S sensor needs to be tightened to a torque of Nm. A bung insert -9J467- is needed to mount the HO2S sensor. It is recommended that the bung insert be installed as shown in the picture below. The centerline of the HO2S can be installed at any inclination at or above 10 of the horizontal plane. Recommended position would be straight up (90 ) to prevent the buildup of condensation on the sensor. This refers to both the pre and post cat sensors. See Figure 3. Figure 3: Heated oxygen sensor orientation to mounted pipe. Originator: KL Page 6 of 16 Date Issued:

The center of the bung must also be located within eight (8) inches of the exhaust flange in the exhaust pipe. If a bend is used in this 8" run of pipe, the center of the bung must be a distance of 1.

7 The center of the bung must also be located within eight (8) inches of the exhaust flange in the exhaust pipe. If a bend is used in this 8" run of pipe, the center of the bung must be a distance of 1.5 times the diameter of the pipe from the outlet (end) of the bend. It is important to mount the bung in a straight run of pipe. engine. See Figure 4. Figure 4: HO2S Sensor location. The immediate area surrounding the grommet of the HO2S sensor should not exceed 392 F (200 C.) Figure 5: HO2S grommet orientation. Originator: KL Page 7 of 16 Date Issued:

8 Catalyst/Muffler Location: A very important component in a low emission engine is the catalytic converter. Engine Distributors Inc. utilizes a three-way catalytic converter. For this type of catalytic converter to work properly, the following two criteria must be met: 1.) The air-to-fuel ratio must oscillate between rich and lean. 2.) The catalyst substrate (also known as a brick, located inside the converter shell) must be kept hot. Mounting the catalytic converter in the proper location will control the substrate temperature. To quickly heat up the catalyst and to ensure an effective operating temperature, the center of the substrate must be located a minimum of 12 inches and a maximum of 65 inches downstream of the exhaust manifold flange. 2 inch diameter pipe should be used before the catalyst. This measurement is made along the length of the exhaust pipe and must take all bends and curves into consideration. Figure 6 depicts an example catalytic converter setup. Figure 6: Catalytic converter mounting. NOTE: EDI suggests that the pipe between the catalyst and muffler or the pipe after the catalyst muffler is made of 409 stainless steel or equivalent material that will last for the engine's useful life (5000 hours or 7 years, whichever comes first). This pipe must be supplied and warranted by the OEM. Be aware that the catalyst internal temperatures may exceed 1600 degrees F. All joints must be leak free throughout the useful life of the engine. Use good engineering judgment when designing the exhaust system for your equipment. Because the catalyst can reach excessive temperatures during normal operation, care should be taken during the installation. Do not install catalyst near flammable material. Protect equipment components with heat shielding. Install catalyst in an open area with good air circulation. Originator: KL Page 8 of 16 Date Issued:

9 Catalyst Monitor Sensor: In order to ensure the proper operation of the catalyst during its lifetime, a catalyst monitor sensor is used. The catalyst monitor sensor is basically a heated exhaust gas oxygen sensor (HO2S). When using the catalyst muffler, the catalyst monitor sensor must be installed in one of the two sensor bungs located in the catalyst muffler outlet pipe. Torque sensor to Nm. Plug the bung that is not used with plug -W using a torque of Nm. When running with a catalyst muffler, there must be at least 10.25" of exhaust pipe attached to the catalyst muffler outlet. Inlet Outlet Figure 7: Catalyst Monitor Sensor mounting. Exhaust pipe material should be stainless 409 or equivalent. All joints must be secured in a manner that does not leak over the duration of useful life of the engine (3500 hours or 5 years, whichever comes first). Care should be taken to ensure that rain, snow, etc. can not enter the exhaust pipe and contact the sensor. This will damage the sensor. Originator: KL Page 9 of 16 Date Issued:

10 Gaseous Fuel Systems The MSG425 gaseous fuel systems engines will include a mixer with a DEPR (Direct Electronic Pressure Regulator). On LPG a vapor regulator is included as well. LPG Fuel System Follow these Vapor Regulator installation instructions when operation on LPG. Orientation: DEPR must be directly mounted to mixer in the upward direction, refer to figure 9 for maximum angles. Looking at the front side of the vapor regulator 0 degrees is preferred, can be tilted up to 15 degrees in any direction, refer to figure 8 below. Mounting: Must utilize all both 6mm mounting points, must utilize vibration isolators if engine mounted. Vibration levels of EPR must not exceed 8 G at any frequency. A clearance of at least 20mm around unit must be maintained. Location: Fuel outlet must not be more than 25 mm (1") below mixer inlet, vapor hose length must not exceed 700mm (27.5"). Take care to eliminate drooping and sharp bends in the hose. Must use LPG rated fuel hose. Do not place the regulator higher than the radiator, if it is higher verify that it will have adequate coolant flow. Reference port must be connected to a clean source of air. Fittings: Fuel outlet ¾ straight, coolant 5/8 straight or 5/8 x 70 degree Up/Down Left/Right Figure 8: Vapor Regulator mounting orientation. Originator: KL Page 10 of 16 Date Issued:

LP Vapor Figure 9: DEPR mounting orientation. LP Vapor the LPG vapor regulator is not required, use the 3/4" NPT threaded fuel inlet fitting on the DEPR.

Customer must provide proper pressure regulators from fuel tank to DEPR to achieve the recommended pressures. DEPR orientation from figure 9 still applies.

11 LP Vapor Figure 9: DEPR mounting orientation. LP Vapor the LPG vapor regulator is not required, use the 3/4" NPT threaded fuel inlet fitting on the DEPR. The lock off valve (low pressure) should be mounted directly to this fitting. Maximum pressure to the DEPR is 14 inches of H2O, recommended pressure is 11" H2O. Customer must provide proper pressure regulators from fuel tank to DEPR to achieve the recommended pressures. DEPR orientation from figure 9 still applies. Natural Gas Fuel System For NG the DEPR inlet fitting is 3/4" NPT threaded fuel inlet fitting on the DEPR. The lock off valve should be mounted directly to this fitting. The maximum pressure to the DEPR is 14 inches of H2O, recommended pressure is 11" H2O. Ensure that the supply pressure does not exceed this. DEPR orientation from figure 9 still applies. Compressed Natural Gas (CNG) Fuel System On CNG the DEPR inlet fitting is 3/4" hose fitting. The high pressure lock off valve should be mounted directly to the last pressure regulator before the DEPR. The maximum pressure to the DEPR is 14 inches of H2O, recommended pressure is 11" H2O. Ensure that the supply pressure does not exceed this. DEPR orientation from figure 9 still applies. Originator: KL Page 11 of 16 Date Issued:

12 Lockoff Solenoid Requirements In order to reduce the possibility of backfires, a lockoff must be used and must be connected to the lockoff connector in the engine harness, In reference to the fuel system the lock off should be located between the fuel tank and the vapor regulator, NOT between the vapor regulator and the mixer. Preferable location would be directly mounted to the vapor regulator to prevent fuel from leaking through the pressure regulator into the intake manifold while the engine is not running. On NG it is recommended to mount the lock off directly to the DEPR. Torque the lockoff to Nm ( ft-lbs). Lockoffs recommended: EDI recommends the following electric lock offs for LPG, CNG and NG. The lockoff must operate at 12 volts with a current draw of approximately 1 ampere. LPG/CNG; no filter: WOODWARD - N (Electric 12V DC lockoff) LPG with filter: ASCO (Electric 12V DC lockoff) Low pressure NG: ASCO 8215G030 (Electric 12V DC lockoff) The electric lockoff wire leads must be terminated at a Metri-pack electrical connector. This 2-pin connector from the lockoff will mate to the main engine harness. The part #'s are as follows. Lockoff valve connector kit: Part # A 2-pin connector, 2 Terminals, Cable seal, Terminal Lock: Installed on a lockoff valve this will directly connect to the engine harness The GCP controls the opening and closing of the lockoff so that as a shut down is commanded, the lockoff is closed, but the ignition system continues to operate to burn off unburned fuel in the manifold. This will cause longer than usual start times, because the manifold must fill up with fuel again before the engine will fire. This will also cause the engine to run for one to four seconds after the key is turned off. The default GCP setting of "Run on" time is three seconds. Originator: KL Page 12 of 16 Date Issued:

13 Intake Depression and Exhaust Backpressure: To ensure that all low emission engines perform to their rated characteristics, it is important that inlet depression and exhaust backpressure on the final product satisfy the following conditions (unless otherwise specified in the Owner s Manual): Intake Depression 1.) Maximum allowable restriction of the installed system. For maximum power this should not exceed 5 H 2 O (1.24 kpa). Exhaust Backpressure 1.) Maximum allowable exhaust restriction, regardless of load, is 6 Hg (20.32 kpa). This value should be measured no more than one (1) inch downstream of the exhaust manifold flange. 2.) Exhaust backpressure should be kept as low as possible. Factors which increase backpressure are: Exhaust pipe diameter too small. Exhaust pipe between manifold and mufflers too long. Excessive number of sharp bends in system. High muffler resistance. Inlet Restriction and Exhaust Backpressure Measurements It is important to determine the full range of inlet restrictions (IR) and exhaust backpressures (BP) over the entire engine s operating range. This may be accomplished by doing the following: 1.) With stock air cleaner and catalyst installed, run WOT from 3200 RPM to 1000 RPM in 100 RPM increments and record IR and BP readings. The readings must be within the specified limits. Originator: KL Page 13 of 16 Date Issued:

14 Figure 12: Intake and exhaust volumes. Originator: KL Page 14 of 16 Date Issued:

GCP Installation: The GCP should be mounted with the connectors facing sideways or down.

forces in excess of 3 Gs. The GCP must not be mounted in any orientation where the connectors can be subjected to direct pressure washing.

Figure 13: Global Control Platform (GCP) Fuse Relay Box Installation Instructions The power distribution box has two drain holes in the bottom of it.

15 GCP Installation: The GCP should be mounted with the connectors facing sideways or down. If the GCP is mounted on the engine, you must use rubber mounting isolators and test this application to ensure the GCP is not submitted to vibration forces in excess of 3 Gs. The GCP must not be mounted in any orientation where the connectors can be subjected to direct pressure washing. Refer to the fuse relay box pictures shown in figure 14 for proper mounting. Figure 13: Global Control Platform (GCP) Fuse Relay Box Installation Instructions The power distribution box has two drain holes in the bottom of it. It must be installed with the holes pointing downward, so that any moisture that may collect inside the box will drain out of the holes in the bottom. Figure 14: Fuse box mounting. Install the Body Side Harness. Refer to the Body Side Harness Installation instructions. Originator: KL Page 15 of 16 Date Issued:

Malfunction Indicator Light (MIL) The function of the MIL is to indicate when the engine control system is measuring conditions that may cause the not to operate properly or cause damage to the

16 Malfunction Indicator Light (MIL) The function of the MIL is to indicate when the engine control system is measuring conditions that may cause the not to operate properly or cause damage to the engine. The light will also be lit when the engine has power to the ignition circuit but is also in a non-running state. The MIL must mount in a location that is readily visible to the operator. The light may be any color except for red and must display Check Engine or Service Engine Soon. You may use sound in addition to the light signal. The MIL is one of two ways to read Diagnostic Trouble Codes (DTCs) from the engine controller. The other way is to utilize the display software that is available through Engine Distributors Inc. Contact EDI for more information about the engine control display software. Emission Control Information If you install the engine is away the makes the engine s emission control information hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40 CFR Figure 15: Emission control label. IN-USE TESTING The U.S. EPA certification regulations for LSI engines require the engine manufacturer EDI to notify the equipment manufacturer that sampling of exhaust emissions must be possible after engines are installed in equipment and placed in service. If this cannot be done by simply adding a 20-centimeter extension to the exhaust pipe, you, as the equipment manufacturer, must demonstrate to EDI how to sample exhaust emissions in a way that prevents diluting the exhaust sample with ambient air Originator: KL Page 16 of 16 Date Issued:

WP06GNA INSTALLATION AND APPLICATION MANUAL

WP06GNA INSTALLATION AND APPLICATION MANUAL EMISSION-RELATED INSTALLATION INSTRUCTIONS FOR WP06GNA ENGINE NON-COMMERCIAL FUELS, NG, LPG & VPG Non-Emergency May 4, 2017 3100 GOLF ROAD, ROLLING MEADOWS,