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MI-04 2.0/2.4L Service Manual 91505B Draft

1. 88 12001 5 88 55 500 Service AVV Air Valve Vacuum Testing 91 dune etia do aeu o up Pena no d 92 NIXUS o NEE 97 WOODWARD 4 TABLE OF CONTENTS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM WOODWARD 5 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM WORKING WITH LPG EQUIPMENT A WARNING Propane Vapor is heavier than air and can collect in low areas when adequate ventilation or air movement is not present to disperse it Never check for leaks with a flame or match Use a leak detector solution or an electronic detector Make sure the container service valve is closed when connecting or disconnecting If the container service valve does not operate properly discontinue use and contact your propane supplier Never insert any object into the pressure relief valve WARNING LP gas is highly flammable To prevent personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system e Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate
2. 27 MI 04 Ignition 31 VR SENSOP 31 CHAPTER 3 0 MI 4 MAINTENANCE SCHEDULE 32 Test Fuel Syster f r Leaks eco tee stetit att Fat a adu E SEO E c dos a 32 Inspect Engine for Fluid Leaks eese 32 Inspect Vacuum Lines and Fittings 32 Iispecr Electrical SV Sle sau aao dude du nao du idt Edu ad 32 Inspect Foot Pedal Operation 33 CHECK Coolant TEES 33 68 A E AOA 33 el i i 33 cilc PONTO 33 PRE DIAC SSO AI el 33 Replace LP Fuel Filter Element 34 esting Fuel Loeko ODGFallOEY RER 35 Pressure Regulator Converter Testing and Inspection 36 Fuel Trim Valve Inspection 36 WOODWARD 2 TABLE OF CONTENTS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM Inspect Air Fuel Valve Mixer 36 Inspect for INTAKE BeaKS 36 InsbecE Thirot e AS SCI DIV wise 36 Checking the TMAP Sensor
3. 45 Hige UU UT UNUM 45 Poor High Speed Performance 45 Excessive Fuel Consumption LPG Exhaust Smell 46 CHAPTER 5 0 MI 04 LP ADVANCED DIAGNOSTICS 48 Advanced DIAGNOSING ERR 48 Reading Diagnostic Fault 48 Displaying Fault Codes DFC From SECM 48 cleanng Faul DIC COGS d Mu nea m su nu etui uta duds 49 EaultAction DescriDIOFIS sso sti itte Cid SEE 49 49 CHAPTER 6 0 04 ELECTRICAL CONNECTIONS 66 RESIStanNce 68 SECM Electrical Mounting 70 04 Speed Limiting Function 70 CHAPTER 7 0 2001 PRESSURE REGULATOR CONVERTER 72 Removal and Installation of N2001 LP Regulator Converter 72 mm 73 CHAPTER 8 0 N CA55 500TR AIR FUEL MIXER 78 Removal and Installation of the N CA55 500TR Mixer 78 Installing the Mixer Throttle Assembly 84 WOODWARD 3 TABLE OF CONTENTS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM CHAPTER 9 0 TEST AND
4. ogee aan ne ner it 11 asa TT 11 12 SEVICE 12 Quick Disconnect 13 mE ERR LUDUM 13 CHAPTER 2 0 04 LPG SYSTEM OPERATIONAL OVERVIEW 2 0L amp 2 4114 MISD4 General 14 Ie Sr LTP Mle RI M 16 MI O4 Fuel Lock OIf 16 04 N 2001 Regulator Converter 17 N 2001 X heory ot 18 MOF N CAS5 500 TR MIXET mte Ime 19 N CA55 500 TR Air Fuel Mixer Theory of Operation 20 MI O4 Electronic Throllle 21 MOS FUSIN 23 Heated Exhaust Gas Oxygen Sensor 24 04 SECM General Description 25 04 SECM Fuel Management 25 CatalyilG r a EOE OPTRA TETT ERIEN 26 04 SECM Load Speed
5. 2 ON OFF ON ON OFF WOODWARD 48 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Clearing Fault DFC Codes To clear the stored fault codes from SECM memory you must complete the reset fault pedal maneuver A CAUTION Once the fault list is cleared it cannot be restored First turn OFF the ignition key Now turn ON the key but do not start the engine As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal pedal maneuver You must fully cycle the foot pedal ten 10 times within five 5 seconds to clear the fault code list of the SECM Simply turn the key OFF to exit the reset mode The code list is now clear and the SECM will begin storing new fault codes as they occur Fault Action Descriptions Each fault detected by the SECM is stored in memory FIFO and has a specific action or result that takes place Listed below are the descriptions of each fault action Engine Shutdown The most severe action is an Engine Shutdown The MIL will light and the engine will immediately shutdown stopping spark with the fuel lock off closing Delayed Engine Shutdown Some faults such as low oil pressure will cause the MIL to illuminate for 30 seconds and then shutdown the engine Disable Throttle The throttle moves to its default position The engine will run at idle but will not accelerate Limp Home Mode
6. 36 Inspect Engine for Exhaust 1 36 General Maintenance 5 38 FAJNE 38 Engine Ignitlol SOCOM 38 Fuel Lock Off Filter Section 38 Maintenance Schedule Continued 39 Pressure Regulator Converter Section 39 Fuel Trim sudes Rus 39 CCU TMT 39 EMISSION SeCLIOFl tue 39 CHAPTER 4 0 04 LP BASIC TROUBLESHOOTING 40 Basic WROUDIGSMOOUING Tm 40 Engine Cranking but Will 5 40 Engine Cranking but Wil Not Start oo 41 T 41 VL NOP ISIN OMUUNUOU 42 Will Not Accelerate Hesitation During Acceleration 42 Will Not Accelerate Hesitation During Acceleration 43 43 ENGINE Stalls Om 44 44
7. il Oil Pressure AL Switch VR Sensor DBW 5 Sensor Foot Pedal B MIL Figure 1 WOODWARD 66 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM T SECMCONNECTOR E 9 5 5 E R01 5 2 120 D o zo T z 2 O o 5 2 0 9 6 9 0 gt gt Og dose x OX 3 6 gt gt 2 oo x 9 123456 189101 123 14 16 718 19 20 21 22 23 24 GND APP _ PWR LOW APP2 OIL 1 12 DC 8 lt n MIL 7 in r 5 SE Bo Figure 2 WOODWARD 67 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Resistance Checks NOTE All resistive checks are made with the sensor or device disconnected from the harness POINT TO POINT EXPECTED RANGE TMAP PIN 1 GND TO PIN4 2 4kQ 8 2kO PRESSURE SIGNAL KPA TMAP PIN PWR TO PIN 4 3 4k
8. 4 MAINTENANCE SCHEDULE RECOMMENDED MAINTENANCE SCHEDULE Suggested maintenance requirements for an engine equipped with an MI 04 fuel system are contained in this section The owner should however develop his own maintenance schedule using the requirements listed in this section and any other requirements listed by the engine manufacturer Test Fuel System for Leaks Obtain a leak check squirt bottle or pump spray bottle Fill the bottle with an approved leak check solution Spray a generous amount of the solution on the fuel system fuel lines and connections starting at the storage container Wait approximately 15 60 seconds then perform a visual inspection of the fuel system Leaks will cause the solution to bubble Repair any leaks before continuing Crank the engine through several revolutions This will energize the fuel lock off and allow fuel to flow to the pressure regulator converter Apply additional leak check solution to the regulator converter fuel connections and housing Repeat leak inspection as listed above Repair any fuel leaks before continuing Inspect Engine for Fluid Leaks Start the engine and allow it to reach operating temperatures Turn the engine off Inspect the entire engine for oil and or coolant leaks Repair as necessary before continuing Inspect Vacuum Lines and Fittings Visually inspect vacuum lines and fittings for physical damage such as brittleness cracks and kinks Repair
9. 04 LP SYSTEM Distributor with Rotor Cap Removed Firing Order 1 3 4 2 Figure G2 3 Remove the distributor rotor and dust cover so that the internal VR sensor and signal rotor gear are visible Figure G3 The internal VR sensor inside the distributor is not used by the SECM for a speed reference with the 2 0L 2 4L engine and it s wiring harness does not connect to the system The distributors internal VR sensor is only used as an alignment reference point for setting the correct distributor position Distributor View of Internal VR Sensor p 4 LI ILS TR 4 a s NNI NUN 7 1 Internal VR Sensor Signal Rotor WOODWARD 93 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 4 Loosen the distributor hold down nut and rotate the distributor so that the signal rotor gear tooth of the 1 cylinder tooth opposite the flat side of the distributor shaft lines up with the sensor pickup Figure G4 Figure G4 Signal rotor 1 Tooth Flat Side of Shaft 5 set the distributor align the center of the 1 cylinder tooth with the leading edge of the VR sensor pickup Figure G5 Keep in mind that the distributor rotates in a clockwise direction Correct Alignment Figure G5 Incorrect Alignments WOODWARD 94 TEST AND ADJUSTMENTS 2 0L 2 4L SERVIC
10. A limp home mode reduces the lift truck power and is provided to enable the operator to drive the lift truck in an unsafe situation but not use the truck for normal operation MIL ONLY The MIL will light by an active low signal provided by the SECM indicating a fault condition but no further action will take place Fault List Definitions Several sensors in the MI 04 system have input low high faults and a sensor range fault These are the coolant temperature sensor the throttle position sensor and the pedal position sensors Signals to these sensors are converted into digital counts by the SECM A low high sensor fault is normal set when the converted digital counts reach the minimum of 0 or the maximum of 1024 1024 5 0 VDC with 204 counts per volt A sensor range fault is set if the parameter measured by the sensor is outside the normal operating range WOODWARD 49 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 1024 Counts Input High Sensor Range 0 Counts Input Low Figure F1 ECTSensorlnputLow Engine Coolant Temperature Sensor Input is Low normally set if the coolant sensor wire has shorted to chassis ground or the sensor has failed ECTSensorlnputHigh Engine Coolant Temperature Sensor Input is High normally set if the coolant sensor wire has been disconnected or the circuit has opened to the SECM ECTRangeHigh Engine Coolant Temperature Range is High the sensor has measured an ex
11. can increase or decrease the amount of oxygen in the exhaust by modulating the FTV Catalyst and adjusting the air fuel ratio This control Efficiency scheme allows the SECM to make sure that the engine is running at close to the stoichiometric point and also to make sure Operational that there is enough oxygen in the exhaust to Range of allow the oxidization catalyst to burn the unburned hydrocarbons Air Fuel Ratio Leaner 04 SECM Load Speed Management Drive by wire refers to the fact that the MI 04 control system has no throttle cable from the foot pedal Figure 26 to the throttle body Instead the SECM is electronically connected both to the foot pedal assembly and the throttle body The SECM monitors the foot pedal position and controls the throttle plate by driving a dc motor connected to the throttle The dc motor actuates the throttle plate to correspond to the foot pedal position when the operator depresses the pedal The use of electronic throttle control ETC ensures that the engine only receives the correct amount of throttle opening for any given situation greatly improving idle quality and drivability Figure 26 WOODWARD 27 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM A Throttle Position Sensor TPS Figure 27 which is integral to the Drive By Wire DBW throttle assembly provides feedback for position control by monitoring the exact posi
12. speed reaches the max governing point the speed is controlled by closing the DBW throttle Using the DBW throttle as the primary engine speed control allows for a smooth transition into and out of the governor If speed exceeds this max governing point spark is interrupted to attempt to bring the speed back to a point that can be controlled by throttle alone If over speed is detected multiple times the engine is shutdown Figure 29 System Power Comparison 60 0 40 0 o c m 200 gt S Woodward system Baseline system 0 0 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 RPM System Torque Comparison 140 0 5 900 o 1000 i o 800 2 L c 60 0 o gt 400 gt 2 20 0 Woodward system Baseline system 0 0 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 RPM WOODWARD 29 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM DBW Flow Diagram Foot Pedal 1 APP 0 100 e Self Calibration e Cross Check of APP1 amp APP2 SECM 5msec Update Rate DBW Throttle Figure 30 Figure 30 describes the signal flow process of the 04 DBW section The foot pedal assembly uses two potentiometers to detect pedal position These two signals accelerator pedal position 1 APP1 and accelerator pedal position 2 APP2 are sent directly to the SECM The SECM uses a series of algorit
13. tubing This prevents the gauge from reading maximum pressure due to the large velocity of compressed air entering the primary chamber Figure R13 9 Make sure there is no leakage at any of the fittings The static pressure should read between 40 60 inches of water column on the Magnahelic gauge and maintain a constant pressure for 60 seconds 10 If the pressure reading begins to increase a leak is most likely present at the primary valve either the primary valve o ring or the valve itself If a leak is present you will need to disassemble the primary side of the regulator repair the cause of the leak re assemble the regulator and test the primary stage again See Chapter 7 for disassembly of the 2001 11 If the pressure begins to decrease the secondary seat is probably not making an adequate seal and is leaking If a leak is present you will need to disassemble the secondary cover of the regulator repair the cause of the leak re assemble the regulator and test the primary and secondary stage again See Chapter 7 for disassembly of the 2001 12 Once the test is successful re install the primary test port plug and check the fittings for leaks See Chapter 7 for installation of the 2001 NOTE i The N2001 Primary stage pressure can also be tested at idle on a running engine The N 2001 primary pressure should be between 40 and 55 water column at 700 RPM idle WARNING LP gas is highly flammable To prevent
14. 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes Pedal2SensorlnputLo APP2 sensor failure or shorted circuit Pedal2SensorlnputHi APP2 signal disconnected open circuit or sensor malfunction Expected faults when APP connector is unplugged CODES 61 amp 66 Pedal2SensorRangeLo APP2 potentiometer malfunction Improper APP2 reading may be due to dirt or oxidation on the sensor traces Pedal2SensorRangeHi APP2 potentiometer malfunction Improper APP2 reading may be due to dirt or oxidation on the sensor traces Pedal1ToPedal2Difference Measured APP2 pedal position signal is different than 1 signal AFRTrimValveOutput FTV modulation driver signal fault WOODWARD MIN power Limit MIN power Limit Stored Fault Code MIL Only Stored Fault Code MIL Only MIN power Limit Stored Fault Code MIL Disable Adaptive learns 62 Probable Fault Corrective Action First Check Check foot pedal connector e Cycle the pedal several times and check APP2 signal at SECM PIN 2 Check foot pedal connector Check APP2 signal at SECM PIN 2 Check foot pedal connector e Cycle the pedal several times and check APP2 signal at SECM PIN 2 Check foot pedal connector e Cycle the pedal several times and check APP2 signal at SECM PIN 2 Check foot pedal connector e Cycle the pedal several times and check 1 signal at SECM PIN 15 Check 2 signal at SECM PIN 2 Check FTV for an
15. 1 pause then flash two times 2 This identifies a twelve 12 which is the beginning of the fault list It will then pause for 1 2 seconds long pause and flash two times 2 pause then flash six times 6 This identifies a twenty six 26 which is the ETCSticking fault If any additional faults were stored the SECM would again have a long pause then display the next fault by flashing each digit Since no other faults were stored there will be a long pause then one flash 1 pause then two flashes 2 This identifies a twelve meaning the fault list will begin again Displaying Fault Codes DFC From SECM Memory To enter code display mode you must turn OFF the ignition key Now turn ON the key but do not start the engine As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal pedal maneuver You must fully cycle the foot pedal three 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is turned OFF An automatic code display feature is activated if a foot pedal fault condition exists This feature enables the service technician to view the fault codes by turning the key to the ON position if a foot pedal malfunction is preventing the retrieval of the stored fault codes from the SECM Malfunction Indicator Light MIL
16. Codes Flash Codes Probable Fault Corrective Action First Check NONE NONE None used as a beginning and Signifies the end of one pass end of the fault list identification through the fault list ECTSensorlnputLow Stored Fault Code Check ECT sensor connector Coolant sensor failure or shorted to MIL Only and wiring for a short to GND SECM SIGNAL PIN 16 to ECT PIN A SECM GND PIN 1 to ECT PIN B ECTSensorlnputHigh Stored Fault Code Check if ECT sensor connector Coolant sensor disconnected or MIL Only is disconnected or for an open open circuit ECT circuit SECM SIGNAL PIN 16 to ECT PIN A SECM GND PIN 1 to ECT PIN B ECTRangeHigh Delayed Engine Check coolant system for Engine Overheating Shutdown radiator blockage proper coolant level and for leaks in the system Possible ECT short to GND check ECT signal wiring SECM SIGNAL PIN 16 to ECT PIN A SECM GND PIN 1 to ECT PIN B e Check regulator for coolant leaks See Chapter 7 0 ThrottleSensorlnputLo Disable Throttle Check throttle connector TPS1 signal disconnected or open connection and TPS1 sensor for circuit an open circuit Expected faults when ETC connector is unplugged ETC PIN 6 to SECM PIN 17 CODES 22 amp 24 SIGNAL ETC PIN 2 to SECM PIN 1 GND WOODWARD 54 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes Probable Fault Corrective Action First Check ThrottleSensorlnp
17. all steady state conditions from idle through full throttle In closed loop mode the FTV duty cycle is based on feedback from the HEGO sensor In order to handle transient loads engine RPM and load is compared to a threshold used by the SECM When this threshold is exceeded the FTV duty cycle will be set to a Feed Forward Adaptive value The SECM then makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer Reducing the fuel pressure leans the air fuel mixture and increasing the fuel pressure enriches the air fuel mixture Control is achieved by modulating the fuel trim Catalytic Muffler All exhaust gases pass through a catalytic converter that is mounted on the exhaust pipe It filters these gases through a dense honeycomb structure coated with precious metals such as platinum palladium and rhodium Chemical reactions occur on these surfaces to convert the pollutants into less harmful gases Catalytic converters store oxygen on lean mixtures less than optimal amount of fuel and release oxygen on rich mixtures more than optimal amount of fuel The primary pollutant produced on the lean swing is nitrous oxide Oxygen is removed from nitrous oxide by the converter resulting in nitrogen gas a harmless emission On the rich cycle the primary pollutant is carbon monoxide By adding the oxygen that was stored on the lean cycle to the carbon monoxide carbon dioxide is produced Inside
18. and operation see mixer section Check N2001 secondary for operation see N2001 Regulator section WOODWARD 63 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes O2SensorSwitching Stored Fault Code Check the FTV for proper O2 sensor is not switching across MIL Disable operation the reference AFR voltage Adaptive learns e Check FTV Hose Connections Check FTV for an open coil by disconnecting the FTV connector and measuring the resistance 260 2Q FTV PIN A SIGNAL TO PIN B PWR OxygenSensorlnputHigh Stored Fault Code Check if O2 sensor is shorted to O2 sensor SECM driver signal is MIL Disable 5VDC or Battery shorted to power Adapts O2 SIGNAL PIN B to SECM PIN 3 AFRTrimValveLowerDC fault should also occur Verify O2 sensor heater circuit is operating by measuring circuit resistance 2 10 0 40 2 HEATER GND to HEATER PWR WOODWARD 64 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM WOODWARD 65 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 6 0 MI 04 ELECTRICAL CONNECTIONS Ignition Switch H Main PWR Relay Battery LE SECM T Te Fuel Lock Off Electronic J Throttle 1 i il n d ape Sensor Fuel Trim Valve ECT Sensor Smart Coil iat Ef
19. liquid fuel valve amp Leak test Pressure regulator freezes Check level in cooling system e Must be full check coolant strength 35F minimum Check coolant hoses e Watch for kinks and or pinched hoses e Verify one pressure hose and one return hose Repair replace Fuel Lock off See Chapter 3 Fuel Lock off ignition problem Diagnostics Service Manual Will Not Fuel container almost LPG Vapor from liquid outlet e Fill fuel contain Accelerate Hesitation 77 2 2 During Acceleration liquid capacity Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve WOODWARD 42 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Probable Cause Corrective Action Will Not Clogged fuel filter Repair replace as required See Chapter 3 Fuel Accelerate Hesitation Filter replacement During Acceleration Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the e Clamps must be tight mixer e Look for kinked pinched and or collapsed hose See Chapter 5 Advanced opening or sticking Diagnostics or intermittent control Service Manual Engine Stalls Fuel container almost LPG Vapor from liquid outlet empty e Fill fuel container Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait fo
20. may be necessary for the certified technician to disassemble clean and service the regulator converter after long periods of operation WARNING Removal and Installation of N2001 LP Regulator Converter e LP gas is highly flammable To prevent personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system e Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area e Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION The regulator converter and mixer are part of a certified system complying with EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble service or replacement of the regulator converter or mixer WOODWARD 72 N2001 REGULATOR CONVERTER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Hose Connections Proper operation of the closed loop control greatly depends on the correct vacuum hose routing and fuel line lengths Refer to the connection diagram Figure R1 for proper routing and maximum hose lengths when reinstalling system components Figure R1 Liquid Propane From comme 4 Fuel Tank Balance Line From Mixer A
21. motion test to confirm sticking problems NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly PredictedTPSDifference Predicted Throttle Position Sensor Difference measured TPS1 is different than SECM Calculated throttle position Normally caused by intake leaks between the throttle assembly and the engine WOODWARD 50 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM ETCSpringTestFailed Electronic Throttle Control Spring Return Test has Failed upon the initial startup of the engine the SECM will perform a safety test of the throttle return spring If this spring has become weak the throttle will fail the test and set the fault NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly ETCDriverFault Electronic Throttle Control Driver has Failed an over current condition has occurred on either ETC or ETC driver signals RunningResetCnt Running SECM Reset Counter an SECM processor reset has occurred due to excessive electrical ignition system noise MapSensorlnputLow Manifold Air Pressure Sensor Input is Low is normally set if the TMAP pressure signal wire has been disconnected or the circuit has opened to the SECM MapSensorlnputHigh Manifold Air Pressure Sensor Input is High is normally set if the TMAP pressure signal wire has become shorted to power shorted to the
22. on metal seal and the second valve uses a metal on metal seal Figure 9 Weakness Ring ME A weakness ring is machined into the filler valve just above the check valves and will allow the filler valve to shear off in case of an accident The valve will break or shear off above the check valves so that the tank will be sealed and no liquid propane can escape WOODWARD 13 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM CHAPTER 2 0 MI 04 LPG SYSTEM OPERATIONAL OVERVIEW 2 0L amp 2 4L 04 General Description Woodward s 04 control system is designed to provide a complete fully integrated solution that will meet or exceed TIER 2 Large Spark Ignited Engines emission standards established by the California Air Research Board CARB and the Environmental Protection Agency EPA for 2004 The MI 04 is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas In order to obtain maximum effect from the catalyst an accurate control of the air fuel ratio is required A small engine control module SECM uses a heated exhaust gas oxygen sensor HEGO in the exhaust system to monitor exhaust gas content 04 System with the N CA55 500 Mixer Fault Light Fuel Filter T LP Fuel Line JM SEY WIEN he 5 Fuel Lock ain Foot Pedal PWR APP Relay pm Air Cleaner Fuel Trim Valve Mixer DBW Throttle at TMAP T SECM Oxygen Sen
23. open wire or FTV connector being disconnected FTV PIN A SIGNAL TO PIN B PWR Check FTV for an open coil by disconnecting the FTV connector and measuring the resistance 26Q 20 FTV PIN A SIGNAL TO PIN PWR ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table a 04 Diagnostic Fault Codes Flash Codes Table 04 Diagnostic Fault Codes Flash Codes Codes Probable Fault Corrective Action First Check 72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air Fuel ratio at FTV duty cycle at lower lean limit MIL Disable the O2 sensor is excessively lean Adaptive learns e Check for intake manifold leaks Check balance line vacuum hose connection at the regulator Check N CA55 500 TR mixer for heavy end build up and operation see mixer section Check N2001 secondary for operation or low primary pressure see N2001 Regulator section AFRTrimValveUpperDC Stored Fault Code Engine measured Air Fuel ratio at FTV duty cycle at high rich limit MIL Disable the O2 sensor is excessively rich Expected fault when FTV Adaptive learns connector is unplugged Check FTV connector wiring for an open circuit FTV PIN A SIGNAL TO PIN B PWR Check FTV for an open coil by disconnecting the FTV connector and measuring the resistance 260 20 FTV PIN A SIGNAL TO PIN B PWR Check N CA55 500 TR mixer for heavy end build up
24. plastic vinyl and Styrofoam except antistatic versions around printed circuit boards Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided A could result in death or serious injury A CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken 2004 by Woodward All Rights Reserved WOODWARD 1 TABLE OF CONTENTS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM TABLE OF CONTENTS 2 WORKING WITH LPG EQUIPMENT 2 2 1 6 CHAPTER 1 0 LPG AND LPG FUEL 8 8 LP GG T Tm 10 installing LPG FUE 10 EPGJIuel
25. service or replacement of the regulator converter or mixer WOODWARD 78 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM N CA55 500TR Mixer Removal Steps 1 Close the liquid outlet valve in the forklift cylinder or fuel storage container 2 Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down 3 Remove the air horn air inlet adapter and hose Figure M1 1 4 Mark the two vacuum lines to the mixer and throttle adapter for identification they must be installed correctly for proper operation Remove the two vacuum lines Figure 1 2 5 Remove the vapor fuel inlet line Figure 2 3 6 Remove the electronic throttle connector Figure 1 4 7 Remove the four bolts that mount the throttle adapter to the electronic throttle body Figure M2 5 8 Remove the mixer adapter assembly from the throttle by gently pulling upwards NOTE There will be a plastic o ring spacer and an o ring inside this adapter be careful not to lose these items when removing the mixer adapter assembly from the throttle Figure M3 Figure M3 Figure M2 WOODWARD 79 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM N CA55 500TR Disassembly and Service 1 With the mixer adapter assembly removed Figure M4 and the Air Horn removed from the mixer remove the four adapter retaining screws from the bo
26. state In the liquid state propane is approximately 270 times as dense as it is in a gaseous form By pressurizing a container of LPG we can effectively raise the boiling point above 44 deg F 42 deg C keeping the propane in liquid form The point at which the liquid becomes a gas boiling point depends on the amount of pressure applied to the container This process operates similarly to an engine coolant system where water is kept from boiling by pressurizing the system and adding a mixture of glycol For example water at normal atmospheric pressure will boil at 212 deg F 100 deg C If an engines operating temperature is approximately 230 deg F 110 deg C then the water in an open un pressurized cooling system would simply boil off into steam eventually leaving the cooling system empty and over heating the engine If we install a 10 PSIG cap on the radiator pressurizing the cooling system to 10 PSIG the boiling point of the water increases to 242 deg F 117 deg C which will cause the water to remain in liquid state at the engines operating temperature WOODWARD 8 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM The same principle is applied to LPG in a container commonly referred to as an LPG tank or cylinder Typically an LPG tank is not filled over 80 capacity allowing for a 20 vapor expansion space Outside air temperature effect s LPG tank and must be considered when using an LPG sy
27. the branch tee connected to the intake side of the mixer forming the balance line and referencing atmospheric pressure The other side of the branch tee fitting connects to the FTV inlet small housing side The FTV outlet large housing connector side connects to the AVV port When the FTV is open AVV is sent to the atmospheric side of the N2001 secondary diaphragm which lowers the reference pressure closing the N2001 secondary valve and leaning the air fuel mixture The MI 04 system is calibrated to run rich without the FTV By modulating pulsing the the SECM can control the amount of AVV applied to the N2001 secondary diaphragm Increasing the amount of times the FTV opens modulation or duty cycle causes the air fuel mixture to become leaner decreasing the modulation duty cycle enriches the mixture Figure 22 shows the Fuel Trim Valve connected in the MI 04 system Balance Line Figure 22 WOODWARD 23 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM Heated Exhaust Gas Oxygen Sensor HEGO The HEGO sensor Figure 24 installed in the exhaust manifold before the catalytic muffler is a basic zirconium type oxygen sensor comprised of a hollow cone shaped internal element made of zirconium dioxide ZrO2 a ceramic material which is coated with a thin layer of micro porous platinum The outer layer is exposed to the exhaust stream while the inner layer is vented to the atmosph
28. the forklift in a well ventilated area e Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane A CAUTION The regulator converter and mixer are part of a certified system complying with EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble service or replacement of the regulator converter or mixer A CAUTION LPG fueled machinery may be garaged anywhere gasoline powered vehicles are garaged When machines are stored for a long period it is advisable to shut off the tank supply valve and run the machine until the fuel trapped down stream of the valve is depleted D NOTE NFPA National Fire Protection Agency 58 covers the procedures for storage and garaging for repair purposes on propane powered equipment WOODWARD 6 WORKING WITH LPG EQUIPMENT 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM A CAUTION Safety is an important consideration for any repair facility and repairing LPG fueled machinery is no exception Refer to the NFPA National Fire Protection Agency for the appropriate fire extinguisher specifications and fluorescent lighting requirements Propane has a heavier than air vapor density and will fall if a leak occurs while natural gas by comparison will rise in the event of a leak Figure 1 This is an importa
29. 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes 31 RunningResetCnt Engine Shutdown Check SECM chassis ground and ignition harness for cracked insulation MapSensorlnputLow Disable Throttle Check TMAP connector and MAP signal disconnected open MAP signal wiring for an open circuit or sensor malfunction circuit Expected faults when TMAP TMAP PIN 4 to SECM PIN 5 connector is unplugged SIGNAL CODES 33 amp 38 TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SECM PIN 18 XDCR 5VDC Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP PIN 1 GND to PIN 4 PRESSURE SIGNAL KPA 2 4 8 2 PIN 3 PWR to 4 PRESSURE SIGNAL KPA 3 4kO 8 2kO circuit circuit TMAP PIN 4 to SECM PIN 5 SIGNAL TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SECM PIN 18 XDCR 5VDC Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP PIN 1 GND to PIN 4 PRESSURE SIGNAL KPA 2 4 8 2 TMAP 3 PWR to PIN 4 PRESSURE SIGNAL KPA 3 4 8 2kQ 34 MapSensorlnputHigh Disable Throttle Check TMAP connector and TMAP sensor failure or shorted MAP signal wiring for a shorted WOODWARD 57 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes Probable Fault Corrective Action First Check lATSenso
30. 500TR mixer WARNING DO NOT spray carburetor cleaner or solvent into the mixer while installed on the engine These chemicals may damage the oxygen sensor and cause pre mature failure of the catalytic muffler WOODWARD 91 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Ignition Timing Adjustment With the MI 04 system both mechanical and vacuum advance are no longer inside the distributor All ignition timing advance is controlled by the SECM The only timing adjustment that can be made by a technician is the mechanical alignment of the distributor The SECM uses a 40 degree timing window from 5 degrees BTDC to 35 degrees BTDC Because of this an accurate adjustment cannot be made with a standard timing light since the SECM will maintain the correct timing even if the distributor is moved as long as the distributor setting remains within the 40 degree window Therefore the ignition timing setting of the distributor becomes very important and is described in the following steps 1 Using the timing indicator on the crankshaft pulley set the engine on 0 degrees Top Dead Center TDC of number 1 cylinder Figure G1 2 Remove the distributor rotor cap and verify that the distributor rotor is lined up with number 1 cylinder on the distributor cap Figure G2 Figure G1 Timing Wheel at 0 degrees TDC 1 Cylinder WOODWARD 92 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505
31. Check Coolant Level 4 ee Inspect coolant hoses and fittings for leaks cracks swelling or deterioration Engine Ignition Section Inspect battery for damage and corroded X cables Inspect ignition system Kf Replace spark plugs PK Fuel Lock Off Filter Section element Inspect lock off and fuel X filter for leaks Ensure lock off stops fuel X flow when engine is off WOODWARD 38 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Maintenance Schedule Continued Interval Hours CHECK POINT Every Every Every Every Every Every Daily 250hrs or 500 or 1000 1500 2600 4500 a month months Hours Hours or Hours Hours or 18 month Pressure Regulator Converter Section Test regulator pressures O XxX SEEDS Inspect pressure regulator build up Inspect regulator assembly for fuel coolant X leaks Inspect valve housing for wear cracks or X deterioration Ensure valve seals in the closed position when the X engine is off Carburetor Section Check air filter indicator X Jj Jj o o messem oo o o x o __ filter system x J mixer assembly o X o p assembly throat Check for vacuum leaks in the intake system including manifold adapter and mixer to throttle adapter Inspect throttle assembly Inspect air fiter X 41442 R
32. D SIGNAL WOODWARD 69 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM SECM Electrical Mounting Recommendations In order to prevent the possibility of any SECM malfunctions due to EMI RFI emissions engine packagers and OEMs should follow industry best practices and the SECM mounting and harness recommendations listed below e The SECM should be mounted in a location that minimizes the amount of EMI the module is exposed to by locating it as far as practical from all high tension components such as ignition coils distributors spark plug wires etc It is recommended that the SECM be mounted at least 75 cm away from the distributor and ignition coil and at least 50 cm from the nearest plug wire e All wiring harnesses should be routed to minimize coupling both radiated and conducted and be securely fastened to minimize movement and maintain proper clearance between the SECM and all ignition system components OEM must ensure that a high quality ground connection between the SECM and battery negative is provided and can be maintained for the useful life of the vehicle This may require the use of star type washers on all ground lug connections between the SECM and the battery and or special preparation of all mating surfaces that complete the ground connection in order to ensure that the connection is sound Engineering judgment must be exercised on all applications to determine if appr
33. E MANUAL 91505 04 LP SYSTEM 6 Once the proper alignment is obtained lock the distributor in place by tightening the hold down nut to the specified torque value and re install the rotor dust cover and rotor cap WARNING Improper alignment of the distributor may cause system ignition problems resulting in ignition misfires or backfires 7 After you have completed setting the distributor alignment you will need to adjust the VR sensor used by the SECM for speed reference This sensor is mounted near the crankshaft pulley wheel Figure G6 Figure G6 04 VR Sensor 8 Rotate the crankshaft pulley so that one of the gear teeth on the timing wheel aligns in the center of the VR sensor Figure G7 Figure G7 m WOODWARD 95 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 9 Using a feeler gauge Figure G8 loosen the sensor retaining bolts and adjust the gap between the sensor and the gear tooth from 1 25mm to 1 5mm Re tighten the sensor retaining bolts when complete 10 Rotate the crankshaft pulley 180 degrees and align a timing gear tooth in the center of the VR sensor pickup as you did in step 8 Verify that the sensor gap is still within 1 25mm to 1 5mm This step is to check timing gear run out and insures proper speed signal amplitude Figure G8 11 If the VR sensor gap is not within the specification repeat steps 9 amp 10 and continue adjusting
34. EGO sensor sends a voltage signal less than 500mV the SECM interprets the air fuel mixture to be lean The SECM then decreases the duty cycle of the FTV lowering the amount of air valve vacuum AVV acting on the atmospheric side of the N2001 secondary diaphragm increasing the regulator vapor propane output to richen the air fuel mixture The opposite is true if the SECM receives a voltage signal above 500mV from the HEGO The air fuel mixture would then be interpreted as being too rich and the SECM would increase the duty cycle of the FTV CAUTION sensor used is calibrated to work with the 04 system Using alternate sensors may impact drivability and the ability of the system to diagnose rich and lean conditions WOODWARD 24 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM 04 SECM General Description The Woodward Small Engine Control Module SECM controller has full authority over spark fuel and air Utilizing Motorola s HCS12 micro controller the SECM has 24 pins of I O and is fully waterproof and shock hardened Figure 23 To optimize engine performance and drivability the SECM uses several sensors for closed loop feedback information These sensors are used by the SECM for closed loop control in three main categories e Fuel Management e Load Speed Management e Ignition Management The SECM monitors system parameters and stores any out of range conditions or malf
35. G tank is 80 full The fixed tube indicator is simply a normally closed valve that is opened during refueling by the fueling attendant When opened during refueling and the tanks LPG level is below 80 a small amount of vapor will exit the valve When the LPG tank level reaches 80 liquid propane will begin exiting the valve in the form of a white mist Always wear the appropriate protective apparel when refueling LPG cylinders In order for this type of gauge to be accurate the tank must be positioned properly When full 80 LPG the valve is closed by turning the knurled knob clockwise Typically a warning label surrounds the fixed tube gauge which reads STOP FILLING WHEN LIQUID APPEARS Pressure Relief Valve A pressure relief valve is installed for safety purposes on all LPG tanks Portable fuel tank safety pressure relief valves are a normally closed spring loaded valve and are calibrated to open at 375 PSIG tank pressure This will allow propane vapor to escape to the atmosphere When tank pressure drops below the preset value the valve closes Service Valve The service valve is a manually operated valve using a small hand wheel to open and close the fuel supply to the service line fuel supply line service valve installs directly into the tank and has 2 Outlet two main categories liquid and vapor service valves Liquid service M valves used on portable LPG tanks use a 3 8 3 8 NPT male pipe thread on the service v
36. IAT signal the TMAP has failed or the SECM has failed lATSensorlnputLow Intake Air Temperature Sensor Input is Low is normally set if the TMAP temperature signal wire has become shorted to ground shorted to the MAP signal the TMAP has failed or the SECM has failed lIATSensorlnputHigh Intake Air Temperature Sensor Input is High normally set if the TMAP temperature signal wire has become disconnected or the circuit is open to the SECM EST1Low Electronic Spark Trigger is a current driver signal and normally set if the signal from the SECM is shorted to ground EST1High Electronic Spark Trigger is a current driver signal and normally set if the signal from the SECM is open or lost LowOilPressure Low Oil Pressure the oil pressure switch has opened or become disconnected normally indicating a low oil condition in the engine BatterySensorlnputLow Battery Voltage Sensor Input is Low normally set if the power to the SECM drops below 8 5 VDC BatterySensorlnputHigh Battery Voltage Sensor Input is High normally set if the power to the SECM increases above 15 9 VDC XDRPSensorlnputLow Transducer Voltage Sensor Input is Low normally set if the sensor power from the SECM drops below 4 8 VDC XDRPSensorlnputHigh Transducer Voltage Sensor Input is High normally set if the sensor power from the SECM increases above 5 9 VDC EngineOverspeed Engine Over speed is set when the engine RPM increases above the SECM maxi
37. M5 wW00DWARD 04 2 0L 2 4L LPG SYSTEM SERVICE MANUAL 91505B DRAFT 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM A WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine or other type of prime mover should be equipped with an over speed over temperature or overpressure where applicable shutdown device s that operates totally independently of the prime mover control device s to protect against runaway or damage to the engine or other type of prime mover with possible personal injury or loss of life should the mechanical hydraulic governor s or electric control s the actuator s fuel control s the driving mechanism s the linkage s or the controlled device s fail To prevent damage to a control system that uses alternator battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all
38. Manual Rough Idle Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the e Clamps must be tight mixer e Look for kinked pinched and or collapsed hose Pressure regulator Test pressure regulator operation malfunction e See Chapter 9 Tests and Adjustments Vacuum leak Check for vacuum leaks Between mixer and throttle body Between throttle body and intake manifold Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer e See Chapter 8 Air Fuel mixer section WOODWARD 44 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Probable Cause Corrective Action Rough Idle Incorrect Idle Incorrect Idle speed control control Incorrect Idle speed control See Chapter 5 Advanced Diagnostics amp Chapter 9 Tests and control Adjustments Manual High Idle Speed See Chapter 5 Advanced Throttle sticking Diagnostics amp Chapter 9 Tests and Adjustments Check pedal return spring travel for binding e See Chapter 5 Advanced Diagnostics Poor High Speed Clogged fuel filter Repair replace as required Perf e See Chapter 3 Fuel Filter errormance replacement Plugged fuel line Remove obstruction from the fuel line Foot pedal sticking or incorrect pedal signal Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liqu
39. O 8 2kO PRESSURE SIGNAL KPA TMAP PIN 1 GND TO PIN 2 SEE TMAP IAT TABLE FOR TEMPERATURE SIGNAL PROPER RANGE TMAP SENSOR IAT TABLE Temperature Temperature in 1 inC 1 MINIMUM NOMINAL MAXIMUM 68 86 104 203 95 oO 5 104 60 80 900 WOODWARD 68 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM SENSOR POINT TO POINT EXPECTED RANGE TPS TPS PIN2 GND TOPIN6 1 25KQ 30 ELECTRONIC THROTTLE TPS1 SIGNAL TPS PIN 3 PWR TO PIN 6 1 25 30 51 SIGNAL TPS PIN 1 DRIVER TO PIN 3 00 30 4 DRIVER POINT TO POINT EXPECTED RANGE SENSOR ECT ECT PIN A SIGNAL TO PIN 2 8KQ AT 25 C 77 COOLANT TEMPERATURE B GND 4 8C POINT TO POINT EXPECTED RANGE SENSOR O2 O2 PIN C HEATER GND TO 2 1 0 4 ohms OXYGEN SENSOR PIN D HEATER PWR SENSOR POINT TO POINT EXPECTED RANGE VR SENSOR VR PIN 1 4 TO PIN 2 3200 CONNECTOR POINT TO POINT EXPECTED RANGE SMART COIL COIL PIN A SIGNAL TO PIN 10KQ B COIL PIN A SIGNAL TO PIN 34KQ D COIL PIN A SIGNAL TO PIN 15KQ E PWR COIL PIN B TO PIND 44KQ COIL PIN B TO PINE PWR 26KQ COIL PIN D TO PINE PWR 17KQ CONNECTOR POINT TO POINT EXPECTED RANGE FTV FTV PIN A SIGNAL TO PIN 260 20 FUEL TRIM VALVE B PWR CONNECTOR POINT TO POINT EXPECTED RANGE FUEL LOCK OFF LOCK OFF PIN A PWR TO 20 250 PIN B GN
40. P SYSTEM 04 Fuel Trim Valve The Fuel Trim Valve FTV is a two way electric solenoid valve and is controlled by a pulse width modulated PWM signal provided by the SECM The FTV is used to bias the output fuel pressure on the LPG regulator converter N 2001 by metering air valve vacuum AVV into the atmospheric side of the N 2001 secondary regulator diaphragm An orifice balance line connected to the air inlet side of the mixer provides atmospheric reference to the N 2001 when the FTV is closed The SECM uses feedback voltage from the O2 sensor to determine the Fuel Trim Valve amount of bias needed to the regulator converter In normal operation the N2001 maintains fuel flow at a constant output pressure due to the calibrated secondary spring The amount of fuel flowing from the N2001 will vary depending on how far the secondary diaphragm opens the secondary valve in response to the negative pressure signal generated by the air fuel mixer One side of the N2001 secondary diaphragm is referenced to atmospheric pressure while the other side of the diaphragm reacts to the negative pressure signal from the mixer If the pressure on the atmospheric side of the N2001 secondary diaphragm is reduced the diaphragm will close the secondary valve until a balance condition exists across the diaphragm reducing fuel flow and leaning the air fuel mixture A branch tee fitting is installed in the atmospheric vent port of the N2001 with one side of
41. TIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 7 0 N2001 PRESSURE REGULATOR CONVERTER Propane is a by product of crude oil and natural gas In the extraction process various hydrocarbons such as gasoline kerosene propane and butane are separated Each of these carry a certain amount of by product residue commonly called heavy ends Under normal circumstances these residues remain suspended in liquid and pass through the system undetected Engine coolant flows through the regulator converter assisting in the propane vaporization process As the coolant temperature rises the regulator converter temperature also rises The gas becomes hot and expands to the point where it cannot carry the heavier hydrocarbons or heavy ends through the system Because of this the heavy ends are deposited dropped out into the regulator converter the vapor line from the regulator to the mixer and even in the mixer itself When these heavy ends cool they form a wax like deposit or sludge HD5 grade propane is recommended for motor fuel use however HD5 propane will carry a certain amount of heavy ends A fuel filter cannot remove this because it is not dirt or debris but part of the liquid propane As these deposits build up over time regulator fuel ports and valve seats can be affected reducing the performance of the regulator All propane systems incorporating a regulator converter are subject to heavy end fouling over time Because of this it
42. UAL 91505B_DRAFT 04 LP SYSTEM Because vapor propane has now left the expansion chamber the pressure in the chamber will drop causing the primary diaphragm spring force to re open the primary valve allowing liquid propane to enter the regulator and the entire process starts again This creates a balanced condition between the primary and secondary chambers allowing for a constant flow of fuel to the mixer as long as the demand from the engine is present The fuel flow is maintained at a constant output pressure due to the calibrated secondary spring The amount of fuel flowing will vary depending on how far the secondary valve opens in response to the negative pressure signal generated by the air fuel mixer The strength of that negative pressure signal developed by the mixer is directly related to the amount of air flowing through the mixer into the engine With this process the larger the quantity of air flowing into the engine the larger the amount of fuel flowing to the mixer 04 N CA55 500TR Mixer Vapor propane fuel is supplied to the N CA55 SOOTR mixer by the N 2001 pressure regulator converter The N CA55 500TR mixer uses a piston type air valve assembly to operate a gas metering valve inside the mixer The gas metering valve is normally closed requiring a negative pressure vacuum signal from a cranking or running engine to open This is the third of the three safety locks in the MI 04 system If the engine stops or is
43. XER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 10 Check for binding of the air valve assembly by Figure M13 pressing down with two fingers on opposite sides of the air valve assembly Figure M13 The air valve assembly should move freely without binding and have full travel If the air valve is binding loosen the four adapter retaining screws re check the air valve for binding and re tighten the adapter retaining SCrews 11 Clean and check the orifice fitting Mixer hose barb for obstruction CAUTION The 1 8 NPT X hose barb fitting that is installed the mixer housing uses a specific machined orifice size through the fitting This orifice fitting is part of the mixer assembly and an integral part of the MI 04 control DO NOT replace this fitting with a standard hose barb fitting or use a drill bit to clean out the fitting passage way If this fitting is damaged the mixer will need to be replaced N CA55 500TR Disassembled Service 1 Clean the air valve assembly with soap and warm water to remove heavy end deposits Inspect the fuel metering valve and sealing ring for wear Replace worn components as necessary 2 Clean the check valve plate with soap and warm water Inspect for wear tears or pinholes in the check valve and deformations that may cause leaks or poor performance Replace components as necessary Replace all gaskets before assembly Clean the mixer body casting with a parts cleanin
44. alve 6 The secondary valve is held closed by the secondary spring on the secondary valve lever 7 The secondary diaphragm controls the secondary lever When the pressure in the expansion chamber reaches 1 5 psi it causes a pressure force imbalance across the primary diaphragm 8 This force is greater than the primary diaphragm spring pressure and will cause the diaphragm to close the primary valve Since the fuel pressure has been reduced from tank pressure to 1 5 psi the liquid propane vaporizes As the propane vaporizes it takes on heat from the expansion chamber This heat is replaced by engine coolant which is pumped through the coolant passage of the regulator At this point vapor propane will not flow past the expansion chamber of the regulator until the secondary valve is opened To open the secondary valve a negative pressure signal must be received from the air fuel mixer When the engine is cranking or running a negative pressure signal vacuum travels through the vapor fuel outlet connection of the regulator 9 which is the regulator secondary chamber and the vapor fuel inlet of the mixer The negative pressure in the secondary chamber causes a pressure force imbalance on the secondary diaphragm which overcomes the secondary spring force opening the secondary valve and allowing vapor propane to flow out of the expansion chamber through the secondary chamber to the mixer WOODWARD 18 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MAN
45. alve outlet for attachment of a quick disconnect coupler Excess Flow Valve An excess flow valve is built into the inlet side of the service valve as a safety device in case of an accidental opening of the service line or damage to the service valve itself The excess flow valve shuts off the flow of liquid propane if the flow rate of the liquid propane exceeds the maximum flow rate specified by the manufacturer CAUTION When the tank is use the service valve should be completely open If the valve is partly open the vehicle may not be getting enough fuel to operate efficiently In addition to possibly starving the engine for fuel a partly open valve may restrict the flow enough to prevent the excess flow valve from closing in the event of a ruptured fuel line Most liquid service valves have an internal hydrostatic relief valve and are usually labeled LIQUID WITH INTERNAL RELIEF The hydrostatic relief valve protects the fuel service line between the tank and the lock off from over pressurization The internal hydrostatic relief valve has a minimum opening pressure of 375 PSIG and a maximum pressure of 500 PSIG These type of relief valves have an advantage over external relief valves because the propane is returned to the tank in the event of an over pressurization instead of venting the propane to atmosphere WOODWARD 12 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM Quick Disconnec
46. ary Replace the body gasket of the coolant chamber and body o ring seal when servicing the N2001 to avoid coolant leaks from the fuel expansion chamber to the Figure R11 coolant passage Clean the regulator body casting with a parts cleaning solvent Be sure to remove all seals and gaskets before cleaning the casting with solvent Make sure all parts Figure R11 are completely dry before re assembly WOODWARD 76 N2001 REGULATOR CONVERTER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM WOODWARD 77 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 8 0 N CA55 500TR AIR FUEL MIXER Propane is a by product of crude oil and natural gas In the extraction process various hydrocarbons such as gasoline kerosene propane and butane are separated Each of these carry a certain amount of by product residue commonly called heavy ends Under normal circumstances these residues remain suspended in liquid and pass through the system undetected Engine coolant flows through the regulator converter assisting in the propane vaporization process As the coolant temperature rises the regulator converter temperature also rises The gas becomes hot and expands to the point where it cannot carry the heavier hydrocarbons or heavy ends through the system Because of this the heavy ends are deposited dropped out into the regulator converter the vapor line from the regulator to the mixer and even in the mixer itself When these hea
47. cessive coolant temperature typically due to the engine overheating ThrottleSensorlnputLo Throttle Position Sensor TPS1 Input is Low is normally set if the TPS1 signal wire has been disconnected or the circuit has opened to the SECM ThrottleSensorlnputHi Throttle Position Sensor TPS1 Input is High is normally set if the TPS1 signal wire has become shorted to power the TPS1 has failed or the SECM has failed ThrottleSensorRangeLo Throttle Position Sensor TPS1 Range has measured Low the TPS1 potentiometer has malfunctioned An improper TPS reading may be due to dirt or oxidation on the sensor traces NOTE The TPS is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly ThrottleSensorRangeHi Throttle Position Sensor TPS1 Range has measured High the TPS1 potentiometer has malfunctioned An improper TPS reading may be due to dirt or oxidation on the sensor traces NOTE The TPS is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly ETCSticking Electronic Throttle Control is Sticking is normally set if either of the ETC driver signals have opened or become disconnected This can also occur if the throttle plate butterfly valve inside the throttle bore is sticking The plate sticking can be due to some type of obstruction a loose throttle plate or worn components shaft bearings Certified technicians using the service tool software can perform a throttle
48. compares this to the actual throttle position based on TPS1 The SECM continuously checks and monitors all sensors and calculations that effect throttle valve position whenever the engine is running If any malfunctions are encountered the SECM s initial response is to revert to redundant sensors and calculated data If no redundant signal is available or calculated data cannot solve the malfunction the SECM will drive the system into one of it s limp home modes or shut the engine down storing the appropriate fault information in the SECM There are multiple limp home modes available with ETC 1 If the throttle itself is suspected of being inoperable the SECM will remove the power to the throttle motor When the power is removed the throttle blade returns to its default position approximately 7 open 2 If the can still control the throttle but some other part of the system is suspected of failure the will enter a Reduced Power mode In this mode the power output of the engine is limited by reducing the maximum throttle position allowed 3 In some cases the SECM will shut the engine down This is accomplished by stopping ignition turning off the fuel and disabling the throttle Throttle Plate Gear Drive DC Drive Motor Bosch 32mm Electronic Throttle Body DV E5 Picture courtesy of Robert Bosch GmbH Figure 21 WOODWARD 22 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 L
49. decrease 10 To obtain an accurate FTV Duty Cycle reading when the tamper proof cap is not installed place your thumb over the idle screw port so that no air will leak past the screw threads 11 If the FTV Duty Cycle reading is above 40 adjust the idle adjustment screw outward and re check the duty cycle reading Continue to do this until the FTV Duty Cycle reading is within the optimum range 25 40 DO NOT adjust the screw so far outward that the tamper proof cap cannot be installed A duty cycle measurement at Closed Loop Idle of 40 50 is acceptable if the optimum range of 25 40 cannot be reached through adjustment If the FTV Duty Cycle cannot be adjusted below 50 the mixer is faulty and should be replaced 12 Turn the ignition key to the OFF position to shut down the engine 13 Install the tamper proof cap on the idle mixture screw adjustment port so that no further adjustments can be made Figure 29 Idle Mixture Screw Tamper Proof Cap Figure 29 If the FTV Duty Cycle reading is cannot be adjusted between 25 50 check for possible vacuum leaks manifold leaks or a faulty mixer WOODWARD 98 TEST AND ADJUSTMENTS M5 w0o0DWARD Woodward Industrial Controls PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 E mail and Home Page www woodward com FM 57982 BS EN ISO 9001 1994 6 March 2001
50. des Probable Fault Corrective Action First Check 43 EST1High Stored Fault Code Check coil driver wiring for Coil driver signal high or over MIL Only open circuit or disconnected current connector SECM PIN 7 EST1 to COIL PINA Verify GND COIL PIN B Verify GND on COIL PIN C Verify GND on COIL PIN D Verify 12vdc on COIL PIN E To check the Smart Coil internal circuit disconnect the coil connector and measure the resistance from pin to pin See Smart Coil resistance check in Chapter 6 0 LowOilPressure Delayed Engine Check engine oil level Low Engine Oil Pressure Shutdown Check electrical connection to the oil pressure switch SECM PIN 23 to Oil Pressure Switch BatterySensorlnputLow Stored Fault Code Check battery voltage Battery voltage measured below MIL Only e Perform maintenance 8 0 VDC check on electrical connections to the battery and chassis ground Check battery voltage during starting and with the engine running to verify charging system and alternator function Measure battery power at the SECM with a multimeter SECM PIN 13 BATT to SECM PIN 14 BATT WOODWARD 59 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table a MI 04 Fault Table MI 04 Diagnostic Fault Codes Flash Codes Table a 04 Diagnostic Fault Codes Flash Codes 0 Codes DFC Probable Fault Corrective Action First Check BatterySensorlnputHigh ot
51. e of the propane is reduced the liquid propane vaporizes and refrigeration occurs inside the regulator due to the large temperature drop inside the regulator from the vaporization of liquid propane To replace heat lost to vaporization engine coolant is supplied by the engine driven water pump and pumped through the regulator Heat provided by this coolant is transferred through to the fuel vaporization rA PF oat as 8 by t 13 chamber Figure 14 shows the N 2001 heat chamber and the Heat Transfer Chamber coolant passage in the N 2001 Coolant Passage Figure 14 WOODWARD 17 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM N 2001 Theory of Operation N 2001 Cutaway View m u 4 N o _ Figure 15 Liquid propane at tank pressure enters the N 2001 through the fuel inlet port 1 Propane liquid then flows through the primary valve 2 The primary valve located at the inlet of the expansion chamber 3 is controlled by the primary diaphragm 4 which reacts to vapor pressure inside the expansion chamber Two springs are used to apply force on the primary diaphragm in the primary diaphragm chamber 5 Keeping the primary valve open when no fuel pressure is present A small port connects the expansion chamber to the primary diaphragm chamber At the outlet of the expansion chamber is the secondary v
52. e engine states Crank when the VR sensor detects any engine revolutions Stall when the key is in the ON position but the VR sensor detects no engine revolutions and the Run state when the engine reaches pre idle RPM When an operator turns on the key switch the lock off is opened but if the operator fails to crank the engine the SECM will close the lock off after 5 seconds To maintain proper exhaust emission levels the SECM uses a heated exhaust gas oxygen sensor HEGO mounted before the catalyst to measure exhaust gas content in the LP gas system Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with TMAP sensor HEGO voltage is converted to an air fuel ratio value This value is then compared to a target value in the SECM The target value is based on optimizing catalyst efficiency for a given load and speed The SECM then calculates any corrections that need to be made to the air fuel ratio WOODWARD 25 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM The system operates in open loop fuel control until the engine has done a certain amount of work This ensures that the engine and HEGO are sufficiently warmed up to stay in control In open loop control the FTV duty cycle is based on engine speed and load Once the HEGO reaches operating temperature the fuel management is in closed loop control for
53. ector is unplugged CODES 61 amp 66 PedallSensorlnputHi APP1 sensor failure or shorted circuit Pedal1SensorRangeLo APP1 potentiometer malfunction Improper APP1 reading may be due to dirt or oxidation on the sensor traces Pedal1SensorRangeHi APP1 potentiometer malfunction Improper APP1 reading may be due to dirt or oxidation on the sensor traces WOODWARD Engine Shutdown Engine Shutdown MIN Power Limit MIN Power limit Stored Fault Code MIL Only Stored Fault Code MIL Only 61 Measure transducer power at the TMAP connector with a multimeter TMAP PIN 3 5VDC to TMAP PIN 1 GND Verify transducer power at the SECM with a multimeter SECM PIN 18 5VDC to SECM PIN 1 GND Verify transducer power at ETC with a multimeter ETC PIN 3 PWR to ETC PIN 2 GND Verify transducer power to the foot pedal with a multimeter Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade Check foot pedal connector Check APP1 signal at SECM PIN 15 Check foot pedal connector Check APP1 signal at SECM PIN 15 Check foot pedal connector e Cycle the pedal several times and check 1 signal at SECM PIN 15 Check foot pedal connector e Cycle the pedal several times and check 1 signal at SECM PIN 15 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505
54. el line Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve Leak test Clogged fuel filter Repair replace as required e See Chapter 3 Fuel Filter replacement Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the e Clamps must be tight mixer e Look for kinked pinched and or collapsed hose Fuel Lock off malfunction Repair replace Fuel Lock off e See Chapter 3 Fuel Lock off Pressure regulator converter Test pressure regulator converter malfunction operation See Chapter 9 Tests Adjustments Incorrect air fuel or See Chapter 5 Advanced ignition spark control Diagnostics WOODWARD 40 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Probable Cause Corrective Action Engine Cran king No VR Sensor Signal Verify the VR signal is present See Chapter 5 but Will Not Advanced Start Diagnostics Difficult to Start Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required e See Chapter 3 Fuel Filter replacement Plugged f
55. eplace air filter element 2 2 l l d tightness and leaks Exhaust amp Emission Section Inspect engine for exhaust X leaks Replace Oxygen Sensor 111 X Replace PCV Valve and X breather element WOODWARD 39 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 4 0 04 LP BASIC TROUBLESHOOTING Basic Troubleshooting The MI 04 systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL and are covered in the Advanced Diagnostics section Items such as fuel level plugged fuel lines clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Small Engine Control Module SECM Below are basic checks that should be made before referring to the Advanced Diagnostics section if engine or drivability problems are encountered Locating a problem in a propane engine is done exactly the same way as with a gasoline engine Consider all parts of the ignition and mechanical systems as well as the fuel system Probable Cause Corrective Action Engine Cranking Fuel container empty Fill fuel container but Will Not Donot exceed 80 of liquid Capacity Start Liquid valve closed Slowly open liquid valve Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound e Slowly open liquid valve Plugged fu
56. ere and attached to a wire that runs to the SECM It operates like a galvanic cell with the zirconium dioxide acting as the electrolyte and the platinum layers serving as electrodes Once the ZrO2 reaches approximately 600 deg F it becomes electrically conductive and attracts negatively charged ions of oxygen These ions collect on the inner and outer platinum surfaces Naturally there s more oxygen in plain air than in exhaust so the inner electrode will always collect more ions than the outer electrode and this causes a voltage potential for electrons to flow The concentration of oxygen in the exhaust stream determines the number of ions on the outer electrode hence the amount of voltage produced If the engine is running rich little oxygen will be present in the exhaust few ions will attach to the outer electrode and voltage output will be relatively high In a lean situation more oxygen will be present and that translates into more ions on the outer electrode a smaller electrical potential and less voltage In order for the sensor to conduct and create an electrical signal below 600 deg F a heated element is added to the sensor housing Two wires provide the necessary 12VDC and ground signal for the heater element A fourth wire provides an independent ground for the sensor Figure 24 HEGO stoichiometric air fuel ratio voltage target is approximately 500mV and changes slightly as a function of speed and load When the H
57. g solvent Be sure to remove all seals and gaskets before cleaning the casting with solvent Make sure all parts are completely dry before re assembly DU NOTE For re assembly of the N CA55 500TR reverse the disassembly steps WARNING DO NOT spray carburetor cleaner or solvent into the mixer while installed on the engine These chemicals may damage the oxygen sensor and cause pre mature failure of the catalytic muffler WOODWARD 83 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Installing the Mixer Throttle Assembly Mixer Throttle Assembly Air Horn Be Air Horn Mixer Gasket Fuel Inlet Fittin a g Orifice Balance Y Line Fitting DO NOT REMOVE Mixer Throttle Adapter Gasket Throttle Adapter FTV Fitting Screws Electronic Throttle Throttle Manifold Gasket Manifold TMAP Adapter Sensor TMAP Bracket Figure M14 WOODWARD 84 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM The mixer throttle assembly consists of a manifold adapter electronic throttle mixer throttle adapter and air horn adapter The manifold adapter is designed to mount the mixer throttle assembly to a two bolt intake manifold The air horn adapter allows the intake hose from the air cleaner to be attached to the mixer air intake along with the vent line from the engine PCV valve 1 Align the Mixer Throttle Adapter gasket Figure M15 be
58. g the engine and running until all trapped fuel in the system is exhausted and the engine shuts down 3 Remove the fuel inlet line Figure R2 1 from the lock off the two vacuum lines 2 from the branch tee fitting in the regulator vent and disconnect the lock off connector 3 4 Remove the two rear mounting bolts that hold the regulator to the support bracket This will allow you easier access to the T ne 2 remaining hose clamps 24 Jua e 5 Remove the two cooling lines 4 from the MT regulator NOTE It will be necessary to either drain the coolant system or clamp off i the coolant lines as close to the regulator as possible to avoid coolant spill when these E x lines are disconnected 6 Remove the fuel vapor outlet hose 5 from the regulator 4 7 f itis necessary to fully disassemble the N2001 regulator you will need to remove the fuel lock off at this time i NOTE For installation of the N2001 reverse the removal steps N2001 Regulator Disassembly Steps Figure R3 1 Remove the six secondary cover screws 1 the secondary cover 2 and the secondary diaphragm 3 2 Remove the six primary diaphragm cover screws 4 and the primary cover assembly 5 Figure R4 WOODWARD 74 2001 REGULATOR CONVERTER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 3 Remove the six Figure R5 primary diaphragm cover screws 4 and the primary cover assembly 5 4 Remove the
59. haust system leaks Repair exhaust system Oxygen sensor failure Replace as necessary e See Chapter 5 Advanced Diagnostics WOODWARD 46 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM WOODWARD 47 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 5 0 MI 04 LP ADVANCED DIAGNOSTICS Advanced Diagnostics The MI 04 systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL as Diagnostic Fault Codes DFC or flash codes and viewed in detail with the use of service tool software When the ignition key is turned ON the MIL will perform a self test illuminate and then go OFF when the engine is started If a detected fault condition exists the fault or faults will be stored in the memory of the small engine control module SECM Once an active fault occurs the MIL will illuminate and remain ON This signals the operator that a fault has been detected by the SECM Reading Diagnostic Fault Codes MI 04 fault codes are two digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 5 seconds between digits and a long pause 1 2 seconds between fault codes A code 12 is displayed at the beginning of the code list EXAMPLE A code 26 has been detected ETCSticking and the engine has shutdown and the MIL has remained ON When the codes are displayed the MIL will flash one time
60. he plastic motor assembly cover of the electronic throttle assembly should be facing opposite of the TMAP sensor mounting holes 6 Place the O ring Spacer over the outside O Ring throat of the throttle This spacer is CA necessary to assure that the O ring which seals the throttle to the adapter properly seats against the throttle adapter 7 Place the throttle adapter O ring over the outside throat of the throttle below the throttle bore retaining lip and on top of the O ring Spacer Figure M19 Apply a generous amount of lubricating grease vacuum grease to the O ring and fully seat it against the machined surface Figure M20 8 Carefully slide the pre assembled mixer throttle adapter assembly over the throat of the throttle using a rocking motion aligning the mounting holes of the adapter with the mounting holes of the throttle Figure M20 Face the fuel inlet of the mixer toward the plastic motor assembly cover of the electronic throttle assembly NOTE i Avoid pinching the O ring in the cutaway of the throttle adapter This will damage the O ring and cause a manifold leak in the system WOODWARD 86 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 9 Tighten the four mounting bolts hand tight using a crossing pattern from one side of the adapter to the other This prevents the adapter O ring from misaligning against the throttle which may cut the O ring and cause an intake leak F
61. hms to self calibrate and cross check the signals from the pedal assembly A demand position for the throttle will then be derived and sent to the throttle as a throttle position sensor demand TPSd The signal will be processed through a PID Proportional Integral Derivative controller in the SECM to achieve the appropriate motor current response then passed to the throttle The throttle moves to the commanded position and provides a feedback signal from the throttle position sensor TPS to the SECM WOODWARD 30 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM 04 Ignition management In the normal course of events with the engine operating at the correct temperature in defined conditions the SECM will use load and engine speed to derive the correct ignition timing In addition to load and speed there are other circumstances under which the SECM may need to vary the ignition timing including low engine coolant temperature air temperature start up idle speed control VR Sensor A Variable Reluctance sensor Figure 31 is an electromagnetic device consisting of a permanent magnet surrounded by a winding of wire The sensor is used in conjunction with a ferrous timing wheel located on the crankshaft pulley The timing wheel is referred to as 30 5 ignition because the wheel has 30 gear teeth with 5 removed at precise locations giving the SECM a very accurate speed reference signal Rotation of the
62. id fuel valve amp Leak test Air filter clogged Check air filter e Clean replace as required Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the Clamps must be tight mixer e Look for kinked pinched and or collapsed hose Pressure regulator Test pressure regulator operation malfunction e See Chapter 9 Tests and Adjustments Air Fuel Mixer malfunction Check mixer e See Chapter 8 Air Fuel mixer section Restricted exhaust system Check exhaust system e Measure exhaust back pressure Incorrect ignition control See Chapter 5 Advanced Incorrect air fuel control Diagnostics amp Chapter 9 Tests and Incorrect throttle position Adjustments WOODWARD 45 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Probable Cause Corrective Action Excessive Fuel Air Fuel Mixer malfunction Check mixer e See Chapter 8 Air Fuel Consumption LPG ie es Exhaust Smell Air filter clogged Check air filter e Clean replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer Repair replace as necessary Pressure regulator Test pressure regulator operation malfunction fuel pressure too e See Chapter 9 Tests and high Adjustments Faulty FTV Check FTV for housing cracks or obstructions e See Chapter 5 Advanced Diagnostics FTV operation e Repair and or replace as necessary control Diagnostics Diagnostics Ex
63. inally tighten the four throttle adapter fasteners to the specified torque values 10 Install the TMAP sensor mounting bracket to the manifold adapter Apply a small amount of vacuum grease to the TMAP sensor O ring and install the sensor into the manifold adapter tighten the fasteners to specified torque values NOTE i Be careful not to over tighten the sensor retaining screw or damage to the sensor housing may result 11 Place mixer intake gasket on top of the mixer Figure M21 then place the air horn adapter on top of the mixer with the intake tube facing the valve cover air cleaner side of the engine Tighten the air horn retaining bolts to specified torque values Air Horn Installed Figure M21 WOODWARD 87 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 9 0 TEST AND ADJUSTMENTS AN WARNING LP gas is highly flammable To prevent personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area e Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION The regulator converter and m
64. ing 4 Atthis point the secondary valve should close If the secondary valve seat or the secondary diaphragm is leaking the gauge needle will continue to fall toward zero proportional to the leak size An excessively rich air fuel mixture can be caused by a secondary valve seat leak repair as necessary See Chapter 7 for disassembly of the N2001 WOODWARD 88 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Union Tee Secondary Stage Test Connection Magnahelic Gauge Vacuum Hand Pump Figure R11 Vapor Outlet Test Fitting EN Stage Test Hardware wr Regulator Fuel Inlet test fitting standard air coupling Test Gauge fitting 1 4 NPT X 1 4 Hose Barb Vacuum hose or vinyl tubing 0 60 in W C Magnehelic Gauge inches of water column Primary Stage Pressure Test 6 Remove the primary test port plug from the side of Figure R12 the regulator and install UNDE I ae c the 74 hose barb pe Test Port fitting Gs Connect a compressed x TEE air line shop air 100 126 to the liquid propane fuel inlet of the N2001 Regulator Figure R12 WOODWARD 89 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 8 Apply compressed air wait for air to exit the hose barb in the test port and then connect the Magnahelic gauge Figure R13 to the hose barb using the vacuum hose or vinyl
65. ing Scribe Point 4 Remove the cover retaining screws 1 Fuel Filter Disassembly WOODWARD 34 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 5 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 6 Replace the filter element 7 7 Check bottom cover O ring seal 6 for damage Replace if necessary 8 Re assemble the filter assembly aligning the scribe lines on the top and bottom covers 9 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 10 Open the fuel valve by slowly turning the valve counterclockwise 11 Crank the engine several revolutions to open the fuel lock off DO NOT START THE ENGINE Turn the ignition key switch to the off position 12 Check the filter housing fuel lines and fittings for leaks Repair as necessary Testing Fuel Lock off Operation Start engine Locate the electrical connector for the fuel lock A Disconnect the electrical connector The engine should run out of fuel and stop within a short period of time Turn the ignition key switch off and re connect the fuel lock off connector NOTE D The length of time the engine runs on trapped fuel vapor increases with any increase in distance between the fuel lock off and the pressure regulator converter WOODWARD 35 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Pressure Regulato
66. ir Intake To Regulator Vent Fitting a Ue I i x t e Lr al 1 QU MU o ET 1 7 M 1 bl ri 1 Lok rms Coolant Inlet Coolant Return From Engine PCV Valve Hn gt IE E Vapor Fuel Line From Regulator Outlet To Mixer Inlet Control Line From Regulator Vent Fitting To Fuel Trim Valve FTV Control Line From FTV To Air Valve Vacuum AVV Hose Type 3 8 Female flare stainless steel braided neoprene high pressure fuel line Fabric braid can be used on assemblies less than 60 inches Fuel Tank Valve Closed 5 8 1 0 Vapor Hose Wire Reinforced 15 inch maximum length 5 8 1 0 Hose Water Maximum length specified by engine manufacturer 1 2 1 0 Rubber Hose length specified by engine manufacturer 7132 1 0 Vacuum Hose 10 inch recommended maximum length 7 32 1 0 Vacuum Hose 11 5 inch recommended maximum length 7132 D Vacuum Hose 18 inch recommended maximum length WOODWARD 73 2001 REGULATOR CONVERTER Ey i 4 Regulator Vent Fitting gt 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM N2001 Removal Steps 1 Close the liquid outlet valve in the forklift Figure R2 cylinder or fuel storage container 2 Purge the system of fuel by startin
67. ixer are part of a certified system complying with EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble service or replacement of the regulator converter or mixer N2001 Service Testing After overhaul or for simply checking the N2001 regulator converter operation the following tests can be performed See Chapter 7 for removal installation of the N2001 To check the secondary regulation output a simple vacuum hand pump can be used to simulate the vacuum signal transmitted from the air fuel mixer when the engine is running You will need the following hardware Secondary Stage Test Hardware Hand vacuum pump Regulator vapor outlet test fitting X 74 hose barb Union Tee 74 NPT with three 74 NPT X 74 hose barb Vacuum hose 0 3 in W C Magnehelic Gauge inches of water column UE ad Se SECAR AY Stage Break Off Test Connect the vacuum pump the Magnahelic gauge and the regulator vapor outlet to the Union Tee fitting Figure R11 Make sure there is no leakage at any of the fittings 2 Using the vacuum pump slowly apply enough vacuum to measure above 2 in WC on the gauge This vacuum signal opens the secondary valve in the N2001 regulator converter 3 Release the vacuum pump lever and you will see the gauge needle start falling back toward zero When the pressure drops just below the specified break off pressure 1 2 in WC of the secondary spring the needle should stop mov
68. ixture Adjustment Screw Electronic Throttle Figure 19 Conventional throttle systems rely on mechanical linkage to control the throttle valve To meet fluctuating engine demands a conventional system will typically include throttle valve actuators designed to readjust the throttle valve opening in response to engine demand together with idle control actuators or idle air bypass valves In contrast the MI 04 system uses electronic throttle control ETC The SECM controls the throttle valve based on engine RPM engine load and information received from the foot pedal Two mutually opposed potentiometers on the foot pedal assembly monitor accelerator pedal travel The electronic throttle used in the MI 04 system is a Bosch 32mm Electronic Throttle Body DV E5 Figure 20 The DV E5 is a single unit assembly which includes the throttle valve throttle valve actuator DC motor and the throttle position sensor TPS Figure 21 The SECM calculates the correct throttle valve opening that corresponds to the driver s demand makes any adjustments needed for adaptation to the engine s Figure 20 current operating conditions and then generates a corresponding electrical driver signal to the throttle valve actuator WOODWARD 21 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM In place of a dual TPS design TPS1 and TPS2 the SECM calculates correct throttle position Predicted TPS based on RPM and MAP and
69. l System Smart Coil Fuel a LP a a amy 04 Closed Loop LP Fuel System VR Sensor TMAP Control Module Sensor SECM Oxygen Fuel Trim Sensor Valve Smart Coil Coolant Sensor Oil Small Engine Pressure Switch Fuel LP 85 Electronic Po Catalytic Lock Off Converter Throttle Muffler WOODWARD 15 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM MI 04 LP Fuel Filter After exiting the fuel tank liquid propane passes through a serviceable inline fuel filter to the electric fuel lock off Figure 11 shows a typical inline type LP fuel filter manufactured by Century The primary function of the fuel filter is to remove particles and sediments that have found their way into the tank The LP fuel filter will not remove heavy end solids and paraffin s that build up in LPG fuel systems as a result of vaporization Figure 11 04 Fuel Lock Off Electric The fuel lock off is a safety shutoff valve normally held closed by spring pressure which is operated by an electric solenoid and prevents fuel flow to the regulator converter when the engine is not in operation This is the first of three safety locks in the MI 04 system Figure 12 shows the electric fuel lock assembly In the MI 04 design power is supplied to the fuel lock off with the SECM controlling the lock off ground earth connection The lock off remains in a normally closed NC position until the key
70. mum governing RPM Typically this is in association with one or more throttle faults This fault can be set without additional throttle faults if the operator motors the lift truck down a steep grade hill Pedall SensorlnputLo Accelerator Pedal Position 1 Sensor Input is Low normally set if the APP1 signal wire has become disconnected or the circuit is open to the SECM WOODWARD 51 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM PedallSensorlnputHi Accelerator Pedal Position 1 Sensor Input is High normally set if the APP1 signal wire has become shorted to APP power 1 has failed or the SECM has failed PedallSensorRangeLo Accelerator Pedal Position 1 Sensor Range is Low the APP1 potentiometer has malfunctioned An improper APP1 reading may be due to dirt or oxidation on the sensor traces Pedal1SensorRangeHi Accelerator Pedal Position 1 Sensor Range is High the 1 potentiometer has malfunctioned An improper APP1 reading may be due to dirt or oxidation on the sensor traces Pedal2SensorlnputLo Accelerator Pedal Position 2 Sensor Input is Low normally set if the APP2 signal wire has become shorted to APP power APP2 has failed or the SECM has failed Pedal2SensorlnputHi Accelerator Pedal Position 2 Sensor Input is High normally set if the APP2 signal wire has become disconnected or the circuit is open to the SECM Pedal2SensorRangeLo Accelerator Pedal Position 2 Sensor Range is Low
71. nt property that technicians need to be aware of when performing maintenance When repairing propane machinery the work should be performed in the lowest point of the facility where possible The tank supply should be shut off except when required for running equipment Diesel Figure 1 WOODWARD 7 WORKING WITH LPG EQUIPMENT 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM CHAPTER 1 0 LPG AND LPG FUEL TANKS LPG Fuel Supply Liquefied petroleum gas LPG consists mainly of propane propylene butane and butylenes in various mixtures LPG is produced as a by product of natural gas processing or it can be obtained from crude oil as part of the oil refining process LPG like gasoline is a compound of hydrogen and carbon commonly called hydrocarbons In its natural state propane is colorless and odorless an odorant ethyl mercaptan is added to the fuel so its presence can be detected There are currently three grades of propane available in the United States A propane grade designation of HD5 not exceeding 5 propylene is used for internal combustion engines while much higher levels of propylene HD10 are used as commercial grade propane along with a commercial propane butane mixture APPROXIMATE COMPOSITION OF HD5 PROPANE BY VOLUME Propane Propylene Butane Iso Butane Methane TOTAL C3H8 C4H10 CH4 90 0 min 100 An advantage of LPG is the ability to safely store and transport the product in the liquid
72. opriate measures have been implemented to minimize EMI exposure to the SECM and associated cabling The above recommendations do not provide any guarantee of proper system performance 04 Speed Limiting Function A speed limiting function is available for operating environments that require a maximum speed limit of the lift truck for safety purposes such as certain indoor warehouse operations The SECM PIN 20 is normally open the SECM interprets this as a NEUTRAL state providing normal speed governing operation By grounding SECM PIN 20 with a jumper to battery negative an IN GEAR state is selected switching the maximum engine RPM to a lower configured value Maximum RPM for both the NEUTRAL STATE Normal and IN GEAR STATE Speed Limiting are configurable using the MotoView Service Tool Figure E3 WOODWARD 70 ELECTRICAL CONNECTIONS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Figure E3 shows the Speed Limit screen of the MotoViewer service tool The green boxes are configurable for both the NEUTRAL MAX RPM Setpoint and the IN GEAR MAX RPM Setpoint The switch state SECM PIN 20 is displayed at the bottom of the screen and labeled NEUTRAL SWITCH STATE Software limits of both the NEUTRAL and IN GEAR are displayed on the right side of the Speed Limit screen Values that are entered in the configurable green boxes cannot exceed the upper limit value or fall below the lower limit value WOODWARD 71 ELECTRICAL CONNEC
73. or turns on the key switch the lock off is opened but if the operator fails to crank the engine the SECM will close the lock off after 5 seconds WOODWARD 16 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM 04 N 2001 Regulator Converter After passing through the electric fuel lock off liquid propane enters the N 2001 regulator converter Figure 13 The N 2001 functions as a fuel vaporizer converting liquid propane to vapor propane and as a two stage negative pressure regulator supplying the correct vapor propane fuel pressure to the mixer The regulator is normally closed requiring a vacuum signal negative pressure to allow fuel to flow This is the second of three safety locks in the MI 04 system If the engine stops vacuum signal stops and fuel flow will automatically stop when both the secondary 274 stage valve and the primary 15 stage valve closes Unlike most other regulator converters the N 2001 primary valve closes with fuel pressure rather than against pressure extending primary seat life and adding additional safety Liquid propane must be converted into a gaseous form in order to be used as a jas Nn fuel for the engine When the regulator receives the desired vacuum signal it allows propane to flow to the mixer As the propane flows through the regulator the pressure is reduced in two stages from tank pressure to slightly less than atmospheric pressure As the pressur
74. ored Fault Code Check battery and charging Battery voltage measured above MIL Only system voltage 15 9 VDC e Check battery voltage during starting and with the engine running Check voltage regulator alternator and charging system Check battery and wiring for overheating and damage Measure battery power at the SECM with a multimeter SECM 13 to 5 14 XDRPSensorlnputLow Engine Shutdown Measure transducer power at 5VDC Transducer power supplied the TMAP connector with a by the SECM to the sensors is multimeter below 4 60VDC TMAP PIN 3 5VDC to TMAP Expected faults when Transducer PIN 1 GND power is lost CODES 22 24 33 62 64 66 68 Verify transducer power at the amp 69 SECM with a multimeter SECM PIN 18 5VDC to SECM PIN 1 GND Verify transducer power at ETC with a multimeter ETC PIN 3 PWR to ETC PIN 2 GND Verify transducer power to the foot pedal with a multimeter WOODWARD 60 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes Probable Fault Corrective Action First Check XDRPSensorlnputHigh 5VDC Transducer power supplied by the SECM to the sensors is above 5 20VDC Engine OverSpeed Engine RPM increased beyond maximum RPM set point PedallSensorlnputLo APP1 signal disconnected open circuit or sensor malfunction Expected faults when APP conn
75. ous safety problem CAUTION When empty the tank is exchanged with a pre filled replacement tank When exchanging a tank safety glasses and gloves should be worn WOODWARD 10 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM LPG Fuel Tank Components Fuel Gauge 80 Stop Bleeder Pressure Relief Valve Service Valve Tank end male coupling Filler Valve Alignment Pin Vapor Withdrawal Tube Only used with Vapor Withdrawal 80 Limiter Tube Liquid Withdrawal Tube 10 Foot Ring 11 Fuel Level Float 12 Collar XO OL ee Figure 5 Fuel Gauge In figure 5 a visual fuel gauge is used to show the fuel level in the tank A mechanical float mechanism detects the liquid propane level A magnet on the end of the float shaft moves a magnetic pointer in the fuel gauge Some units have an electronic sending unit using a variable resistor installed in place of a gauge for remote monitoring of the fuel level The gauge may be changed with fuel in the tank DO NOT REMOVE THE FOUR LARGE FLANGE BOLTS THAT RETAIN THE FLOAT ASSEMBLY WITH FUEL IN THE TANK WARNING It is not a legal practice to fill the tank through the liquid contents gauge WOODWARD 11 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM In some applications a fixed tube fuel indicator is used in place of a float mechanism A fixed tube indicator does not use a gauge and only indicates when the LP
76. personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system e Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane WOODWARD 90 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM N CA55 500TR Service AVV Air Valve Vacuum Testing AVV Test Hardware Mixer AVV test fitting NPT X 4 hose barb Union NPT with three X 74 hose barb Vacuum hose 0 20 in W C Magnehelic Gauge inches of water column ee AVV Test 5 Install the Union Tee fitting between the FTV and the AVV fitting 6 Connect the vacuum hose from the Union Tee fitting to the Magnahelic gauge Figure T1 You should now have the gauge inline between the FTV and the mixer to throttle adapter 7 With the engine running at idle 700 RPM the AVV should be between 5 and 10 water column Figure T1 Gauge Fitting AVV Fitting NOTE If the measured water column is excessively high check for a sticking or binding piston diaphragm assembly inside the mixer See Chapter 8 for removal installation and disassembly of the N CA55
77. plate sticking inside the throttle body or the ETC driver signal is open ETCSpringTestFailed Upon initial key up the internal throttle return spring has become weak ETCDriverFault Throttle driver over current or driver signals shorted 27 PredictedTPSDifference Measured 51 is different than SECM Calculated throttle position WOODWARD Engine Shutdown Engine Shutdown Power Limit Disable Throttle 56 Check for debris obstructions inside the throttle body e Perform the Throttle test using the Service Tool and re check for fault Check throttle plate shaft for bearing wear Check the ETC driver wiring for an open circuit ETC PIN 1 to SECM PIN 22 ETC PIN 4 to SECM PIN 24 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 DRIVER to PIN 4 DRIVER 3 00 30 Check for manifold leaks between the throttle and the engine Perform throttle spring test by cycling the ignition key and re check for fault Check ETC driver wiring for a shorted circuit ETC PIN1 to SECM PIN 22 ETC PIN 4 to SECM PIN 24 Perform Throttle test and with the Service Tool and re check for fault Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 DRIVER to PIN 4 DRIVER 3 0Q 30 ADVANCED DIAGNOSTICS 2 0L 2
78. primary diaphragm by sliding the diaphragm to one side releasing the primary valve pin Figure R6 Figure R6 5 Turn the regulator body over with the rear fuel Figure inlet plate facing up Remove the primary valve access plug 7 the primary valve 8 and the primary valve o ring seal 9 The primary valve goes through the inlet plate then through the body assembly and is retained by the primary diaphragm Figure R9 Figure R8 Figure R9 WOODWARD 75 2001 REGULATOR CONVERTER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 6 Remove the body gasket 10 Figure R10 body o ring seal 11 and the fuel inlet plate exposing the fuel inlet expansion chamber and the coolant passage NOTE For re assembly of the N2001 regulator converter reverse the steps for disassembly Tighten all fasteners to recommended torque values and test the regulator before installing in the vehicle Torque primary cover screws to 40 50 inch Ibs secondary cover screws to 15 18 inch Ibs N2001 Disassembled Service 1 Clean the primary and secondary valves with soap and warm water to remove heavy end deposits Inspect the valve seats and o rings for wear Replace worn components as necessary Clean the primary and secondary diaphragms with soap and warm water Inspect for wear tears or pinholes and deformations that may cause leaks or poor performance of the regulator converter Replace components as necess
79. r m Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax e mail information for all locations is available on our website
80. r Converter Testing and Inspection e Visually inspect the pressure regulator converter B housing for coolant leaks Refer to the pressure regulator converter section of the service manual if maintenance is required NOTE For pressure testing and internal inspection of the pressure regulator converter refer to the pressure regulator converter section of the service manual Fuel Trim Valve Inspection FTV e Visually inspect the Fuel trim valve C for abrasions or cracking Replace as necessary ensure the valve is not leaking a blow by test can be performed 1 With the engine off disconnect the electrical connector to the FTV 2 Disconnect the vacuum line from the FTV to the pressure regulator converter at the converter s tee connection 3 Lightly blow through the vacuum line connected to the FTV Air should not pass through the FTV when de energized If air leaks past the FTV when de energized replace the Inspect Air Fuel Valve Mixer Assembly Refer to the LP mixer G section of the service manual for procedures Inspect for Intake Leaks e Visually inspect the intake manifold throttle assembly D and manifold adapters E for looseness and leaks Repair as necessary Inspect Throttle Assembly e Visually inspect the throttle assembly motor housing for coking cracks and missing cover retaining clips Repair and or replace as necessary NOTE Refer to the LP mixer and throttle section of the service man
81. r a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required e See Chapter 3 Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve amp Leak test WOODWARD 43 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Problem Probable Cause Corrective Action Engine Stalls Fuel Lock off malfunction Repair replace Fuel Lock off e See Chapter 3 Fuel Lock Off Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the e Clamps must be tight mixer e Look for kinked pinched and or collapsed hose Pressure regulator freezes Check level in cooling system e Must be full check coolant strength e 35F minimum Check coolant hoses e Watch for kinks and or pinched hoses e Verify one pressure hose and one return hose Pressure regulator Test pressure regulator operation malfunction e See Chapter 9 Tests and Adjustments Vacuum leak Check for vacuum leaks Between mixer and throttle body Between throttle body and intake manifold Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer See Chapter 8 Air Fuel mixer section Engine Mechanical See Engine Manufacturers Service
82. replace as required Solvent or oil damage may cause vacuum lines to become soft resulting in a collapsed line while the engine is running If abnormally soft lines are detected replace as necessary Inspect Electrical System Check for loose dirty or damaged connectors and wires on the harness including Fuel lock off TMAP sensor O2 sensor Electronic throttle Control Relays Fuel Trim Valve Foot Pedal and Distributor sensor Repair and or replace as necessary WOODWARD 32 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Inspect Foot Pedal Operation e Verify foot pedal travel is smooth without sticking Check Coolant Level e The items below are a general guideline for system checks Refer to the engine manufacturers specific recommendations for proper procedures e Engine must be off and cold WARNING NEVER REMOVE THE PRESSURE CAP ON A HOT ENGINE e The coolant level should be equal to the COLD mark on the coolant recovery tank e Add approve coolant to the specified level if the system is low Inspect Coolant Hoses e Visually inspect coolant hoses and clamps Remember to check the two coolant lines that connect to the pressure regulator converter e Replace any hose that shows signs of swelling cracking abrasion or deterioration Inspect Battery System e Clean battery outer surfaces with a mixture of baking soda and water e Inspect battery outer surfaces for damage and replace as nece
83. rge venturi The variable venturi air fuel mixer constantly matches venturi size to engine demand To prevent engine reversion pulses commonly encountered in small displacement engines from having an effect on the piston AVV chamber a check valve is incorporated on the check valve plate control port to the AVV chamber The check valve is held open with gravity and remains open with any negative pressure signal from the engine If a reverse pressure pulse caused by engine reversion travels up the intake manifold toward the mixer it will close the check valve for the duration of the pulse preventing the pulse from entering the AVV chamber N CA55 500TR A main mixture adjustment valve on the fuel inlet of the N CA55 500TR is not used in the MI 04 system however an idle mixture adjustment is incorporated into the mixer Figure 19 The idle mixture adjustment is an air bypass port adjusting the screw all the way in blocks off the port and enriches the idle mixture Backing out the idle adjustment screw opens the port and leans the idle mixture The idle mixture screw is a nylon type screw that is factory set with a tamper resistant cap installed after adjustment Accurate adjustment of the idle mixture can only be accomplished by adjusting for a specific fuel trim valve FTV duty cycle with the service tool software and should be only be adjusted by trained service technicians 04 Electronic Throttle Air Intake Idle M
84. rlnputLow Stored Fault Code Check TMAP connector and IAT TMAP sensor failure or shorted MIL Only signal wiring for a shorted circuit circuit TMAP PIN 2 to SECM PIN 4 SIGNAL TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SECM PIN 18 5VDC To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance See the table in Chapter 6 0 lIATSensorlnputHigh Stored Fault Code Check TMAP connector and IAT IAT signal disconnected open MIL Only signal wiring for an open circuit circuit or sensor malfunction TMAP PIN 2 to SECM PIN 4 SIGNAL TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SECM PIN 18 XDCR 5VDC To check the sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance See the IAT table in Chapter 6 0 EST1Low Stored Fault Code Check coil driver wiring and Coil driver signal low or under MIL Only connector for shorts current SECM PIN 7 EST1 to COIL PINA Verify GND on COIL PIN B Verify GND on COIL PIN C Verify GND on COIL PIN D Verify 12vdc on COIL PIN E To check the Smart Coil internal circuit disconnect the coil connector and measure the resistance from pin to pin See Smart Coil resistance check in Chapter 6 0 WOODWARD 58 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table a 04 Diagnostic Fault Codes Flash Codes Table 04 Diagnostic Fault Codes Flash Codes 0 Co
85. ructed in accordance with the DOT TC United States Department of Transport Transport Canada The cylinders are referred to as universal because they can be mounted in either a vertical or horizontal position Figure 4 Figure 4 NOTE i A 375 psig relief valve is used on a DOT forklift tank The relief valve must be replaced with a new valve after the first 12 years and every 10 years thereafter The tank must be discarded if the collar is damaged to the point that it can no longer protect the valves It must also be replaced if the foot ring is bent to the point where the tank will not stand or is easily knocked over Installing LPG Fuel Tanks When installing a tank on a lift truck the tank must be within the outline of the vehicle to prevent damage to the valves when maneuvering in tight spaces Horizontal tanks must be installed on the saddle that contains an alignment pin which matches the hole in the collar of the tank When the pin is in the hole the liquid withdrawal tube is positioned to the bottom of the tank A common problem is that often these guide pins are broken off allowing the tank to be mounted in any position This creates two problems 1 When the liquid withdrawal tube is exposed to the vapor space it may give a false indication that the tank is empty when it actually is not 2 The safety relief valve may be immersed in liquid fuel If for any reason the valve has to vent venting liquid can cause a seri
86. sor Oil Pressure Switch Coolant Temp Sensor Figure 10 WOODWARD 14 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer by modulating the fuel trim valve FTV connected to the regulator Reducing the fuel pressure leans the air fuel mixture and increasing the fuel pressure enriches the air fuel mixture To calculate any necessary corrections to the air fuel ratio the SECM uses a number of different sensors to gain information about the engines performance Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with a TMAP sensor The MI 04 is a drive by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP feedback Even engine coolant temperature and adequate oil pressure is monitored by the SECM The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors such as ambient temperature fuel variations ignition component wear clogged air filter and other operating variables are compensated Open Loop LP Fue
87. ssary e Remove battery cable and clean repair and or replace as necessary Inspect Ignition System e Remove and inspect the spark plugs Replace as required Test secondary wires with Ohmmeter maximum resistance is exceeded repair and or replace e Remove distributor cap and perform visual inspection Replace cap and rotor if corrosion is found on the contacts e Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required i Api Spark Plugs Using a gentle twisting motion remove the high voltage leads from the spark plugs Replace any damaged leads Remove the spark plugs e the new spark plugs to the proper specifications Apply anti seize compound to the spark plug threads and install CAUTION DO NOT OVERTIGHTEN THE SPARK PLUGS Re install the high voltage leads WOODWARD 33 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Replace LP Fuel Filter Element Park the lift truck in an authorized refueling area with the forks lowered parking brake applied and the transmission in Neutral 1 Close the fuel shutoff valve on the LP Fuel tank Run the engine until the fuel in the system runs out and the engine stops 2 Turn off the ignition switch 3 Scribe a line across the filter housing covers which will be used for alignment purposes when re installing the filter cover Filter Hous
88. stem Figure 2 shows the relationship between pressure and temperature in a LPG tank at a steady state condition LPG Tank Pressure VS Temperature e Pressure psig 20 0 20 40 60 80 100 120 140 Figure 2 Temperature deg With 128 PSIG vapor pressure acting against the liquid propane the boiling point has been raised to slightly more than 80 deg F 27 deg C Compressed Vapor 128 PSIG Liquid Propane LPG Tank Figure 3 NOTE i Vapor pressure inside an LPG tank depends on the propane temperature not the amount of liquid inside the tank A tank that is full of liquid propane at 80 deg will contain the same vapor pressure as a tank that is only 74 full of liquid propane LPG s relative ease of vaporization makes it an excellent fuel for low rpm engines on start and stop operations The more readily a fuel vaporizes the more complete combustion will be Because propane has a low boiling point 44F and is a low carbon fuel engine life can be extended due to less cylinder wall wash down and little if any carbon build up WOODWARD 9 LPG AND LPG FUEL TANKS 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM LPG Fuel Tanks The two styles of LPG storage containers available for industrial use and lift truck applications are portable universal cylinders and permanently mounted tanks Portable universal cylinders are used primarily for off highway vehicles and are const
89. switch is activated this supplies power to the lock off and the SECM but will not open the lock off until the SECM provides the lock off ground connection This design gives the SECM full control of the lock off while providing additional safety by closing the fuel lock off in the unlikely event of a power failure wiring failure or module failure Figure 12 When the liquid service valve in the fuel container is opened liquid propane flows through the LP filter and through the service line to the fuel lock off Liquid propane enters the lock off through the 74 NPT liquid inlet port and stops with the lock off in the normally closed position When the engine is cranked over the main power relay applies power to the lock off and the SECM provides the lock off ground causing current to flow through the windings of the solenoid creating a magnetic field The strength of this magnetic field is sufficient to lift the lock off valve off of its seat against spring pressure When the valve is open liquid propane at tank pressure flows through the lock off outlet to the pressure regulator converter A stall safety shutoff feature is built into the SECM to close the lock off in case of a stall condition The SECM monitors three engine states Crank when the VR sensor detects any engine revolutions Stall when the key is in the ON position but the VR sensor detects no engine revolutions and the Run state when the engine reaches pre idle RPM When an operat
90. t Coupling The liquid withdrawal or service valve on a DOT tank has male threads and accepts the female portion of a quick disconnect coupling Figure 8 The female portion is adapted to the liquid hose going to the fuel system Both halves are equipped with 100 shutoffs which open when coupled together to allow fuel flow The coupler has two seals One is an o ring and the other is a flat washer The o ring prevents leakage from the shaft on the other coupling and the flat washer seals when the coupler is fully connected NOTE i The flat seal and or the o ring will sometimes pop off when disconnecting and slide up the shaft of the mating connector causing the valve not to open when fully mated The extra washer or o ring must be removed from the shaft and the coupling reconnected Figure 8 Knur Extemal Thread Check Valve 22222 4 Internal Thread Check Filler Valve The liquid filler valve Figure 9 has a male thread to receive a fuel nozzle and typically has a plastic or brass screw on cap that is retained with a small chain or plastic band to keep debris out of the filler valve The filler valve is a one way flow device that uses two check valves to allow fuel to enter the tank but prevent it from exiting Both check valves are backpressure type check valves designed so that backpressure from the tank assists the check valves own spring pressure to close the valve The first valve uses a neoprene
91. the APP2 potentiometer has malfunctioned An improper APP2 reading may be due to dirt or oxidation on the sensor traces Pedal2SensorRangeHigh Accelerator Pedal Position 2 Sensor Range is Low the APP2 potentiometer has malfunctioned An improper APP2 reading may be due to dirt or oxidation on the sensor traces Pedal1ToPedal2Difference Accelerator Pedal Position Sensor 1 and Accelerator Pedal Position Sensor 2 are Different normally set when APP1 measured pedal position is different from APP2 measured pedal position AFRTrimValveOutput Air Fuel Ratio Trim Valve FTV Driver is normally set when the FTV driver signal is open due to the connector becoming disconnected AFRTrimValveLowerDC Air Fuel Ratio Trim Valve FTV Lower Duty Cycle normally set when the duty cycle of the FTV reaches the minimum limit running too lean AFRTrimValveUpperDC Air Fuel Ratio Trim Valve FTV Upper Duty Cycle normally set when the duty cycle of the FTV reaches the maximum limit running too rich O2SensorSwitching Oxygen Sensor Switching is set when the O2 sensor can no longer switch or be driven above and below 500mv by the SECM OxygenSensorlnputHigh Oxygen Sensor Input is High OxygenSensorlnputLow Oxygen Sensor Input is Low WOODWARD 52 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM WOODWARD 53 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table MI 04 Diagnostic Fault
92. the catalytic muffler is a three way catalyst as well as sound dampening and spark arresting features The three way catalyst section consists of a honeycomb coated with a mixture of platinum palladium and rhodium As engine exhaust gases flow through the converter passageways they contact the coated surface which initiate the catalytic process The reduction catalyst is the first stage of the catalytic converter It uses platinum and rhodium to help reduce the NOx emissions The oxidation catalyst is the second stage of the catalytic converter It reduces the unburned hydrocarbons and carbon monoxide by burning oxidizing them over a platinum and palladium catalyst Cerium is also used to promote oxygen storage and improve oxidation efficiency Oxidation and Reduction Process Reduction NOx CO gt CO2 Oxidation HC CO 2 gt H20 2 3 Way Catalytic Converter Figure 25 WOODWARD 26 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM As exhaust and catalyst temperatures rise the following reaction occurs e Oxides of nitrogen NOx are reduced into simple nitrogen N2 and carbon dioxide 2 e Hydrocarbons HC and carbon monoxide CO are oxidized to create water 2 and carbon dioxide 2 The third stage is the MI 04 control system that monitors the exhaust stream and uses this information to control the air fuel mixture By using the signal from the HEGO the SECM
93. the sensor gap until you are within tolerance This completes setting ignition timing and sets the center of the SECM ignition control range at 15 degrees BTDC WOODWARD 96 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Idle Mixture Adjustment The method for making the idle mixture adjustment to a running engine is to use the Service Tool software by connecting a laptop Figure G7 computer to the SECM If you do not have the Service Tool a multimeter capable of measuring Duty Cycle such as a Fluke 87 can be used Connect the meter positive lead to between battery positive and the meter negative to the FTV signal wire Set the range for 4 or 40 and the MIN MAX setting to usually the default setting of the meter The multimeter will then read the Duty Cycle percentage the same as the Service Tool In order to use the Service Tool a USB Universal Serial Bus to CAN Controller Area Network communication adapter by Kavaser will be required along with a Crypt Token Figure G7 The Crypt Token acts as a security key allowing the laptop to retrieve the necessary data from the SECM 1 Install the Crypt Token in an available USB port in the computer Figure G8 2 With the ignition key in the OFF position connect the Kavaser communication cable from a second USB port on the computer to the CAN communications cable on the engine f your laptop computer does not have a second USB port an appropriate USB H
94. timing wheel near the tip of the sensor changes the magnetic flux creating an analog voltage signal in the sensor coil The MI 04 system is capable of operating with either a distributor based ignition system or a distributor less ignition system The current application uses a distributor based ignition system The distributor will have no internal advance mechanisms giving the SECM consistent authority over ignition timing The spark is sent to the appropriate cylinder in the conventional way via the rotor arm and spark plug wires The SECM uses the signal from the VR Variable Reluctance sensor mounted near the crankshaft pulley to determine the engine position and RPM at any time It uses this information together with the information from the TPS sensor and TMAP to calculate the appropriate ignition timing settings for the smart coil Figure 31 The MI 04 system uses a single coil which incorporates the ignition driver circuitry inside the coil itself The SECM signals the smart coil when to begin its dwell cycle then the coil waits for the trigger signal from the SECM SmartCoil The smart eliminates the need for a driver circuit inside the SECM or externally from the coil Using a single VR sensor and smart coil eliminates multiple sensors and coil packs used in more complex ignition systems WOODWARD 31 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM CHAPTER 3 0
95. tion of the throttle valve Note The DV E5 is not a serviceable assembly If the TPS sensor fails the assembly should be replaced Figure 27 SECM self calibration and cross checking of the TPS is accomplished by comparing the TPS signal to a calculated throttle position in the SECM software Predicted TPS In addition to the throttle position sensor a Temperature Manifold Air Pressure Sensor TMAP is used to monitor intake manifold temperature and pressure Figure 28 This enables the SECM full control capabilities monitoring actual airflow in relationship to desired airflow The TMAP sensor is a single unit Figure 28 incorporating both intake manifold temperature and manifold pressure measurement WOODWARD 28 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM The MI 04 system also performs minimum min and maximum max governing through the SECM and DBW throttle For min governing or idle speed control the idle speed is fixed by the SECM Unlike a mechanical system the idle speed is not adjustable by the end user The idle speed is adjusted by the SECM based on engine coolant temperature At these low engine speeds the SECM uses spark and throttle to maintain a constant speed regardless of load The MI 04 system eliminates the need for air velocity governors This substantially increases the peak torque and power available for a given system as shown in Figure 29 When the engine
96. ttom of the mixer Figure 4 2 Gently remove the throttle adapter from the Figure M5 bottom of the mixer Figure M5 3 Components of the N CA55 500TR and the mixer body are shown in Figure M6 WOODWARD 80 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 4 Replace the air valve sealing ring as shown Figure M7 Figure M7 The ring is similar to a piston ring and forms a seal from the air valve assembly to the mixer main body Small raised circular formations can be found on one side of this ring Place the ring so that these circular markings face upward toward the fuel metering pin for proper sealing 5 Insert the air valve assembly into the main body Figure M8 Figure M8 6 Next install the air valve spring Figure 9 Figure M9 WOODWARD 81 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 7 After the air valve spring install the check valve plate Figure M10 Figure M10 8 Place the mixer to throttle body gasket over the check valve plate Figure M11 To properly install the Figure M11 gasket the hole for the idle port in the throttle adapter must be aligned with the idle port in the gasket 9 Align the check valve notch in the throttle adapter with the mixer check valve and the adapter idle port with the mixer idle port Install the throttle adapter tamper resistant screws to the mixer Figure M12 WOODWARD 82 N CA55 500TR MI
97. turned off the air valve assembly closes the gas metering valve stopping fuel flow past the mixer The gas metering valve controls the amount of fuel to be mixed with the incoming air at the proper ratio The air fuel mixture then travels past the throttle through the intake manifold and into the engine cylinders where it is compressed ignited and burned Figure 15 Figure 16 shows the N CA55 500TR mixer installed with the electronic throttle Figure 16 WOODWARD 19 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM N CA55 500 TR Air Fuel Mixer Theory of Operation i Air Valve Piston 5 View of Venturi Air Intake Figure 17 Gas Metering D Valve open u ia Figure 18 The air fuel mixer is mounted in the intake air stream between the air cleaner and the throttle The design of the main body incorporates a cylindrical bore or mixer bore fuel inlet 1 and a gas discharge jet 2 In the center of the main body is the air valve assembly which is made up of the piston air valve 3 the gas metering valve 4 and air valve sealing ring 5 air valve spring 6 and the check valve plate 7 The gas metering valve is permanently mounted to the piston air valve with a face seal mounted between the two parts When the engine is not running this face seal creates a seal against the gas discharge jet preventing fuel flow with the aid upward force of the air val
98. tween the mixer and the throttle adapter Figure M15 and then attach the mixer to the adapter using the four tamper resistant retaining screws CAUTION The mixer must be installed with the idle port aligned with the idle port in the adapter and the mixer check valve aligned with the valve recess in the adapter to operate properly Figure M16 Figure M16 CHECK VALVE zi IDLE PORT 2 Tighten the four tamper proof retaining screws Figure M17 to the specified torque Figure M17 WOODWARD 85 N CA55 500TR MIXER 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 3 Check for free travel of the mixer s piston diaphragm assembly by pushing the piston Figure M18 diaphragm downward Figure M18 If you y a detect any binding loosen the retaining screws re align the gasket and re tighten the retaining screws Check for binding again if the piston assembly moves freely re torque the fasteners and continue 4 Install the manifold adapter by placing the manifold gasket between the manifold and the manifold adapter The manifold adapter should be mounted with the TMAP sensor ports facing the thermostat housing Tighten the two internal socket bolts to specified torque values o Place the throttle bottom gasket between the electronic throttle assembly and the manifold adapter Place the throttle assembly on top of the gasket aligning the four mounting holes with the threaded holes in the manifold adapter T
99. ual for procedures on removing the mixer and inspecting the throttle plate the TMAP Sensor Verify that the TMAP sensor F is mounted tightly into the manifold adapter E with no leakage e TMAP is found to be loose remove the TMAP retaining screw and the TMAP sensor from the manifold adapter e Visually inspect the TMAP O ring seal for damage Replace as necessary e Apply a thin coat of an approved silicon lubricant to the TMAP o ring seal Reinstall the TMAP sensor into the manifold adapter and securely tighten the retaining screw Inspect Engine for Exhaust Leaks e Start the engine and allow it to reach operating temperatures e Perform visual inspection of exhaust system Repair any all leaks found WOODWARD 36 MAINTENANCE SCHEDULE 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM WOODWARD 37 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM MAINTENANCE SCHEDULE Interval Hours Every Every Every Every Every Every 250hrs or 500 1000 1500 2600 4500 CHECK POINT a month Hours or Hoursor Hours or Hours or Hours or Daily months 6 months 9 months 18 month General Maintenance Section Leaks ass xT TT leaks mue 1 and fittings Inspect electrical system check for loose dirty or damaged wires and connections ad 1 hoses eee and operation Engine Coolant Section
100. ub will need to be used 3 Connect a timing light to the engine 4 Turn the ignition key to the ON position Do Not Start the Engine Figure G9 o Launch the MotoView program on your computer and open the Service Tool display 6 Start the engine you should now see the idle RPM on your Service Tool display Run Screen Figure G9 NOTE Service Tool software MotoTuneViewer and the security Crypt Token is obtainable by certified technicians through authorized dealers WOODWARD 97 TEST AND ADJUSTMENTS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM 7 Adjust the idle mixture screw on the mixer until a reading of 25 40 is reached for the FTV Duty Cycle in Closed Loop Idle Figure G12 8 make this adjustment you will need to adjust the idle mixture screw all the way inward If the FTV Duty Cycle measures between 25 40 no further adjustment is necessary If the measured FTV Duty Cycle is above 40 adjust the screw outward until the duty cycle drops below 40 INTAKE MANIFOLD TEMP INTAKE MANIFOLD TEMP COOLANT TEMP 9 Use the accelerator pedal to increase Figure 28 RPM above idle momentarily Rev the engine then release the pedal to return to idle RPM The duty cycle setting should remain within the adjustment range 25 40 Place your thumb over the adjustment port for a more accurate reading by preventing air from leaking past the mixture adjustment screw which may cause the duty cycle to
101. uel line Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve Leak test Faulty vapor connection Check connection between the pressure e Verify no holes in hose regulator converter and the e Clamps must be tight mixer e Look for kinked pinched and or collapsed hose Pressure regulator converter Test pressure regulator converter malfunction operation See Chapter 9 Tests and Adjustments Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container Do not exceed 80 of liquid capacity e Clean replace as required control Diagnostics WOODWARD 41 BASIC TROUBLESHOOTING 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Probable Cause Corrective Action Will Not Run Continuously Fuel container almost LPG Vapor from liquid outlet empty Fill fuel container Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required See Chapter 3 Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open
102. unctions as faults in SECM memory Engine run hours are also stored in memory SECM Stored fault codes can be displayed on the Malfunction Indicator Light MIL as flash codes or read by the MI 04 Service Tool software through a CAN Controller Area Network communication link Battery power 12 VDC is supplied through the fuse block to the main power relay The ignition key switch is used to energize the main power relay A main power relay supplies 12 VDC power to the SECM the Figure 23 heated element of the oxygen sensor Fuel Lock Off Fuel Trim Valve FTV and the Smart Coil The SECM supplies positive voltage to the electronic throttle actuator oil pressure switch and the coolant temperature sensor Transducer or sensor power 5 VDC is regulated by the SECM and supplied to the Temperature Manifold Air Pressure Sensor TMAP Throttle Position Sensor TPS and the Accelerator Pedal Position Sensors APP1 2 The SECM provides a constant voltage VCC to the Smart Coil Driver transducer ground for the all sensors and a low side driver signal controlling the fuel lock off MIL and FIV 04 SECM Fuel Management During engine cranking at startup the SECM provides a low side driver signal to the fuel lock off which opens the lock off allowing liquid propane to flow to the N2001 regulator A stall safety shutoff feature is built into the SECM to close the lock off in case of a stall condition The SECM monitors thre
103. utHi Disable Throttle Check throttle connector and TPS1 sensor failure or shorted TPS1 sensor wiring for a circuit shorted circuit ETC PIN 6 to SECM PIN 17 SIGNAL ETC PIN 2 to SECM PIN 1 GND ThrottleSensorRangeLo Stored Fault Code Check the throttle connector TPS1 potentiometer malfunction MIL Only and pins for corrosion Improper TPS reading may be due e Perform Throttle test to dirt or oxidation on the sensor with the Service Tool traces several times to clean sensor To check the TPS disconnect the throttle connector and measure the resistance 1 25 30 from TPS 2 GND to PIN 6 TPS1 SIGNAL TPS PIN 3 PWR to PIN 6 TPS1 SIGNAL See Chapter 6 0 for sensor checks ThrottleSensorRangeHi Stored Fault Code Check the throttle connector TPS1 potentiometer malfunction MIL Only and pins for corrosion Improper TPS reading may be due e Perform Throttle test to dirt or oxidation on the sensor with the Service Tool traces several times to clean sensor To check the TPS disconnect the throttle connector and measure the resistance 1 25 30 from TPS 2 GND to PIN 6 TPS1 SIGNAL TPS PIN 3 PWR to PIN 6 TPS1 SIGNAL See Chapter 6 0 for sensor checks WOODWARD 55 ADVANCED DIAGNOSTICS 2 0L 2 4L SERVICE MANUAL 91505 04 LP SYSTEM Table 04 Diagnostic Fault Codes Flash Codes Probable Fault Corrective Action First Check ETCSticking Throttle
104. ve spring The outer surface of the piston air valve forms the venturi section of the mixer while the inner portion of the piston is hollow and forms the air valve vacuum chamber The check valve plate seals off the bottom of the air valve vacuum AVV chamber and the air valve sealing ring seals the top portion of the AVV chamber as the piston moves against the air valve spring When the engine is cranked over it begins to draw in air creating a negative pressure signal This negative pressure signal is transmitted through a port in the check valve plate to the AVV chamber A pressure force imbalance begins to build across the air valve piston between the AVV chamber below the piston and atmospheric pressure above the piston Approximately 6 W C Water Column of negative pressure is required to overcome the air valve spring force and push the air valve assembly piston downward off the valve seat Approximately 24 W C pushes the valve assembly to the bottom of its travel in the full open position The amount of negative pressure generated is a direct result of throttle position and the amount of air flowing through the mixer to the engine At low engine speeds low AVV causes the piston WOODWARD 20 MI 04 SYSTEM OVERVIEW 2 0L 2 4L SERVICE MANUAL 91505B_DRAFT 04 LP SYSTEM air valve to move downward a small amount creating a small venturi At high engine speeds high AVV causes the air valve piston to move much farther creating a la
105. vy ends cool they form a wax like deposit or sludge HD5 grade propane is recommended for motor fuel use however HD5 propane will carry a certain amount of heavy ends A fuel filter cannot remove this because it is not dirt or debris but part of the liquid propane As these deposits build up over time regulator fuel ports and valve seats can be affected reducing the performance of the regulator All propane systems incorporating a regulator converter are subject to heavy end fouling over time Because of this it may be necessary for the certified technician to disassemble clean and service the regulator converter after long periods of operation Removal and Installation of the N CA55 500TR Mixer A WARNING e LP gas is highly flammable To prevent personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system e Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area e Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION The regulator converter and mixer are part of a certified system complying with A EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble

MI-04 2.0/2.4L Service Manual 91505B Draft

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