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Hướng dẫn chuyển đổi động cơ sử dụng nhiên liệu diesel sang sử dụng nhiên liệu CNG (Compressed Natural Gas) của hãng NGV Motori Italy. Động cơ chuyển đổi có công suất tương đương động cơ diesel, chất lượng khí thải được cải thiện, góp phần bảo vệ môi trường.
NGV 2700 CONVERSION KIT GENERAL MANUAL Index INDEX Pagina di SECTION 01 – PRELIMINARIES CONTROLS ON THE ENGINE 01.01 DISASSEMBLY OF THE ENGINE 01.02 ENGINE COMPONENTS CHECK SECTION 02 – WORKING ON THE ORIGINAL DIESEL COMPONENTS 02.01 CYLINDER HEAD 02.02 PISTON 02.03 INLET MANIFOLD 02.04 TEMPERATURE SENSOR SEAT 02.05 LAMBDA SENSOR SEAT 02.06 ORIGINAL OIL PIPES 02.07 DIESEL PUMP SUPPORT MODIFICATION 02.08 RADIATOR CAP SECTION 03 – ENGINE REASSEMBLY 03.01 ENGINE REASSEMBLY SECTION 04 – VALVES GAP MODIFICATIONS 04.01 VALVES GAP MODIFICATIONS SECTION 05 – CONVERSION KIT COMPONENTS INSTALLATION 05.01 TOOTHED WHEEL 05.02 REVOLUTIONS SENSOR 05.03 REVOLUTIONS SENSOR SETTINGS 05.04 COILS 05.05 SPARK PLUGS 05.06 THROTTLE VALVE 05.07 MIXER 05.08 SPARK PLUG CABLES Conversion of the engine – from Diesel to GAS (cng/lpg) Index INDEX 05.09 WATER TEMPERATURE SENSOR 05.10 REDUCER 05.11 GAS LINE 05.12 LAMBDA SENSOR 05.13 PRESSURE DISCHARGING LINE 05.14 ENGINE HARNESS 05.15 ECU 05.16 DIAGNOSIS SYSTEM 05.17 ECU HARNESS SECTION 06 – ECU CONFIGURATION 06.01 ECU-PC CONNECTION 06.02 PARAMETERS TO SET 06.02.01 TOOTHED WHEEL TYPE 06.02.02 ON ENGINE REVOLUTIONS 06.02.03 NUMBER OF CYLINDERS 06.02.04 24V – 12V 06.02.05 RPM OVERRUN THRESHOLD 06.02.06 OPTION DEFAULT STUCK 06.02.07 TYPE OF LAMBDA PROBE 06.02.08 NUMBER OF LAMBDA PROBES 06.02.09 CUTOFF OPTION 06.02.10 LEVEL SENSORS 06.02.11 PRESSURE CONTROL SECTION 07 – SWITCH ON THE ENGINE – CONTROL 07.01 TIMING ADVANCED 07.02 IDLE ENGINE REVOLUTIONS 07.03 LAMBDA SENSOR 07.04 TEMPERATURE SENSOR 07.05 TPS 07.06 THROTTLE VALVE IDLE Conversion of the engine – from Diesel to GAS (cng/lpg) Pagina di Index INDEX SECTION 08 – ROAD TEST 08.01 MODALITY 08.02 TEST CONTROLS 08.03 END TEST CONTROLS SECTION 09 – DELIVERY FOR CUSTOMERS 09.01 INFORMATIONS FOR CUSTOMERS SECTION 10 – TROUBLE SHOOTING 10.01 TROUBLE SHOOTING 10.02 ERROR CODE MANUAL 10.03 FLOW CHART 10.03.01 THE ENGINE IS NOT STARTING 10.03.02 THE ENGINE SUPPLIES NOT ENOUGH POWER 10.03.03 THE ENGINE RUNS UNEVENLY 10.03.04 BACKFIRINGS 10.04 CONTROLS 10.04.01 COMPRESSION TEST 10.04.02 VALVES GAP 10.04.03 SPARK PLUGS SECTION A1 – STANDARD COMPONENTS A1.01 LAMBDA SENSOR HOUSING A1.02 LAMBDA SENSOR A1.03 TOOTHED WHEEL TYPES A1.04 REVOLUTION SENSOR A1.05 ECU A1.06 COIL A1.07 THROTTLE VALVE FLANGE A1.08 THROTTLE VALVE A1.09 MIXER A1.10 TEMPERATURE SENSOR A1.11 SPARK PLUG CABLE Conversion of the engine – from Diesel to GAS (cng/lpg) Pagina di Index INDEX A2 HARNESS A2.01 ECU HARNESS A2.01.01 HARNESS DRAWING A2.01.02 FUNCTIONAL DRAWING A2.01.03 PIN – OUT A2.02 CYLINDERS ENGINE HARNESS A2.02.01 HARNESS DRAWING A2.02.02 FUNCTIONAL DRAWING A2.02.03 PIN – OUT A2.03 CYLINDERS ENGINE HARNESS A2.03.01 HARNESS DRAWING A2.03.02 FUNCTIONAL DRAWING A2.03.03 PIN – OUT A2.04 CYLINDERS ENGINE HARNESS A2.04.01 HARNESS DRAWING A2.04.02 FUNCTIONAL DRAWING A2.04.03 PIN – OUT Conversion of the engine – from Diesel to GAS (cng/lpg) Pagina di PRELIMINARIES CONTROLS ON THE ENGINE Section 01 01.01 DEASSEMBLY OF THE ENGINE 01.02 ENGINE COMPONENTS CHECK 01.01 DISASSEMBLY OF THE ENGINE PHASE DESCRIPTION 01 Disassemble the original engine head 02 Disassemble the original valves 03 Disassemble the original camshaft 04 Disassemble the original crankshaft 05 Disassemble the original bearings 06 Disassemble the original pistons 07 Disassemble the original piston rings 08 Disassemble all the original diesel feeding system Conversion of the engine – from Diesel to GAS (cng/lpg) Page of 01.02 ENGINE COMPONENTS CHECK Page of PHASE DESCRIPTION 01 Check the conditions of the valves 02 Check the conditions of the valve seats 03 Check the conditions of the camshaft 04 Check the conditions of the crankshaft 05 Check the conditions of the original block bearings 06 Check the conditions of the original connector rod bearings 07 Check the conditions of the original pistons If the components previously checked are damaged, replace or repair them (the crankshaft and the camshaft can be refaced) Conversion of the engine – from Diesel to GAS (cng/lpg) ORIGINAL DIESEL COMPONENTS MODIFICATIONS Section 02 02.01 CYLINDER HEAD 02.02 PISTON 02.03 INLET MANIFOLD 02.04 TEMPERATURE SENSOR SEAT 02.05 LAMBDA SENSOR SEAT 02.06 ORIGINAL OIL PIPES 02.07 DIESEL PUMP SUPPORT MODIFICATIONS 02.08 RADIATOR CAP Section 02 – Working On The Original Diesel Components 02.01 CYLINDER HEAD Page of PHASE DESCRIPTION The engine head modifications are necessary to be able to replace the original diesel injectors with the adequate spark plugs 01 Disassemble the original cylinder head 02 Measure the diameter of the original injector seat (D picture 01), in order to chose the type of spark plug (the thread): if the original diameter is mm or less, it is possible to use a spark plug with the thread M10x1; if the diameter is bigger, until to 10,75 mm diameter, it must be used a spark plug with the thread M12x1,25 03 Verify the length L (picture 01), in order to chose the type of spark plug (length of the thread) Consider that when the spark plug is completely screwed in the seat, the only part of it that must enter in the combustion chamber is the electrode, as shown in the picture 02 picture 01 – ORIGINAL ENGINE HEAD picture 02 – ELECTRODE IN THE COMBUSTION CHAMBER Conversion of the engine – from Diesel to GAS (cng/lpg) HARNESS A2.01 ECU HARNESS A2.01.01 HARNESS DRAWING A2.01.02 FUNCTIONAL DRAWING A2.01.03 PIN – OUT A2.02 CYLINDERS ENGINE HARNESS A2.02.01 HARNESS DRAWING A2.02.02 FUNCTIONAL DRAWING A2.02.03 PIN – OUT A2.03 CYLINDERS ENGINE HARNESS A2.03.01 HARNESS DRAWING A2.03.02 FUNCTIONAL DRAWING A2.03.03 PIN – OUT A2.04 CYLINDERS ENGINE HARNESS A2.04.01 HARNESS DRAWING A2.04.02 FUNCTIONAL DRAWING A2.04.03 PIN – OUT Section A2 Section A2 - Harness A2.01.03 Pin - Out CNT/PIN C1/1 C1/2 C1/3 C1/4 C1/5 C1/6 C1/7 C1/8 C1/9 C1/10 C1/11 C1/12 C1/13 C1/14 C1/15 C1/16 C1/17 C1/18 C1/19 C1/20 C1/21 C1/22 C1/23 C1/24 C1/25 C1/26 C1/27 C1/28 C1/29 C1/30 C1/31 C1/32 70002 70010 10100 10120 21100 21120 SIZE (mm ) WHITE 0,5 YELLOW 0,5 WHITE 0,5 BROWN 0,5 WHITE 0,5 BROWN 0,5 74000 13135 13120 13100 13110 09915 00030 WHITE GREEN BROWN WHITE YELLOW YELLOW RED 0,5 0,5 0,5 1,5 1,5 54101 54104 54103 54102 55101 55104 55103 55102 60500 60600 60100 WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 1 60200 60300 70001 70020 15110 15100 WHITE WHITE WHITE BROWN YELLOW WHITE 1 0,5 0,5 0,5 0,5 CODE COLOUR DESCRIPTION CNT/PIN SERIAL INTERFACE Tx SIGNAL SERIAL INTERFACE +24V SUPPLY RPM SENSOR SIGNAL RPM SENSOR GROUND TEMPERATURE SENSOR SIGNAL TEMPERATURE SENSOR GROUND NOT CONNECTED DIAGNOSIS LIGHT LAMBDA SENSOR HEATING GROUND LAMBDA SENSOR GROUND LAMBDA SENSOR SIGNAL LAMBDA SENSOR HEATING +24V SUPPLY +24V IGNITION +24V BATTERY C4/3 C4/4 Y1a/15 Y1a/16 Y1a/1 Y1a/2 TURBO STEPPER MOTOR "A" TURBO STEPPER MOTOR "D" TURBO STEPPER MOTOR "C" TURBO STEPPER MOTOR "B" CARBURATION STEPPER MOTOR "A" CARBURATION STEPPER MOTOR "D" CARBURATION STEPPER MOTOR "C" CARBURATION STEPPER MOTOR "B" COIL COIL COIL NOT CONNECTED COIL COIL SERIAL INTERFACE Rx SIGNAL SERIAL INTERFACE GROUND TPS SENSOR +5V SUPPLY TPS SENSOR SIGNAL Free Y1a/27 Y1a/30 Y1a/29 Y1a/28 F2 F1 Y1a/11 Y1a/12 Y1a/13 Y1a/14 Y1a/8 Y1a/5 Y1a/6 Y1a/7 Y1a/3 Y1a/10 Y1a/24 Y1a/23 Y1a/25 C4/2 C4/1 Y1a/32 Y1a/34 Conversion of the engine – from Diesel to GAS (cng/lpg) SIZE (mm ) 1,5 1,5 CNT/PIN R1/87 R1/30 R1/30 SIZE CNT/PIN (mm ) 1,5 Free wire Section A2 - Harness A2.01.03 Pin - Out CNT/PIN SIZE (mm ) BROWN 0,5 BROWN 0,5 WHITE 0,5 YELLOW 0,5 CODE COLOUR C1/33 C1/34 C1/35 C1/36 C1/37 C1/38 C1/39 C1/40 C1/41 C1/42 15120 16020 16000 16010 DESCRIPTION CNT/PIN TPS SENSOR GROUND CNG/LPG LEVEL SENSOR GROUND CNG/LPG LEVEL SENSOR SIGNAL CNG/LPG LEVEL SENSOR SUPPLY NOT CONNECTED NOT CONNECTED LAMBDA SENSOR SIGNAL NOT CONNECTED NOT CONNECTED ECU GROUND Y1a/33 C3/2 C3/1 C3/3 13200 WHITE 0,5 00031 BROWN C1/43 C1/44 C1/45 C1/46 C1/47 C1/48 C1/49 C1/50 C1/51 C1/52 C1/53 C1/54 C1/55 C1/56 59135 76035 72000 71000 GREEN GREEN WHITE WHITE 1 0,5 0,5 75035 GREEN 55204 55201 55202 55203 WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 60400 WHITE GAS VALVE OUTPUT OPTIONAL SIGNAL OUTPUT AIR CONDITIONER INPUT ORIGINAL INDICATOR OUTPUT NOT CONNECTED OPTIONAL SIGNAL INPUT NOT CONNECTED NOT CONNECTED IDLE STEPPER MOTOR "D" IDLE STEPPER MOTOR "A" IDLE STEPPER MOTOR "B" IDLE STEPPER MOTOR "C" NOT CONNECTED COIL Y1a/4 Y1a/9 Y1a/26 60115 60215 60315 YELLOW YELLOW YELLOW 1 COIL +24V SUPPLY COIL +24V SUPPLY COIL +24V SUPPLY F3 C2/2 59115 YELLOW GAS VALVE +24V SUPPLY F2 R1/86 00015 YELLOW 0,5 MAIN RELAY +24V IGNITION SUPPLY Free wire SIZE (mm ) CNT/PIN Free wire 1,5 R1/87 Y1a/18 R1/85 R1/85 C2/1 Y1a/31 Free wire Free wire Free Y1a/19 Y1a/20 Y1a/21 Y1a/22 Y1a/17 Conversion of the engine – from Diesel to GAS (cng/lpg) SIZE CNT/PIN (mm ) Section A2 - Harness A2.02.03 Pin - Out DESCRIPTION CNT/PIN WHITE BROWN SIZE (mm ) 0,5 0,5 TEMPERATURE SENSOR SIGNAL TEMPERATURE SENSOR GROUND S2/1 S2/2 55104 55103 55102 55101 WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 CARBURATION STEPPER MOTOR "D" CARBURATION STEPPER MOTOR "C" CARBURATION STEPPER MOTOR "B" CARBURATION STEPPER MOTOR "A" S4/D S4/C S4/B S4/A Y1b/11 Y1b/12 Y1b/13 Y1b/14 54101 54104 54103 54102 WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 TURBO STEPPER MOTOR "A" TURBO STEPPER MOTOR "D" TURBO STEPPER MOTOR "C" TURBO STEPPER MOTOR "B" S3/A S3/D S3/C S3/B Y1b/15 Y1b/16 10100 10120 WHITE BROWN 0,5 0,5 RPM SENSOR SIGNAL RPM SENSOR GROUND S8/2 S8/1 Y1b/4 Y1b/24 60115 60100 YELLOW WHITE 1 COIL +24V SUPPLY COIL signal S6/1 S6/2 Y1b/9 Y1b/23 60215 60200 YELLOW WHITE 1 COIL +24V SUPPLY COIL signal S7/1 S7/2 Y1b/27 Y1b/28 Y1b/29 Y1b/30 13135 13110 13100 13120 GREEN YELLOW WHITE BROWN 1 0,5 0,5 LAMBDA SENSOR HEATING GROUND LAMBDA SENSOR HEATING +24V SUPPLY LAMBDA SENSOR SIGNAL LAMBDA SENSOR GROUND S1/2 S1/1 S1/4 S1/3 Y1b/32 Y1b/33 Y1b/34 15110 15120 15100 YELLOW BROWN WHITE 0,5 0,5 0,5 TPS SENSOR +5V SUPPLY TPS SENSOR GROUND TPS SENSOR SIGNAL S5/1 S5/3 S5/2 CNT/PIN CODE COLOUR Y1b/1 Y1b/2 21100 21120 Y1b/5 Y1b/6 Y1b/7 Y1b/8 Y1b/3 Y1b/10 Y1b/17 Y1b/18 Y1b/19 Y1b/20 Y1b/21 Y1b/22 Y1b/25 Y1b/26 Y1b/31 NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED Conversion of the engine – from Diesel to GAS (cng/lpg) Section A2 - Harness A2.03.03 Pin - Out DESCRIPTION CNT/PIN WHITE BROWN SIZE (mm ) 0,5 0,5 TEMPERATURE SENSOR SIGNAL TEMPERATURE SENSOR GROUND S2/1 S2/2 55104 55103 55102 55101 WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 CARBURATION STEPPER MOTOR "D" CARBURATION STEPPER MOTOR "C" CARBURATION STEPPER MOTOR "B" CARBURATION STEPPER MOTOR "A" S4/D S4/C S4/B S4/A Y1b/11 Y1b/12 Y1b/13 Y1b/14 54101 54104 54103 54102 WHITE WHITE WHITE WHITE 0,5 0,5 0,5 0,5 TURBO STEPPER MOTOR "A" TURBO STEPPER MOTOR "D" TURBO STEPPER MOTOR "C" TURBO STEPPER MOTOR "B" S3/A S3/D S3/C S3/B Y1b/15 Y1b/16 10100 10120 WHITE BROWN 0,5 0,5 RPM SENSOR SIGNAL RPM SENSOR GROUND S9/2 S9/1 Y1b/4 Y1b/24 60115 60100 YELLOW WHITE 1 COIL +24V SUPPLY COIL signal S6/1 S6/2 Y1b/9 Y1b/23 60215 60200 YELLOW WHITE 1 COIL +24V SUPPLY COIL signal S7/1 S7/2 Y1b/26 Y1b/25 60315 60300 YELLOW WHITE 1 COIL +24V SUPPLY COIL S8/1 S8/2 Y1b/27 Y1b/28 Y1b/29 Y1b/30 13135 13110 13100 13120 GREEN YELLOW WHITE BROWN 1 0,5 0,5 LAMBDA SENSOR HEATING GROUND LAMBDA SENSOR HEATING +24V SUPPLY LAMBDA SENSOR SIGNAL LAMBDA SENSOR GROUND S1/2 S1/1 S1/4 S1/3 Y1b/32 Y1b/33 Y1b/34 15110 15120 15100 YELLOW BROWN WHITE 0,5 0,5 0,5 TPS SENSOR +5V SUPPLY TPS SENSOR GROUND TPS SENSOR SIGNAL S5/1 S5/3 S5/2 CNT/PIN CODE COLOUR Y1b/1 Y1b/2 21100 21120 Y1b/5 Y1b/6 Y1b/7 Y1b/8 Y1b/3 Y1b/10 Y1b/17 Y1b/18 Y1b/19 Y1b/20 Y1b/21 Y1b/22 Y1b/31 NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED Conversion of the engine – from Diesel to GAS (cng/lpg) Section A2 - Harness A2.04.03 Pin - Out DESCRIPTION CNT/PIN WHITE BROWN SIZE (mm ) 0,5 0,5 TEMPERATURE SENSOR SIGNAL TEMPERATURE SENSOR GROUND S6/1 S6/2 60115 55104 55103 55102 55101 60215 60415 YELLOW WHITE WHITE WHITE WHITE YELLOW YELLOW 0,5 0,5 0,5 0,5 1 COIL +24V SUPPLY CARBURATION STEPPER MOTOR "D" CARBURATION STEPPER MOTOR "C" CARBURATION STEPPER MOTOR "B" CARBURATION STEPPER MOTOR "A" COIL +24V SUPPLY COIL +24V SUPPLY S1/1 S8/D S8/C S8/B S8/A S2/1 S4/1 54101 54104 54103 54102 10100 10120 60400 13200 53104 53101 53102 53103 60200 60100 60300 60315 13135 13235 13110 13210 13100 13120 13220 WHITE WHITE WHITE WHITE WHITE BROWN WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE YELLOW GREEN GREEN YELLOW YELLOW WHITE BROWN BROWN 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 1 1 1 1 0,5 0,5 0,5 TURBO / CARBURATION STEPPER MOTOR "A" TURBO / CARBURATION STEPPER MOTOR"D" TURBO / CARBURATION STEPPER MOTOR "C" TURBO / CARBURATION STEPPER MOTOR"B" RPM SENSOR SIGNAL RPM SENSOR GROUND COIL signal LAMBDA SENSOR SIGNAL IDLE / TURBO STEPPER MOTOR "D" IDLE / TURBO STEPPER MOTOR "A" IDLE / TURBO STEPPER MOTOR "B" IDLE / TURBO STEPPER MOTOR "C" COIL signal COIL signal COIL signal COIL +24V SUPPLY LAMBDA SENSOR HEATING GROUND LAMBDA SENSOR HEATING GROUND LAMBDA SENSOR HEATING +24V SUPPLY LAMBDA SENSOR HEATING +24V SUPPLY LAMBDA SENSOR SIGNAL LAMBDA SENSOR GROUND LAMBDA SENSOR GROUND S9/A S9/D S9/C S9/B S5/2 S5/1 S4/2 S12/4 S10/D S10/A S10/B S10/C S2/2 S1/2 S3/2 S3/1 S11/2 S12/2 S11/1 S12/1 S11/4 S11/3 S12/3 15110 15120 15100 YELLOW BROWN WHITE 0,5 0,5 0,5 TPS SENSOR +5V SUPPLY TPS SENSOR GROUND TPS SENSOR SIGNAL S7/1 S7/3 S7/2 CNT/PIN CODE COLOUR Y1b/1 Y1b/2 21100 21120 Y1b/4 Y1b/5 Y1b/6 Y1b/7 Y1b/8 Y1b/9 Y1b/11 Y1b/12 Y1b/13 Y1b/14 Y1b/15 Y1b/16 Y1b/17 Y1b/18 Y1b/19 Y1b/20 Y1b/21 Y1b/22 Y1b/23 Y1b/24 Y1b/25 Y1b/26 Y1b/27 Y1b/28 Y1b/29 Y1b/30 Y1b/32 Y1b/33 Y1b/34 Y1b/3 Y1b/10 Y1b/31 NOT CONNECTED NOT CONNECTED NOT CONNECTED Conversion of the engine – from Diesel to GAS (cng/lpg) ... relation to the flow of the air) the MIXER, in order to the mixture of gas and air doesn’t flow into the compressor Conversion of the engine – from Diesel to GAS (cng/lpg) Section 02 – Working On The. .. POSITIONING PISTON 11 With the comparator verify if the piston is coaxial with the lathe machine picture 09 – VERIFYING COAXIAL WITH THE LATHE Conversion of the engine – from Diesel to GAS (cng/lpg)... Conversion of the engine – from Diesel to GAS (cng/lpg) Pagina di PRELIMINARIES CONTROLS ON THE ENGINE Section 01 01.01 DEASSEMBLY OF THE ENGINE 01.02 ENGINE COMPONENTS CHECK 01.01 DISASSEMBLY OF THE ENGINE