Home

3.0L Operations Manual

1. SERVICE TOOL ITEM RICH LEAN Pre catalyst Oe A D Consistently gt 250 Consistently lt 170 counts Pre catalyst O2 sensor switching between high Always high ADC Always low ADC and low Trim valve duty cycle gt 90 lt 10 Fuel injector pulse width at idle lt 1 0 msec gt 8 msec e Pre catalyst O sensor e Pre catalyst O2 failed rich sensor failed lean Malfunction codes e Pre catalyst O sensor e Pre catalyst O2 high sensor low e Fuel adapts e Fuel adapts Closed loop operation Stuck in open loop Stuck in open loop The duty cycle injector pulse width criteria for lean or rich operation apply only if the O sensor is functioning properly If the sensor is not operating properly the criteria may be reversed RICH OPERATION LP Trim valve duty cycle gt 90 e Inspect hoses from AVV port port on bottom of mixer to trim valves and regulator for leaks or blockages replace as necessary e Inspect in line orifices for blockages in wye replace as necessary e Check trim valves for proper operation replace as necessary e Check regulator out pressure replace if out of spec e Inspect fuel cone for damage replace mixer assembly as necessary Gasoline Injector Pulse Width lt 1 0 msec e Check gasoline fuel pressure e Check injectors for sticking replace as necessary LEAN OPERATION LP Trim valve duty cycle lt 10 e Check for vacuum leaks replace hoses o rings and gaskets as necessary
2. Dual Dither SECM 48 CA100 Mixer Fuel Fuel Coolant Temp Lockoff PZ Sa MIL ie Pre CAT 02 Sensor SS ef N 2007 Speed Regulator Switch 1 LR Speed Switch 2 L ma Bosch Electronic Throttle Crankshaft Sensor Foot Oil Pressure Switch Pedal Coil Driver A Fuel Pump Y Fuel Injectors Gasoline Manifold Pressure Temperature Sensor Figure 1 MI 07 Bi Fuel System for 3 0L Engines 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 dual fuel trim valves 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 engine s performance Engine speed is monitored by the SECM through a variable reluctance VR or Hall Effect sensor Intake manifold air Woodward 3 Manual 36553 MI 07 Engine Control System for 3 0L Engines temperature and absolute pressure are monitored with a TMAP sensor The MI 07 system implements 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 p
3. 161 16 151 15 Woodward 83 Manual 36553 Table 1 MI 07 Engine Control System for 3 0L Engines Fault List Definitions cont d FAULT DESCRIPTION CODE MI04 CODE ECTRangeLow Engine Coolant Temperature Sensor Input is Low Normally set if the coolant sensor wire has shorted to chassis ground or the sensor has failed 141 14 ECT_IR_Fault Engine Coolant Temperature not changing as expected 171 EST1_Open EST1 output open possibly open EST1 signal or defective spark module 421 EST1_Short ETCSpringTest EST1 output shorted high or low EST1 signal shorted to ground or power or defective spark module Electronic Throttle Control Spring Return Test has Failed The SECM will perform a safety test of the throttle return spring following engine shutdown If this spring has become weak the throttle will fail the test and set the fault NOTE Throttle assembly is nota serviceable item and can only be repaired by replacing the DV EV throttle assembly 431 42 481 28 ETC_Open_Fault Electronic Throttle Control Driver has failed Normally set if either of the ETC driver signals have opened or become disconnected electronic throttle or SECM is defective 471 ETC_Sticking Electronic Throttle Control is Sticking This can occur if the throttle plate butterfly valve inside the throttle bore is sticking The plate sticking can
4. Woodward 96 Manual 36553 Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION PROBABLE FAULT EST1_Open EST1 output open possibly open EST1 signal or defective spark module TurnOnMil EST1_Short EST1 output shorted high or low EST1 signal shorted to ground or power or defective spark module TurnOnMil ETC_Sticking Electronic Throttle Control is sticking This can occur if the throttle plate butterfly valve inside the throttle bore is sticking The plate 1 sticking can be due to TurnOnMil some type of 2 obstruction a loose EngineShu throttle plate or worn tdown components shaft 3 bearings CutThrottle NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly ETC_Open_Fault Electronic Throttle Control Driver has failed normally set if either of the ETC driver signals have opened or become disconnected electronic throttle or SECM is defective Woodward MI 07 Engine Control System for 3 0L Engines CORRECTIVE ACTION FIRST CHECK Check ignition module wiring and connector for open circuit SECM Pin A9 EST1 to ignition module Pin B Verify GND on ignition module Pin C Verify 12 Vdc on ignition module Pin A Refer to application manual for specific engine details Check ignition module wiring and connector for shorts SECM Pin A9 EST1 to ignition module Pin B Verify GN
5. YOSNIS VID iv gt is0d CONNECTOR CONNECTOR WW PIN 1635 1175 WW PIN 1635 1176 PIN 4 1437287 5__ PIN 4 1437267 6 DWG NO 9930 1067 Figure 21 SECM Wiring Diagram for Bi Fuel System Woodward 30 Manual 36553 MI 07 Engine Control System for 3 0L Engines RED 18AWG IB5_CRNK KEY_ON_AN14_88 IB6_CRNK MPRD_A22 LSOT_A5 LSO2_A8 E ILON T 3LON OMY NI Suv SIZIS JJM OSCH SSIMYSHLO GEHT Lg ILON NNOO ie EI Cas B11_CAM11 LSO4_A7 LSO3_A4 OMY SL Suv SIDS IAM TIY L krasmaiag LSO9_MIL ORVP_A23 JYV SNOUWLWNINYAL HOLD IB2_AN6_NOT_USED IB9_AN13_NOT_USED COLOR YEO _ANI3_OPS 3GIS TYNINY3 LON 20 SYWANO NMOHS 7 EST1_AQ EST3_A3_NOT_USED PLAN EST4_A6_NOT_USED mee 4B21_CAN t conor 4A12_EST7_FSS LP LSO6_A14 A15_EST8_FSS LIO DIS A g IgetS OL 2LCH 22 13N3 coor 4B7_AN4_APP1 1403 ISOLTLY HAT CES KEE ELW Q3SN SIHOLUMS 193735 ON 2 816_AN5_APP2 SNNOSY9 YOs 19 OL SLY USAW DRVG A_A16 CLOR 4B14_AN10_FTS D DRVG B_B17 CO EMS EEN ans COLOR FA19_ESTS_SPD1 acr JA21_EST6_SPD2 FUELP_LO_LSO8_A11 4 o 28 am gg 28 3 23 as coor 4B18_AN1_MAP coven 4B12_ ANS MAT vun Leo Ai wna caor 4824_XDRP_XPWR coor 4B 1_XDRG_XGND VLV2_LSO10_A2 u YSHLIC TAAWA LINA 45051007 wha om 4B 15 ANS ECT OILP_FUELPMP_LSO5_A13 IB23_AN2_TPS1 AN3 Rig N E Te A17 Hie ETC TB 02A _AN11_B13F uo A20_LSO7_02
6. RED 18 AWG BATT BZ reo B5_CRNK KEY_ON_AN14_B8 mp B6_CRNK MPRO_A22 coucr LS01_A5 cour LS02 A8 coor ES SLON CALON SSIMSSHLO SSJINN OMY NI ZAY SINS IAA TIV T SLON OMY N Say SIAS JAM 1 ILON Jeun Ca COLOR 511 CAM LS04_A7 L 07 Adem Eier zl A 22 L 09 ML DRVP_A23 mo B2_AN6_NOT_USED B9_AN13_NOT_USED B9_AN13_OPS Dep BW EST An coor MAM IYS be ECK EST3_A3_NOT USED B31_CANt EST4_A6_NOT USED eer 1B20_CANt LS06_A14 p coor A12 EST FSSLP A12_EST8_FSS LIQ HOLS 493135 ans BOIS WNINHAL LON JAS JAMNO NMOHS 27 SNOUYNINYSL YOLOSNNOO Thy ILON LOSS 1394 LOVES UNY Dat HELLS OL Od B7 AH App O en ILSA SIJAN dI Y0 t8 OL ZLY SIJAN Y O3SNSIHOUMS 193735 ON JI Wd3d Lo I816_ANS_APP2 DRVG A_A18 EA Aug Ers Ehlen BE gp WOAS SNITOS YD X404 t8 OL St SIMAN o T emml Tg EST Ston d 033dS GN CH gy ooxctyA21_EST6_SPO2 or o 2g Be ZS 8 ae E S93 28 Shh 29 R EN T FUELP_LO_LS08_A11 couor VLV1_LS011_A1 coven H B18_AN1_MAP B12_AN8_MAT Is24_XORP_XPWR 1B1_XDRG_XGNO VLV2_LS010_A2 H ZEN BATWA 350 o TINT SLL H SNIS anal caoR B15_ANS_ECT WANO KE Sr i dtd vans OILP_FUELPMP_LS05_A13 e omor4B23_AN2_TPS1 covon 164 AN3 TPS2 A caca ATS_HEETC_Te t CRON AIT H1sETC_TB ago8 TUL EC A20_LS07_026_HTR DIET ANTL Et
7. PART NO DESCRIPTION 1751 6068 ig Control Module SECM 48 crankshatt Postion Sensor TMP Sensor P Coolant Sensor Engine Oi Pressure swin SSES 8062 1052 CA100 Mixer 6945 5001 Throttle DV E5 40mm Woodward 109 Manual 36553 MI 07 Engine Control System for 3 0L Engines CA100 Mixer Refer to Figure 39 exploded view on facing page Parts List CA100 Mixer DESCRIPTION 2 lt Torx Screws T 25 10 24 x 5 8 Lockwashers T 210 10 SST Mixer Cover Mixer Spring Diaphragm Air Valve Assembly Gas Valve Cone part of air valve assembly Mixer Body Expansion Plug Cap 1 2 x 1 16 thick 12 7mm x 27mm Fuel Inlet Air Horn Gasket Air Horn Adapter 2 1 16 52 37mm Fillister Head Screws SEMS Lockwasher 10 24 UNC x 5 8 Throttle Body Gasket Fillister Head Screws SEMS Split Lockwasher 12 24 x 5 8 Woodward 110 Manual 36553 MI 07 Engine Control System for 3 0L Engines Exploded View CA100 Mixer DWG NO 9097 2008 Rev 2 Figure 39 CA100 Certified Mixer Exploded View Woodward 111 Manual 36553 MI 07 Engine Control System for 3 0L Engines N 2007 Regulator Refer to Figure 40 exploded view on facing page Parts List Regulator RE F DESCRIPTION QTY NO 1 N 2007 Body 1 2 Diaphragm Primary Assembly 1 3 Springs Primary Assembly 2 4 Cover Primary Assembl
8. After exiting the fuel tank liquid propane passes through a serviceable inline fuel filter to the electric fuel lock off Figure 3 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 paraffins that build up in LPG fuel systems as a result of vaporization Figure 3 Inline LP Fuel Filter MI 07 Fuel Lock Off Electric The fuel lock off is a safety shutoff valve normally held closed by spring pressure It incorporates 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 07 system Figure 4 Electric Fuel Lock Assembly In the MI 07 design power is supplied to the fuel lock off via the main power relay with the SECM controlling the lock off ground earth connection The lock off remains in a normally closed NC position until the key switch is activated This supplies power to the lock off and the SECM but will not open the lock off via the main power relay 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 When the liquid service valve in the
9. This could be caused by oxygen leak before or just after sensor catalyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O sensor faults are set diagnose these first and after correcting these 872 LiqPostO2FailedLean LiqPostO2Inactive Reserved these faults recheck if this fault sets sensed the O sensor is not responding as failed Post catalyst Op sensor control on gasoline has reached lean limit and sensor still reads too rich This could be caused by catalyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O2 sensor faults are set diagnose these first and after correcting Post catalyst O sensor control on gasoline has expected If any Pre Oz sensor faults are set diagnose these first and after correcting these faults recheck if this fault sets Possible causes for this fault are sensor disconnected sensor heater failed sensor element failed heater relay or SECM control of heater relay is disconnected or 852 842 843 LowOilPressureFault Low engine oil pressure 521 52 MAPRangeHigh failed Manifold Absolute Pressure Sensor Input is High normally set if the TMAP pressure signal wire has become shorted to power shorted to the IAT signal the TMAP has failed or the SECM has 342 MAPRangeLow circuit has opened to the SECM Manifold Absolute Pressure Sensor I
10. sound Slowly open liquid valve Repair replace as required agosa ae aar See Chapter 4 Fuel Filter Replacement Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line Plugged fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve amp leak test b Repair replace fuel lock off Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Check level in cooling system e Must be full check coolant strength e 35 F 37 C minimum Check coolant hoses e Watch for kinks and or pinched hoses e Verify one pressure hose and one return hose Test regulator See Chapter 6 Check for vacuum leaks Between mixer and throttle body Vacuum leak Between throttle body and intake manifold Between intake manifold and cylinder head Excess flow valve closed Faulty vapor connection between the pressure regulator converter and the mixer Pressure regulator freezes Related MIL Faults EST faults ETC Sticking fault Pre catalyst adapts error Woodward 72 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Cuts Out Misses Steady pulsation or jerking that follows engine speed usually more pronounced as engine load increases sometimes above 1500 RPM The exhaust has a steady spitting sound at
11. 1 TurnOnMil The sensor has 2 DelayedEngine measured an Shutdown excessive coolant 3 temperature typically CheckEngineLight due to the engine overheating ECT_IR_Fault Engine coolant temperature not None changing as expected FuelSelectConflict Conflict in fuel select signals normally set if both of the fuel ERR select signals are shorted to ground CamEdgesFault No CAM signal when engine is known to be rotating broken None crankshaft sensor leads or defective CAM sensor CamSyncFault Loss of synchronization on the CAM sensor normally due to noise None on the signal or an intermittent connection on the CAM sensor CrankEdgesFault No crankshaft signal when engine is known to be rotating None broken crankshaft sensor leads or defective crank sensor Fault actions shown are default values specified by the OEM CORRECTIVE ACTION FIRST CHECK Check coolant system for radiator blockage proper coolant level and for leaks in the system Possible ECT short to GND check ECT signal wiring SECM Signal Pin B15 to ECT Pin A SECM Sensor GND Pin B1 to ECT PinB SECM System GND Pin A16 B17 Check regulator for coolant leaks Check for coolant system problems e g defective or stuck thermostat Check fuel select switch connection for a short to GND SECM SIGNAL Pin A12 SECM SIGNAL Pin A15 SECM Sensor GND Pin B1 Check CAM sensor connections at distributor SECM
12. Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 and the regulator should be replaced Figure 30 Secondary Stage Test Connection Pressure Test Primary Stage Test Hardware Shop air pressure regulator adjusted to 100 psi Shop air hose fitting 1 4 NPT to air hose Air hose Test gauge fitting 1 16 NPT x 1 4 hose barb Vacuum hose or vinyl tubing 0 60 WC Magnehelic gauge inches of water column Ol ONS Primary Stage Pressure Test 1 Remove the primary test port plug from the side of the regulator and install the 1 16 NPT hose barb fitting Figure 31 2 Connect a compressed air line shop air 100 psi to the liquid propane fuel inlet of the N 2007 regulator Figure 31 Figure 31 Primary Stage Test Connection Woodward 53 Manual 36553 MI 07 Engine Control System for 3 0L Engines 3 Apply compressed air wait for air to exit the hose barb in the test port and then connect the Magnehelic gauge Figure 32 to the hose barb using the vacuum hose or vinyl tubing This prevents the gauge from reading maximum pressure due to the large velocity of compressed air entering the primary chamber 4 Make sure there is n
13. Manual 36553 MI 07 Engine Control System for 3 0L Engines Connection of MI 07 Service Tool To use the Service Tool a Universal Serial Bus USB to Controller Area Network CAN communication adapter by KVaser will be required along with a Crypt Token Figure 34 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 35 With the ignition key in the OFF position connect the KVaser communication cable from a second USB port on the computer to the CAN communications cable on the engine If your laptop computer does not have a second USB port an appropriate USB hub will need to be used Connect a timing light to the engine Turn the ignition key to the ON ef position Do Not Start the Engine Launch the MotoView program on your computer and open the Service Tool display Figure 36 Figure 34 KVaser Communication Adapter Figure 36 Opening the Service Tool Display Woodward 56 Manual 36553 MI 07 Engine Control System for 3 0L Engines Idle Mixture Adjustment NOTE Be sure engine is fully warm ECT gt 180 F 82 C before performing the idle mixture adjustment The CA100 mixer requires adjustment of the idle mixture screw to assure optimal emissions and performance This adjustment accounts for minor part to part variations in the fuel system and assures stable performance of t
14. Oe FesiGallianigeLow low sensor signal shorted to ground ate SensVoltRangeHigh Sensor reference voltage XDRP too high ee SensVoltRangeLow Sensor reference voltage XDRP too low SE ServiceFault1 Service Interval 1 has been reached 991 ServiceFault2 Service Interval 2 has been reached 992 ServiceFault3 Service Interval 3 has been reached 993 Service Interval 4 has been reached time to EE replace HEGO sensors oat ServiceFault5 Service Interval 5 has been reached 995 Engine speed has exceeded first level SECHER 1 of 3 of overspeed protection ae WT Learned WOT value of TPS sensor range TES kacti lower than expected ae SysVoltRangeHigh System voltage too high a SysVoltRangeLow System voltage too low Ze Learned WOT value of TPS sensor range 251 TS agape higher than expected 25 vo Learned WOT value of TPS sensor range TPS1AdaptHiMin lower than expected 271 Learned closed throttle value of TPS sensor TPS1AdaptLoMax range higher than expected ES Learned closed throttle value of TPS sensor 241 Troteeeiilovalit range lower than expected 24 TPS sensor voltage out of range high 231 TPS1RangeHigh normally set if the TPS signal has shorted to 23 power or ground for the sensor has opened TPS sensor voltage out of range low normally 224 TPS1RangeLow set if TPS signal has shorted to ground circuit 22 has opened or sensor has failed Learned WOT value of TPS sensor range TPS2AdaptHiMax higher than expected 252 Woodward 89 Manual 3
15. Post catalyst O sensor 1 TurnOnMil condensation in exhaust has inactive on gasoline open Oz 2 DisableLiqPost been removed by exhaust heat sensor signal or heater leads O2Ctrl Post O Heater Relay has defective O sensor SECM DRVP 12V applied to the relay coil power The relay coil ground is controlled by SECM Pin A20 to activate the relay to flow current through the post O heater Verify O sensor heater circuit is operating by measuring heater resistance 2 10 0 49 O Pin C GND to Pin D power Check for vacuum leaks 1 TurnOnMil Low gasoline fuel pressure 2 DisableLiquid perform gasoline pressure test Injector problems e g plugged defective injector Correct other faults that may contribute to 852 e g faults pertaining to Injectors MAP IAT Pre Cat O Post Cat O LiqPostO2FailedLean 1 TurnOnMil sensor Post catalyst O2 sensor 2 DisableLiqPost Look for leaks in exhaust indicates extended lean O2Ctrl catalytic converter HEGO operation on gasoline sensors repair leaks Check all sensor connections see fault 842 corrective actions LigO2FailedRich High gasoline fuel pressure q 1 TurnOnMil perform gasoline pressure test Pre catalyst O gt sensor eet indicates extended rich SE E Injector problems e g leaking operation on gasoline defective injector LiqO2FailedLean Pre catalyst O gt sensor indicates extended lean O2ctrl operation on gasoline Fault
16. e Check balance line for blockage replace as necessary e Check vapor hose for restrictions replace as necessary e Check trim valves for proper operation replace as necessary e Check regulator out pressure replace if out of spec Gasoline Injector Pulse Width gt 8 msec e Check system voltage e Check fuel pressure e Check injectors for sticking or obstructions Woodward 77 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chart T 1 Restricted Exhaust System Check Proper diagnosis for a restricted exhaust system is essential before replacement of any components The following procedures may be used for diagnosis depending upon engine or tool used CHECK AT PRE CATALYST OXYGEN 02 SENSOR Carefully remove pre catalyst oxygen Oz sensor Install exhaust backpressure tester or equivalent in place of Op sensor using Snap On P N EEVPV311A kit and YA8661 adapter or Mac tool see illustration After completing test described below be sure to coat threads of O sensor with anti seize compound prior to re installation Courtesy of GM 1991 Service Manual for Chevrolet Camaro 1990 ILLUSTRATION NOTES 1 Backpressure gage 2 Pre catalyst Oxygen O2 sensor 3 Exhaust manifold DIAGNOSIS 1 With the engine idling at normal operating temperature observe the exhaust system backpressure reading on the gage Reading should not exceed 1 25 psig 8 61 kPa Increase engine speed to 2000 RPM and observe g
17. expected Learned idle value of APP APP2AdaptLoMin sensor range lower than expected APP sensor voltage out of range high normally set if the APP2RangeHigh APP2 signal has shorted to power or the ground for the sensor has opened APP sensor voltage out of range low normally set if the APP2RangeLow APP signal has shorted to ground circuit has opened or sensor has failed APP position sensors do no not track well intermittent 691 connections to APP or 69 defective pedal assembly No CAM signal when engine is known to be rotating broken CAM sensor leads or defective CAM sensor Loss of synchronization on the CAM sensor normally due to CamSyncFault noise on the signal or an 192 intermittent connection on the CAM sensor No crankshaft signal when engine is known to be rotating CrankEdgesFault broken crankshaft sensor 193 leads or defective crank sensor Loss of synchronization on the crankshaft sensor normally CrankSyncFault due to noise on the signal or 194 an intermittent connection on the crankshaft sensor Engine Coolant Temperature is High The sensor has ECTOverTempFault measured an excessive coolant temperature typically due to the engine overheating Engine Coolant Temperature Sensor Input is High Normally ECTRangeHigh set if coolant sensor wire has been disconnected or circuit has opened to the SECM 632 67 622 66 612 65 APP_Sensors_ Conflict CamEdgesFault 191
18. 5811 e Fax 1 970 498 3058 Email and Website www woodward com 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 email information for all locations is available on our website 2007 3 Niles
19. A faulty in tank fuel pump check valve will allow the fuel in the lines to drain back to the tank after engine is stopped To check for this condition perform fuel system diagnosis Check FTV system for proper operation Check for proper ignition voltage output with spark tester Check spark plugs Remove spark plugs check for wet plugs cracks wear improper gap burned electrodes or heavy deposits Repair or replace as necessary Ignition system malfunction Check for Bare or shorted wires Loose ignition coil ground Pickup coil resistance and connections Related MIL Faults ETC spring check ETC faults EST faults TPS conflict Woodward 65 Manual 36553 MI 07 Engine Control System for 3 0L Engines APP faults Encoder error MAP faults Injector faults Oil pressure faults Woodward 66 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Lack of Power Slow to Respond Poor High Speed Performance Hesitation During Acceleration Engine delivers less than expected power Little or no increase in speed when accelerator pedal is pushed down part way Momentary lack of response as the accelerator is pushed down May occur at all vehicle speeds Usually most severe when first trying to make vehicle move as from a stop May cause engine to stall PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Drive
20. Check fuel supply while condition exists Check in line fuel filter Replace if dirty or plugged Check fuel pressure Check for proper ignition voltage output using spark tester Check spark plugs Remove spark plugs check for wet Ignition system malfunction plugs cracks wear improper gap burned electrodes or heavy deposits Repair or replace as necessary Check condition of spark plug wires Check ignition timing Check vacuum lines for kinks or leaks Component malfunction Check alternator output voltage Repair if less than 9 or more than 16 volts Check condition of exhaust system Exhaust backpressure Check backpressure before catalyst It should be less than 3 5 psig 24 13 kPa Refer to Table 1 for description of gaseous and liquid O adapts Related MIL Faults Pre catalyst O sensor errors O control errors Dither valve DC faults EST faults ETC faults Woodward 63 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Engine Cranking but Will Not Start Difficult to Start Engine cranks OK but does not start for a long time Does eventually run or engine starts but immediately dies PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Be sure driver is using correct method to start engine as explained in operator s manual Use clear flood mode during cranking by fully depressing the ped
21. Dither valve duty cycle EST faults Fuel adapt faults Low coolant temperature Woodward 74 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d High Idle Speed Engine idles above the range of 750 1000 RPM PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter PROBABLE CAUSE CORRECTIVE ACTION Check all hoses and gaskets for cracking kinks or leaks Incorrect idle speed control Verify that there are no vacuum leaks See Chapter 8 Advanced Diagnostics amp Chapter 6 Tests and Adjustments er Replace throttle Throttle sticking See Fault Code 461 ETC Sticking Check pedal return spring travel for binding Check APP function with Service Tool Verify smooth change of APP reading with pedal movement See Chapter 8 Advanced Diagnostics Foot pedal sticking or incorrect pedal signal Check for vacuum hose leak Engine mechanical Check for PCV malfunction Check for defective intake gasket Related MIL Faults ETC Sticking fault Idle adapt out of range MAP Sticking fault MAP high value Woodward 75 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Excessive Exhaust Emissions or Odors Vehicle has high CO emissions NOTE Excessive odors do not necessarily indicate excessive emissions PRELIMINARY CHECKS Verify that no stored codes exist If emission test
22. SIGNAL Pin B10 to distributor connector Pin B SECM Sensor GND Pin B1 to distributor connector Pin A SECM 5V PWR to distributor connector Pin C Check for defective CAM sensor in distributor housing Check CAM sensor connections at distributor SECM SIGNAL Pin B10 to distributor connector Pin B SECM Sensor GND Pin B1 to distributor connector Pin A SECM 5V PWR to distributor connector Pin C Check for defective CAM sensor in distributor housing Check Crankshaft sensor connections SECM SIGNAL Pin B5 to Crank sensor Pin C SECM Sensor GND PIN B1 to Crank sensor Pin B SECM 5V PWR to Crank sensor Pin A Check for defective Crank sensor Woodward 92 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC FAULT CORRECTIVE ACTION mi o4 PROBABLE FAULT ACTION FIRST CHECK CrankSyncFault Check Crankshaft sensor connections Loss of SECM SIGNAL Pin B5 to Crank synchronization on the sensor Pin C crankshaft sensor SECM Sensor GND Pin B1 to Crank normally due to noise None sensor Pin B on the signal or an intermittent connection SECM 5V PWR to Crank sensor Pin on the crankshaft A sensor Check for defective Crank sensor TPS1RangeLow Check throttle connector connection TPS sensor voltage and TPS sensor for an open circuit out of range low or short to GND normally set if the TurnOnmil SECM Pin B23 signal to ETC Pin 6 TPS sign
23. adjustment port using a large pin punch so that no further adjustments can be made Figure 38 Woodward 60 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 7 Basic Troubleshooting Preliminary Checks MI 07 systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL and are covered in Chapter 8 Advanced Diagnostics However items such as fuel level plugged fuel lines clogged fuel filters and malfunctioning pressure regulators may not set a fault code and usually can be corrected with the basic troubleshooting steps described on the following pages If engine or drivability problems are encountered with your MI 07 system perform the checks in this section before referring to Advanced Diagnostics NOTE Locating a problem in a propane engine is done exactly the same as with a gasoline engine Consider all parts of the ignition and mechanical systems as well as the fuel system BEFORE STARTING 1 Determine that the SECM and the MIL are operating Verify operation by keying on engine and checking for flash of the MIL When the ignition key is turned on the MIL will illuminate and remain on until the engine is started Once the engine is started the MIL will go out unless one or more fault conditions are present If a detected fault condition exists the fault or faults will be stored in the memory of the SECM Once an active fault occ
24. 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 Exposure of the liquid withdrawal tube to the vapor space may give a false indication that the tank is empty when actually it 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 serious safety problem CAUTION A Exchange empty tank with a pre filled replacement tank Wear safety glasses and gloves when exchanging a tank Woodward 116 Manual 36553 MI 07 Engine Control System for 3 0L Engines LPG Fuel Tank Components ech Fuel Gauge Vapor Withdrawal Tube used only with vapor withdrawal 80 Limiter Tube Liquid Withdrawal Tube 2 80 Stop Bleeder 3 Pressure Relief Valve 4 Service Valve Tank end male coupling 5 Filler Valve 6 Alignment Pin T 8 9 Figure A3 LPG Fuel Tank Components Fuel Gauge In Figure A3 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
25. at the SECM with a multimeter SECM Pin B24 PWR to SECM Pin B1 sensor GND Verify transducer power at ETC with a multimeter ETC Pin 3 PWR to ETC Pin 2 sensor 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 Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the vehicle was motored down a steep grade Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the vehicle was motored down a steep grade Check foot pedal connector e Check APP signal at SECM PIN B7 Fault actions shown are default values specified by the OEM Woodward 99 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d og PROBABLE FAULT 612 65 621 62 622 66 631 63 632 67 641 64 642 68 APP2RangeLow APP sensor voltage out of range low normally set if the APP signal has shorted to ground circuit has opened or sensor has failed APP1RangeHigh APP sensor voltage out of range high normally set if the APP signal has shorted to power or the ground for the sensor has opened APP2RangeHigh APP sensor voltage out of range high normally set if th
26. 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 CAUTION The regulator converter and mixer are part of a certified system complying with EPA and CARB 2007 requirements Only trained certified technicians should perform disassembly service or replacement of the regulator converter or mixer Woodward 46 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 below for proper routing and maximum hose lengths when reinstalling system components NOTE Preferred mounting of regulator is off engine Hose Specifications Vacuum hose to comply to SAE 1403 Type L or SAE J30 R7 R8 EPDM textile reinforced 40 F to 257 F 40 C 125 C Inside Diameter 7 32 5 56mm MIXER VIEW REGULATOR VIEW DWG NO 5555 1206 Figure 25 Hose Connections for 3 0L Engines DIAGRAM NOTES Trim valves must be positioned vertically with flow in direction shown Only one 90 fitting permissible on vapor fuel line between mixer an
27. be due to some type of obstruction a loose throttle plate or worn components shaft bearings NOTE Throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly 461 26 FuelSelectConflict Conflict in fuel select signals normally set if one or both of the fuel select signals are shorted to ground 181 FuelTempRangeHigh Fuel Temperature Sensor Input is High Normally set if the fuel temperature sensor wire has been disconnected or the circuit has opened to the SECM 932 FuelTempRangeLow GasFuelAdaptRangeHi Fuel Temperature Sensor Input is Low Normally set if the fuel temperature sensor wire has shorted to chassis ground or the sensor has failed In LPG mode system had to adapt lean more than expected 931 731 73 GasFuelAdaptRangeLo In LPG mode system had to adapt rich more than expected 721 72 GasO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on LPG 751 Woodward 84 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 1 Fault List Definitions cont d FAULT DESCRIPTION CODE MI04 CODE GasO2FailedLean Pre catalyst Oz sensor indicates extended lean operation on LPG 751 GasO2FailedRich Pre catalyst Oz sensor indicates extended rich operation on LPG 771 77 GasO2NotActive Pre catalyst Oz sensor inactive on LPG open O
28. comply with 40 CFR Part 1048 105 These standards apply only to volatile liquid fuels such as gasoline Note that the engine crankcase must be closed As defined in applicable regulations the engine control system is designed to maintain emissions compliance for seven 7 years or 5000 hours whichever occurs first provided appropriate maintenance is performed as defined in the service manual for the system Maintenance intervals shall be defined and approved by the regulating body Component warranty shall comply with regulatory requirements 40 CFR Part 1048 120 for all emission related components Warranty for non critical emissions components will be as defined in the individual purchase agreement North American Compliance The N 2007 regulator is UL listed per Category ITPV LP Gas Accessories Automotive Type The N 2007 regulator and CA100 mixer have tamper resistant features approved by the California Air Resources Board CARB Woodward v Manual 36553 MI 07 Engine Control System for 3 0L Engines Special Conditions for Safe Use Field wiring must be suitable for at least 248 F 120 C SECM 48 inputs are classified as permanently connected International Electrotechnical Commission IEC measurement Category To avoid the danger of electric shock do not use inputs to make measurements within measurement categories Il III or IV See Woodward publication 26377 SECM 48 Manual Chapter 2 for additional information on t
29. high engine speeds high AVV causes the air valve diaphragm assembly to move much farther creating a large venturi The variable venturi air fuel mixer constantly matches venturi size to engine demand Figure 11 CA100 Mixer Installed with Electronic Throttle Woodward 13 Manual 36553 MI 07 Engine Control System for 3 0L Engines A main mixture adjustment valve on the fuel inlet of the CA100 is not available in the MI 07 system however an idle mixture adjustment is incorporated into the mixer Figure 12 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 screw with locking threads that is factory set with a tamper resistant cap installed after adjustment Accurate adjustment of the idle mixture can be accomplished by adjusting for a specific fuel trim valve FTV duty cycle with the Service Tool software or with a voltmeter NOTE Adjustments should only be performed by trained service technicians New Photo to Come Figure 12 Idle Mixture Adjustment Screw Fuel Trim Valve FTV 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 Two FTVs are used to bias the output fuel pressure on the LPG regulator converter N 2007 by metering air val
30. in two stages from tank pressure to slightly less than atmospheric pressure As the pressure of the propane is reduced the liquid propane vaporizes and refrigeration occurs inside the regulator due to 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 chamber N 2007 Operation Refer to Figure 6 Liquid propane at tank pressure enters the N 2007 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 Woodward 9 Manual 36553 MI 07 Engine Control System for 3 0L Engines A small port connects the expansion chamber to the primary diaphragm chamber At the outlet of the expansion chamber is the secondary valve 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 psig 10 342 kPa it causes a pressure force imbalance across the primary dia
31. includes software to learn the actual range of the pedal position and throttle position sensors in order to take full advantage of the sensor range Faults are set if the learned values are outside of the normal expected range of the sensor e g APP1AdaptLoMin Table 1 Fault List Definitions CODE FAULT DESCRIPTION MI04 CODE Learned full pedal value of 641 APP1AdaptHiMax APP sensor range higher 64 than expected Learned full pedal value of APP1 AdaptHiMin APP sensor range lower 651 than expected Learned idle value of APP APP AdaptLoMax sensor range higher than 661 expected Learned idle value of APP 631 APP1AdaptLoMin sensor range lower than 63 expected APP sensor voltage out of range high normally set if the 621 APP1RangeHigh APP signal has shorted to 62 power or the ground for the sensor has opened APP sensor voltage out of range low normally set if the 611 APP1RangeLow APP signal has shorted to 61 ground circuit has opened or sensor has failed Learned full pedal value of 642 APP2AdaptHiMax APP sensor range higher 68 than expected Woodward 82 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 1 Fault List Definitions cont d CODE FAULT DESCRIPTION MI04 CODE Learned full pedal value of APP2AdaptHiMin APP sensor range lower than 652 expected Learned idle value of APP APP2AdaptLoMax sensor range higher than 662
32. intake and air filter e Gaseous fuel mixer Woodward 4 Manual 36553 MI 07 Engine Control System for 3 0L Engines Gaseous fuel pressure regulator Fuel trim valves Fuel trim orifices Small engine control module SECM firmware and calibration Fuel system sensors and actuators Ignition system including spark plugs cables coils and drivers Gasoline injectors and fuel pressure regulator bi fuel systems only Components of MI 07 system manufactured by Woodward MI 07 System Features The MI 07 system uses an advanced speed density control strategy for fuel spark and air throttle control Key features include the following Closed loop fuel control with fuel specific controls for LPG and gasoline MPI fuels Speed load spark control with tables for dwell timing and fuel type Speed load throttle control with table for maximum TPS limiting Closed loop fuel control with two oxygen sensors one installed pre catalyst and one installed post catalyst The pre catalyst oxygen sensor includes adaptive learn to compensate for fuel or component drift The post catalyst oxygen sensor includes adaptive learn to compensate the pre catalyst oxygen sensor setting for oxygen sensor drift and catalyst aging The pre catalyst oxygen sensor function includes parameters for transport delay O set point excursion rich lean jump back rich lean and perturbation LPG fuel temperature compensation Min max speed governing All sp
33. of the mating connector causing the valve not to open when fully mated Remove the extra washer or o ring from the shaft and reconnect the coupling Filler Valve The liquid filler valve Figure A6 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 on metal seal and the second valve uses a metal on metal seal Weakness Ring 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 Figure A6 Liquid Filler Valve Woodward 120 Manual 36553 MI 07 Engine Control System for 3 0L Engines Woodward 121 Manual 36553 ACFM AFR BHP Bi Fuel CTS CNG Dual Fuel ECM FPP FPV FTS FTV GPM HEGO LAT LPG MAP MAT MIL MOR OEM PHI RPM SECM TMAP TPS VDC VE WOT Woodward MI 07 Engine Control System for 3 0L Engines Abbreviations Actua
34. shows excessive CO and HC check items that cause vehicle to run rich If emission test shows excessive NOx check items that cause vehicle to run lean or too hot PROBABLE CAUSE Cooling system malfunction Fuel system malfunction Ignition system malfunction Component malfunction Related MIL Faults Low side driver Fuel adapt faults EST faults CORRECTIVE ACTION If the Service tool indicates a very high coolant temperature and the system is running ean e Check engine coolant level e Check engine thermostat for faulty part always open or for wrong heat range e Check fan operation If the system is running rich refer to Diagnostic Aids chart on the next page If the system is running ean refer to Diagnostic Aids chart on the next page Check for properly installed fuel system components Check fuel pressure Check ignition timing Check spark plugs plug wires and ignition components Check for vacuum leaks Check for contamination for catalytic converter look for the removal of fuel filler neck restrictor Check for carbon build up Remove carbon with quality engine cleaner Follow instructions on label Check for plugged PCV valve Check for stuck or blocked PCV hose Check for fuel in the crankcase Woodward 76 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Diagnostic Aids for Rich Lean Operation
35. the assembly until it rests on the throttle body Be careful not to pinch the O ring See Figure 28 Attach the mixer throttle body assembly to the intake manifold making sure gasket is in place Tighten the four mounting bolts Connect the wiring harness to the throttle body See Figure 28 for location of connector Connect the fuel temperature sensor connector 5 to the sensor Install the vapor fuel inlet line 3 to the fuel temperature sensor fitting Install the two vacuum lines 2 to the mixer using the previous marks for identification Vacuum lines must be installed correctly for proper operation 10 Install the air cleaner hose 1 Woodward 51 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 6 Tests and Adjustments WARNING PROPER USE 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 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 CAUTION The regulator converter and mixer are part of a certified system complying with EPA and CARB 2007 req
36. working with liquid Woodward 54 Manual 36553 MI 07 Engine Control System for 3 0L Engines AVV Air Valve Vacuum Testing Purpose of Test Check for excessive or inadequate pressure drop across CA100 mixer AVV Test Hardware 1 Union Tee fitting 1 4 6 35mm NPT with three 1 4 6 35mm NPT x 1 4 6 35mm hose barbs 2 Vacuum hose 3 0 20 H20 differential pressure Magnehelic gauge AVV Test 1 Install Union Tee fitting in the hose between the FTVs and the AVV fitting Connect this fitting to the low pressure port of the Magnehelic gauge Figure 33 2 Leave high pressure port of the Magnehelic gauge exposed to ambient pressure Figure 33 3 With the engine fully warmed up and running at idle 750 RPM place the transmission in Neutral The AVV should be between 5 and 8 H2O of pressure vacuum 4 Ifthe measured pressure drop is excessively high check for sticking or binding of the diaphragm air valve assembly inside the mixer Replace mixer if necessary 5 Ifthe measured pressure drop is low check for vacuum leaks in the manifold throttle mixer TMAP sensor and attached hoses Gauge Fitting AVN Fitting Figure 33 Magnehelic Gauge Connection Ignition Timing Adjustment With the MI 07 system ignition timing advance is controlled by the SECM The initial ignition timing needs to be set by the MOR This setup requires a specific technique for each engine installation Woodward 55
37. 6553 MI 07 Engine Control System for 3 0L Engines TPS2AdaptHiMin Learned WOT value of TPS sensor range lower than expected 272 Table 1 Fault List Definitions cont d FAULT DESCRIPTION CODE MI04 CODE TPS2AdaptLoMax Learned closed throttle value of TPS sensor range higher than expected 282 TPS2AdaptLoMin Learned closed throttle value of TPS sensor range lower than expected 242 TPS2RangeHigh TPS sensor voltage out of range high normally set if the TPS signal has shorted to power or ground for the sensor has opened 232 TPS2RangeLow TPS sensor voltage out of range low normally set if TPS signal has shorted to ground circuit has opened or sensor has failed 222 TPS_Sensors_Conflict Woodward TPS sensors differ by more than expected amount NOTE The TPS is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly 291 90 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes rey PROBABLE FAULT NONE Signifies the end of one pass through the fault list InjiOpen Gasoline Injector 1 open circuit broken injector 1 wire or defective injector Inj2Open Gasoline Injector 2 open circuit broken injector 2 wire or defective injector Inj3Open Gasoline Injector 3 open circuit broken injector 3 wire or defective inj
38. AN woopwapn Service Manual MI 07 Integrated Engine Control System for 3 0L KEM Engines LP amp Bi Fuel Systems 2007 Emission Certified Systems Manual 36553 WARNING DANGER OF DEATH OR PERSONAL INJURY WARNING FOLLOW INSTRUCTIONS 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 WARNING OUT OF DATE PUBLICATION This publication may have been revised or updated since this copy was produced To verify that you have the latest revision be sure to check the Woodward website www woodward com pubs current pdf The revision level is shown at the bottom of the front cover after the publication number The latest version of most publications is available at www woodward com publications If your publication is not there please contact your customer service representative to get the latest copy WARNING OVERSPEED PROTECTION The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also b
39. B_HTR TAE AN Le CONNECTOR CONNECTOR WW PAN 1635 1175 WW PIN 1635 1176 PIN 4 1437287 5 PIN 4 1437287 6 DWG NO 9930 1068 Figure 22 SECM Wiring Diagram for LP System Woodward 31 Manual 36553 MI 07 Engine Control System for 3 0L Engines RED 12AWG ES ILON G3LON JSWMYJHLO SSSINN OMS Sev SIAS Sav TN CS SLON OMY NI 20 SAZIS Zei L ILON les crams key ILR mm B5_CRANK KEY ON AND Sl pa B6_CRANK MPRD_A22 couok LSO1_A5 covor LS02 A4 cover 4D018 CN JE CAM IB11_CAM Lem AT LS03_A4 cccon A24_LS09_MIL SOS WNINYAL NO LON JOS JIM NO NMOHS Suv SH Lettre YOLISNNOD TW DRVP_A23 ren 4 I82_AN6_NOT_USED D I89_AN13_NOT_USED nm AN OS EST1_AS EST3_A3_NOT_USED EST4_A6_NOT_USED HOLIMS E WEI 10 Come CANT B20_CAN1 beer JVSNY A12_EST7_FSS_LP LS06_A14 HOLMS 19373S 203 coLor4A15_ESTB_FSS LIO ONAM S2lavls OL COLOR 4B7_AN4 APP 1 ION LONS 133 m covor E AUS APE a O 140318 OLLY 82 CDe 38 er AIMN Y ISN SIHILMS 193735 ON d Wd 1004 Cu ata Bid ANIOFTS p DRVGBLBI7 x ZS oa 3 E D 3 D Q gt KA KH z m am J419_EST5_SPD1 covor 4A21_ESTB_SPD2 FUELP_LO_LS08_A11 H JUMS HOLIMS Le Le 19373S caor 4B 18_AN1_MAP VLV1_LSO11 At COORIB12 ANS MAT E VLV2_LS010_A2 covor 824_XDORP_XPWR COLORIE 1_XDRG_XGND coondB15_AN9_ECT YOSN3S anal Agog ZU 1NY1009 ech e REPT Fd XOSNI
40. Bosch Electronic Throttle Body 16 Figure 15 Throttle Body Assembly Exploded View 17 Figure 16 HEGO Ops Gensor sae eeeeeeeseeeeeseaeeeeaeeneeeeeeeees 20 igure 17 ee 23 Figure 18 Throttle Position Sensor TPS on DV E5 Throttle cesses 23 Figure 19 Peak Torque and Power Available with MI 07 Gvsiem 24 Figure 20 Drive By Wire Signal Flow Process 25 Figure 21 SECM Wiring Diagram for Bi Fuel System ccccccseeeeseeeeereeees 30 Figure 22 SECM Wiring Diagram for LP System 0 ccccecceeeeeeeeteeeeteeeeeeeeees 31 Figure 23 SECM Wiring Diagram for Gasoline System ccceeeeeseeeeeereees 32 Figure 24 MI 07 System Installed on GM 3 0L Engine n 42 Figure 25 Hose Connections for 3 0L Engines ssessesseesseesseesseresrerrrerrrnenee 47 Figure 26 N 2007 Regulator Installed on Engine sseessessseesseeeeeeseeeseerenere 48 Figure 27 CA100 Mixer Installed on Engine 50 Figure 28 O Ring and Spacer Within Mixer Adapter Aesembly 50 Figure 29 Throttle Adapter Mount Screws amp Vacuum Port Barbe 50 Figure 30 Secondary Stage Test Connection cccccceeeeeeceeeeeeeeeeeeeeeeeneeees 53 Figure 31 Primary Stage Test Connection cccccceeeeeseeeeeeeeeeeeeeeeaeeeenaeeeeeneees 53 Figure 32 Magnehelic Gauge Connection to Hose Barb cceeeeeseeeeereees 54 Figure 33 Magnehelic Gauge Connection 55 Figure 34 KVaser Communication Adatpter 56 Figure 35 Crypt Token Installed
41. CM Pin B18 E set if Ge signal ressure signa e Ee er TMAP Pin 1 to SECM Pin B1 to power shorted to the sensor GND IAT signal the TMAP TMAP Pin 3 to SECM Pin B24 has failed or the SECM PWR has failed 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 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal kPa 3 4kQ 8 2kQ Check the MAP sensor by Fault actions shown are default values specified by the OEM Woodward 95 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION FIRST CHECK MAPRangeHigh Check TMAP connector and MAP Manifold Absolute signal wiring for a shorted circuit Pressure Sensor Input TMAP Pin 4 to SECM Pin B18 signal is High normally set if F TMAP Pin 1 to SECM Pin B1 the TMAP pressure sensor GND signal wire has become shorted to 1 TMAP Pin 3 to SECM Pin B24 power shorted to the TurnOnMil PWR IAT signal the TMAP 2 Check the MAP sensor by has failed or the CutThrottle disconnecting the TMAP connector SECM has failed and measuring at the sensor TMAP Pin 1 GND to Pin 4 pressure signal kPa 2 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal kPa 3 4kQ 8 2kQ iinet indicates Check for vacuum leaks Check that higher press re than TMAP se
42. Controls Printed Circuit Boards and Modules Woodward vii Manual 36553 MI 07 Engine Control System for 3 0L Engines Woodward 2 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 1 LPG System Overview MI 07 General Description Woodward s emission certified MI 07 control system provides a complete fully integrated engine management system that meets or exceeds 2007 emission standards for Large Spark Ignited LSI engines established by the California Air Resources Board CARB and the Environmental Protection Agency EPA The control system is applicable to naturally aspirated engines ranging in size from 1 5L to 8 1L 25 HP to 170 HP with up to 8 cylinders running on LPG and or gasoline in mobile industrial applications It provides accurate reliable and durable control of fuel spark and air over the service life of the engine in the extreme operating environment found in heavy duty under hood on engine electronic controls MI 07 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 two heated exhaust gas oxygen sensors HEGO in the exhaust system to monitor exhaust gas content One HEGO is installed in front of the catalytic muffler and one is installed after the catalytic muffler Ignition Switch
43. D on ignition module Pin C Verify 12 Vdc on ignition module Pin A Refer to application manual for specific engine details Check for debris or obstructions inside the throttle body e Check throttle plate shaft for bearing wear Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle ETC Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Q Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle ETC Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 00 Fault actions shown are default values specified by the OEM 97 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d GC PROBABLE FAULT FAULT ACTION HbridgeFault_ETC Electronic Throttle Control Driver has failed Indeterminate fault on Hbridge driver for electronic throttle control Possibly either ETC or ETC driver signals have been shorted to ground 491 29 521 52 LowOilPressureFault Low engine oil pressure SysVoltRangeLow System voltage too low 531 53 541 54 Fault actions shown are default values speci
44. EM Woodward 93 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT CORRECTIVE ACTION PROBABLE FAULT ACTIONS FIRST CHECK Check the throttle connector and pins for corrosion To check the TPS disconnect the TPS2AdaptLoMin throttle connector and measure the Learned closed throttle resistance from value of TPS sensor None TPS Pin 2 GND to range lower than Pin 5 TPS SIGNAL 1 3K Q expected 30 TPS PIN 3 PWR to PIN 5 TPS SIGNAL 0 6K Q 30 TPS1AdaptHiMax Learned WOT value of Nene TPS sensor range higher than expected TPS2AdaptHiMax Learned WOT value of None TPS sensor range higher than expected TPS1AdaptHiMin Learned WOT value of None TPS sensor range lower than expected TPS2AdaptHiMin Learned WOT value of None TPS sensor range lower than expected TPS1AdaptLoMax Learned closed throttle value of TPS sensor None range higher than expected TPS2AdaptLoMax Learned closed throttle N value of TPS sensor None range higher than expected TPS_Sensors_Conflict TPS sensors differ by more than expected 1 amount TurnOnMil NOTE The TPS is not 2 Engine a serviceable item and Shutdown can only be repaired by replacing the DV EV throttle assembly Fault actions shown are default values specified by the OEM N A N A N A N A N A A Perform checks for DFCs 241 amp 242 Woodward 94 M
45. Engines Basic Troubleshooting cont d Lack of Power Slow to Respond Poor High Speed Performance Hesitation During Acceleration cont d PROBABLE CAUSE CORRECTIVE ACTION Check SECM grounds for cleanliness and secure connection See SECM wiring diagrams Check alternator output voltage Repair if less than 9 volts or more than 16 volts Check for clogged air filter and clean or replace as required Check exhaust system for possible restriction Refer to Chart T 1 on later pages Inspect exhaust system for damaged or collapsed pipes e Inspect muffler for heat distress or possible internal failure Check for possible plugged catalytic converter by comparing exhaust system backpressure on each side of engine Check backpressure by removing Pre catalyst O2 sensor and measuring backpressure with a gauge Component malfunction See Engine Manufacturer s Service Manual Engine mechanical Check engine valve timing and compression Check engine for correct or worn camshaft Related MIL Faults EST faults ETC faults ETC spring check TPS faults APP faults Encoder error Delayed Shutdown faults Woodward 68 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Detonation Spark Knock A mild to severe ping usually worse under acceleration The engine makes sharp metallic knocks that change with throttle opening similar to the sound of hail striking a metal r
46. R Trim Vales select locked under box labeled Lock DC 10 Use the Mototune Service Tool to monitor throttle position TPS and Exhaust gas oxygen equivalence ratio Oz Value in Figure 1 While monitoring O2 slowly increase the pedal input APP to achieve a TPS value of 15 11 Use the Mototune Service Tool to unlock the FTV duty cycle Set display parameter DitherValveDC_ovr unlocked displayed in screen tab Manual Override 1 under AFR Trim Vales select unlocked under box labeled Lock DC 12 If at any time in step 10 O2 was greater than 1 2 go to step 13 If 02 remained below 1 2 proceed to Step 15 Woodward 58 Manual 36553 MI 07 Engine Control System for 3 0L Engines 13 Adjust the idle mixture screw on the mixer until a reading of 50 55 is reached for the FTV Duty Cycle in Closed Loop Idle Figure 37 14 Use the accelerator pedal to increase 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 50 55 NOTE If the FTV Duty Cycle reading is NOT between 25 60 check for possible vacuum leaks manifold leaks or a faulty mixer 15 Turn the ignition key to the OFF position to shut down the engine 16 Install the tamper proof cap on the idle mixture screw adjustment port using a large pin punch so that no further adjustments can be made Figure 38 Figure 38 Installing Tamper Pr
47. S EE OLP_FUELPMP_LS0S_A 13 caor r dd 23_AN2_TSP1 PA Aus Tei A18 HIEI Te A17 HI ETC TB R A20_LSO7_026_HTR DEER WOSNIS 870 LWD1SOd CONNECTOR CONNECTOR WW PINI635 1175 WAW P N1635 1176 d PMA 67 6 DWG NO 9930 1069 Figure 23 SECM Wiring Diagram for Gasoline System Woodward 32 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 2 Gasoline Engines Gasoline Fuel System A gasoline fuel system includes the following components Gasoline fuel pump Fuel filter Fuel rail Pressure regulator Fuel injectors Small engine control module SECM and related sensors and equipment Supplied by customer Multi Point Injection MPI is supplied with this system However the SECM lacks sufficient channels to drive each injector individually therefore the injectors are driven in batches of two 1 and 4 2 and 5 3 and 6 Fuel injection pressure and flow rate depend on engine specific fuel injection requirements A variety of regulators and injectors can be used to fit individual needs The gasoline fuel pressure regulator is a one way non return configuration All gasoline specific components are automotive production parts and validated to strict automotive standards Four 4 injection channels are supported by the SECM but only three are used in this application Use of unleaded gasoline of 87 octane or higher is recommended for optimal performance of th
48. actions shown are default values specified by the OEM Woodward 105 Manual 36553 Table 2 Diagnostic Fault Codes Flash Codes cont d DFC FAULT CORRECTIVE ACTION mi o4 PROBABLE FAULT ACTION FIRST CHECK Fault actions shown are default values specified by the OEM LiqPostO2FailedRich Post catalyst O2 sensor indicates extended rich operation on gasoline O2RangeLow Pre catalyst Oo sensor voltage out of range low sensor signal shorted to ground O2_PostCatRangeLow Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground O2RangeHigh Pre catalyst O2 sensor voltage out of range high sensor signal shorted to power O2_PostCatRangeHigh Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground FuelTempRangeLow Fuel Temperature Sensor Input is Low normally set if the fuel temperature sensor wire has shorted to chassis ground or the sensor has failed MI 07 Engine Control System for 3 0L Engines 1 TurnOnMil 2 DisableLiqPost O2Ctrl 1 TurnOnMil 2 DisableLiquid O2Ctrl 3 DisableGas O2Ctrl 1 TurnOnMil 2 Disable Gasoline Post catalyst O2Ctrl 3 Disable LPG Post catalyst O2Ctrl 1 TurnOnMil 2 DisableLiquid O2Ctrl 3 DisableGas O2Ctrl 1 TurnOnMil 2 Disable Gasoline Post catalyst O2Ctrl 3 Disable LPG Post catalyst O2Ctrl TurnOnMil Correct other faults that may contribute to 872 e g faults pertaining to In
49. acuum Lines and Fittings e Visually inspect vacuum lines and fittings for physical damage such as brittleness cracks and kinks Repair replace as required e Solvent or oil damage may cause vacuum lines to become soft resulting in a collapsed line while the engine is running e H abnormally soft lines are detected replace as necessary Inspect Electrical System e Check for loose dirty or damaged connectors and wires on the harness including fuel lock off TMAP sensor Oz sensors electronic throttle control relays fuel trim valves crank position sensor and cam position sensor e Repair and or replace as necessary Woodward 39 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 manufacturer s specific recommendations for proper procedures e Engine must be off and cold WARNING PROPER USE 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 leakage swelling cracking abrasion or de
50. aeeeeeeeeeeeeeeaeeseeeeeeeeees 38 CHAPTER 4 RECOMMENDED MAINTENANCE 2 2scsseceeececcssesseneeeeeeeeneanens 39 Maintenance Tests amp INSPECTIONS 000 0 eceeceee eee eeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeeeeaaeeeeneaas 39 Test Fuel System for Leaks cccccccseseseeceeeeeceeeeeeeaeseeeeeeseeeeeaeeeenaeeneneeeaas 39 Inspect Engine for Fluid Leaks 39 Inspect Vacuum Lines and Fittings ccceseeceeeeeeeeeeeeeeeeeeeseeeeeseaeeseeeeeas 39 Inspect Electrical System AA 39 Inspect Foot Pedal Operation 40 Check Coolant Level serasi ceased deeg Ck aaan 40 Inspect Coolant HOSES A 40 Inspect Battery Gvstem nenn 40 Inspect Ignition System cecccecesceeeeeeeeeeeeeeeseeeeeseaeeeeaaeseeneeesaeeesaeeeeneeeaas 40 Replace Spark PIUS piirsin isni inniinn iaaii iina iaaii aa 40 Replace LP Fuel Filter Element 41 Testing Fuel Lock off Operation 42 Pressure Regulator Converter Inspection ss essesssessrsssrrssrnssrresrnssrnssrnnsns 42 Fuel Trim Valve Inspection FTV cccccceeesceceeeeeseeeeeeeaeeeeeeeseaeeesaeeeeneeeeas 42 Inspect Air Fuel Valve Mixer Assembly sssssssessesssessrsssrnssrnssrrssrrssrnssrnssns 42 Inspect for Intake Leaks eecececeeeeeceeeeeeeeeeeceeeeeceaeeeseaeeseeeesaeeeeaaeeeeneeeeas 42 Inspect Throttle Assembly 0 2 cceceeeeeceeeeeeeeeeceeeeeeeaeeeseaeseeneeseaeeeeeaaeeeeneeeeas 43 Checking the TMAP Sensor ssseseseesenesinssinssrrssrrssrrsssrnssrnssrnssrnssrnssrnssnns 43 Inspect Engine
51. age Reading should not exceed 3 psig 20 68 kPa If the backpressure at either speed exceeds specification a restricted exhaust system is indicated Inspect the entire exhaust system for a collapsed pipe heat distress or possible internal damage split welds or cracked pipe If there are no obvious reasons for the excessive backpressure the catalytic converter is restricted and should be replaced using current recommended procedures Woodward 78 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 8 Advanced Diagnostics MI 07 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 the Service Tool software When the ignition key is turned on the MIL will illuminate and remain on until the engine is started Once the engine is started the MIL lamp will go out unless one or more fault conditions are present 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 All MI 07 fault codes are three digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 0 5 secon
52. al and cranking the engine If engine does not start continue troubleshooting PROBABLE CAUSE CORRECTIVE ACTION Improper fuel selected Verify selected fuel with Service Tool Make sure fuel select switch is in proper position Check for LPG vapor from LPG liquid outlet valve on tank Fill fuel container Do not exceed 80 of liquid capacity Liquid valve closed Slowly open liquid valve Reset excess flow valve in LPG tank Close liquid valve Wait for a click sound slowly open liquid valve Remove obstruction from the fuel line e Close liquid fuel valve e 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 Repair replace as required fuel fil EE See Chapter 4 Fuel Filter replacement Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Repair replace fuel lock off Fuel lock off malf See Chapter 4 Fuel Lock off Pressure regulator converter Test regulator converter operation and pressure malfunction See Chapter 6 Tests and Adjustments Incorrect air fuel or ignition spark control No crankshaft position Verify the crankshaft position signal is present sensor signal See Chapter 8 Advanced Diagnostics Fuel container empty Propane excess flow valve closed Plugged fuel line Faulty vapor connection between the pr
53. al has SECM Pin B1 sensor GND to shorted to ground le ETC Pin 2 circuit has opened or sensor has failed SECM system GND Pin A16 B17 TPS2RangeLow Check throttle connector connection TPS sensor voltage and TPS sensor for an open circuit out of range low or short to GND normally set if the TurnOnmil SECM Pin B4 signal to ETC Pin 5 TPS signal has SECM Pin B1 sensor GND to shorted to ground E ETC Pin 2 circuit has opened or sensor has failed SECM system GND Pin A16 B17 TPS1RangeHigh TPS sensor voltage Check throttle connector and TPS out of range high sensor wiring for a shorted circuit e V mg TurnOnMil SECM Pin B23 signal to ETC Pin 6 1 signal has shorted to power or the Ge B1 sensor GND to ground for the sensor in has opened TPS2RangeHigh TPS sensor voltage Check throttle connector and TPS out of range high sensor wiring for a shorted circuit Hee TurnOnMil SECM Pin B4 signal to ETC Pin 5 TPS signal has shorted to power or the SECM pin B1 sensor GND to ground for the sensor ETC Pin 2 has opened Check the throttle connector and pins for corrosion TPS1AdaptLoMin To check the TPS disconnect the Learned closed throttle throttle connector and measure the value of TPS sensor None resistance from range lower than TPS Pin 2 GND to expected Pin 6 TPS SIGNAL 0 7 Q 30 TPS Pin 3 PWR to Pin 6 TPS SIGNAL 1 4 Q 30 Fault actions shown are default values specified by the O
54. 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 The system may return to open loop operation when engine load or engine speed vary beyond a chosen threshold The SECM 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 valves Throttle Management Drive by wire DBW refers to the fact that the MI 07 control system has no mechanical linkage from the operator to the throttle body Instead the SECM controls the throttle based on input commands such as foot pedals speed select switches or even CAN messages The SECM monitors the input command request and controls the throttle plate by driving a DC motor connected to the throttle The DC motor rotates the throttle plate to correspond to the requested load by the operator The SECM will override the torque request based on governor configuration and engine safety protocols The use of electronic throttle control ETC ensures that the engine receives only the correct amount of throttle opening for any given situation greatly improving idle quality and drivability Two throttle position sensors TPS and TPS which are integral to the DBW throttle assembly provide feedback fo
55. anual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT CORRECTIVE ACTION PROBABLE FAULT ACTIONS FIRST CHECK Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute sensor GND Pressure sensor input is TMAP Pin 3 to SECM Pin B24 low normally set if the PWR ua pressure signal None Check the MAP sensor by wire as peen disconnecting the TMAP connector disconnected or snorteg and measuring at the sensor to ground or the circuit g has opened to the TMAP Pin 1 GND to Pin 4 SECM pressure signal kPa 2 4kQ 8 2kQ TMAP Pin 3 PWR to Pin 4 pressure signal kPa 3 4kQ 8 2kQ Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal MAPRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute sensor GND Pressure sensor input is TMAP Pin 3 to SECM Pin B24 low normally set if the 1 PWR TMAP pressure signal TurnOnMil wire has been 2 disconnected or shorted CutThrottle ee is oo to ground or the circuit 9 has opened to the TMAP Pin 1 GND to Pin 4 SECM pressure signal kPa 2 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal kPa 3 4kQ 8 2kQ MAPTimeRangeHigh Check TMAP connector and MAP Manifold Absolute signal wiring for a shorted circuit Pressure Sensor Input is TMAP Pin 4 to SE
56. at 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 29 5 749 mm away from the distributor and ignition coil and at least 20 508 mm 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 e The 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 appropriate 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 Woodward 26 Manual 36553 MI 07 Engine Control System for 3 0L Engines SECM Sensors The 48 pin Small Engine Control Module SECM and sensors provide the computational power algorithm logic sensor inpu
57. ate Checking the TMAP Sensor Verify that the TMAP sensor F is mounted tightly into the manifold or manifold adapter E with no leakage If the TMAP is found to be loose remove the TMAP retaining screw and the TMAP sensor from the manifold adapter Visually inspect the TMAP O ring seal for damage Replace as necessary Apply a thin coat of an approved silicon lubricant to the TMAP O ring seal Re install the TMAP sensor into the manifold or manifold adapter and securely tighten the retaining screw Inspect Engine for Exhaust Leaks Start the engine and allow it to reach operating temperatures Perform visual inspection of exhaust system from the engine all the way to the tailpipe Any leaks even after the post catalyst oxygen sensor can cause the sensor output to be effected due to exhaust pulsation entraining air upstream Repair any all leaks found Ensure the length from the post catalyst sensor to tailpipe is the same as original factory Ensure that wire routing for the oxygen sensors is still Keeping wires away from the exhaust system Visually inspect the oxygen sensors to detect any damage Woodward 43 Manual 36553 MI 07 Engine Control System for 3 0L Engines Maintenance Schedule NOTE The MI 07 fuel system was designed for use with LPG fuel that complies with HD5 or HD10 LPG fuel standards Use of non compliant LPG fuel may require more frequent service intervals and will disqualify the user from
58. ated fuel These other possibilities should all be ruled out before the distributor control module is replaced A SECM controlled engine that cranks but fails to start in many cases will often have a problem in the crankshaft or camshaft position sensor circuits Loss of sensor signals may prevent the SECM from properly synchronizing thereby preventing the engine from starting and running IGNITION SYSTEM CHECKS The ignition coil can be tested with an ohmmeter Measure primary and secondary resistance and compare to specifications If resistance is out of specifications the coil is bad and needs to be replaced Also pay close attention to the tube that wraps around the spark plug Cracks can allow voltage to jump to ground causing a misfire The spark plug terminal should also fit tightly If a coil tests bad and is replaced cleaning the connector and wiring harness terminals of the coil and distributor can often avoid future problems Corrosion at either place can cause intermittent operation and loss of continuity which may contribute to component failure Applying dielectric grease to these connections can help prevent corrosion and assure a good electrical connection Magnetic crankshaft position sensors can be tested with an ohmmeter and the sensor output voltage and waveform can be read with an oscilloscope The variable reluctance crankshaft position sensor can be checked with an ohmmeter The resistance of the sensor should be
59. ates a potentially hazardous situation which if not avoided could result in damage to equipment or property A NOTE provides other helpful information that does not fall under the warning or caution categories Revisions Text changes are indicated by a black line alongside the text 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 Woodward 2007 All Rights Reserved Manual 36553 MI 07 Engine Control System for 3 0L Engines Contents REGULATORY COMPLIANCE 00 c cceeececccseeseeeeeeeececeanasseeeeeeeeesuenesseneeeeeseeneas V EPA CARB Emissions Certification cccccccccseceeeeeceeeeeeeaeeeeneeseeeeeseaeeesaeenenees v North American Compliance 0cccccccceeeceeeeeeeeeeeeeeeeeseeeeeceaeeesaaeeeeeeeseaeeesaeeseeeeeaes Vv SPECIAL CONDITIONS FOR SAFE USE c0c cccceseeeseresennnecseennneeesesens VI Electromagnetic Compatibility EM vi Electrostatic Discharge Awareness nnt vii CHAPTER 1 LPG SYSTEM OVERVIEW sssecccesesneeeeeeseeeeeeeeseneeeeneeneeaeeneeenees 3 MI 07 General Description ccccecceeeceeceeeeeeeaeeeeeee scenes eae eeeaaeeeeeeeesaeeseaaeeeeneeeeas 3 MI 07 System Components AA 4 Key Componenfg srira iaaii aaia aiaa aaia ia 4 MI 07 Syst
60. bly which is made up of the air valve 3 the gas metering valve 4 the air valve diaphragm 5 and air valve spring 6 The gas metering valve is permanently mounted to the air valve diaphragm assembly with a face seal mounted between the two parts When the engine is not running this face seal creates a barrier against the gas discharge jet preventing fuel flow with the aid downward force of the air valve spring When the engine is cranking it begins to draw in air creating a negative pressure signal This negative pressure signal is transmitted through four vacuum ports in the air valve Figure 9 Parts View of CA100 Mixer Woodward 12 Manual 36553 MI 07 Engine Control System for 3 0L Engines A pressure force imbalance begins to build across the air valve diaphragm between the air valve vacuum AVV chamber above the diaphragm and atmospheric pressure below the diaphragm Approximately 6 inches H2O 14 945 mbar of negative pressure is required to overcome the air valve spring force and push the air valve assembly upward off the valve seat Approximately 24 inches H2O 59 781 mbar pulls the valve assembly to the top 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 air valve diaphragm assembly to move upward a small amount creating a small venturi At
61. body Take note of the adapter orientation on the mixer as it must be reinstalled correctly for proper fit on the throttle Remove the four mounting screws that attach the throttle body adapter to the mixer Remove the fuel temperature sensor not shown from the tee 4 Remove the fuel temperature sensor fitting from the mixer Take note of the fitting s orientation on the mixer as it must be reinstalled correctly for proper fit Remove the short vacuum port barb from the mixer See Figure 29 for location of port barb on mixer Woodward 49 Manual 36553 MI 07 Engine Control System for 3 0L Engines New photo to COME Figure 27 CA100 Mixer Installed on Engine Wiring Harness Connection O Ring Spacer _ gt Figure 28 O Ring and Spacer Within Mixer Adapter Assembly New Photo to COME Figure 29 Throttle Adapter Mount Screws amp Vacuum Port Barbs Woodward 50 Manual 36553 MI 07 Engine Control System for 3 0L Engines CA100 Mixer Installation Steps Refer to Figure 27 Pon gt Install the vacuum port barb onto the mixer 9 Install the fuel temperature sensor fitting 4 onto the mixer Install the fuel temperature sensor into the fitting Install the four mounting screws that attach the throttle adapter 7 to the mixer See Figure 29 Position the mixer adapter assembly onto the throttle body 8 then drop in the four mounting bolts 6 and gently push down on
62. d 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 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 the atmosphere Woodward 119 Manual 36553 MI 07 Engine Control System for 3 0L Engines Quick Disconnect 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 A5 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 Extemal Thread Check Valve VW gl V dt d i Wi 4 d ON gt XO ONS SCS SVT al du d A Ai aS SS eK d AN Le KS DS s pS e YS KG Internal Thread Check Valve Figure A5 Quick Disconnect Coupling NOTE The flat seal and or the o ring will sometimes pop off when disconnecting and slide up the shaft
63. d regulator As shown the temp sensor adaptor is considered the one 90 fitting Vapor fuel fittings IX regulator and mixer must have minimum ID of 0 59 15mm Vapor hose length to be as short as possible and have no restrictions for best regulator performance Fuel outlet must be min 15 below horizontal position Setting Idle Adjustment 1 Set idle adjustment to correct setting 2 Lock with supplied set screw 3 Cap after adjustment and locking screw N 2007 Regulator Plastic WYE Fitting black color for 1 4 6 35mm ID Tube Hose Valve TEV Bosch Canister Plastic WYE Fitting CG blue color for 1 4 6 35mm ID Tube Hose Adapter Cs temperature sensor Sensor coolant Ce temperature Nipple 625 hex 4mp 2 5L steel e Solenoid AFS Lock Off Valve Brass Tee Fitting 1 4 Tube x 1 8 NPTF x 1 4 Tube 1 4 6 35mm hose barb to 1 8 3 2mm male pipe 125HBL 062 flow ID Ci CA100 Mixer 1 4 28 UNF x 1 4 Ce 6 35mm hose barb Woodward 47 Manual 36553 MI 07 Engine Control System for 3 0L Engines Removal and Installation of N 2007 LP Regulator Converter Follow the procedures below for removal and reinstallation of the N 2007 regulator in certified systems N 2007 Removal Steps Refer to Figure 28 1 2 Close the liquid outlet valve in the forklift cylinder or fuel storage container Purge the system of fuel by starting t
64. de The FTV outlet large housing connector side connects to the AVV port When the FTVs are open AVV is sent to the atmospheric side of the N 2007 secondary diaphragm which lowers the reference pressure closing the N 2007 secondary valve and leaning the air fuel mixture The MI 07 system is calibrated to run rich without the FTVs By modulating pulsing the FTVs the SECM can control the amount of AVV applied to the N 2007 secondary diaphragm Increasing the amount of time the FTVs remain open modulation or duty cycle causes the air fuel mixture to become leaner decreasing the modulation duty cycle enriches the mixture LOCKOFF VALVE ORIFICE Y COLOR BLUE Y FITTING A ZS g COLOR BLACK REGULATOR CA 100 MIXER Figure 13 Fuel Trim Valves Connected to MI 07 System Woodward 15 Manual 36553 MI 07 Engine Control System for 3 0L Engines Electronic Throttle System The electronic throttle system controls engine output speed and torque through electronic control of mass airflow to the engine Any DC motor actuated or Limited Angle Torque motor LAT actuated throttle with less than 5A peak and 2A steady state can be controlled The TPS must be directly coupled to the throttle shaft for direct shaft position measurement A commonly used throttle is the Bosch DV E5 This throttle is available in a variety of bore sizes to meet specific engine needs 32mm 40mm and 54mm are readily available throttle bore sizes
65. ds between digits and a long pause 1 2 seconds between fault codes A code 12 is displayed at the end of the code list EXAMPLE A code 461 ETC Sticking has been detected and the engine has shut down and the MIL has remained ON When the codes are displayed the MIL will flash four times 4 pause then flash six times 6 pause then flash one time 1 This identifies a four sixty one 461 which is the ETC Sticking 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 signifying the end of the fault list This list will then repeat 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 Clearing Fault DFC Codes To clear the stored fault codes from SECM memory you must complete the reset fault pedal maneuver CAUTION Once th
66. e APP signal has shorted to power or the ground for the sensor has opened APP1AdaptLoMin Learned idle value of APP sensor range lower than expected APP2AdaptLoMin Learned idle value of APP sensor range lower than expected APP1 AdapitHiMax Learned full pedal value of APP sensor range higher than expected APP2AdapitHiMax Learned full pedal value of APP sensor range higher than expected APP1 AdaptHiMin Learned full pedal value of APP sensor range lower than expected APP2AdaptHiMin Learned full pedal value of APP sensor range lower than expected APP1AdaptLoMax Learned idle value of APP sensor range higher than expected APP2AdaptLoMax Learned idle value of APP2 sensor range higher than expected FAULT ACTION TurnOnMil 1 TurnOnMil 2 CheckEngine Light TurnOnMil Fault actions shown are default values specified by the OEM CORRECTIVE ACTION FIRST CHECK Check foot pedal connector e Check APP signal at SECM PIN B16 Check foot pedal connector e Check APP signal at SECM PIN B7 Check foot pedal connector e Check APP signal at SECM PIN B16 Check APP connector and pins for corrosion e Cycle the pedal several times and check APP signal at SECM Pin B7 Check APP connector and pins for corrosion e Cycle the pedal several times and check APP signal at SECM Pin B16 Woodward 100 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Dia
67. e MI 07 system Gasoline Fuel System Specifications Fuel 87 octane R M 2 method automotive grade fuel Fuel System One way returnless Fuel Pump Minimum of 200 ml min at rated pressure Fuel Pressure 3 bar Regulator Injectors Bosch High Impedance OEM installed Woodward 33 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 3 Specifications LP Fuel System Requirements Operating Temperature Long term Storage Temperature Short term Storage Temperature Heat Soak LPG Composition Requirements Fuel Filter Micron Size 20 F to 221 29 C to 105 C 40 F to 140 F 40 to 60 C lt 257 F 125 C HD5 HD10 LPG Failure to use fuel compliant with HD5 or HD10 standards will void the user warranty 10 micron or better at 99 efficiency Environmental Electrical Specifications Ambient Operating Temperature LPG Fuel Temperature Operating Voltage Over Voltage Operation Woodward 20 F to 221 29 C to 105 C 20 F to 120 F 29 C to 49 C Due to the low vapor pressure of LPG below 20 F 29 C repeated cranking to start the engine may be required 8 16 Vdc 18 Vdc for less than 5 minutes 24 Vdc for less than 1 minute 34 Manual 36553 MI 07 Engine Control System for 3 0L Engines N 2007 Pressure Regulator Specifications Fuel Supply Pressure Fuel Inlet Fitting Fuel Outlet Fitting Fuel Sup
68. e 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 Woodward 79 Manual 36553 MI 07 Engine Control System for 3 0L Engines The code list is now clear and the SECM will begin storing new fault codes as they occur Woodward 80 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 closing the fuel lock off and turning off the fuel pump and fuel injectors Delayed Engine Shutdown Some faults such as low oil pressure will cause the MIL to illuminate for 30 seconds and then shut down the engine Cut Throttle The throttle moves to its default position The engine will run at idle but will not accelerate Turn on MIL The MIL will light by an active low signal provided by the SECM indicating a fault condi
69. e needed for safety as appropriate WARNING PROPER USE Any unauthorized modifications to or use of this equipment outside its specified mechanical electrical or other operating limits may cause personal injury and or property damage including damage to the equipment Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings CAUTION POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY CAUTION BATTERY CHARGING To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system CAUTION ELECTROSTATIC DISCHARGE Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts 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 Avoid all 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 A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION indic
70. eFault1 Service Interval 1 has been reached ServiceFault2 Service Interval 2 has been reached ServiceFault3 Service Interval 3 has been reached ServiceFault4 Service Interval 4 has been reached replace HEGO sensors ServiceFault5 Service Interval 5 has been reached TurnOnMil TurnOnMil TurnOnMil CORRECTIVE ACTION FIRST CHECK Check if fuel temp sensor connector is disconnected or for an open FTS circuit SECM signal Pin B14 to FTS Pin 1 SECM sensor GND Pin B1 to FTS Pin 2 Perform service procedure related to Service Interval 1 determined by OEM Perform service procedure related to Service Interval 2 determined by OEM Perform service procedure related to Service Interval 3 determined by OEM Replace Pre catalyst HEGO sensor Replace Post catalyst HEGO sensor Perform service procedure related to Service Interval 5 determined by OEM Fault actions shown are default values specified by the OEM Woodward 107 Manual 36553 MI 07 Engine Control System for 3 0L Engines THIS PAGE INTENTIONALLY LEFT BLANK Woodward 108 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 9 Parts Description Fuel System Components for 3 0L Engines The chart below lists the MI O7 components required for 3 0L engines Components shown with part numbers are supplied by Woodward as part of the MI 07 system package Components shown with a dot e are supplied by customer
71. ector ECTRangeLow Coolant Sensor failure or shorted to GND FAULT ACTION x NONE TurnOnMil TurnOnMil TurnOnMil TurnOnMil CORRECTIVE ACTION FIRST CHECK None used as end of the fault list identification Check INJ1 wiring for an open circuit SECM Signal A5 to Injector 1 PinA Switched 12V to Injector 1 Pin B Check Injector 1 Resistance 12 to14 ohms cold Check INJ2 wiring for an open circuit SECM Signal A4 to Injector 2 PinA Switched 12V to Injector 2 Pin B Check Injector 2 Resistance 12 to14 ohms cold Check INJ3 wiring for an open circuit SECM Signal A to Injector 3 Pin A Switched 12V to Injector 3 Pin B Check Injector 3 Resistance 12 to14 ohms cold Check ECT sensor connector and wiring for a short to GND SECM Signal Pin B15 To ECT PinA SECM Sensor GND Pin B1 to ECT Pin B SECM System GND Pin A16 B17 Check if ECT sensor connector is 1 TurnOnMil disconnected or for an open ECT ECTRangeHigh 2 circuit Coolant sensor DelayedEngine SECM Signal Pin B15 to ECT disconnected or open Shutdown Pin A circuit 3 CheckEngineLight SECM Sensor GND Pin B1 to ROE ECT Pin B Fault actions shown are default values specified by the OEM Woodward 91 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION ECTOverTempFault Engine coolant temperature is high
72. ed Visually physically check vacuum hoses for splits kinks and proper connections PROBABLE CAUSE CORRECTIVE ACTION Check for faulty gasoline pressure regulator Check for leaking injector Fuel system Check that dither valve duty cycle is lt 15 malfunction Check for too high propane pressure at mixer gt 1 positive pressure Monitor Pre catalyst O2 sensor with Service Tool Check engine coolant level Check engine thermostat for faulty part always open or for wrong heat range Cooling system malfunction Check ignition timing Check for weak ignition and or spark control Ignition system Check spark plugs Remove spark plugs and check malfunction for wet plugs cracks wear improper gap burned electrodes or heavy deposits Repair or replace as necessary Check for exhaust system restriction or leaks Check induction system and crankcase for air leaks Check for clogged air filter clean or replace as required Component malfunction Check FTVs for housing cracks or obstructions repair or replace as required Check for vacuum leak Check system vacuum hoses from regulator to FTVs and mixer Repair or replace as required Pressure regulator Test regulator operation and pressure Ifuncti fuel E mae high EES See Chapter 6 Tests and Adjustments Check compression Engine mechanical Refer to Engine Manufacturer s Service Manual Related MIL Faults Pre catalyst O sensor faults Low side driver
73. ed 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 Woodward 10 Manual 36553 MI 07 Engine Control System for 3 0L Engines CA100 Mixer The mixer is installed above the throttle body and meters gaseous fuel into the airstream at a rate that is proportional to the volumetric flow rate of air The ratio between volumetric airflow and volumetric fuel flow is controlled by the shaping of the mixer fuel cone and biased by the controllable fuel supply pressure delivered by the pressure regulator Fuel flow must be metered accurately over the full range of airflows Pressure drop across the mixer air valve must be minimized to assure maximum power output from the engine The mixer fuel inlet is fitted with a thermistor type temperature sensor This permits the SECM to correct fuel pressure to compensate for variations in fu
74. ed 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 Butane Methane C3H8 Propylene C4H10 Iso Butane CH4 TOTAL An advantage of LPG is the ability to safely store and transport the product in the liquid 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 F 42 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 F 100 C If an engine s operating temperature is approximately 230 F 110 C then the water in an open un pressurized cooling system would simply boil off into steam eventually leaving the cooling system empty and overheating the engine If we install a 10 psig cap on the radiator pressurizing the cooling
75. eed isochronous governing Fixed speed isochronous governing with three switch selectable speeds Fuel enrichment and spark timing modifiers for temperature and fuel type Transient fuel enrichment based on rate of change of TPS Transient wall wetting compensation for gasoline Input sensor selection and calibration Auxiliary device control for fuel pump fuel lock off solenoid tachometer MIL interlocks vehicle speed limiting etc CANBus data transfer for speed torque etc Anti restart strategy to inhibit starter engagement while running Other system features include Tamper Resistance Special tools equipment knowledge and authorization are required to effect any changes to the MI 07 system thereby preventing unauthorized personnel from making adjustments that will affect performance or emissions Diagnostics MI 07 is capable of monitoring and diagnosing problems and faults within the system These include all sensor input hardware control output hardware and control functions such as closed loop fuel control limits and adaptive learn limits Upon Woodward 5 Manual 36553 MI 07 Engine Control System for 3 0L Engines detecting a fault condition the system notifies the operator by illuminating the MIL and activating the appropriate fault action The action required by each fault shall be programmable by the OEM customer at the time the engine is calibrated Diagnostic information can be communicated through both the ser
76. el temperature Left uncorrected fuel temperature variations can cause significant variations in air fuel ratio A higher flow mixer is required on larger engines A lower flow mixer is required on smaller engines Figure 7 CA100 Mixer CA100 Mixer Operation Vapor propane fuel is supplied to the CA100 mixer by the N 2007 pressure regulator converter The mixer uses a diaphragm 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 07 system If the engine stops or is 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 8 CA100 Mixer Attached to Throttle Body Woodward 11 Manual 36553 MI 07 Engine Control System for 3 0L Engines Refer to Figure 9 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 assem
77. el Tanka rE eege EE 116 Installing LPG Fuel Tanks esssesseeeseessessseresrnesrnssrrssrnssrrnssrnssrnssrnssrnssrnssnns 116 LPG Fuel Tank Components ccccceceeseeceeceeeeneeesaeeeeneeeseaeeesaeeseneeeeaees 117 Fuel Gauge EE 117 Pressure Relief Valve iss scceccsscccncnnsscceeved ccveceesdcenes aa aiia iaa eiai 118 Service ET 118 Quick Disconnect Coupling eccceecceeceeeeeeeeeeeeseeeeeseaeeeeeeeeseeeeeaeenaeed 120 SITE UE 120 ee re TEE 122 Woodward iii Manual 36553 MI 07 Engine Control System for 3 0L Engines List of Figures Figure 1 MI 07 Bi Fuel System for 3 0L Engines seseeeeeseeeeeseesrsssrresnssrnsens 3 Figure 2 MI 07 Closed Loop Fuel Gvstem 4 Figure 3 Inline LP Fuel Filter 8 Figure 4 Electric Fuel Lock Assembly ccccccceeceeeeeeeeeeecaeeeeaeeseeeeesaeeesaeeeenees 8 Figure 5 N 2007 PReoulator nenn 9 Figure 6 Parts View of N 2007 Regulator cccceceeceeeeeeeeeeeeeeeeeeeaeeeeeaeeeeenees 10 Figure 7 CA100 Mixer 11 Figure 8 CA100 Mixer Attached to Throttle Boch 11 Figure 9 Parts View of CA100 Mixer 12 Figure 10 Bottom View of Air Valve Assembly sseessessseeeeeeseeseeenreesrnsernereene 13 Figure 11 CA100 Mixer Installed with Electronic Throttle 00 0 eeeeeeeeeees 13 Figure 12 Idle Mixture Adjustment Screw c cceeeeeeeeeeeeeeeseeeeeseaeeeeaeeeeeeees 14 Figure 13 Fuel Trim Valves Connected to MI 07 System cecseeeeeeeretereeees 15 Figure 14
78. em Features isein enie aaas 5 BE ele o r e O E a ege a 6 Customer Supplied Components 6 LPG Fuel System Operation s sosseesneesseeeseessnessessnesnnesnnsstnrtnnttnntnnntrnnsrnnnrnnennnnt 7 MIFO LP Fuel Filter iaicccccdenceccevecccccsdenccceciaateccdcdesccersiutccersdesscadcdatscedcdasteedeisunes 8 MI 07 Fuel Lock Off Electric 8 N 2007 Pressure Regulator VaporiZer c ccceecceceeeceeeneeeeeeeeseeeeessaeeeeeeeeaes 9 CGATOO MIXE EE 11 Fuel Trimi EI EISS KA 14 Electronic Throttle System cceccceceeeeeeeeeeeseeceeeeeeeaeeeeaaeeeeeeeeseaeeeeaaesteneeseeeeess 16 MI O7 Electronic Throttle 0 ccceccceeeeeeeeeeeeeeneeceeeeeeeaeeeeaeeseeeeeseaeeeseaeeneaeeess 16 IQMITIOM SV DEE 18 General Motors GM High Energy Ignition HEI System eee 18 Exhaust EE 20 Catalytic dl 20 SECM oaeen eane Eaa aE ee eege eedEE 22 STEET Le GET 22 Throttle Management 23 Engine Speed Governing Modes c cccccceeeseeceeeeeeeeaeeeeeeeseeeeeseaeeeeeeeeeas 24 Ignition Management 26 SECM Electrical Mounting Hecommendatlons eneee 26 SECM J SENSON Sonna A REE EAE E 27 Analog Bue EE 27 Frequency Position INPuts cccccceeeceeeeeeeeeeeceeeeeeeaeeeeaaeeseeeeesaeeesaeeeeeeeseas 27 Digital le EE 27 EE ee EE DEE ee Ee 28 SECM 48 Wiring Diagram cccccceceeeeeeeeeeeeeeeeeecaeeeeaaeeseeeeesaeeesaeeseneeeeaees 29 CHAPTER 2 GASOLINE ENGINES 0022 0cccensssescennenccneessncenceeensseesnecennsceeneens 33 Gasol
79. emission requirements a 3 way catalyst is necessary The MI 07 control system monitors the exhaust stream pre and post catalyst and uses this information to control the air fuel mixture By using the signals from the HEGOs the SECM can increase or decrease the amount of oxygen in the exhaust by modulating the FTVs and adjusting the air fuel ratio This control scheme allows the Woodward 20 Manual 36553 MI 07 Engine Control System for 3 0L Engines SECM to make sure that the engine is running at the correct air to fuel ratio so that the catalyst can perform as required to meet the emissions certification Woodward 21 Manual 36553 MI 07 Engine Control System for 3 0L Engines SECM The Woodward Small Engine Control Module SECM controller has full authority over spark fuel and air Utilizing a Freescale micro controller the SECM has 48 pins of I O and is fully waterproof and shock hardened 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 malfunctions as faults in SECM memory Engine run hours are also stored in memory Stored fault codes can be displayed on the Malfunction Indicator Light MIL as flash codes or read by the MI 07 Service To
80. en vaporized and regulated down to the appropriate pressure to supply the mixer The regulator controls the fuel pressure to the gas air mixer Dual Dither Valve The key to meeting emissions requirements when operating in LPG is the dual dither valve hardware in the fuel system Similar to the Woodward MI 04 system the dual dither system modulates the fuel pressure regulator outlet pressure by providing an offset to the regulator secondary stage reference pressure By adding a second dither valve or fuel trim valve FTV the MI O7 system provides smoother more accurate control of supply pressure resulting in better control of air fuel ratio and emissions This smoother control also minimizes wear on fuel system components such as the regulator diaphragm and lever by significantly reducing the pressure pulsations observed with a single FTV Regulator Pressure Offset Regulator pressure offset is achieved through the use of a fixed orifice and a variable orifice in series The inlet to the fixed orifice is connected to a mixer port that monitors inlet air pressure roughly equal to ambient pressure The outlet of the fixed orifice is connected to both the pressure regulator reference port and the inlet to the two FTVs the variable orifice that act in parallel The outlets of the FTVs are connected to a port at the mixer outlet referred to as Air Valve Vacuum AVV Thus by modulating the FTVs the pressure regulator reference pressure can be
81. ensor housing Two wires provide the necessary 12 Vdc and ground signal for the heater element A fourth wire provides an independent ground for the sensor The pre catalyst sensor heater is powered by the main power relay and is always powered The post catalyst sensor heater is powered from an additional relay that is controlled by the SECM This relay is only energized when the SECM calculates that water condensation in the exhaust system and catalytic muffler prior to the sensor should be evaporated This is to avoid thermal shock of the sensor that could prematurely fail the sensor The HEGO stoichiometric air fuel ratio voltage target is approximately 500 mV and changes slightly as a function of speed and load When the pre catalyst HEGO sensor sends a voltage signal less than 450 mV the SECM interprets the air fuel mixture as lean The SECM then decreases the PWM duty cycle sent to the fuel trim valves in order to increase the fuel pressure to the mixer inlet thus richening air fuel mixture The opposite is true if the SECM receives a voltage signal above 450 mV 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 trim valves CAUTION The HEGO sensors are calibrated to work with the MI 07 control system Use of alternate sensors may impact performance and the ability of the system to diagnose rich and lean conditions Catalytic Muffler In order to meet 2007
82. es extended lean leaking valve or hose O2Ctrl SS G operation on LPG Check for missing orifice s Correct other faults that may contribute to 752 e g faults pertaining to fuel trim valves Pre Cat Oo Post Cat O sensor aT e 1 TurnOnMil Check for vacuum leaks indicates Geen Kam 2 DisableGasPost Check for leaks in exhaust operation on LPG O2Ctrl catalytic converter HEGO P sensors repair leaks Check all sensor connections see fault 742 corrective actions GasO2FailedRich e Check fuel trim valves e g 1 TurnOnMil i Pre catalyst Oo sensor 2 DisableGas plugged valve or hose indicates extended rich O2Ctrl Check for plugged orifice s operation on LPG Fault actions shown are default values specified by the OEM Woodward 103 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC CORRECTIVE ACTION MI 04 PROBABLE FAULT FAULT ACTION FIRST CHECK Fault actions shown are default values specified by the OEM GasPostO2FailedRich Pre catalyst O sensor indicates extended rich operation on LPG LiqFuelAdaptRangeHi In Gasoline mode system had to adapt lean more than expected LiqFuelAdaptRangeLow In Gasoline mode system had to adapt rich more than expected LiqO2NotActive Pre catalyst O2 sensor inactive on gasoline open O2 sensor signal or heater leads defective O2 sensor 1 TurnOnMil 2 DisableGasPost O2Ct
83. essure regulator converter and the mixer See Chapter 8 Advanced Diagnostics continued on next page Woodward 64 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Engine Cranking but Will Not Start Difficult to Start cont d PROBABLE CAUSE CORRECTIVE ACTION Check Engine Coolant Temperature ECT sensor using the Service Tool compare coolant temperature with ambient temperature on cold engine If coolant temperature reading is 5 greater than or less than ambient air temperature on a cold engine check resistance in coolant sensor circuit or sensor itself Compare ECT resistance value to Diagnostic Aids chart at end of this section Verify that there is no code for Electronic Throttle Controller ETC spring check fault Check for 0 APP during cranking Cycle key ON and OFF and listen for throttle check movement on key OFF SECM control system malfunction Check for oil pressure switch faults Check for ETC sticking faults Check Throttle Position Sensor TPS for stuck binding or a high TPS voltage with the throttle closed Check fuel lock off propane or fuel pump The lock off or fuel pump may turn ON for some seconds when ignition switch is turned ON calibration specific Check fuel pressure Check for contaminated fuel Fuel system malfunction Check fuses visually inspect Check propane tank valve amp pickup
84. f connector New photo to COME Figure 24 MI 07 System Installed on GM 3 0L Engine Pressure Regulator Converter Inspection e Visually inspect the pressure regulator converter B housing for coolant leaks e Refer to Chapter 5 if the pressure regulator converter requires replacement Fuel Trim Valve Inspection FTV e Visually inspect the fuel trim valves C for abrasions or cracking Replace as necessary e To ensure a valve is not leaking a blow by test can be performed 1 With the engine off disconnect the electrical connector to the FTVs 2 Disconnect the vacuum line from the FTVs to the pressure regulator converter at the converter s tee connection 3 Lightly blow through the vacuum line connected to the FTVs Air should not pass through the FTVs when de energized If air leaks past the FTVs when de energized replace the FTVs Inspect Air Fuel Valve Mixer Assembly e Refer to Chapter 5 for procedures regarding the LP mixer D Inspect for Intake Leaks e Visually inspect the intake throttle assembly E and intake manifold for looseness and leaks Repair as necessary Woodward 42 Manual 36553 MI 07 Engine Control System for 3 0L Engines Inspect Throttle Assembly Visually inspect the throttle assembly motor housing for coking cracks and missing cover retaining clips Repair and or replace as necessary NOTE Refer to Chapter 5 for procedures on removing the mixer and inspecting the throttle pl
85. facturer to confirm that the overall system s EMC performance is in compliance with all standards that they wish to apply for their particular use Woodward vi Manual 36553 MI 07 Engine Control System for 3 0L Engines Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pipes cabinets equipment etc 2 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible CAUTION ELECTROSTATIC DISCHARGE To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic
86. fied by the OEM SysVoltRangeHigh System voltage too high Woodward TurnOnMil TurnOnMil z DelayedEngine Shutdown 3 CheckEngine Light TurnOnMil TurnOnMil CORRECTIVE ACTION FIRST CHECK Check ETC driver wiring for a shorted circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle ETC Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Q Check engine oil level Check electrical connection to the oil pressure switch SECM Pin B9 to Oil Pressure Switch Check battery voltage e Perform maintenance check on electrical connections to the battery and chassis ground e Check battery voltage during starting and when the engine is running to verify charging system and alternator function e Measure battery power at SECM with a multimeter with key on SECM Pin A23 DRVP to SECM Pin A16 DRVG SECM Pin A23 DRVP to SECM Pin B17 DRVG Check battery and charging system voltage e Check battery voltage during starting and when the engine is running e Check voltage regulator alternator and charging system e Check battery and wiring for overheating and damage e Measure battery power at SECM with a multimeter with key on SECM Pin A23 DRVP to SECM Pin A16 DRVG SECM Pin A23 DRVP to SECM Pin B17 DRVG 98 Manual 36553 Table 2 Diag
87. for Exhaust Leaks 43 Maintenance SCHEGUIC c ccicccetcececsensatecssnceceestedseessncadeaesstcadeasstedcecestecdeassteacoesatia 44 CHAPTER 5 INSTALLATION PROCEDURES 00sssssseeeeeeeecesceseesenseeeesneeeanens 46 Hose elteren 47 Removal and Installation of N 2007 LP Regulator Converter sessesseesseeseese 48 Removal and Installation of CA100 Mixer 49 CHAPTER 6 TESTS AND ADJUSTMENTS ccccscssssesseeeseeeececenessenseeeeseeneasens 52 N 2007 Regulator Service Testing cccccccceeeeeeeeeeeeeeeeeeeeeeeseeeeeseaeeeeaeeeeneeees 52 Break Off TeSt sates neces deens enee see deeg ege N ENEAN EEk 52 Press re EE 53 AVV Air Valve Vacuum Testing cccccceceeceeeeeeeceeeeeeaeeeeaeeseeeeeseaeeesaeeseneeetaas 55 Ignition Timing Adjustment eceeeeceeeeeeeeeeeeeeeceeeeeeaeeeeaaee sense seaeeeeaeeeeaeeteeeees 55 Connection of MI O7 Service Tool 56 Idle Mixture Adiustmemt cece eeeaaeeeeaeeeceaeeeseaeeseaeeseeeesaeeeeaaeeees 57 CHAPTER 7 BASIC TROUBLESHOOTING ccccccesssssseeeeeesecceceneeseeseeseeeeneanens 61 Preliminary GHECKS EE 61 Basic TroubleShooting A 62 Intermittent Fault AA 62 Surges and or Stumble A 63 Engine Cranking but Will Not Start Difficult to Grant 64 Lack of Power Slow to Respond Poor High Speed Performance Hesitation During Acceleration ccccccecseeeeeeeeeeeeceeeeeeeseeeeeeseaeeteeeeeeeeees 67 Detonation Spark knock nenn 69 BACK EE 70 NIE lte Di n E 70 Rough Un
88. 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 WHEN FUEL IS IN THE TANK WARNING A It is not a legal practice to fill the tank through the liquid contents gauge 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 LPG 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 Woodward 117 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 T
89. 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 1 4 NPT liquid inlet port and stops with the lock off in the normally closed position When the engine is cranking 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 Woodward 8 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 crankshaft position sensor detects any engine revolutions Stall when the key is in the ON position but the crankshaft position sensor detects no engine revolutions and Run 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 a number of seconds calibration specific N 2007 Pressure Regulator Vaporizer The pressure regulator vaporizer receives liquid LPG from the fuel storage tank dr
90. function Check for liquid fuel in propane pressure regulator hose If fuel is present replace regulator assembly The pre catalyst oxygen Os sensor should respond quickly to different throttle positions If it does not then check the pre catalyst O2 sensor for contamination If the pre catalyst O sensor is aged or contaminated the SECM will not deliver correct amount of fuel resulting in a drivability problem Check for LPG vapor from LPG liquid outlet valve on tank Fill fuel container Do not exceed 80 of liquid capacity Ignition system Check ignition system wires plugs etc malfunction LPG pressure regulator Test regulator operation and pressure malfunction See Chapter 6 Tests and Adjustments Check throttle for sticking or binding Check PCV valve for proper operation by placing finger over inlet hole in valve end several times Valve should snap back If not replace valve Check alternator output voltage Repair if less than 9 or more than 16 volts Perform linder compression check Engine mechanical SONLA CY ER pre See Engine Manufacturer s Service Manual continued on next page Fuel container empty Component malfunction Woodward 71 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Rough Unstable Incorrect Idle or Stalling cont d PROBABLE CAUSE CORRECTIVE ACTION Reset excess flow valve e Close liquid valve e Wait for a click
91. g notches on the crankshaft flywheel or harmonic balancer The crank sensor signal goes to the small engine control module SECM where it is used to turn the ignition coil on and off via the GM HVS control interface The operation of the ignition system is essentially the same as any other ignition system The coil has a low primary resistance 0 4 to 0 6 ohms and steps up the Woodward 18 Manual 36553 MI 07 Engine Control System for 3 0L Engines primary system voltage from 12 volts to as much as 40 000 volts to produce a spark for the spark plug The distributor assures that the voltage is directed to the spark plug of the proper cylinder Resistor spark plugs are generally used to suppress electromagnetic interference EMI MISFIRES Common ignition system ailments include misfiring hard starting or a no start Spark plugs can still be fouled by oil or fuel deposits as well as pre ignition and detonation If the crankshaft position sensor fails the loss of the basic timing signal will prevent the system from generating a spark and the engine will not start or run A failed driver circuit within the SECM will also prevent proper ignition system operation It is important to remember that ignition misfire can also be caused by other factors such as worn or fouled spark plugs loose or damaged coil connector or terminals dirty fuel injectors low fuel pressure intake vacuum leaks loss of compression in a cylinder or even contamin
92. gnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION APP_Sensors_Conflict APP position sensors do no not track well 1 TurnOnMil intermittent connections 2 Level PowerLimit to APP or defective pedal assembly LSDFault_Dither1 Dither Valve 1 Fault signal has opened or shorted to ground or TurnOnMil power or defective dither 1 valve LSDFault_Dither2 Dither Valve 2 Fault signal has opened or shorted to ground or TumOnMil power or defective dither 2 valve LSDFault_CrankDisable Crank Disable Fault signal has opened or shorted to ground or Nore power or defective crank disable relay LSDFault_LockOff Fuel lock off Valve Fault signal has opened or e shorted to ground or TurmOnMil power or defective Fuel lock off valve Fault actions shown are default values specified by the OEM CORRECTIVE ACTION FIRST CHECK Check APP connector and pins for corrosion e Cycle the pedal several times and check APP signal at SECM Pin B7 Cycle the pedal several times and check APP signal at SECM Pin B16 Check FTV for an open wire or FTV connector being disconnected FTV Pin 1 signal to SECM Pin A1 FTV Pin 2 power to SECM DRVP Pin A23 Check FTV for an open coil by disconnecting the FTV connector and measuring the resistance 26Q 20 Check FTV for an open wire or FTV connector being disconnected or signal shorted to GND FTV 2 Pin 1 signal to SECM P
93. greater than 100Q and less than 100kQ On most vehicles a defective crank position sensor will usually set a fault code that can be read with the Service Tool Woodward 19 Manual 36553 MI 07 Engine Control System for 3 0L Engines Exhaust System Heated Exhaust Gas Oxygen Sensors HEGO The MI 07 system utilizes two HEGO Oz sensors One sensor is a pre catalyst sensor that detects the amount of oxygen in the exhaust stream and is considered the primary control point Based upon the O sensor feedback the MI 07 system supplies a stoichiometric air fuel ratio to the catalytic converter The catalytic converter then reduces emissions to the required levels The second sensor is a post catalyst sensor that detects the amount of oxygen after the catalyst This sensor is used as a secondary control point to adjust the pre catalyst setpoint to ensure proper catalyst conversion efficiency Once a HEGO sensor reaches approximately 600 F 316 C it becomes electrically active The concentration of oxygen in the exhaust stream determines the voltage produced If the engine is running rich little oxygen will be present in the exhaust and voltage output will be relatively high Conversely in a lean situation more oxygen will be present and a smaller electrical potential will be noticed Figure 16 HEGO O2 Sensor In order for the sensor to become active and create an electrical signal below 600 F 316 C a heated element is added to the s
94. he engine and running until all trapped fuel in the system is exhausted and the engine shuts down Key switch in OFF position Remove the fuel inlet line 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 Remove the four rear mounting bolts that hold the regulator to the support bracket This will allow easier access to the remaining hose clamps Remove the two cooling lines 4 from the regulator NOTE Either drain the coolant system or clamp off the coolant lines as close to the regulator as possible to avoid a coolant spill when these lines are disconnected Remove the fuel vapor outlet hose 5 from the regulator Remove the nipple extension 6 with the lock off from the regulator Figure 26 N 2007 Regulator Installed on Engine N 2007 Installation Steps Refer to Figure 26 1 2 3 4 6 Install the nipple extension 6 with the lock off to the regulator Install the fuel vapor outlet hose 5 to the regulator Install the two cooling lines 4 to the regulator Install the four rear mounting bolts that hold the regulator to the support bracket Use a torque wrench and tighten each bolt to 60 70 Ibf in 6 78 7 91 N m Install the fuel inlet line 1 to the lock off the two vacuum lines 2 to the branch tee fitting in the regulator vent and re connect the lock off connector 3 Open the liquid outlet valve in the fork
95. he engine at idle Once adjusted the idle mixture screw is sealed with a tamper proof cap after which it need not be adjusted for the life of the vehicle Therefore the only situations in which the idle mixture screw needs to be adjusted are when the engine is initially fitted with a fuel system at the factory and following the field replacement of the mixer Under these situations follow the procedures below for adjustment of the idle mixture screw Factory Test Preparation 1 Install the MI 07 fuel system wiring harness and SECM 48 control module on the engine 2 All coolant hoses should be attached filled with coolant and bled to remove any air Attach LPG fuel lines Attach wiring harness to battery power Attach exhaust system If present set fuel select switch to LPG fuel D orep When operated at the factory it is critical to simulate the airflow found on a forklift at idle as nearly as possible in order to achieve the proper air valve lift in the mixer It may be necessary to place a load on the engine to achieve the required airflow without overspeeding the engine Means of achieving this load include a Place an electrical load on the alternator The alternator should be able to briefly hold loads of approximately 1 2 kW b Attach the engine to a dynamometer Woodward 57 Manual 36553 MI 07 Engine Control System for 3 0L Engines Factory Adjustment Procedure NOTE Be sure engine is fully warm ECT g
96. his 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 The service valve installs directly into the tank and has two main categories liquid and vapor service valves Liquid service valves used on portable LPG tanks use a 3 8 NPT male pipe thread on the service valve outlet for attachment of a quick disconnect coupler 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 Outlet Excess Flow Valve Figure A4 Service Valve Woodward 118 Manual 36553 MI 07 Engine Control System for 3 0L Engines CAUTION The service valve should be completely open when the tank is in use If the valve is partly open the vehicle may not get 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 an
97. idle or low speed PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter PROBABLE CAUSE CORRECTIVE ACTION Check fuel system specifically for plugged fuel filter low pressure Check for contaminated fuel Check injector drivers Disconnect all injector harness connectors Use injector test light or equivalent 6 volt test light between the harness terminals of each connector and observe if light blinks while cranking If test light fails to blink at any connector it is a faulty injector drive circuit harness connector or terminal Check lock off for intermittent connection Check dither valve operation Check for spark on the suspected cylinder s using a shop oscilloscope or spark tester or equivalent If no spark check for intermittent operation or miss If there is a spark remove spark plug s in these cylinders and check for cracks wear improper gap burned electrodes heavy deposits Ignition system Check spark plug wires by connecting ohmmeter to malfunction ends of each wire in question If meter reads over 30 000 Q replace wire s Visually inspect wires for moisture dust cracks burns etc Spray plug wires with fine water mist to check for shorts Check engine ground wire for looseness or corrosion Fuel system malfunction Check for electromagnetic interference EMI A missing condition can be caused by EMI on the reference circuit EMI can usuall
98. in A2 FTV2 Pin 2 power to SECM DRVP Pin A23 Check FTV for an open coil by disconnecting the FTV connector and measuring the resistance 260 20 Check fuel lock off valve for an open wire or connector being disconnected or signal shorted to GND Lockoff Pin B signal to SECM Pin A11 Lockoff Pin A power to SECM DRVP Pin A23 Check CSV for an open coil by disconnecting the CSV connector and measuring the resistance 26Q 3Q Woodward 101 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC a CORRECTIVE ACTION MI 04 PROBABLE FAULT FAULT ACTION FIRST CHECK LSDFault_MIL Malfunction Indicator Lamp Check MIL lamp for an 718 Fault signal has opened or None g shorted to ground or power open wire or short to GND or defective MIL lamp Check for vacuum leaks EE Check fuel trim valves e g zad a daet cimae an S TumOnMil leaking valve or hose expected Check for missing orifice s GasFuelAdaptRangeHi o a a Kee e g In LPG mode system had to plugged valve or hose fans adapt lean more than ZEENE Check for plugged expected orifice s Check that Pre catalyst O sensor connections are OK O signal Pin B to SECM Pin B13 i O Pin C GND to SECM GasO2NotActive DRVG GND Pins A16 Pre catalyst Oo sensor 1 TurnOnMil B17 741 74 inactive on LPG open O 2 DisableGas O Pin 1 power to SECM sensor signal or heate
99. ine Fuel Systemi e edetes eeieetianceesacvdenevesdccdenaeeeensateacbaliastustbessdedensienetebtesdddes 33 Gasoline Fuel System Specifications eeeeeeeeeeeeeeeneeneenernesrnessrnesens 33 CHAPTER 3 SPECIFICATIONS esdege deeg ege geen 34 LP Fuel System Requirement ccccccececeeeeeeeeeeeee seer eeeaeeeeaeeeseeeeeaeeseeeeeneees 34 Environmental Electrical Specifications ccccceeceeeeeseeceeneeeeeeeeseeeeseeeteeeeees 34 N 2007 Pressure Regulator Specifications cccccceceeeeeseeeeeeeeseneeeeeaeeeeeeeees 35 CA100 Mixer Specifications cccececceceeeeeeeeeceeeeeceneeeceaeeesaaeeseeeeesaeeesaeeeeeeseaees 36 Electronic Throttle System Specifications ccccceceeeeeeeeeeeeeeeeeeeeseeeeteeeeeeeeees 36 SECM Specifications cccccccccecceeeeeseeeeeeeeeeaeeseaeeseeeeeseaeeesaaeseeeeeescaeeesaeeseaeeseaees 37 Fuel Trim Valve FTV Gpeclflcations srne 37 Ignition System Specifications ccceccccccceeeeseceeeeeeeeeeeeaeeeeeeeseeeeesecaeeseeeeeeeeess 37 System Control Performance Specifications c ccceccceceeeeeeeeeeceeeeeseeeeeneeseaees 38 POWER Kelte UC 38 Exhaust EMISSIONS cee eeeeaeeeeeeeeeeaeeeeaaeseeaeeseeeeseaeeesaeeseeeeeeeeess 38 Woodward i Manual 36553 MI 07 Engine Control System for 3 0L Engines Drivability Transient Hesponse cece eeeeaeeeeeeeeseaeeesaaeeneaeeeeeeees 38 LOW IGle SPCC ET 38 Maximum Speed High Idle cceeeceeeeceeeeeeeeeeeeeeeeeeeeeese
100. ines Chapter 4 Recommended Maintenance SSS aaa a a a eee Suggested maintenance requirements for an engine equipped with an MI 07 fuel system are contained in this section The operator should however develop a customized maintenance schedule using the requirements listed in this section and any other requirements listed by the engine manufacturer Maintenance Tests amp Inspections Test Fuel System for Leaks e Obtain a leak check squirt bottle or pump spray bottle e Fill the bottle with an approved leak check solution e Spray a generous amount of the solution on the fuel system fuel lines and connections starting at the storage container e Wait approximately 15 60 seconds then perform a visual inspection of the fuel system Leaks will cause the solution to bubble e Listen for leaks e Smell for LPG odor which may indicate a leak e Repair any leaks before continuing e 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 e Repair any fuel leaks before continuing Inspect Engine for Fluid Leaks e Start the engine and allow it to reach operating temperatures e Turn the engine off e Inspect the entire engine for oil and or coolant leaks e Repair as necessary before continuing Inspect V
101. ing in vertical orientation Electronic Throttle System Specifications Minimum Electrical 45 ohms Resistance of Throttle Actuator Woodward 36 Manual 36553 Operating Temperature ong term Storage Temperature ihort term Storage Temperature Heat Soak Operating Voltage Operating Environment MI 07 Engine Control System for 3 0L Engines SECM Specifications 20 F to 221 29 C to 105 C 40 F to 140 F 40 to 60 C lt 257 F 125 C 8 16 Vdc SECM microprocessor may reset at voltages below 6 3 Vdc On engine mounting underhood automotive Capable of withstanding spray from a pressure washer Fuel Trim Valve FTV Specifications Actuator Type Operating Voltage Coil Type Coil Supply Voltage linimum Open Circuit Voltage Minimum Coil Energy Maximum Dwell Time Operating Temperature Long term Storage Temperature Short term Storage Temperature Heat Soak Woodward On off two position valve compatible with LPG 8 16 Vdc Ignition System Specifications Inductive 8 16 Vdc gt 30 kV 35 mJ 4 msec 20 F to 221 29 C to 105 C 40 F to 140 F 40 to 60 C lt 257 F 125 C 37 Manual 36553 MI 07 Engine Control System for 3 0L Engines System Control Performance Specifications Power Torque The MI 07 system maximizes engine power and torque while meeting customer specific needs for emissions fuel consumption durability and dr
102. ition is fuel off Customer Supplied Components MI 07 requires additional components to operate that are not included with the system These include the wire harness mixer to throttle adapter air horn adapter mounting brackets non critical fittings and hoses These items are application specific and are the responsibility of the packager manufacturer of record MOR or original equipment manufacturer OEM Woodward will provide assistance as needed to ensure proper fitting to the MI 07 system components NOTE It is the responsibility of the customer to consult with Woodward regarding the selection or specification of any components that impact emissions performance or durability Woodward 6 Manual 36553 MI 07 Engine Control System for 3 0L Engines LPG Fuel System Operation The principles outlined below describe the operation of MI 07 on an LPG fuel system An LPG fuel system consists of the following components e Fuel filter Supplied by customer e Electric fuel lock off solenoid valve e Fuel pressure regulator vaporizer e Two orificed fuel trim valves e Gas Air mixer with fixed orifice for trim system and fuel temperature sensor e Miscellaneous customer supplied hoses and fittings Fuel is stored in the customer supplied LPG tank in saturated liquid phase and enters the fuel system from the tank as a liquid and at tank pressure Fuel passes through a high pressure fuel filter and lock off solenoid and is th
103. ivability Bear in mind that engine power is dependent on many variables other than the fuel control system i e compression ratio friction valve timing etc Exhaust Emissions MI 07 is capable of meeting EPA 2007 LSI engine emission standards when operating properly with an approved three way catalyst Emission standards must be met on both the LSI engine off highway transient emissions test cycle and the ISO 8178 type C2 steady state emissions test cycle The fuel control logic for both LPG and gasoline employs a closed loop exhaust gas oxygen control algorithm in order to compensate for fuel system tolerances aging altitude and fuel composition The algorithm utilizes dual heated exhaust gas oxygen HEGO sensors with an output that switches high and low at stoichiometry When operated with LPG the control logic compensates for variations in fuel temperature as measured at the mixer inlet Drivability Transient Response The engine will meet requirements of the EPA LSI engine transient emissions test cycle It should start run accelerate decelerate and stop without hesitation or miss fire Low Idle Speed The low idle speed setpoint ranges between 500 RPM and 800 RPM as defined by the OEM during calibration Maximum Speed High Idle The maximum governed speed setpoint ranges between 1800 RPM and 3000 RPM as defined by the OEM during calibration Woodward 38 Manual 36553 MI 07 Engine Control System for 3 0L Eng
104. jectors MAP IAT Pre Cat Os Post Cat O sensor Look for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 842 corrective actions Check if O sensor installed before the catalyst is shorted to GND or sensor GND O signal Pin B to SECM Pin B13 SECM DRVG GND Pins A16 B17 SECM sensor GND Pin B1 Check if O installed after the catalyst sensor is shorted to GND or sensor GND O signal Pin B to SECM Pin B19 Possible sources SECM DRVG GND Pins A16 B17 and SECM sensor GND Pin B1 Check if O sensor installed before catalyst is shorted to 5Vdc or battery O signal Pin B to SECM Pin B13 SECM PWR Pin B24 SECM power Pin A23 Check if O sensor installed after catalyst is shorted to 5Vdc or battery O signal Pin B to SECM Pin B19 Possible voltage sources SECM PWR Pin B24 and SECM power Pin A23 Check fuel temp sensor connector and wiring for a short to GND SECM signal Pin B14 to FTS Pin 1 SECM sensor GND Pin B1 to FTS Pin 2 SECM GND Pin A16 B17 Woodward 106 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC FAULT M04 PROBABLE FAULT ACTON FuelTempRangeHigh Fuel Temperature Sensor Input is High normally set if the fuel temperature sensor wire has been disconnected or the circuit has opened to the SECM Servic
105. l cubic feet per minute at the specified suction conditions Air fuel ratio Brake horsepower Able to operate on either of two fuels Coolant temperature sensor Compressed natural gas Able to run simultaneously on two fuels e g diesel and natural gas Often this term is incorrectly used to describe bi fuel operation Spark ignited engines are typically bi fuel while compression ignition engines are dual fuel Engine control module Foot pedal position Fuel primer valve Fuel temperature sensor Fuel trim valve Gallons per minute of flow Heated exhaust gas oxygen sensor Limited angle torque motor Liquified petroleum gas Manifold absolute pressure Manifold air temperature Malfunction indicator lamp Manufacturer of record for emissions certification on the engine Original equipment manufacturer Relative fuel air ratio or percent of stoichiometric fuel actual fuel air ratio stoichiometric fuel air ratio Revolutions per minute Small engine control module Temperature and manifold absolute pressure Throttle position sensor Voltage of direct current type Volumetric efficiency Wide open throttle 122 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication W woopwarRD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482
106. lectronic Throttle Control Possibly either ETC or ETC driver signals have been shorted to ground 491 29 HardOverspeed Woodward Engine speed has exceeded the third level 3 of 3 of overspeed protection 571 57 85 Manual 36553 MI 07 Engine Control System for 3 0L Engines Woodward 86 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 1 Fault List Definitions cont d FAULT IATRangeHigh IATRangeLow DESCRIPTION Intake Air Temperature Sensor Input is High normally set if the IAT temperature sensor wire has been disconnected the circuit has opened to the SECM or a short to Vbatt has occurred Intake Air Temperature Sensor Input is Low normally set if the IAT temperature sensor wire has shorted to chassis ground or the sensor has failed CODE MI04 CODE 381 38 371 37 IAT_IR_Fault Inj1Open Intake Air Temperature not changing as expected Gasoline Injector 1 open circuit broken injector 1 wire or defective injector 391 131 Inj2Open Inj3Open Gasoline Injector 2 open circuit broken injector 2 wire or defective injector Gasoline Injector 3 open circuit broken injector 3 wire or defective injector 132 133 LSDFault_CrankDisable Crank Disable Fault signal has opened or shorted to ground or power or defective crank disable relay 715 LSDFault_Dither1 Dither Valve 1 Fault signal has opened or sho
107. lift cylinder or fuel storage container Woodward 48 Manual 36553 MI 07 Engine Control System for 3 0L Engines Removal and Installation of CA100 Mixer Follow the procedures below for removal and reinstallation of the CA100 mixer in certified systems CA100 Certified Mixer Removal Steps Refer to Figure 27 1 2 P 10 11 12 13 14 15 Close the liquid outlet valve in the forklift cylinder or fuel storage container 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 Key switch in OFF position Remove the air cleaner hose 1 Mark the two vacuum lines 2 to the mixer for identification as they must be reinstalled correctly for proper operation Remove the two vacuum lines Remove vapor fuel inlet line 3 from the fuel temperature sensor fitting 4 Disconnect the fuel temperature sensor connector 5 Disconnect the wires leading to the electronic throttle body by pinching the lock tabs on either side of the wiring harness connector See Figure 28 for location of connector Loosen the four bolts 6 that secure the mixer adapter throttle body assembly to the intake manifold Remove the mixer 9 the adapter 7 and the throttle body 8 as an assembly by gently pulling upwards Take care not to drop anything down the intake manifold Gently wiggle and pull to separate mixer and adapter from the throttle
108. ll when the key is in the ON position but the crankshaft position sensor detects no engine revolutions Run state when the engine reaches a calibration specific 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 a calibration specific number of 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 or Hall Effect type sensor Intake manifold air temperature and absolute pressure are monitored with a TMAP sensor The 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 22 Manual 36553 MI 07 Engine Control System for 3 0L Engines The system operates in open loop fuel control mode 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 mode 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 mode for
109. nostic Fault Codes Flash Codes cont d as PROBABLE FAULT FAULT ACTION SensVoltRangeLow 551 S f 55 ensor reference voltage XDRP too low SensVoltRangeHigh 561 Sensor reference 56 voltage XDRP too high HardOverspeed Engine speed has exceeded the third level 3 of 3 of overspeed protection MediumOverspeed Engine speed has exceeded the second level 2 of 3 of overspeed protection SoftOverspeed Engine speed has exceeded the first level 1 of 3 of overspeed protection APP1RangeLow APP sensor voltage out of range low normally set if the APP signal has shorted to ground circuit has opened or sensor has failed MI 07 Engine Control System for 3 0L Engines 1 TurnOnMil 2 EngineShutdown 1 TurnOnMil 2 EngineShutdown 1 TurnOnMil 2 HardRevLimit 1 TurnOnMil 2 MediumRevLimit 1 TurnOnMil 2 SoftRevLimit 1 TurnOnMil 2 CheckEngineLight CORRECTIVE ACTION FIRST CHECK Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 PWR to TMAP Pin 1 sensor GND Verify transducer power at the SECM with a multimeter SECM Pin B24 PWR to SECM Pin B1 sensor GND Verify transducer power at ETC with a multimeter ETC Pin 3 PWR to ETC Pin 2 sensor GND Verify transducer power to the foot pedal with a multimeter Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 PWR to TMAP Pin 1 sensor GND Verify transducer power
110. nput is Low normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the 332 MAPTimeRangeHigh failed Manifold Absolute Pressure Sensor Input is High normally set if the TMAP pressure signal wire has become shorted to power shorted to the IAT signal the TMAP has failed or the SECM has 341 34 MAPTimeRangeLow circuit has opened to the SECM Manifold Absolute Pressure Sensor Input is Low normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the 331 33 MAP_IR_HI MAP sensor indicates higher pressure than expected 351 MAP_IR_LO MAP sensor indicates lower pressure than expected 352 Woodward 88 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 1 Fault List Definitions cont d CODE FAULT DESCRIPTION MI04 CODE MAP_STICKING MAP sensor not changing as expected 353 Engine speed has exceeded the second level EE 2 of 3 of overspeed protection SE S Pre catalyst O sensor voltage out of range O2RangeHigh high sensor signal shorted to power A Pre catalyst O sensor voltage out of range Oenangelow low sensor signal shorted to ground ot Post catalyst O sensor voltage out of range GE high sensor signal shorted to voltage source 922 5V or battery Post catalyst Os sensor voltage out of range
111. nsor is mounted properly 9 p Possible defective TMAP sensor expected MAP_IR_LO MAP sensor EE None Possible defective TMAP sensor lower pressure than expected MAP_STICKING Check that TMAP sensor is mounted MAP sensor not properly Possible defective TMAP changing as expected sensor Check TMAP connector and IAT IATRangeLow signal wiring for a shorted circuit Intake Air TMAP Pin 2 to SECM Pin B12 signal Temperature Sensor TMAP Pin 1 to SECM Pin B1 Input is Low normally sensor GND set if the IAT TurnOnMil temperature sensor To check the IAT sensor of the TMAP disconnect the TMAP connector and wire has shorted to chassis ground or the measure the IAT resistance sensor has failed Resistance is approx 2400 ohms at room temperature IATR High Check TMAP connector and IAT angerig signal wiring for a shorted circuit Intake Air Temperature Sensor TMAP Pin 2 to SECM Pin B12 signal Input is High normally TMAP Pin 1 to SECM Pin B1 set if the IAT TurnOnMil sensor GND temperature sensor To check the IAT sensor of the TMAP wire has been disconnect the TMAP connector and disconnected or the measure the IAT resistance circuit has opened to the SECM Resistance is approx 2400 ohms at room temperature See Check connections to TMAP sensor Temperature not Check that TMAP sensor is properly pe mounted to manifold changing as expected Fault actions shown are default values specified by the OEM
112. ntain the driver circuitry necessary to energize the primary spark coil otherwise an intermediary coil driver device must be provided The SECM controls spark energy dwell time and spark discharge timing General Motors GM High Voltage Switch HVS System The GM 3 0L engine has a distributed ignition system comprised of one coil and a distributor driven from the engine camshaft The camshaft rotates at half the speed of the engine thereby guaranteeing that each spark plug will fire once for every two revolutions of the engine The GM HVS system provides a control interface that allows external control modules to control engine timing and dwell When the SECM sends a 5 volt signal to the control interface the coil control module begins charging the coil When the SECM signal returns to the ground state the coil discharges into the distributor which directs the charge to the appropriate spark plug In this way the amount of time the SECM signal is in the high state determines the coil dwell The moment that the signal returns to the ground state determines when the spark plug fires The spark timing cannot be altered by rotating the distributor The SECM uses the crankshaft position sensor to determine the ignition timing so changing the position of the distributor will have no effect on the timing IGNITION SYSTEM COMPONENTS In a typical distributed ignition system a crankshaft position sensor generates a basic timing signal by readin
113. o leakage at any of the fittings The static pressure should read between 40 60 of water column on the Magnehelic gauge and maintain a constant pressure for 60 seconds Figure 32 Magnehelic Gauge Connection to Hose Barb 5 Ifthe 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 the regulator is defective 6 Ifthe pressure begins to decrease the secondary seat is probably not making an adequate seal and is leaking The regulator is defective 7 Ifthe test is successful re install the primary test port plug and check the fittings for leaks See Chapter 5 for installation of the N 2007 regulator NOTE The N 2007 primary stage pressure can also be tested at idle ona running engine The N 2007 primary pressure should be between 40 inH20 99 635 mbar and 55 inH20 136 999 mbar at 750 RPM idle 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 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
114. ol software through a Controller Area Network CAN communication link Constant battery power 12 Vdc is supplied through the fuse block to the SECM and the main power relays Upon detecting a key switch ON input the SECM will fully power up and energize the main power relays The energized main power relays supply 12 Vdc power to the heated element of the oxygen sensors fuel lock off fuel trim valves FTVs gasoline injectors gasoline fuel pump crank sensor cam sensor and the ignition coils The SECM supplies voltage to the electronic throttle actuator oil pressure switch fuel temperature sensor and the coolant temperature sensor Transducer or sensor power 5 Vdc is regulated by the SECM and supplied to the manifold temperature air pressure TMAP sensor throttle position sensor TPS and the accelerator pedal position sensors APP A APP2 The SECM provides a transducer ground for all the sensors and a low side driver signal controlling the fuel lock off MIL gasoline injectors gasoline fuel pump and FTVs 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 N 2007 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 three engine states Crank when the crankshaft position sensor detects any engine revolutions Sta
115. olenoid valve Low side switch 10A peak 4A continuous 45 V max Gasoline fuel pump drive Low side switch 10A 4A continuous 45 V max Electronic Spark Timing EST 4 TTL compatible outputs Software configured for distributed ignition system Throttle control 1 H Bridge 5A peak 2 5A continuous at 2500 Hz PWM includes current feedback for diagnostic purposes MIL Malfunction Indicator Lamp Low side switch sufficient to drive a 7W incandescent lamp continuously CANBus CAN 2 0b serial communication for J1939 communications programming and diagnostics Requires proper termination resistance per CAN 2 0b Crank Defeat Relay Stops starter from engaging while engine is running Post Cat O Sensor Heater Relay Turns on heater to prevent oxygen sensor damage during warmup Check Engine Lamp User configurable warning lamp 28 Manual 36553 MI 07 Engine Control System for 3 0L Engines SECM 48 Wiring Diagrams CAUTION PROPER WIRING To prevent system faults be sure to follow good wiring practices Poor wiring may cause unexpected or intermittent failures not related to MI 07 components NOTE Always refer to MOR furnished wiring diagrams for your specific application The schematics on the next pages are wiring diagrams for all types of 3 0L engine systems Figure 21 Bi fuel system Figure 22 LP system Figure 23 Gasoline system Woodward 29 Manual 36553 MI 07 Engine Control System for 3 0L Engines
116. ombustion will be Because propane has a low boiling point 44 F 42 C 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 115 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 constructed 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 A2 Figure A2 Portable Universal Cylinder NOTE 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
117. ome other part of the system is suspected of failure the SECM 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 Picture courtesy of Robert Bosch GmbH Figure 15 Throttle Body Assembly Exploded View Woodward 17 Manual 36553 MI 07 Engine Control System for 3 0L Engines Ignition System Spark ignited engines require accurate control of spark timing and spark energy for efficient combustion The MI 07 ignition system provides this control The system consists of the following components e SECM e Ignition coil s e Crankshaft position sensor e Crankshaft timing wheel e Cam position sensor for sequential ignition or fuel injection only e Cam timing wheel for sequential ignition or fuel injection only e Spark plugs Customer supplied components The SECM through use of embedded control algorithms and calibration variables determines the proper time to start energizing the coil and fire the spark plug This requires accurate crank camshaft position information an engine speed calculation coil energy information and target spark timing The SECM provides a TTL compatible signal for spark control The coil must co
118. on These two signals accelerator pedal position 1 APP and accelerator pedal position 2 APP2 are sent directly to the SECM The SECM uses a series of algorithms to self calibrate and cross check the input signals A demand position for the throttle will then be derived and sent to the throttle as a throttle position sensor demand TPSd This 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 sensors TPS and TPS to the SECM Woodward 25 Manual 36553 MI 07 Engine Control System for 3 0L Engines 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 and idle speed control 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 th
119. on Laptop 56 Figure 36 Opening the Service Tool Display 56 Figure 37 FTV Duty Cycle Percentage Displayed on Service Tool 58 Figure 38 Installing Tamper Proof Cap 59 Figure 39 CA100 Certified Mixer Exploded View 111 Figure 40 N 2007 Certified Regulator Exploded View 113 Figure A1 LPG Tank Pressure vs Temperature 115 Figure A2 Portable Universal Cylinder sssssessseesseessressressnnssnnssnnssennssnnssnnes 116 Figure A3 LPG Fuel Tank Components cccccceseeeeeeeeceeeeeceteeeeeaeeeteneeeeaees 117 Figure A4 Service Valve ooo cee ceeeceeecceceeeeeeesaeeeeneeceeeeesaaeseenaesdeneeesaeseeaaesseneeesaees 118 Figure A5 Quick Disconnect Coupling sssssssssessssrsssrsssressnnssnnssnnssnnsnnnssnnnen 120 Figure A6 Liquid Filler Valve ceccceccsccesseeeeeeeeeeeeeseaeeesaaeceeeeeesaeeesaaeeseneeenaes 120 Woodward iv Manual 36553 MI 07 Engine Control System for 3 0L Engines Regulatory Compliance EPA CARB Emissions Certification When properly applied and calibrated Woodward s MI 07 control system is capable of meeting Environmental Protection Agency EPA 2007 Large Spark Ignition LSI emission standards 40 CFR Part 1048 101 when operating properly with an approved three way catalyst The emission standards including appropriate deterioration factors over the useful life of the system are as follows HC NO 2 0 g hp hr 2 7 g kW hr CO 3 3 g hp hr 4 4 g kW hr Evaporative emissions
120. oof PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter PROBABLE CAUSE CORRECTIVE ACTION Check for proper fuel level e Check for LPG vapor from LPG liquid outlet valve on tank Fill fuel container Do not exceed 80 of Fuel system liquid capacity malfunction Check fuel pressure To determine if the condition is caused by a rich or lean system the vehicle should be driven at the speed of the complaint Monitoring with the Service tool will help identify problem Check for obvious overheating problems Low engine coolant Loose water pump belt Restricted air flow to radiator or restricted water flow through radiator Inoperative electric cooling fan Correct coolant solution should be a mix of anti freeze coolant or equivalent and water High coolant temperature Ignition system Check ignition timing malfunction Check spark module wiring Check exhaust backpressure Check for debris clogging the catalyst Check that pre catalyst Op sensor is functioning Cooling system malfunction Exhaust system malfunction Check for excessive oil in the combustion chamber and or blow by from excessive PCV flow Check combustion chambers for excessive carbon build up Check combustion chamber pressure by performing a compression test Check for incorrect basic engine parts such as cam heads pistons etc Engine mechanical Related MIL Faults EST fault
121. oof Cap Idle Mixture Screw Under Cap Se Tamper _ lt q Proof Cap z Woodward 59 Manual 36553 MI 07 Engine Control System for 3 0L Engines Field Adjustment Procedure The idle mixture adjustment should only be necessary on a new mixer that does not have the tamper proof cap installed The method for making the idle mixture adjustment to a running engine is to use the Service Tool software by connecting a laptop computer to the SECM If you do not have the Service Tool a multimeter capable of measuring duty cycle such as a Fluke 87 Ill can be used If using a multimeter connect the meter positive lead to the battery positive wire and the meter negative to the FTV signal wire For the Fluke 87 press the RANGE button until 4 or 40 appears in the lower right hand corner of the display Press the Hz button twice so that the percent sign appears on the right hand side of the display The multimeter will then read the duty cycle percentage the just like the Service Tool shown in Figure 37 1 After installing a new mixer operate the engine on LPG fuel Start the engine and permit it to warm up until the coolant temperature ECT on Mototune display is approximately 180 F 82 C 2 Place the transmission in Neutral 3 Mototune display parameter LP Fuel Control must display Closed Loop 4 Use the Mototune Service Tool to monitor Duty Cycle on the Mototune display 5 To adjust the idle mixture
122. ops the pressure changes the LPG phase from liquid to vapor and provides vapor phase LPG at a regulated outlet pressure to the mixer To offset the refrigeration effect of the vaporization process the regulator will be supplied with engine coolant flow sufficient to offset the latent heat of vaporization of the LPG A thermostat installed in the coolant supply line maintains regulator outlet coolant temperature at or below 140 F 60 C which minimizes the deposit of fuel contaminants and heavy ends in the regulator and assures a more controlled vaporization process with reduced pressure pulsations A higher flow pressure regulator is required on larger engines Figure 5 N 2007 Regulator 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 07 system If the engine stops vacuum signal stops and fuel flow will automatically stop when both the secondary GP stage valve and the primary 1 stage valve closes Unlike most other regulator converters the N 2007 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 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
123. osition in relation to the accelerator pedal position sensor APP command Engine coolant temperature and adequate oil pressure are also 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 MI 07 Closed Loop LP Fuel System PRE CATALYST OXYGEN SENSOR POST CATALYST OXYGEN SENSOR CAMSHAFT SENSOR CRANK SENSOR SMALL ENGINE CONTROL MODULE COOLANT FUEL TEMP FUEL TRIM ae IGNITION PRESSURE COILS SWITCH CATALYTIC MUFFLER ELECTRONIC THROTTLE MIXER CONVERTER ENGINE Figure 2 MI 07 Closed Loop Fuel System MI 07 System Components The MI 07 control system provides electronic control to the following subsystems on mobile industrial engines e Fuel delivery system e Spark ignition control system e Air throttle e Sensors Switches Speed inputs Key Components The MI 07 system functions primarily on engine components that affect engine emissions and performance These key components include the following e Engine Combustion chamber design e Intake Exhaust valve configuration timing and lift e Intake Exhaust manifold design e Catalytic converter and exhaust system e Throttle body e Air
124. other sizes are possible The Bosch throttle is a fully validated automotive component incorporating a brushed DC motor with gear reduction dual throttle position sensors throttle plate and cast aluminum housing In the event of an electrical disconnection or other related failure the throttle plate returns to a limp home idle position at a no load engine speed above curb idle speed This provides sufficient airflow for the engine to move the vehicle on level ground Any throttle bodies used for MI 07 meet or exceed the specification for the Bosch throttle bodies In terms of response the throttle is capable of fully opening and closing in less than 50 msec Position resolution and steady state control should be 0 25 of full travel or better MI 07 Electronic Throttle Conventional throttle systems rely on a mechanical linkage to control the throttle valve To meet fluctuating engine demands a conventional system will typically include a throttle valve actuator designed to readjust the throttle opening in response to engine demand together with an idle control actuator or idle air bypass valve In contrast the MI 07 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 potentiometers on the foot pedal assembly monitor accelerator pedal travel The electronic throttle used in the MI 07 system is a Bosch 32mm or 40mm electronic thr
125. ottle body DV E5 Figure 14 The DV E5 is a single unit assembly which includes the throttle valve throttle valve actuator DC motor and two throttle position sensors TPS 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 current operating conditions and then generates a corresponding electrical driver signal to the throttle valve actuator Figure 14 Bosch Electronic Throttle Body Woodward 16 Manual 36553 MI 07 Engine Control System for 3 0L Engines The MI 07 uses a dual TPS design TPS and TPS2 The SECM continuously checks and monitors all sensors and calculations that effect throttle valve position whenever the engine is running H 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 its limp home modes or shut the engine down storing the appropriate fault information in the SECM There are multiple limp home modes available with electronic throttle control 1 Ifthe 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 SECM can still control the throttle but s
126. phragm 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 psig 10 342 kPa 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 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 Figure 6 Parts View of N 2007 Regulator 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 balanc
127. ply Temperature at Tank Outlet Primary Pressure Tap Max Flow Coolant Flow to Vaporizer Fuel Outlet Pressure Setpoints Mounting Woodward 10 psi to 250 psi 68 95 kPa to 1723 69 kPa 1 4 NPT One 3 4 NPT plug One 3 4 NPT to 5 8 hose fitting 20 F to 120 F 29 C to 49 C 1 8 NPT with plug 50 Ibm hr LPG gt 1 0 gpm 100bhp equipped with 140 F 60 C thermostat 0 7 0 2 inH2O 1 7 lbm hr LPG 1 744 0 498 mbar 1 7 lbm hr LPG 2 0 0 2 inH2O 50 lbm hr LPG 4 982 0 498 mbar 50 lbm hr LPG Regulator should be installed with centerline of outlet at least 15 below horizontal to permit drainage of any liquid precipitates from LPG fuel Diaphragm should be vertically oriented 35 Manual 36553 MI 07 Engine Control System for 3 0L Engines CA100 Mixer Specifications Fuel LPG Fuel Inlet Fitting 5 8 hose to 1 2 NPT fitting Fuel inlet fitted with Delphi temperature sensor Air Intake Flange 2 25 57 15mm ID inlet four 10 24 screws in 1 94 49 28mm square pattern Mixer Mounting Flange 4 87 47 49mm ID outlet four 12 24 screws arranged in a rectangular pattern Reference Pressure Ports Two 1 8 NPT ports Pressure readings must be identical within 0 25 inH2O 0 623 mbar at all airflows Air Valve Vacuum AVV 1 4 28 UNF Port Size Fuel Inlet Adjustments None Idle Air Adjustment None Mounting Suitable for on engine mount
128. r position control by monitoring the exact position of the throttle valve See Figure 18 SECM self calibration and cross checking compares both signals and then checks for errors Figure 17 Foot Pedal Figure 18 Throttle Position Sensor TPS on DV E5 Throttle Woodward 23 Manual 36553 MI 07 Engine Control System for 3 0L Engines NOTE The DV E5 throttle is not a serviceable assembly If a TPS sensor fails the assembly should be replaced Engine Speed Governing Modes For idle speed control the idle speed is driven 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 system governs engine speed through two modes 1 Accelerator Pedal Position APP 2 All Speed Governor ACCELERATOR PEDAL POSITION APP In APP mode the MI 07 system has minimum and maximum speed governing through the SECM and DBW throttle This mode provides automatic minimum speed governing at a specified idle speed and maximum speed governing at a specified rated speed In between these speeds is a manufacturer defined pedal follower function The pedal vs TPS request table is manufacturer configurable to provide smooth seamless drivability The MI 07 system eliminates the need for air velocity governors This
129. r O2Ctrl DRVP 12V Pin A23 leads defective O sensor i Verify O2 sensor heater circuit is operating by measuring heater resistance 2 19 0 4Q O Pin C GND to Pin D power Fault actions shown are default values specified by the OEM Woodward 102 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC CORRECTIVE ACTION MI 04 PROBABLE FAULT FAULT ACTION FIRST CHECK Check that Post catalyst O2 sensor connections are OK O signal Pin B to SECM Pin B19 Oz Pin C GND to SECM DRVG GND Pins A16 B17 O Pin D power to Post O2 Heater Relay Relay pin 87 This relay only turns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM DRVP 12V applied to the relay coil power The relay coil ground is controlled by SECM Pin A20 to activate the relay to flow current through the post O heater Verify O2 sensor heater circuit is operating by measuring heater resistance 2 10 0 4Q Oz Pin C GND to Pin D power GasPostO2NotActive Post catalyst O sensor 1 TurnOnMil inactive on LPG open Oz 2 DisableGasPost sensor signal or heater leads O2Ctrl defective O sensor m em o GasO2FailedLean Check for vacuum leaks 1 TurnOnMil Check fuel trim valves e Pre catalyst O2 sensor 2 DisableGas 6 9 indicat
130. ransient over voltage input ratings SECM 48 input power must be supplied from a power supply battery charger certified to IEC standard with a Safety Extra Low Voltage SELV classified output Input power should be properly fused according to the wiring diagram in Woodward publication 26377 SECM 48 Manual SECM 48 inputs and outputs may only be connected to other circuits certified as SELV The IP 56 Ingress Protection rating of the control depends on the use of proper mating connectors See Woodward publication 26377 SECM 48 Manual Chapter 2 Installation Wiring Connections Table 2 1 for information on the proper mating connectors for use with this control WARNING EXPLOSION HAZARD Do not connect or disconnect while circuit is live unless area is known to be non hazardous Substitution of components may impair suitability for Class I Division 2 or Zone 2 applications Electromagnetic Compatibility EMC All MI 07 active electronic components manufactured by the Woodward Governor Company have been developed and individually tested for electromagnetic compatibility using standardized industry methods under laboratory test conditions Actual EMC performance may be adversely affected by the wiring harness design wire routing the surrounding structure other EMC generating components and other factors that are beyond the control of the Woodward Governor Company It is the responsibility of the vehicle and or application manu
131. rl TurnOnMil TurnOnMil 1 TurnOnMil 2 DisableLiquid O2Ctrl Correct other faults that may contribute to 772 e g faults pertaining to FTVs Pre Cat Os Post Cat O sensor Look for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 742 corrective actions Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector Low gasoline fuel pressure perform gasoline pressure test Injector problems e g leaking defective injector Check that Pre catalyst O3 sensor connections are OK O signal Pin B to SECM Pin B13 Oz Pin C GND to SECM DRVG GNG Pins A16 B17 O Pin D power to SECM DRVP 12V PIN A23 Verify O2 sensor heater circuit is operating by measuring heater resistance 2 1Q 0 4Q Ox Pin C GND to Pin D power Woodward 104 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 2 Diagnostic Fault Codes Flash Codes cont d DFC FAULT CORRECTIVE ACTION MI 04 PROB ABE FAULT ACTION FIRST CHECK Check that Post catalyst O2 sensor connections are OK O sensor GND Pin A to SECM Pin B1 Op Pin C GND to SECM DRVG GND Pins A16 B17 O Pin D power to Post O2 Heater Relay Relay pin 87 This relay only turns on after engine has been running for some time and SECM has LiqPostO2NotActive calculated that water
132. rted to ground or power or defective dither 1 valve 711 71 LSDFault_Dither2 Dither Valve 2 Fault signal has opened or shorted to ground or power or defective dither 2 valve 712 LSDFault_FuelPump Fuel Pump Fault signal has opened or shorted to ground or power or defective fuel pump 716 LSDFault_LockOff Fuel lock off Valve Fault signal has opened or shorted to ground or power or defective Fuel lock off valve 717 LSDFault_MIL Malfunction Indicator Lamp Fault signal has opened or shorted to ground or power or defective MIL lamp 718 LiqFuelAdaptRangeHi In Gasoline mode system had to adapt rich more than expected 821 LiqFuelAdaptRangeLow In Gasoline mode system had to adapt lean more than expected 831 LiqO2FailedLean Pre catalyst O sensor indicates extended lean operation on gasoline 851 LiqO2FailedRich Pre catalyst O sensor indicates extended rich operation on gasoline 871 Woodward 87 Manual 36553 MI 07 Engine Control System for 3 0L Engines Table 1 Fault List Definitions cont d FAULT DESCRIPTION CODE MI04 CODE LiqO2NotActive sensor Pre catalyst O sensor inactive on gasoline open O sensor signal or heater leads defective O 841 LiqPostO2FailedRich faults recheck if this fault sets Post catalyst O sensor control on gasoline has reached rich limit and sensor still reads too lean
133. s Encoder error High coolant temperature faults Woodward 69 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Backfire Fuel ignites in intake manifold or in exhaust system making loud popping noise PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Simulate condition by reviewing operation procedure practiced by vehicle operator PROBABLE CAUSE CORRECTIVE ACTION Perform fuel system diagnosis check Fuel system e Check for fuel leaks malfunction e Check for MIL faults e Check for damaged components Check proper ignition coil output voltage with spark tester Check spark plugs Remove spark plugs check for wet Ignition system plugs cracks wear improper gap burned electrodes malfunction or heavy deposits Repair or replace as necessary Check spark plug wires for crossfire also inspect spark plug wires and proper routing of plug wires Check ignition timing Check compression look for sticking or leaking valves Check intake and exhaust manifold for casting flash and gasket misalignment Refer to Engine Manufacturer s Service Manual Engine mechanical Related MIL Faults EST faults ETC faults Encoder error Pre catalyst O sensor faults Dieseling Run on Engine continues to run after key is turned OFF but runs very roughly If engine runs smoothly check ignition switch and adj
134. screw use a hex or Allen type wrench Turning the screw in clockwise should increase the duty cycle turning the screw out counterclockwise should decrease the duty cycle 6 Adjust the idle mixture screw on the mixer until a reading of 45 55 is reached for the FTV Duty Cycle in Closed Loop Idle Figure 37 If engine idle performance is unstable screw the idle screw in slightly to see if stability is obtained but in no case should duty cycle exceed 60 7 Use the accelerator pedal to increase 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 45 55 8 Ifthe FTV duty cycle reading is above 55 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 45 55 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 60 is acceptable if the optimum range of 45 55 cannot be reached through adjustment If the FTV duty cycle cannot be adjusted below 60 the mixer is faulty and should be replaced NOTE If the FTV Duty Cycle reading is NOT between 25 60 check for possible vacuum leaks manifold leaks or a faulty mixer 9 Turn the ignition key to the OFF position to shut down the engine 10 Install the tamper proof cap on the idle mixture screw
135. sensor signal or heater leads defective O sensor or defective FTVs 741 74 GasPostO2FailedRich Post catalyst O gt sensor control on LPG has reached rich limit and sensor still reads too lean This could be caused by oxygen leak before or just after sensor catalyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O sensor faults are set diagnose these first and after correcting these faults recheck if this fault sets 772 GasPostO2FailedLean Post catalyst O sensor control on LPG has reached lean limit and sensor still reads too rich This could be caused by catalyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O sensor faults are set diagnose these first and after correcting these faults recheck if this fault sets 752 GasPostO2Inactive Post catalyst O gt sensor control on LPG has sensed the Oz sensor is not responding as expected If any Pre O sensor faults are set diagnose these first and after correcting these faults recheck if this fault sets Possible causes for this fault are sensor disconnected sensor heater failed sensor element failed heater relay or SECM control of heater relay is disconnected or failed 742 Reserved for Future Use 743 HbridgeFault_ETC Electronic Throttle Control Driver has Failed Indeterminate fault on Hbridge driver for E
136. stable Incorrect Idle or Stalling cccccccssecceesssteeeeessteeeeeeaes 71 GUtS Out GE 73 Poor Fuel Economy Excessive Fuel Consumption LPG Exhaust Smell 74 High Idle SPCC EE 75 Excessive Exhaust Emissions or Odors sssessessesirssirnesrrssrnssrnssrnssrnssns 76 Diagnostic Aids for Rich Lean Operation cccccceeeeeeeeeceeeeeeseeseneeeeees 77 Chart T 1 Restricted Exhaust System Check 78 CHAPTER 8 ADVANCED DIAGNOSTICS cccccccesssseceeeeeeeeseecesesseneeeeeeneneanens 79 Woodward ii Manual 36553 MI 07 Engine Control System for 3 0L Engines Reading Diagnostic Fault COdeS ccccceccceeceeeeeeeeeeeeeeeeeaeeeeaeeseeeeeeeeeeseeeeeeeees 79 Displaying Fault Codes DFC from SECM Memon 79 Clearing Fault DFC Codes 79 Fault Action Descriptions cccccccceeceeeeneeeeeeceeeeeeeaeeesaeeseeeeescaeeesaeeeeneeeeas 81 Fault List Definitions ccccccceeseeceeeeeeeeeeeeeaeeseeeeecaeeeseaeeseeeeseaeeesaeeeeeneeeaas 82 Table 1 Fault List Definitions ccc ccccecceseeeeeeeeeeeeseaeeeeseaeeeeesseaeeeeseaas 82 Table 2 Diagnostic Fault Codes Flash Codes cceccccseeeeesteeeseeeees 91 CHAPTER 9 PARTS DESCRIPTION sssececececcssessseeeeeeececescsseneeeeeeneceanseess 109 LP Fuel System Components for 3 0L Engines seeseeseesseeeeeeeeeee neern 109 GA100 MEET 110 N 2007 Reg lat t ET 112 IAPPENDIX nde REENEN EE A ENEE ERC g 114 LPG amp EPG KIC REI 114 LPG Fu
137. substantially increases the peak torque and power available for a given system as shown in Figure 19 When the engine 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 excessive over speed is detected the engine is shut down MI 07 System 3 0L LPG amp Gasoline Performance Curves New curves to COME Figure 19 Peak Torque and Power Available with MI 07 System ALL SPEED GOVERNOR This function allows the operator to control the engine through an isochronous governor strategy within the torque limits of the engine The speed set point can be configured by the manufacturer for the engine operating range The set point for the governor can be foot pedal speed select switches or CAN message J1939 PGN 0000 TSC1 SPN898 These modes can be individually selectable Woodward 24 Manual 36553 MI 07 Engine Control System for 3 0L Engines Drive By Wire Signal Flow Process FOOT PEDAL OTHER INPUT OPTIONS SPEED SWITCH 1 SPEED SWITCH 2 CAN MESSAGE DBW CONTROL LOO TPSD DEMAND e ppw APP ACCELERATOR PEDAL POSITION THROTTLE TPS THROTILE POSITION SENSOR Figure 20 Drive By Wire Signal Flow Process Figure 20 describes the signal flow process of the MI 07 DBW section The foot pedal assembly uses two potentiometers to detect pedal positi
138. switch Scribe a line across the filter housing covers which will be used for alignment purposes when re installing the filter cover FUEL FILTER DISASSEMBLY Steps 4 7 10 11 Woodward Remove the cover retaining screws 1 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 Replace the filter element 7 Check bottom cover O ring seal 6 for damage Replace if necessary Re assemble the filter assembly aligning the scribe lines on the top and bottom covers Install the cover retaining screws tightening the screws in an opposite sequence across the cover Open the fuel valve by slowly turning the valve counterclockwise 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 Check the filter housing fuel lines and fittings for leaks Repair as necessary 41 Manual 36553 MI 07 Engine Control System for 3 0L Engines Testing Fuel Lock off Operation e Start engine e Locate the electrical connector for the fuel lock A e Disconnect the electrical connector e The engine should run out of fuel and stop within a short period of time NOTE 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 e Turn the ignition key switch off and re connect the fuel lock of
139. system to 10 psig the boiling point of the water increases to 242 F 117 C which will cause the water to remain in liquid state at the engine s operating temperature 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 to allow for a 20 vapor expansion space Outside air temperature affects an LPG tank and must be considered when using an LPG system Figure A1 shows the relationship between pressure and temperature in a LPG tank at a steady state condition Woodward 114 Manual 36553 MI 07 Engine Control System for 3 0L Engines LPG Tank Pressure VS Temperature 150 100 Pressure psig 50 20 0 20 40 60 80 100 120 140 Temperature deg F Figure A1 LPG Tank Pressure vs Temperature With 128 psig vapor pressure acting against the liquid propane the boiling point has been raised to slightly more than 80 F 27 C Compressed Vapor 128 psi Liquid Propane NOTE Vapor pressure inside an LPG tank depends on the propane temperature not the amount of liquid inside the tank A tank that is 3 4 full of liquid propane at 80 F 27 C will contain the same vapor pressure as a tank that is only 1 4 full of liquid 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 c
140. t 180 F 82 C before performing the idle mixture adjustment 1 Operating the engine on LPG fuel start the engine and permit the engine to warm up until the coolant temperature ECT on Mototune display is approximately 180 F 82 C 2 Set APP input to minimum 3 Adjust the load until engine speed reaches 750 RPM 4 Mototune display parameter LP Fuel Control must display Closed Loop 5 Use the Mototune Service Tool to monitor Duty Cycle on the Mototune display 6 To adjust the idle mixture screw use a 3 16 hex or Allen type wrench Turning the screw in clockwise should increase the duty cycle turning the screw out counter clockwise should decrease the duty cycle 7 Adjust the idle mixture screw on the mixer until a reading of 40 47 is reached for the FTV Duty Cycle in Closed Loop Idle Figure 37 aFRCONTROL uP Closed Loop Duty Cyce am e UP Adapt Otse ooo Duty Cycle AFR CONTROL Gasoline Gasoline Fuel n OponLoop Gasoline Adapt Factor vumm ce Figure 37 FTV Duty Cycle Percentage Displayed on Service Tool 8 Use the accelerator pedal to increase 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 40 47 9 Use the Mototune Service Tool to lock the FTV duty cycle Set display parameter DitherValveDC_ ovr locked displayed in screen tab Manual Override 1 under AF
141. t be present or able to be recreated in order to locate the problem If a fault is intermittent use of diagnostic code charts may result in the unnecessary replacement of good components CORRECTIVE ACTION Most intermittent problems are caused by faulty electrical connections or wiring Perform careful visual physical check for e Poor mating of the connector halves or terminal not fully seated in the connector body backed out Improperly formed or damaged terminal All connector terminals in problem circuit should be carefully reformed or replaced to insure proper contact tension Loose connections or broken wires Poor terminal to wire connection crimp If a visual physical check does not find the cause of the problem perform the following 1 Drive the vehicle with a voltmeter or Service tool connected to a suspected circuit Check if circuit is active and signal is reasonable Using the Service tool monitor the input signal to the SECM to help detect intermittent conditions An abnormal voltage or Service reading when the problem occurs indicates the problem may be in that circuit If the wiring and connectors check OK and a diagnostic code was stored for a circuit having a sensor check sensor An intermittent Service Engine Soon light with no stored diagnostic code may be caused by e Ignition coil shortage to ground and arcing at spark plug wires or plugs e MIL wire to ECM shorted to ground e SECM gro
142. tance 2 wire 200 Vpp max or 0 5 V Hall Effect with calibration selectable pull up resistor for open collector sensors Permits speed resolution of 0 25 RPM and crankshaft position resolution of 0 5 e Camshaft position Variable reluctance 2 wire 200 V max or 0 5 V Hall Effect with calibration selectable pull up resistor for open collector sensors Digital Inputs e Oil pressure switch Normally open internal pull up resistor provided to detect external switch to ground e Fuel select switch Three position switch for bi fuel applications to detect gasoline mode LPG mode and fuel off center switch position Woodward 27 Manual 36553 MI 07 Engine Control System for 3 0L Engines Outputs Woodward Ground speed select switch Permits selecting two different maximum engine speeds Vswitched Switched battery voltage Can Input Governs requested speed Speed Switch Input Two position switch for RPM governing Saturated injector drivers 4 10A peak 45 V max 1 injector per channel capable of continuous on time Driver circuit designed for minimum turn on turn off delay Minimum pulse width resolution of 1 usec FTV drivers 2 10A peak 45V max To drive an on off fuel trim valve with a minimum impedance of 5 ohms Capable of continuous on time Drive circuit designed for minimum turn on turn off delay FTVs will be pulse width modulated between 8 and 40 Hz with a minimum pulse width resolution of 50 usec Fuel lock off s
143. terioration 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 necessary e Remove battery cables and clean repair and or replace as necessary Inspect Ignition System e Remove and inspect the spark plugs Replace as required e Remove and inspect distributor cap Check for cracks or abnormal wear on the output contacts Replace as required e Remove and inspect distributor rotor Check for abnormal wear on the rotor arm contact Replace as required e Inspect the ignition coil for cracks and heat deterioration Replace as required Replace Spark Plugs e Using a gentle twisting motion remove the high voltage leads from the spark plugs Replace any damaged leads e Remove the spark plugs e Gap the new spark plugs to the proper specifications e Apply anti seize compound to the spark plug threads and install e Re install the high voltage leads CAUTION Do not over tighten the spark plugs Woodward 40 Manual 36553 MI 07 Engine Control System for 3 0L Engines Replace LP Fuel Filter Element Park the lift truck in an authorized refueling area with the forks lowered parking brake applied and 1 2 3 Filter Housing Scribe Point the transmission in Neutral 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 Turn off the ignition
144. tion The MIL may illuminate with no other action or may be combined with other actions depending on which fault is active Soft Rev Limit Medium Rev Limit Hard Rev Limit System will follow various sequences to bring engine speed back to acceptable levels Level4 Power Limit Level3 Power Limit Level2 Power Limit Level1 Power Limit The maximum engine power output will be limited to one of four possible levels The engine power is calculated from measured engine parameters e g MAP RPM fuel flow etc Disable Gas O Control In LPG mode closed loop correction of the air fuel ratio based on the Pre catalyst O sensor is disabled Disable Liquid O Control In Gasoline mode closed loop correction of the air fuel ratio based on the Pre catalyst O sensor is disabled Woodward 81 Manual 36553 MI 07 Engine Control System for 3 0L Engines Fault List Definitions All the analog sensors in the MI 07 system have input sensor range faults These are the coolant temperature sensor fuel temperature sensor throttle position sensors pedal position sensors manifold pressure sensor HEGO sensors and intake air temperature sensor Signals to these sensors are converted into digital counts by the SECM A low high range sensor fault is normally 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 Sensor Range 0 Counts Input Low Additionally the SECM
145. tor vapor hose for deposit build up Clean or replace as necessary Inspect regulator assembly for fuel coolant leaks Fuel Trim Valve Inspect valve housing for wear cracks or deterioration Ensure valve seals in the closed position when the engine is off Replace FTV When indicated by MIL Carburetor Check air fiter indicator x Ir TI Check for air leaks in the xX filter system Inspect air fuel valve mixer assembly for cracks loose hoses and fittings Repair or replace as necessary Check for vacuum leaks in the intake system including manifold adapter and mixer to throttle adapter Repair or replace throttle a assembly When indicated by MIL Inspectairfiter EEX PP Replace rier deren XT Check TMAP sensor for X tightness and leaks Exhaust amp Emission Inspect engine for exhaust leaks Replace PCV valve and breather element Replace HEGO sensors When indicated by MIL Gasoline Engines Replace gasoline fuel filter xX element Inspect gasoline fuel system for leaks Confirm gasoline supply Pressure should be 45 55 psig 310 26 379 21 kPa pressure is correct Woodward 45 Manual 36553 MI 07 Engine Control System for 3 0L Engines Chapter 5 Installation Procedures WARNING PROPER USE 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
146. ts and control outputs to control the system The SECM receives signals from the sensors digitizes these signals and then through algorithms and calibration maps computes the desired output response to effect control of fuel spark and air to the engine The SECM also provides a variety of other functions and features These include system monitoring and diagnostics to aid in maintaining efficient system operation and auxiliary control SECM sensor inputs and control output specifications are specific to the application but include a selection of the following Analog Inputs The 48 pin SECM is equipped with sufficient analog inputs for the following sensors e Manifold Absolute Pressure MAP bar MAP 0 to 5 V e Manifold Air Temperature MAT 40 F to 266 F 40 C to 130 C range 48 kQ to 85 Q sensor range e Throttle Position Sensor 1 amp 2 TPS1 amp TPS2 0to5V e Foot Pedal Position 1 amp 2 FPP1 amp FPP2 0to5V e Coolant Temperature Sensor CTS 40 F to 266 F 40 C to 130 C range 48 kQ to 85 Q sensor range e Fuel Temperature Sensor FTS 40 F to 266 F 40 C to 130 C range 48 kQ to 57 Q sensor range e HEGO 3 0to1V e Auxiliary Analog Input 2 0 to 5 V e Battery Voltage Vbatt 1 8 18 V With the exception of battery voltage all inputs are 0 5 Vdc ground referenced Resolution should be 0 1 or better Accuracy should be 2 or better Frequency Position Inputs e Crankshaft position Variable reluc
147. uirements Only trained certified technicians should perform disassembly service or replacement of the regulator converter or mixer N 2007 Regulator Service Testing For checking the N 2007 regulator converter operation the following tests can be performed See Chapter 5 for removal installation of the N 2007 regulator 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 See listing below for required hardware Break Off Test Secondary Stage Test Hardware Hand vacuum pump Regulator vapor outlet test fitting 3 4 NPT x 1 4 hose barb Union Tee 1 4 NPT with three 1 4 NPT x 1 4 hose barb Vacuum hose 0 3 WC Magnehelic gauge inches of water column OF PO Ne Secondary Stage Break Off Test 1 Connect the vacuum pump the Magnehelic gauge and the regulator vapor outlet to the Union Tee fitting Figure 30 Make sure there is no leakage at any of the fittings 2 Using the vacuum pump slowly apply enough vacuum to measure above 2 WC on the gauge This vacuum signal opens the secondary valve in the N 2007 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 0 5 0 35 WC of the secondary spring the needle should stop moving Woodward 52
148. unds refer to SECM wiring diagrams Check for improper installation of electrical options such as lights 2 way radios accessories etc EST wires should be routed away from spark plug wires distributor wires distributor housing coil and generator Wires from SECM to ignition should have a good connection Woodward 62 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Surges and or Stumbles Engine power varies under steady throttle or cruise Surging and stumbling is characterized by the feeling that the vehicle is speeding up and slowing down with no change in the acceleration pedal PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Be sure driver understands vehicle operation as explained in the operator manual PROBABLE CAUSE CORRECTIVE ACTION The fuel management system should maintain a stoichiometric air fuel ratio under all steady state operating conditions following engine warmup Failure of the Pre catalyst O2 sensor should cause an Os sensor fault that can be diagnosed with the MIL or Service Tool Oxygen sensor malfunction NOTE To determine if the condition is caused by a rich or lean system the vehicle should be driven at the speed of the complaint Monitoring pre catalyst Op adapts dither valve duty cycle or mechanical injector pulse width will help identify Fuel system malfunction problem
149. urs the MIL will illuminate and remain ON This signals the operator that a fault has been detected by the SECM 2 Determine that there are no diagnostic codes stored or there is a diagnostic code but no MIL VISUAL PHYSICALCHECK Several of the procedures call for a Careful Visual Physical Check which should include e SECM grounds for being clean and tight e Vacuum hoses for splits kinks and proper connection e Air leaks at throttle body mounting and intake manifold e Exhaust system leaks e Ignition wires for cracking hardness proper routing and carbon tracking e Wiring for pinches and cuts Also check e Connections to determine that none are loose cracked or missing e Fuel level in vehicle is sufficient e Fuel is not leaking e Battery voltage is greater than 11 5 volts e Steering brakes and hydraulics are in proper condition and vehicle is safe to operate NOTE The Visual Physical check is very important as it can often correct a problem without further troubleshooting and save valuable time Woodward 61 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting Intermittent Faults An intermittent fault is the most difficult to troubleshoot since the MIL flashes on at random causing uncertainty in the number of flashes or the conditions present at the time of the fault Also the problem may or may not fully turn ON the MIL or store a code Therefore the fault mus
150. ustment PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter PROBABLE CAUSE CORRECTIVE ACTION Fue system Check for fuel leaks or leaking injector malfunction Si Ee Make sure power to system is shut off when key is in Ignition switching OFF position Fuel lock off valve Make sure lock off valve is closing properly Ignition system malfunction Check spark advance at idle Related MIL Faults EST faults ETC faults Pre catalyst O2 sensor faults Woodward 70 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Rough Unstable Incorrect Idle or Stalling Engine cranks OK but does not start for a long time Does eventually run or may start but immediately dies PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Check for vacuum leaks Check that SECM grounds are clean and tight See SECM wiring diagram PROBABLE CAUSE CORRECTIVE ACTION Monitor oxygen feedback to help identify the cause of the problem If the system is running lean or if the system is running rich evaluate further i e dither valve duty cycle and injector pulse width Check for incorrect minimum idle speed that may be caused by foreign material accumulation in the throttle bore on the throttle valve or on the throttle shaft Fuel system Check that the injectors are clean and functioning mal
151. varied between mixer inlet pressure and AVV For a given change in the pressure regulator reference pressure the pressure regulator outlet pressure changes by the same amount and in the same direction The end result is that a change in FTV modulation changes the outlet pressure of the regulator fuel inlet pressure of the mixer and thus the AFR A major benefit of this trim system results from the use of mixer inlet pressure and AVV as the reference pressure extremes The pressure differential across the mixer fuel valve is related to these same two pressures and thus so is fuel flow Given this arrangement the bias pressure delta scales with the fuel cone pressure delta The result is that the trim system control authority and resolution on AFR stays relatively constant for the entire speed and load range of the engine SECM The Small Engine Control Module SECM controls the LPG lock off solenoid valve and the FTVs The lock off solenoid is energized when fueling with LPG and the engine is turning FTV modulation frequency will be varied as a function of RPM by Woodward 7 Manual 36553 MI 07 Engine Control System for 3 0L Engines the SECM in order to avoid resonance phenomena in the fuel system FTV control signals will be altered by the SECM in order to maintain a stoichiometric air fuel ratio Control signals are based primarily on feedback from the exhaust gas oxygen sensor with an offset for fuel temperature MI 07 LP Fuel Filter
152. ve vacuum AVV into the atmospheric side of the N 2007 secondary regulator diaphragm An orifice balance line connected to the air inlet side of the mixer provides atmospheric reference to the N 2007 when the FTVs are closed The SECM uses feedback voltage from the O sensor to determine the amount of bias needed to the regulator converter In normal operation the N 2007 maintains fuel flow at a constant output pressure due to the calibrated secondary spring The amount of fuel flowing from the N 2007 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 N 2007 secondary diaphragm is referenced to FTV control pressure while the other side of the diaphragm reacts to the negative pressure signal from the mixer If the pressure on the reference side of the N 2007 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 Woodward 14 Manual 36553 MI 07 Engine Control System for 3 0L Engines Branch Tee Fitting A branch tee fitting is installed in the atmospheric vent port of the N 2007 with one side of 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 si
153. vehicle verify problem exists Remove air filter and check for dirt or other means of plugging Replace if needed PROBABLE CAUSE CORRECTIVE ACTION Check for restricted fuel filter Check fuel supply Check for LPG vapor from LPG liquid outlet valve on tank Check for contaminated fuel Check for clogged fuel filter and repair or replace as required See Chapter 4 Fuel Filter replacement Check for plugged fuel line and remove any 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 and leak test Check for faulty vapor connection between pressure regulator converter and mixer e Verify that there are no holes in hose e Observe that clamps are tight e Look for kinked pinched and or collapsed hose Monitor pre catalyst O with Service Tool Check for proper pressure regulator operation See Chapter 6 Test and Adjustments Check for proper air fuel mixer operation Fuel system malfunction Check spark advance for excessive retarded ignition timing Use Service Tool Check secondary voltage using an oscilloscope or Ignition system malfunction a spark tester to check for a weak coil Check spark plug condition Check poor spark plug primary and secondary wire condition continued on next page Woodward 67 Manual 36553 MI 07 Engine Control System for 3 0L
154. vice tool interface and the MIL With the MIL it is possible to generate a string of flashing codes that correspond to the fault type These diagnostics are generated only when the engine is not running and the operator initiates a diagnostic request sequence such as repeated actuations of the pedal within a short period of time following reset Limp Home Mode The system is capable of limp home mode in the event of particular faults or failures in the system In limp home mode the engine speed is approximately 1000 RPM at no load A variety of fault conditions can initiate limp home mode These fault conditions and resulting actions are determined during calibration and are OEM customer specific Service Tool A scan tool monitoring device is available to monitor system operation and assist in diagnosis of system faults This device monitors all sensor inputs control outputs and diagnostic functions in sufficient detail through a single access point to the SECM to allow a qualified service technician to maintain the system This Mototune software licensed by Mototron Communication is secure and requires a crypt token USB device to allow access to information Bi Fuel System A bi fuel system operates on either LPG or gasoline The engine will run on only one fuel at a time The fuel type can be switched while the engine is stopped or running at low speeds and low loads The fuel selection switch is a three position type where the center pos
155. warranty claims INTERVAL HOURS CHECK POINT Every 250 Every 500 Every Every Every 1000 1500 2500 Hours or 1 Hours or month 3 months Hours or Hours or Hours or 6 months 9 months 1 year General Maintenance Test fuel DEE for leaks Prior to any service or maintenance activity Inspect engine for fluid leaks engine for fluid leaks Inspect all vacuum lines and fittings Inspect electrical system check for loose dirty or damaged wires and connections Inspect isolation mounts on engine control module for cracks and wear replace as necessary nn s f e hoses SLL LL S operation Replace timingbelt J Check for MIL lamp test at key on If MIL lamp remains illuminated indicating a X fault use pedal to recover fault code s Repair faults Engine Coolant Checkcoolantlevel III II Inspect coolant hoses and fittings for leaks cracks swelling or deterioration Engine Ignition e a E RE EE NEE EENEG and corroded cables Inspect ignition system II CE O CX S Replace spark plugs d T It Fuel Lock Off Filter Replace LP fuel filter X element Inspect lock off and fuel filter for leaks Ensure lock off stops fuel flow when engine is off Woodward Manual 36553 MI 07 Engine Control System for 3 0L Engines INTERVAL HOURS Every Every Every CHECK POINT Every 250 Every 500 1000 1500 2500 aily Hours or 1 Hours or Ho Pressure DEE E Inspect pressure regula
156. y 1 5 Spring Secondary Seat Red 1 6 Dowel Pin 0 094 x 1 L 2 39mm x 25 4mm L A Hardened Steel 7 Diaphragm Secondary Assembly 1 8 Lever Secondary 1 9 Seat Secondary 1 10 Valve Primary 1 11 Fillister Head Screws SEMS Split Lockwasher 12 24 x 5 8 6 12 Pan Head Screw SEMS Ext Tooth Lockwasher 12 24 x 1 4 1 13 Body Gasket 1 14 Back Plate 1 15 O ring Size 107 GLT Viton 1 16 Bottom Plate Gasket 1 17 Plate Cover 1 18 Fillister Head Screws SEMS Split Lockwasher 12 24 x 1 3 8 6 19 Hex Head Screws SEMS Split Lockwasher 1 4 20 x 5 8 4 20 Plug Socket Head Pipe T 086 1 21 Cover Secondary Diaphragm 1 22 Lockwasher Int Tooth T 210 8 SST 6 23 Torx Screws T 15 8 32 x 5 8 6 Woodward 112 Manual 36553 MI 07 Engine Control System for 3 0L Engines Exploded View P N 5233 1018 N 2007 Regulator DWG NO 1326 4039 Rev 100 Figure 40 N 2007 Certified Regulator Exploded View Woodward 113 Manual 36553 MI 07 Engine Control System for 3 0L Engines Appendix LPG amp LPG Fuel Tanks 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 add
157. y be detected by monitoring engine RPM with Service Tool A sudden l increase in RPM with little change in actual engine Component malfunction RPM indicates EMI is present If problem exists check routing of secondary wires and check distributor ground circuit Check intake and exhaust manifolds for casting flash or gasket leaks Perform compression check on questionable cylinders If compression is low repair as necessary Check base engine Remove rocker covers and check for bent pushrods worn rocker arms broken valve springs worn camshaft lobes and valve timing Repair as necessary Engine mechanical Related MIL Faults EST faults ETC Sticking fault Woodward 73 Manual 36553 MI 07 Engine Control System for 3 0L Engines Basic Troubleshooting cont d Poor Fuel Economy Excessive Fuel Consumption LPG Exhaust Smell Fuel economy as measured during normal operation is noticeably lower than expected Also economy is noticeably lower than what it has been in the past Propane fuel smell near vehicle sets off carbon monoxide sensors PRELIMINARY CHECKS Perform the visual checks as described at start of Basic Troubleshooting chapter Verify operator complaint identify operating conditions Check operator s driving habits Are tires at correct pressure Are excessively heavy loads being carried Is acceleration too much too often Check air cleaner element filter for being dirty or plugg

3.0L Operations Manual

Contents

Download Pdf Manuals

Related Search

Related Contents