Assembly and Maintenance

Directions For mechanical part of conversion kit for engine

CATERPILLAR 3406C TA
(Gas Supply Pressure up to 0,2 bars)

Gas train Mxx

User guide

August 2005 ComAp, spol. s r.o.

Prague, Czech Republic Světova 7, 180 00 Praha 8, Czech Republic
Copyright © 2004 ComAp s.r.o. Tel: +420 266790611, Fax: +420 266316647
Written by: Ing. Jaromír Machyček E-mail: info@comap.cz, www.comap.cz
 Table of Contents
Table of Contents........................................................................................................................... - 2 -
Introduction .................................................................................................................................... - 3 -
Group by Group Assembly ............................................................................................................. - 3 -
Gas Train and Natural Gas Supply............................................................................................. - 4 -
Controlling Equipment................................................................................................................ - 4 -
Gas Mixer .................................................................................................................................. - 5 -
Group by Group Connecting....................................................................................................... - 6 -
Boost Air Temperature After Intercooler Sensor………………………………………………………..- 7 -
Sensor of Exhaust Gases Temperature………………………………………………………………... - 7 -
Cam Shaft Position Sensor…………………………………………………………………………… ..- 8 -
Knocking Sensors ...................................................................................................................... - 9 -
Set-up .......................................................................................................................................... - 10 -
Gas Pressure Regulator Outlet Pressure………………………………………………………………- 10 -
Air/gas ratio control with solenoid valve GVI..ML……………………………………………………..- 10 -
Pressure Switch Switching Levels ............................................................................................ - 11 -
Compensating Wing Bolt Position ……………………………………………………………………..- 12 -
Maintenance ................................................................................................................................ - 13 -
Gas Filter................................................................................................................................. - 13 -
Gas Pressure Regulator........................................................................................................... - 13 -
Generally ................................................................................................................................. - 13 -
Warning ....................................................................................................................................... - 14 -

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 Introduction
The goal of this document is to help with success installation of mechanical part of delivery during conversion
to dual fuel operation of high speed engine Caterpillar 3406C TA. It consists of all mechanical parts assembly
directions and advices for carrying out of main tuning operation, which are concerned with mechanical part of
conversion kit and which affect to total system tuning. There are some basic maintenance commendations
and basic trouble-shooting in the end of this document. It is necessary to use following drawing for proper
exploitation of this manual:

- picture 1 Gas Train M32 (gas inlet 0,2 bar )

- picture 1a

Picture 1 – Gas train M32

Gas Train M32

5 Governors with solenoid valve
3 Solenoid valve for gas
7 Actuator – Throttle body
4 Filter
2 Hand valv

Plug for pressure switch of gas level

Succion Air – feedback connection
Mixer

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 Group by Group Assembly
Gas Train and Natural Gas Supply

Gas train is intended for natural gas conditioning and brings chance to close gas by manual or electrical
form. It consists (in gas flow direction) of:

- closing hand valve

- gas filter, there is a pressure switch to indicate gas supply competent pressure on gas filter body
- solenoid double closing valve
- gas pressure regulator with outlet feedback part with pressure switch to indicate proper function of
regulator
- actuator – throttle body

Proper assembled gas train is shown on the picture 1:

- Closing hand valve (item 2) is mounted between gas filter (item 4) and inlet pipe, take care on
gas filter orientation regarding to flow direction.
- On the second side is gas filter, by means of o-ring and four bolts and nuts, joined
solenoid closing valve for gas (item 3).
- This valve is then, by means of o-ring , four bolts and nuts , joined gas pressure governor with
solenoid valve (item 5).
- By means of o-ring, four bolts and nuts is joined outlet flange to the second side of gas pressure
governor.

- Outlet flange is then joined with outlet pipe.

-
Assembled gas train is by means of inlet pipe connected to natural gas supply (delivered piece of
pipe can be used). Complete gas supply designed position (if local built-in conditions doesn’t
intercept it) is shown at the picture 1. Gas train is supported by means of two clips and brackets .
Height of brackets can be modified to reach required height of gas train axe above floor (maximal
height is 1000 mm). Complete gas supply can be placed by analogy also on the second side of
genset.

Controlling Equipment will be fixed on the outlet flange of gas train (see picture 1a and chapter 1.2)

Controlling Equipment

The assembly, which consists of controlling and splitting equipment, is intended for controlling of
natural gas amount entering to the engine, splitting of this flow into the both banks of cylinders and
possibility to compensate this splitting regard to exhaust gases temperature equalizing.
The ATB SERIES integral throttle body electric actuator ( picture 2 ) is designed to control the air or
an air/fuel mixture to a gaseous-fueled engine. They are typically used to control an engine by
working in tandem with a conventional fuel mixer. The design baseline for the ATB SERIES 4
incorporates fast response, multi-voltage usage, and proven reliability to allow for efficient and more
precise control. The ATB SERIES actuator directly drives the throttle plate. Two internal return
springs provide for a normally closed valve for fail-safe operation. This insures that the throttle plate
returns to the minimum fuel position when the actuator becomes de-energized. ATB SERIES
actuators are also designed to accept system battery voltages of either 12 or 24 VDC and are
available with a throttle position feedback sensor.

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 ATB series
Electric Throttles

Picture 2

Gas Mixer

The function of gas mixer is to create a mixture, which is consists of natural gas and inletting air. By this
arrangement it’s not necessary to make a homogenous mixture directly in the mixer, because these
components will be intensively mix up during following passage thorough compressors of turbochargers.

picture 3

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- At first the original inlet manifold pipe between air filter and compressor is removed. Make a hole with
diameter of 33 mm into this pipe.
- Weld the pipe (item 4) into this hole. Keep the dimensions and orientation, which are shown at the
picture 2. On the second side of mixer, there is this air filter outlet overthrusted on this mixer over the
rubber collar .
- Weld a welded-on piece (item 26) on the original manifold pipe as well. Then make a hole with
diameter of 5 mm into this pipe (see picture 4).
- Place a manifold pipe to the original place, welded pipe (item 4) is oriented to the gas train.

Picture 4
Welded on piece (item 26)

Pipe (item 4)

Picture 5

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Group by Group Connecting

There is a need to connect mounted assemblies by hoses to assured safety and reliable natural gas
supply to the engine. The hoses lengths are modified according to the local situation to protect hoses
cross section against deformations. A wrong hose length could also cause the damage of connection
thickness.

- Two hoses onnect gas train outlet terminations with inlet pipes by gas mixers, connections are
assured by hose clips ( picture 6).

picture 6

Boost Air Temperature After Intercooler Sensor

Its function is to measure temperature of boost air after intercooler. One of holes with G3/4“ or G1/2“
thread is used for assembly again.

- Temperature sensor is screwed into the adapter , which has a thread G1/2“, in the case of hole with
G3/4“ thread utilization there is a need to use reducer .
- Complete sensor is screwed into the hole with thread G3/4“ or G1/2“.

Exhaust Gases Temperature Sensors

Its function is to measure temperature of exhaust gases before or after turbocharger

- Temperature sensors are screwed into adapter .

- Complete sensors are screwed into cleared holes in turbines outlets.

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 picture 7

Cam Shaft Position Sensor

Its function is to send the information to control system that combustion process of some cylinder is in
some phase just now. In the concrete, our effort is that this chosen mark will mean the compression top
dead center of the first cylinder.

picture 8

- Engine is by means of turning device turned to the required position, the first cylinder top dead center
(TDC). This position is signalized by mark on flywheel or by possibility to insert indicating bolt into the
hole in flywheel thorough the flywheel housing. Combustion process has two TDCs, compression and
exhaust. Compression TDC is indicated by statement of rocker arms of the first cylinder valve gear. In
the case of compression TDC the rocker arms are free, valve clearance is simply visible. In the case

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 of exhaust TDC the rocker arms are fixed (valves cut occurs right now), then we have to turn with
crank shaft by one revolution.
- Remove a cover of camshaft or camshaft wheel.
- Signaling bolt with nut is fixed on a camshaft or camshaft wheel (make a hole with M6 thread and
depth of 15 mm).
- Make a hole with M12x1 thread opposite to signaling bolt (prebored by 10.9 mm drill) to camshaft
cover.
- Cam shaft cover is assembled back and cam shaft position sensor is screwed into this cover, a
distance between sensor and signaling bolt or belt is tuned on 1 mm (sensor is drew up to the bolt and
moved back by one revolution). Sensor position is fixed by fixing nut.

Knocking Sensors

Their function is to sense mechanical vibrations in the place which is competently close to the combustion
chamber. By means of this signal following analyze is recognized whether detonating combustion occurs.
Original free holes threaded by W3/8”, which are on the cylinder head edge, are used for its assembly
(see pictures 9 and 10).

picture 9 and 10

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 - Neighborhood of chosen hole is released from color and this sensor contact surface is adapted by
snagging by means of abrasive paper.
- Bolt ( picture 9 )) is, by means of two nuts , fixed into the hole.
- Knocking sensor is overthrusted on this bolt. Sensor is then assured by washer and nut ( picture 10 )
which is drew up by torque of 20 Nm.

Set - up
Gas Pressure Regulator Outlet Pressure to engine

Gas regulator outlet pressure is the most important tuned parameter on the mechanical part of conversion
kit. Gas mass flow depends directly on this pressure, it means final dual ratio also. Regulator spring
compression indicates difference between regulator outlet pressure and reference pressure
(underpressure after engine air filters). This is a way to set total pressure gradient to constant. Next
regulation is executed by throttle actuator only. Gas regulator outlet pressure has to be in according with
proper throttle regulating range.

The schedule of values, which assignments value of throttle actuator current to boost air pressure value,
has to correspond to some regulator outlet pressure. Every change of outlet pressure value activates this
schedule reconstruction.

The schedule of values, which assignments value of throttle actuator current to boost air pressure value,
has to correspond to some regulator outlet pressure. Every change of outlet pressure value activates this
schedule reconstruction.

Air/gas ratio control with solenoid valve GVI..ML

For safeguarding steplessly controlled burners with pneumatic link between gas and air.
Function: when the solenoid valve opens, the governor maintains the gas outlet pressure constant
dependent on the air control pressure. In the minimum flow range, the gas-air mixture can be varied by
adjusting the governor spring. High fire is set by means of restrictors on the burner.
Technical data
Inlet pressure pe: max. 200 mbar.
Air control pressure pL: 0.5 to 120 mbar.
Outlet pressure pG: 0.2 to 120 mbar.
Range of adjustment at minimum flow: -3 to +8 mbar.
Transmission ratio: 1:1.
The inlet pressure must always be higher than the air control pressure.
Connection of the impulse line: compression fitting for pipe 8 or 6 x 1 mm.

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 picture 11

picture 12 picture 13

Pressure Switch Switching Levels

There is one pressure switch installed on the gas train (picture 1a). One on the gas filter block, which has
a function to inform us in the case of gas supply breakdown. The switching pressure value of the switch is
maximal value before gas train. Pressure level tuning is executed by adjustable bolt which is situated in
the center of switch.

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 picture 14 picture 15

Technical Data
Type of gas: Natural gas, town gas, LPG (gaseous), biologically produced methane, air and fumes.
Pressure connections (picture 19):
1 and 2: excess pressure Rp 1/4
3 and 4: negative pressure Rp 1/8,
5: test point acc. to DIN 3391, Ø 9 mm
Max. test pressure: temporarily <15 min. 2 bar
Ambient temperature: -15° C to +80° C
Temperature of the gas: -15° C to +80° C
Storage and transportation temperature: -40° C to +80° C
Fitting position: arbitrary, but preferably with horizontal or vertical diaphragm, please make sure that dirt or humidity
does not get into the connections open for aeration. The switch point is achieved with increasing ressure and with the
diaphragm in a vertical position. (DG..N with decreasing pressure). With the diaphragm in a horizontal position the
switching pressure is approx. 0.2 mbar higher than the reading. With the diaphragm suspended (connection 1, Rp
1/4, uppermost) the switching pressure is approx. 0.2 mbar less than the reading.The readings are approximations.
The reverse and cut of additionally according to the different constructions is made if the adjusted switch point won't
be reached or will be exceeded.

Recommended connections ( see picture 16 )

picture 16

Compensating Wing Bolt Position

There is possible to increase by hand ball valves deviation gas mass flow to one bank of cylinders at the
expense of the second one. That is a way to compensate differences between exhaust gases
temperatures of each bank if they are caused by different mass flow into these banks

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Maintenance
Gas Filter

Its function is to resist of mechanical part inletting into the engine. There is a need to keep its filtrating
properties and don’t increase its pressure loses for proper engine operation. That is why we recommend these
maintenance intervals:

- The first 50 operating hours - filter insert visual check, compressed air cleaning or displacement if needed.
- Each next 1000 operating hours - filter insert visual check, compressed air cleaning or displacement if
needed.
- After 12 000 operating hours (at the latest after two years) - filter insert displacement.

Gas Pressure Regulator

Its proper function importance was mentioned above. That is why we recommend these maintenance
intervals:

- After 12 000 operating hours (at the latest after two years) – seat contact surfaces and spring visual
check, two working diaphragms, unloading diaphragm and shaft with plate displacement.

Generally

Complete device periodic visual check, to check tightness of connections and parameters measured by
controller also.

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Warning
This device is intended for natural gas supplying into the engine.

Gas fuel (natural gas, sewage gas, biogas and next) is flammable and explosive compound and in the
case of blast explosion threats.

A device has to be periodically checked. In the case of gas loses, it is necessary to remove them
immediately.

In the place, where is this device installed, smoking and open fire using is prohibited.

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