User Manual for EFI Fuel Systems
Contents
1.2. Outputs Fuel control Spark control Throttle control Engine Sensors O sensor MAP sensor IAT sensor ECT sensor Magnetic speed TPS Oil pressure sensor Exhaust gas emission control Engine
3. ane NN ET Lac el AO LINT HH OMHE Be KANAN Md OF Gasoline Fuel System Plumbing Schematic 3 0L gasoline fuel system return line fuel injector pressure regulator Gaseous Fuel Plumbing Schematic LP TANK LP Fuel Filter Air Cleaner VAPORIZER SN COOLANT IN ATMOSPHERIC HOSE or Filter ENGINE 2 1 1 3 4 4 2 1 1 1 2 1 1 1 1 GM 3 0 LPG ONLY 94050020 HE1 4A 269HB 12 8 H177 3 4 HOSE 10 110FB DC 125HBL 10 8 H200 08 PC 7688 12 10068571 NOO 51 01 735 4970 4 1142 PC7764 630 1049 PC7686 2024 4 AFC A155 LWOS PC7762 BHMO5CO75 PC7771 230404 125HLB 4 6 125HBL 12 8 122 60 BHS0420350 2059 3046 211P 2 211P 6 222P 2 2 388 Service Parts 3 0 LP ONLY FUEL KIT 1 8 NPT X 1 4 BARB 90 DEG 3 4 X 1 2 BARB 90 DEG 3 8 USCG FUEL HOSE 3 4 LPG HOSE CLAMP BUSHING 1 2M X 3 8 FM FACE MT 5 8 X 1 2 HOSE BARB 5 8 PCV PUSH ON JIFFY HOSE S S HOSE CLAMP ACCESSORY BRACKET S S HOSE CLAMP MAP SEN BRACKET 1 8 VAC FITTING VC GROMMET CERTIFICATION LABEL MIXER ADPT GROMMET MAP SEN SUPPORT BRACKET Ya NPT X 6 90 LP FILTER 5 16 LOCK WASHER PVC LINE RESTRICTOR 5 16 NC X 3 4 BOLT CUSTOMER INTERFACE HARNESS OIL SAFETY SWITCH 1 4 NPT X 3 8 BARB 3 4 X 1 2 BARB JET 1 4NC X 3 1 2 BOLT BREATHER FILTER 1 8 NPT PLUG 3 8 NPT PLUG 1 8F X 1 8 M ADAPTER HOSE 1 1 1 1 2 2
4. O2 D wire is open Table 6 Harness O2 heater check 7 2 If battery voltage 1s present from step 7 1 measure resistance between the 2 white wires on the O2 sensor They should be between 1 5 and 3 52 ohms at room temperature If the heater 15 open or shorted replace the sensor A warm sensor will read higher resistance than a cold sensor If no wires are open or shorted verify the rest of the fueling system is operating properly If everything else checks out replace the oxygen sensor Code 14 The engine coolant reads too high It is possible to receive this code if the engine has severely overheated above 280 F Code 15 The engine coolant reads too low This may occur 1f the temperature 1s below 30 F or if the CTS sensor is unplugged To verify the coolant temp wiring 1 Disconnect the coolant temp sensor and measure the resistance of the coolant temperature sensor This will vary depending on the sensor s temperature The resistance should be within 5 of that listed in Table 7 If the sensor differs replace the sensor Table 7 CTS resistance Degrees F CTS Resistance Resistance 22 52594 51791 gt 21371 21044 32 9399 12073 68 3511 3457 71 2193 2452 36 2240 2205 95 1806 1778 1465 1443 671 660 395 398 334 329 242 238 207 204 178 175 100 9 99 2 Turn ignition power ON 2 Measure the voltage betw
5. Precision Governors LLC 2322 Seventh Avenue Rockford IL 61104 phone 815 229 5300 fax 815 229 5342 www precisiongovernors com ISO 9001 Certified User Manual for EFI Fuel Systems Table of Contents Contact list Engine Management System Overview a ECM System components b Governed Throttle Body Fuel Components d ECM e Engine Sensor f Cold Start Capability Closed Loop Operation Diagnostics a Summary of Diagnostic Error Codes b Description of Error Codes Basic Trouble Shooting Assembly Detail a Fuel Systems b ECM Connector amp Harness Layout Schematics a Electrical b Plumbing Service Parts Nomenclatures Appendix a LPG Fuel System Retrofit Procedure Contact List Please direct all questions and inquiries to KEM Equipment at KEM Equipment Inc Don Abel Service and Warranty Coordinator 10800 S W Hermann Rd Tualat n OR 97062 Phone 503 692 5012 Fax 503 692 1098 Dona kemequipment com Precision Governors LLC Paul Hanson Customer Service and Repair 2322 Seventh Avenue Rockford IL 61104 Phone 815 229 5300 Fax 815 229 5342 phanson precisiongovernors com EFI Engine Management System Overview EFI Fuel System Integrated product design built around off the shelf automotive components Certified to meet EPA CARB 2004 off road large spark ignition engine emission requirements Advanced Speed governin
6. 13 1 1 psu ros Buon Re N I REOR dom INO P N PG 2560 PG 2561 PG 2562 PG 2585 PG 3143 PG 3206 PG 3322 PG 3329 PG 3357 PG 3360 PG 3362 PG 3363 PG 3364 PG 3435 PG 3436 PG 3446 PG 3455 PG 3462 PG 3464 PG 3466 PG 3482 PG 3487 PG 4089 PG 7624 PG 7638 PG 7655 PG 7656 PG 7657 PG 7663 PG 7670 PG 7687 PG 7707 PG 7713 PG 7714 PG 77350020 PG 9397 List of Service Items PG 94050020 Kit Description Map Sensor Oxygen Sensor Coolant Temp Sensor Autotronix Solenoid Valve 3 8 16 x Y2 Socket Hd Cap Screw O Ring EFI Hose Neoprene Vapor 5 8 Brass 3 8 Barb x 1 8 NPT 90 Elbow Brass 3 8 Compression x 4 NPT Hose 3 8 24 Minimum Brass 5 8 Barb x 1 2 NPT 90 Elbow Brass 5 8 Barb x 3 8 NPT Brass 5 8 Barb x 3 8 NPT 90 Elbow Brass 1 8 x 1 8 NPT Male Brass 1 8 x 1 8 x 1 8 NPT Female Nut 14 20 Flange Hd Serrated 3 8 x 3 8 x 3 8 NPT Female Tee Fitting Hose 4 Nolff N00 5101 14 28 to 1 4 I D Hose Brass Fitting 1 8 NPT x Barb Hose 3 16 Fuel Hose 14 20 x 3 Socket Head Cap Screw ECM Cover Plate Top LP Gasket Throttle Body to Plate EFI Malfunction Indicator Lamp Face Plate Hose Clamp 12 1 1 8 Clamp Dia Hose Clamp 1 5 16 3 14 Clamp Dia GM 3 0L Manifold Adapter Plate Throttle Body Assembly 3 0 LP Lockoff Solenoid Valve for KEM Gasket 3 0L Intake Manifold Nolff Mixer CA
7. ECM Harness 10 10 Ground wire 1s open ECM Harness 40 5 volt wire 1s open ECM Harness 9 TPS signal wire 15 open ECM Harness 10 ECM Harness 40 Open or lt 1000 Q if DBW pot 5 volt wire shorted to ground ECM Harness 10 ECM Harness 8 Open TPS signal shorted to ground ECM Harness 40 Table 8 TPS wiring troubleshooting ECM Harness 9 TPS signal shorted to 5 volts If all other TPS tests check out reconnect all sensors Measure the voltage from TPS pin C to ground while manually opening the throttle plate The voltage should read gt 0 5 volts at closed throttle and lt 4 5 volts at WOT and move smoothly between closed and open throttle If the voltage has dead spots or spikes replace the TPS sensor If the voltage s within the range and moves smoothly replace the ECM Code 22 The Throttle body actuator is not responding the fault s either caused by a short circuit or the actuator is unplugged Code 23 Code 24 The Inlet Air temperature reads too low This may occur if the temperature is below 40 F or 1f the IAT sensor is unplugged The engine coolant reads too high While unlikely if this sensor is above 2709 F this code will be sent To Verify the Inlet Air Temperature sensor wiring 1 PN MR 21 2 2 2 Disconnect the IAT sensor and measure its resistance This will vary depending on the sensors
8. and battery positive This should be near 0 Code 41 MAP sensor system error The MAP sensor code can be set if map output wire is grounded shorted to 5 volts or if the MAP pressure does not change between key on and engine run time Verify 1 MAP sensor is plugged in Vacuum hose to the MAP sensor 15 connected properly with no leaks 3 Disconnect MAP sensor electrical connector Turn ignition power on Measure the voltage from pins A Bk Y1 to C Rd BU This should read 4 75 5 25 volts If it outside of this range proceed with step 3 1 3 1 Perform the following measurements 3 2 Turn ignition power OFF Disconnect the ECM from the wiring harness Disconnect the TPS sensor and drive by wire pot if it us used and easily to disconnect Perform the measurements in Table 10 Meter mode Desired Result If defective Ohms ECM Harness 10 10 Ground wire 15 open ECM Harness AO 5 volt wire 18 open ECM Harness 8 TPS signal wire 1s open ECM Harness 10 ECM Harness 40 Open or lt 1000 Q if DBW pot is connected 5 volt wire shorted to ground ECM Harness 10 ECM Harness 7 Open MAP signal shorted to ground 4 Ifall other MAP tests check out reconnect all sensors and turn 1gnition power on Measure ECM Harness 40 Table 10 MAP wiring troubleshooting ECM Harness 7 MAP signal shorted to 5 volts the voltage from MAP pin
9. orifice hole 0 100 plug in the vacuum manifold hose to the PCV valve is correct Verify the Orifice size 0 060 to the tee adapter elbow on top port of the vaporizer is installed Install the PG electrical harness The harness should not be routed close to exhaust pipes or make sharp bends There should be sufficient length to flex across the stationary positions and the engine block Install Sensors O2 map air temp coolant temp oil pressure sender Assemble the throttle body inserting the gasket material and sealer between stages Install the vaporizer to the engine mount Install the LPG lock off valve to the vaporizer Insert vacuum hoses and crank case vacuum hoses on the engine ports Check the air cleaner condition replace if necessary The Map sensor must be connected to manifold vacuum The LPG fuel trim vacuum valve must be connected to the vacuum port at the LPG mixer install the vapor line to the LP mixer Check vapor pressure line for leaks Assemble engine coolant hoses Connect all the sensors connectors in place to the engine Check oil level and coolant level in engine Connect the ECM to the engine harness Unplug Actuator if connected Start engine and warn up with mechanical idle speed to approx 750 rpm Adjust the minimum Air adjustment screw Tighten and lock the minimum idle speed adjustment screw Plug the connector back to the Actuator Test Throttle responsiveness and stability Veri
10. ports vacuum solenoid valve engine vacuum pressure line LPG Gaseous Fuel System Assembl 1 6L Engine typical LPG Vaporizer Resulator LPG inlet Port Coolant Inlet Outlet Ports Vacuum Propane Vapor Reference Port Outlet Port ECM Connector DEUTSCH usa SN 7 Deutsch 40 Pin Connector Layout for Harness Deutsch Part Number DRC16 40S Quantity 1 Pin Part Number 0462 201 16141 Quantity 26 Functional layout 1 2 3 4 9 Ignition Coil B Ignition Coil A vacuum valve Injector 1 Fuel Sel Gov Sel 1 MAP B 79 06 ET A Analog GND Gov Sel 2 CPS A DBW hego Emergency kill CAM Analog knock transmit Actuator pwm B LPShutoff Actuator A Aux out PowerGND Dwel out Spark bypass Flash 3 receive SV Ref 31 32 3 34 35 Color Layout 6 7 8 9 PK w we am mo BUY WH WHITE RD RED PR PURPLE BN BROWN OR ORANGE GR GREEN BK BLACK TN TAN GY GREY YL YELLOW BU BLUE Ex WH BK amp BN White with Black and Brown stripes Schematics E PH DELTERH TEBAK FAA CRT rut DUM uh 18 LL LITE CA _ AO A o RAW AA i 1 1 OF 2 HEN wRE LEGEM TT E E a F Wed 3 II A kanne L Aii 11
11. read between 40 45 psi And or fuel pump Fuel injector is spraying Check fuel injection wiring Fuel injector is not leaking Replace injector o rings or injector Spark plugs are not fouled or wet Disconnect the fuel injector connectors for 15 seconds while cranking to un flood the engine Condition Engine runs too Rich with Gasoline Verify each item below Remedy for each item below Verify vacuum leaks to the MAP sensor Replace hose Restricted fuel return line Replace fuel line Shut off LPG tank valve replace clean LPG shut off valve does not close LPG shut off valve Check fuel pressure should be 40 45 psi enlace A gasoline at the fuel port 5 Check for bad MAP sensor Replace with new MAP sensor Check for a bad IAT ECT sensor Replace with new sensor 2 Check for exhaust air leaks before the O Repair air leaks in the exhaust system sensor Check to see if there is excessive smoke Check and replace fouled spark plugs while running Condition Engine runs lean or misfires on Gasoline Verify each item below Remedy for each item below Visually inspect fuel filter for restriction Replace fuel filter Verify the fuel pressure is 40 45 psi use gage readings from the fuel port Replace fuel pressure regulator Check for clogged fuel injectors Clean Replace fuel injectors Condition Engine runs lean or misfires on LPG Verify Each item below Remedy for each item below Re fill Tank LPG tank
12. vacuum Inlet air temperature Engine coolant temperature Speed sensing Throttle position sensor Low oil pressure shutdown Engine Safety Shutdown Features High engine coolant temperature Programmable Currently set at 230 F e Can be customized Low oil pressure shutdown eShuts engine down by shutting off fuel Cold Start Performance Gasoline engines to 20 F 30 C LPG engines to 0 F 17 C Closed Loop Emissions Control HI Stoichiometric e O sensor indicates rich or lean condition e Air fuel ratio is controlled to optimize catalyst efficiency e Automatic altitude compensation Diagnostics Malfunction Indicator light MIL diagnostics MIL diagnostics for critical engine components including throttle body actuator gas injector ECM amp all engine sensors Easy for field troubleshooting Uses simple error blink codes Summary of Diagnostic Error Codes Error Codes 12 13 14 15 21 22 23 24 25 31 32 41 43 51 53 52 61 62 63 64 Error Description Diagnostic mode indicator Oxygen sensor error Engine coolant temp high Engine coolant temp low Throttle position sensor error Throttle body actuator not responding Inlet air temp sensor low Inlet air temp sensor high Electronic ignition control error Drive by wire error System voltage low Manifold absolute pressure sensor error Fue
13. 100 w Feedback Diaphragm Nolff NJ Vaporizer Regulator w Blue Spring Harness GM 3 0L LP EFI Controller ECM UNG CTS DBW DIS ECM ECT EFI ESA GUI HEGO IAT LED LP MAP NG PWM Nomenclatures typically used in EFI systems Compress Natural Gas Coolant Temperature Sensor Drive by Wire Distributorless Ignition System Engine Control Module Engine Coolant Temperature Electronic Fuel Injection Electronic Spark Advance Graphical User Interface Heated Exhaust Gas Oxygen Oxygen sensor Inlet Air Temperature Light Emitting Diode Liquid Propane Liquid Petroleum Manifold Air Pressure Natural Gas Pulse Width Modulated Throttle Position Sensor Appendix nern 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 LPG FUEL SYSTEM RETROFIT PROCEDURE Remove the old fuel system throttle body assembly and electrical cable harness Check distributor cap and rotor Check spark plug wire Replace if worn Check fuel lines and connectors for leaks Install the PG throttle body and mixer to the intake manifold Install the exhaust system including the exhaust manifolds and catalytic converter if required and weld the O2 sensor weld boss to the exhaust manifold Verify the Spark Plugs Gap 0 030 typ and then install new spark plugs Install and verify the
14. B to ground while manually applying vacuum to the vacuum fitting on the map sensor The voltage will depend on the vacuum but should read from 0 1 volt under high vaccum to 4 7 5 volts at atmosphere pressure and sea level If the voltage is within the range replace the ECM Code 43 Fuel injector error The fuel injector circuit 1s not responding properly The circuit has an open short or lost power from the power relay If the injector shows a true fault t s unlikely the engine would run on gasoline The injector could be turned on all the time and therefore 1t would squirt gasoline continuously when the ignition relay is active This would tend to flood the engine however it may run depending on loading and other conditions Verifying Fuel injector fault 2 Verify the ignition relay is operating properly as described in Code 64 The ignition relay provides power to the fuel injector Disconnect the fuel injector Connect a volt meter between ground and injector pin Rd Bk Switch the ignition from off to on and verify the injector pin has battery voltage applied for the 2 second fuel pump prime time period If this voltage is not present continue with step Reference 2 1 2 1 Connect voltmeter between ground and pin 87 of the ignition coil and fuel injector relay Switch the ignition power off to on Verify 12 volts is present at in 87 during the 2 second initial prime period If the voltage is present p
15. een CTS sensor pin A Wh BK and ground This should read near 5 volts If it does not proceed to step 2 1 1 2 1 1 Turn off ignition power and disconnect the ECM 2 1 2 Measure resistance from ECM pin 9 to CTS pin A It should read less than I If it does not repair the wire 2 1 3 Measure resistance from ECM connector pin 10 to CTS sensor pin B Bk Y It should read less than I If it does not repair the wire 2 2 If no sensor or wiring problems are found replace the ECM Code 21 The TPS sensor is reading incorrectly Make sure the TPS 15 plugged in To verify the TPS sensor and wiring l Disconnect the TPS sensor from the harness 1 1 Measure TPS resistance between TPS pins A and B This should read 2 5 7 5kQ If it is outside this range replace the sensor 1 2 Measure resistance from pin A to pin C while slowly manually move the throttle plate The resistance should increase smoothly without dips or spikes If it is not smooth replace the sensor 2 Turn ignition power ON Measure voltage from harness TPS connector pins A and B This should measure 4 75 5 25 volts If not proceed to step 2 1 2 Perform the following measurements 2 2 Turn ignition power OFF Disconnect the ECM from the wiring harness Disconnect the MAP sensor and drive by wire pot 1f it 1s used and easily to disconnect Perform the measurement in Table 8 Meter mode From Desired Result If defective Ohms
16. fy that no exhaust leaks occurs before the O2 sensor Adjust Mixture till the O2 feedback is between 1 5 1 7 Disconnect coolant temperature sensor Stop Engine Verify the error light flashes a code 15 OR the diagnostic error screen shows an error 15 This ensures the ECM is in timing check mode when the engine speed is below 1000 RPM Disconnect the actuator power Disconnect the O sensor Start the engine Set engine speed to 750 RPM via idle screw Check timing is 0 degrees Do not exceed 1050 RPM when timing or it will exit timing mode Set minimum Air Base Idle Speed Customer Specific 900 RPM
17. g with TPS feedback Advanced Spark ignition timing for each fuel type EFI System Overview Precision KEM Certified Engines 2004 Certified Emissions Results ECM System Components Governed Throttle body Fueling components Gasoline LP components Engine sensors e Harness Governed Throttle Body Dual Fuel GM Engine Throttle Position Quick Sensor response actuator Certified On the Following GM Engines 1 6 L 3 0 L 4 3 L 5 7 L Speed Governing Modes e 4 Discrete speeds e Ramp up ramp down speed select e Drive by wire Potentiometer Foot pedal e Custom plus Gasoline Fuel System Siemens fuel injectors ograms second 42 psi e Throttle body fuel injection Gaseous Fuel System for LP NG amp CNG e Use conventional gaseous fuel components for LPG and CNG e Lockoff valve Vaporizer Vacuum Valve LP mixer e Proven field reliability e Avoids known problems with LP injectors Microprocessor 4 A T E HIE e E a 9 9 p WUER 22712 4 4 4 r n BANG ew HOT E er 9 Mor COE a HE o R Ti A Y 4 2 E E m Y gt 5 p 40 pin Deutsch sealed connector x 1 2 20 Qd GERT p
18. ime The oil pressure wire has been shorted to ground or power this input depends on how the ECM and machine 15 configured The low pressure shutdown system 15 intended for use with a low pressure switch not an analog pressure sensor If the system uses a pressure sensor it must be replaced with a switch Some machines may also use the shutdown wire for other shutdowns such as over temperature overload or others as the OEM deems appropriate Ensure these are not causing the problem To verify the oil pressure fault wire 1 Disconnect oil pressure wire Turn ignition power on Measure the voltage present on the 1 1 1 2 1 3 1 4 1 3 1 6 1 7 oil pressure wire PU Wh If the voltage is less than battery voltage proceed to step Reference 1 1 Verify the engine contains the proper level of oil Turn ignition power off and disconnect ECM from the harness Measure resistance from ECM pin 14 to the oil pressure shutdown terminal This should be lt 10 If the resistance is higher repair the wire Measure the resistance from ECM pin 14 oil pressure to ECM pin 25 ground If this is not open the wire contains a short repair the wire Measure the resistance from ECM pin 14 oil pressure to ECM pin 11 power If this is not open the wire contains a short repair the wire To test functionality of the wire connect the ECM and start the engine For engines with a standard short to ground on fau
19. l injector error EEPROM fault Oil pressure too low fault Analog to digital converter fault LP solenoid relay fault Fuel pump relay fault Dual fuel relay fault Ignition power relay output error MIL Diagnostic Description The machine s diagnostic LED is mounted in a place visible to the operator The LED is a 2 wire device and it must be wired according to the diagram If it is not connected correctly the LED will not light Many machine or fueling problems are wiring or wiring related First perform a visual inspection of the system Unplugged cut or damaged connections and wires should be corrected or replaced before attempting further diagnosis The diagnostic LED provides a method to identify a systemic malfunction The code format will consist of a number of blinks a pause a second number of blinks then a longer pause The first set of blinks is the 10 s digit of the error code The second set of blinks 15 the one s digit of the error code After the longer pause the next error code will be sent At the conclusion of the error codes a code 12 will be sent then the sequence will repeat itself The error codes are repeated sequentially until the malfunction 15 fixed or the engine has begun running The first error code that 15 blinked 15 code 12 then all active error codes in ascending order then it 1s finally concluded with a code 12 again Error code diagnostics below Code 12 Code 12 s a s
20. level LPG fuel filter is not contaminated and Replace LPG filter use air pressure to verify restriction Clogged fuel lines Clean fuel lines LPG pressure regulator vaporizer is not Check for air leaks purge air from frozen and or icing coolant hoses add coolant Visually inspect Vacuum hose for breaks Verify Timing with timing light Adjust distributor timing Verify the air filter for the vaporizer is Replace air filter not clogged Vaporizer primer button becomes hard to Replace Clean LPG fuel lock off depress when the fuel is present Condition Engine runs too Rich with LPG Verify each item below Remedy for each item below Verify that there is no air leaks into the hos vacuum port on the LPG mixer Check for Clogged Air Filter Repair Replace Check for exhaust air leaks before the Repair air leaks in the exhaust system O2 sensor Verify the O2 sensor is working properly See error code 13 Verify idle air screw is adjusted at idle Turn ccw the adjustment screw to lean out Fuel trim valve will have a 50 duty cycle the air fuel mixture Replace if LPG vapor pressure is not Faulty LPG vaporizer greater than Atm Pressure 2 W C Condition Engine will not start LPG Verify each item below Remedy for each item Fuel Tank Level Add Fuel Check fuel shut off valve Check for obstruction from fuel line Cycle ignition switch on off fuel shut off Check wiring and fuse relay valve
21. lt sensor short the wire to ground The engine should shutdown within 15 seconds If it fails to shutdown perform step 1 6 For engines with a connect to power on fault sensor short the shutdown wire to switched power The engine should shutdown within 15 seconds If it fails to shutdown perform step 1 5 Verify the engine s oil pressure per the engine manufacturer s recommendations 1 7 1 If the engine oil pressure is within spec replace the oil pressure switch sensor 1 8 If the shutdown will not kill the engine and it s enabled n the ECM replace the ECM Code 61 Code 62 Code 63 Code 64 LP power solenoid fault Verify connections Fuel Pump Relay fault Verify connections Dual fuel relay fault Verify connections Ignition power relay output error Verify connections Basic Trouble Shooting Guide The following s a guide to the most common engine performance complaints The guide is used to diagnose problems that are due to worn out components and or bad adjustments in the Fueling system Condition Engine will not start Gasoline Verify each item below Remedy for each item Fuel Tank Level Add Fuel Check fuel pump Check wiring and fuse relay Cycle ignition switch on off fuel pump should run for 2 seconds Use a pressure gage connected to fuel Check and or Replace fuel filter and or port Verify the fuel pressure should And or Fuel Pressure regulator
22. ottle plate The voltage should move smoothly between low speed and high speed If the voltage has dead spots or spikes replace the DBW device If the voltage 15 within the range and moves smooth replace the ECM Code 32 System voltage too low 2 1 2 2 22 This indicates the ECM 15 receiving a low battery voltage measurement Verify the battery voltage measures above 10 volts while the engine is running Measure the system battery voltage during normal operation If it is below 12 5 volts the charging system should be diagnosed Normal running battery voltage should read approximately 13 14 5 volts If the battery voltage 1s low the charging system or machine wiring should be diagnosed Turn ignition power off then disconnect the ECM Turn ignition power ON Measure the voltage between pins ground 25 or 35 and switched power 11 and then the battery voltage The 2 readings should be within 0 5 volts If the readings very considerably proceed with step 0 Acceptable voltage drops should be less than 0 5 volts unless the machine draws current for other functions If any wires show considerable voltage drops that wire should be inspected for damage or poor connections Measure the voltage between battery ground and ECM pin 25 This voltage should be near 0 Measure the voltage between battery ground and ECM pin 35 This voltage should be near O With ignition power still ON measure voltage between ECM pin 11
23. pecial code signifying the beginning or end of the error codes Code 13 Code 13 indicates the oxygen sensor has not warmed up or has stuck rich lean or neutral for a period of time Other fuel system issues can cause this for example incorrect fuel pressure or a leak in the MAP sensor hose To verify the O2 sensor wiring 1 Verify fuses are intact 2 Disconnect O2 sensor connector and turn ignition power on 3 Measure voltage across harness O2 connector pins A and B This should read near 0 45 volts 4 If not Turn off power 5 Disconnect ECM 6 Check connections shown in Table 5 Meter mode Desired If defective Result Harness 02 A lt 1 0 wire 1s open Harness O2 B wire 15 shorted Harness O2 A This wire s open Harness O2 B wire 15 shorted Table 5 Harness O2 sensor check 7 Turn on ignition power 7 1 Measure the voltage across harness O2 sensor connector pins C and D This This should read near the battery voltage 1f not proceed to the step 7 1 1 7 1 1 Perform the first measurements in Table 6 Meter mode Desired Result If defective Voltage Ground Harness O2 C Battery voltage 10 14 02 C wire is open Voltage Battery Harness O2 C lt 1 volt 02 C wire is open Voltage Ground Harness O2 D O2 D wire is open Voltage Battery Harness O2 D Battery voltage 10 14
24. re E Alas 7 Nr LE 128 abang 22900 e Motorola Microprocessor controlled eEnvironmental SAE J1211 4 2 Vibration Mil STD 202G at 9 2G Temperature Rating 40 deg to 185 deg F EMISAEJ1113 21 60 VOLTS METER Integral Heat sink Aluminum enclosure Additional I 0 capability for accessories e Remotely vertically mounted away from the engine Engine Control System Inputs 02 IAT ECT MAP TPS Oil pressure Engine speed
25. roceed with step 2 1 1 2 1 1 Recheck the ignition power relay as described in Code 64 2 2 Turn off ignition power Measure resistance from relay pin 87 Rd Bk of the ignition coil and fuel injector relay and injector pin Rd Bk This should measure lt 10 If the measurement is greater repair the wire Turn off the ignition power Measure the resistance of the fuel injector The resistance of a room temperature injector should read 1 2 Replace the injector if the resistance 15 considerably outside this range Disconnect the ECM from the harness Measure the resistance from ECM harness pin 4 and injector connector This should read lt 1 Q If it is greater repair the wire Measure the resistance from ECM harness pin 25 and injector connector pin B This should read open If t shows continuity repair a short to ground Measure the resistance from ECM pin 11 switched battery voltage and injector connector pin B This should read open If t shows continuity repair a short to battery voltage If no short is found and the injector squirts fuel during the initial prime period replace the ECM If no short is found and the injector does not squirt fuel during the initial prime period but the engine runs normally without flooding investigate battery voltage and charging system malfunctions Otherwise replace the ECM Code 53 Low oil pressure fault The engine has exhibited low o l pressure during run t
26. rom the harness if possible and disconnect the ECM 1 2 Measure the resistance between DBW control ground Harness wire Bk Y1 and supply Harness wire RD BU This should read close to the pots resistance in the range of 1kQ to IOk 2 however if it reads open or shorted the unit is defective 1 3 Measure the resistance from the pots ground lead to the output lead harness GN YL The resistance should start low when the pot 1s turned to the low side and increase smoothly as the pot 1s turned to the high side If the resistance does not smoothly increment or has discontinuities replace the DBW device Turn ignition power OFF Disconnect the ECM from the wiring harness Disconnect the MAP sensor and TPS Perform the measurements 1n Table 9 Desired Result If defective ECM Harness 10 DBW GND BK YL Ground wire 15 open ECM Harness AO DBW 5 RD BU 5 volt wire is open ECM Harness 9 DBW output GN YL DBW s gnal wire 1s open ECM Harness 10 ECM Harness 40 Open lt 1000 Q if DBW pot is connected 5 volt wire shorted to ground ECM Harness 10 ECM Harness 18 Open TPS s gnal shorted to ground ECM Harness AO ECM Harness 18 Table 9 DBW wiring troubleshooting TPS s gnal shorted to 5 volts 1 4 If all other DBW tests check out reconnect all sensors Measure the voltage from DBW output to ground while manually opening the thr
27. should click off after 2 seconds Clogged fuel filter Close liquid fuel valve Repair replace fuel filter Open liquid fuel valve check for leaks fuel trim vacuum valve is stuck open Clean valve Check wiring Clogged small air filter on top of the Clean Replace air filter and orifice jet vaporizer Carburetor malfunction Check diaphragm for holes and damage Repair Replace Assembly Detail Gasoline v Fuel A sas 1 On alv H1 Assem Injection lt NI in away z 47976 3 0 3 Engine typic 1 connector Fuel Inlet TPS Sensor TB actuator Dual Fuel System Detail Assembly 4 3L and 5 7L typical LPG Gaseous Fuel System Assembly 4 3L and 5 7L engine typical a I i ET 7 Y IE LS oe T N Lx jT pu 27 Eg 4 Se Coolant Hoses LPG Vaporizer Regulator Atmospheric pressure port Propane vapor
28. temperature The resistance should be within 5 of that listed 1n Table 7 If the sensor differs replace the sensor Turn ignition power ON and disconnect the IAT sensor Measure the voltage between IAT harness sensor pin A purple and eround This should read near 5 volts If 1t does not proceed to step Turn off 1gnition power and disconnect the ECM Measure resistance from ECM pin 19 to IAT harness pin A It should read less than 1 Q If it does not repair the wire Measure resistance from ECM connector pin 10 to IAT sensor pin B Bk Y1 It should read less than I Q If it does not repair the wire If no sensor or wiring problems are found replace the ECM Code 31 Drive by wire fault the drive by wire voltage is too low or too high This code can be setin some systems if the drive by wire pot is set to one extreme or the other First set the pot at least 1 8 of a turn from either end If the error code is gone there is no problem If the machine does not utilize the DBW device this error can be 1gnored As the DBW device 15 OEM specific the resistance values can vary depending on what device is used Recommended potentiometer ranges are 1kQ to 10 To verify the DBW sensor and wiring l Turn ignition power ON Measure voltage from harness DBW ground wire Bk Yl and 5 volts Rd Bu This should measure 4 75 5 25 volts If not proceed to step 1 1 1 1 Turn off the ignition power disconnect the DBW sensor f
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