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    Gaseous Fuel System™

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    Glossary

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    Gaseous Fuel Systems

  • Air-Gas Mixer Installation
  • Mounting of Gas Train
  • ECS Installation
  • LED CNG Level Indicator
  • Indicator Lamps
  • EGT Thermocouple
  • GPT Harness
  • Aneroid Control Valve
  • Diesel Control Valve
  • Gases Fuel System

    Installation

    Air-Gas Mixer Installation

    The Air-Gas Mixer (AGM) is installed in the engine air intake system between the air filter housing and turbocharger compressor inlet. The AGM is typically installed using either the existing "hump hose" connectors in the intake conduit, or with hump hose connectors or adaptors supplied with the Gaseous Fuel System.

    The AGM is unidirectional and will not function if installed backwards. Install the AGM with the pointed diffuser "cone" facing towards the engine air filter and the diffuser exhaust orifices facing the turbocharger compressor inlet.

    The AGM may be installed at any angle as required by the geometry of the original air intake system.

    The AGM is connected to the gas train using a flexible fuel delivery hose. The flexible fuel hose attaches to the AGM integral power valve inlet nipple using the provided t-bolt clamp.

    Mounting of Gas Train

    Ambient temperature range of the gas train is -40°F to +150°F (-40°C to +60°C).

    Installation of ECS

    The ECS controller is configured for use with 12 volt DC supply power. Voltages higher than 13 volts may result in damage to the ECS unit and/or other Gaseous Fuel System components.

    CAUTION! No modification may be made to the ECS control module or associated components. Unauthorized modification of the ECS components may result in improper operation of the engine and/or damage to the converted engine.

    The ECS control module requires a +12 volt DC power source which is energized when the engine is running (key "on") and de-energized when the engine is stopped (key "off").

    L.E.D. CNG Level Indicator

    The CNG level indicator is supplied with a light sensitive diode which will automatically adjust l.e.d. brightness depending on ambient light conditions.

    The CNG level indicator should be installed in a location that allows for easy viewing by the vehicle operator. The CNG level indicator is connected to the ECS controller via a 3-wire harness and is provided with male and female 3-pin connectors.

    Indicator Lamps (Low CNG / High EGT)

    The indicator lamps are connected to the ECS controller via two (2) independent 2-wire harnesses. Connection to the ECS control harnesses require the use of electrical connectors (solderless-type, insulated butt connectors are recommended).

    EGT Thermocouple

    The EGT thermocouple is installed in the engine exhaust system. Typical mounting locations include the exhaust manifold, turbocharger exhaust outlet or exhaust collector pipe. In all cases, the EGT thermocouple should be installed as close to the cylinders as possible and should not be installed downstream of the exhaust silencer.

    The EGT thermocouple is supplied with a bore-through, compression-type adaptor fitting with 1/8" male NPT threads. Most engine exhaust systems have one or more existing ports (typically threaded with a plug installed) which may be utilized for installation of the EGT thermocouple. If no port is available, it will be necessary to drill and tap a 1/8" female NPT threaded port in the exhaust system.

    The thermocouple is supplied with a 2-wire harness (red/yellow) which will need to be routed through the engine compartment firewall (using a rubber grommet for protection) for connection to the ECS control module located in the operator cab.

    GPT Harness

    The ECS kit includes a three-wire harness which connects the ECS control module to the gas pressure transducer.

    Installation of Aneroid Control Valve

    The ACV is not compatible with normally-aspirated diesel engines and should only be used on injection systems which utilize an OEM aneroid control device.

    Assemble and Mount ACV

    The ACV consists of a 3-way valve body, a 12 volt DC coil and a threaded coil locknut/adaptor fitting (supplied loose).

    Wiring ACV

    Once installed, the ACV must be connected to the ECS +12 volt DC power supply (Gaseous Fuel mode) and to chassis ground.

    Installation of Diesel Control Valve

    CAUTION! No modification may be made to the diesel control valve. Unauthorized modification of the DCV may result in improper operation of the engine and/or damage to the converted engine.

    The DCV is compatible with both in-line (Bosch type) injection systems as well mechanical fuel rail type systems (Cummins PT type). The DCV is not compatible with electronic diesel injection systems.

    Mount DCV

    The DCV consists of a 3-way valve body, a 12 volt DC coil, an adjustable needle valve cartridge and a threaded coil locknut. The DCV is supplied pre-assembled with the coil and needle valve cartridge installed.

    Plumb DCV Into Engine Fuel System

    For in-line injection pumps, the DCV will be plumbed between the injection pump fuel inlet and the fuel filter housing outlet. For fuel rail systems (Cummins PT or similar), the DCV will be plumbed between the fuel pump outlet and the fuel rail inlet.

    Wiring DCV

    Once installed, the DCV must be connected to the ECS +12 volt DC power supply (Gaseous Fuel mode) and to chassis ground.

    Installation of One-Way Check Valve (In-Line Pumps only)

    In some applications, it will be necessary to install the one-way check valve provided in the DCV kit. Depending on the design of the fuel system, it is possible for the injection pump to siphon diesel fuel from the vehicle fuel tank through the fuel return outlet located on the pump, thereby allowing the engine to make full power with the DCV energized.

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