Home

Installation manual - Medic-car

1. page 16 4 8 Installing the Electronic control unit page 20 4 9 Installing the EMU FAST electronic control unit page 21 50 Electrical CONNCE OMS cou uuu L a TEES QU NIAI EVE a page 23 ME 6 RENE page 23 5 2 Lambda probe signal before catalyser page 23 5 3 Connecting the reducer temperature SEenSsor page 23 5 4 Connecting the level page 24 5 5 Connecting the LPG multivalve and lock off valve page 24 5 6 Connecting the injector power connector page 24 5 7 Connecting the power supply e 24 6 0 Wiring diagram U iaia page 25 10 Pheumauc diagram E a rr 26 9 USEF IT OI A OND ciao page 27 9 0 FASTCOM calibration and diagnostics software page 29 9 1 Programme installation guide ei page 29 9 2 Connection between PC and control unit page 29 SN MEE WOO page 30 9 4 Progr
2. Fixing screws for the EMU FAST control unit EMU FAST control unit 22 FAST G LOVATO 5 0 Electrical connections 5 1 RPM signal FAST is a phased Sequential Injection system and as such the revs input is used to synchronise the whole system In order to optimise conversion assess the capture method with care The selection criteria is the following Always prefer the RPM signal from the petrol control unit locate its position on the connec tor with the wiring diagram of the car or by directly visualising the signals with an oscillo In some recent models of car RPM counter signal is conveyed on the Can Bus and contains no phase information In this case choose the negative signal on the ignition coil When capturing this signal remember that if the grounds of the ignition coil are not in good condition discharge may be incorrect and generate impulses on the low voltage side that may disturb system operation in these cases if it is not possible to eliminate the cause use a rev amplifier to decouple the circuits Make the electrical connection to the rev counter signal or the ignition coil negative signal by stripping the signal wire for a sufficient length to allow the BLACK wire from the FAST control unit to be soft soldered insulate the connection with insulating tape If the FAST control unit does not detect a correct RPM signal the system will not allow the car to shift fro
3. 7 2 PII ET CHG 22 7 74 Gruppo elettroiniettori E 2 Electro injectors assembly Zn 1 N gt Vista dall alto view VA Y O Centralina di controllo Control Unit Collettore di aspirazione P P 7 Inlet manifold T LU f gt 2 fi C g C 2 Collegato sul fondo C 2 Connected on the bottom C D C N gt P V
4. Tar 7 p Insert Row 2 Col 2 8222 R2C2 E var rem 766 cas e RICE race Read Close The values of the MAP RPM multipliers are displayed These parameters are used by the control unit to calculate Tgas The RPM MAP work area of the car is displayed by the red cell inside the map For a precise indication of the position inside the red cell refer to the fine position box the cell is divided into nine boxes in which a mobile yellow cursor indicates the area of the cell on the map currently identified by MAP and RPM When the yellow cursor is positioned in the central box of the nine element matrix it means that the values of MAP and RPM correspond to the centre of the cell illuminated in red on the map To modify a cell or group of cells 1 block the cursor by clicking on start stop cursor 2 select the cell or group of cells by dragging the mouse 3 enter the new value and press new value To work on an individual cell you can also use the suggested value and attempt to reach the displayed Tbenz target value To activate the hints mechanism the Suggestions box must 45 G LOVATO D beselected For the suggestion to work correctly the Petrol Times map must already be present The most important sensors are also displayed in this window The Calibration constant shows the value obtained during the calibration phase to which the map re
5. H Ore 59 LOVATO E PDE D DGM 59534 GPL E LETO fA LA ma LE i CORNETTORE h TADS 2 ELETTROINIETTORI a ALIMENTAZIONE SCHALE GRI EAE m BF mu e 60 FSD D LOVATO DGM 59534 GPL Componenti del sistema di alimentazione a GPL tipo STIL SLAVE Variante B Riduttore LOVATO STIL RED E13 67R00 67R01 0195 02 LOVATO SECU El3 67R00 67RD1 0249 00 E13 72 245 95 54 2094 X LOVATO SEMU EI13 67RO00 67RD1 0250 Q0 El13 72 245 93 354 2098 00 MATRIX E13 67R00 67RQ01 0167 03 E13 10R00 10R02 1763 00 E13 67R00 67R01 0181 01 E13 67R00 67R01 0145 01 Gruppo di elettroiniazione Matrix satora Centralina elettronica Sensore temperatura pressione Filtro GPL C LOVATO EU DGM 59534 GPL E 3 o Capacit di a di circa S kgrora di GPL merciale 70 butano 30 propano con una circola zione di circa 8 litrimin di acqua a BO Dimensione di ingombro 130x886 62 FERES LOVATO w a 63 D LOVATO n a ci DGM 59534 GPL CENTRALINA ELETTRONICA LOVATO TIPO SECU JE J oc
6. ai 4 gt _ _ p STACCA INIETTORI TWY ALULWCADCHE pr NNT sil SONORA LATA SE T BIG sistema STIL SLAVE pu essere montato su velcoli che rispondano alla direttiva 2002 B0 CE fase 2001 100 fase A B 2001 1 CE fase 1999 102 fase 98 69 fase A B 96 69 CE 96 44 CE 94 12 CE con motore aspirato ad iniezione compreso nella fascia di cilin drata 900 2250 Senza limitazione di cilindrata pu essere montato su veicoli che rispondano alla direttiva 93 59 91 441 CEE e precedenti 64
7. reducer to the car the reducer to the lt Eg body work car body work ld H Reducer Vaporiser Hoses for heating the reducer vaporiser Mount the reducer vertically see paragraph 4 2 so that the pressure adjustment screw is easy to reach and the LPG outlet connector the MAP nozzle the overpressure valve and the water pipes are roughly directed towards the relative components Take care to prevent it from touching mov ing or hot parts Make pneumatic connections from the reducer to the injector assembly from the overpressure valve to the nozzle upline from the butterfly valve and from the upper cover of the 17 1 gt h cal LOVATO reducer to the MAP tap downline from the butterfly valve Connecting the reducer to the cooling circuit of the car T shaped water union 2 Hose clamp 16 27 Install the reducer heating circuit as shown below taking care to reduce the loss of liquid coolant to a minimum 1 cut the two engine coolant hoses at the bulkhead between the engine compartment and the interior and insert the two T shaped unions 1 attach the hoses for heating the reducer to the other ends of the unions attach the hoses to the relative pipes on the reducer tighten the entire hydraulic circuit installed with the hose clamps D 16 27 2 vent the cooling system 20 gt 5 Connecting the reducer to the injector assembly Gas hose E67 R01 12x19 Gas Tempera
8. veicoli catalirzat rispondenti alle direttive JI MM ACE 93 35 94 12 965 44 CE 96 69 CE 98 69 CE fase 1994102 CE 200L L CE 2001 17 Omologa dal Ministero delle Indrestrumure dei Trasporti ee DGM 59534 GPL del 10 marzo 2004 ANNO Componenti del sistema di alimentazione a GPL tipo STIL SLAVE Variante A Riduttore Centralina Emulatore inbettori 54 Gruppo di elettroiniezione LOVATO STIL f 5 AE Tubazione GPL LOVATO STIL RED pepe E13 67R00 67R01 0195 02 LOVATO Hi E13 67R00 67R01 0249 gi EI3 72 245 05 54 2094 00 LOVATO SE ET MEE EI3 67RD0 67RO1 0250 VSS E13 72 245 95 54 2098 00 Ha fer E13 67R00 67R01 0194 01 EI3 67R00 67R01 0145 01 p T n de 57 A LOVATO lt TES ZZ TE A W ues idi T CARATTERISTICHE COSTRUTTIVE RIDUTTORE STIL RED Uno stadio di riduzione a membrana e molla T Capacit di erogazione di circa 30kg ora di GPL com merciale 7096 butane 30 propane con una circola Camera di vaporizzazicne zione di circa 6 lirimin di acqua 60 C Riscaldamento del vaporizzatore con circolazione Dimensione di ingombro 130x884 forzata di liquide di raffreddamento del motore Massa 1 1 kg circa 58 kam LOVATO DGM 59534 GPL val ipa VICENZA
9. Avoid any contact between metallic parts and nozzles Put back carefully and in order the external seal the lamina and the linea o ring Put back the flaps according to Original sequence with the racking area turned up Be sure that all the flaps have been correctly placed into corresponding seats O LOVATO Put back in position the magnetic gap on the two referring stakes located on the flaps support avoiding to bend deform the component Lean the rail on the flaps support making reference to the lateral stakes Fig 16 Keep in close contact the rail with the flaps support and overturn at 180 mp i e ra T Tighten the flaps support on the rail with the two short screws without forcing The two screws haven t a rigid seal function LOVATO Fig 19 52 FAST Be sure that the surfaces of the rail and the flaps support are perfectly in contact On the contrary the flaps or the seal aren t correctly positioned Put back in position the seal o ring on the flaps support and check that in the referring seats there are foreing matters Put back the front flange ensuring that the seals position corresponds axially to the nozzles on the flaps support Fasten the complete rail with the 4 screws giving a tightening torque of 12 Kg cm Note before setting up the the rail and failing of adequate equipment connect the seal of compressed air inlet at 4 6 bar
10. Direzione Generale della Motorizzazione e della Sicurezza del Tra sporto Terrestre CERTIFICATO DI OMOLOGAZIONE N DGM 59534 GPL Visto il Codice della Strada emanato con Decreto Legislativo 30 aprile 1992 n 285 Visto il Decreto Legislativo 10 settembre 1993 360 art 128 comma 1 lettera c Visto il Regolamento di esecuzione e di attuazione del Codice della Strada emanato con Decreto del Presidente della Repubblica 16 dicembre 1932 n 495 art 407 Visto il Decreto del Ministro dei Trasporti e della Navigazione n 277 in data 2 maggio 2001 recante norme sulle procedure amministrative di omologazione Viste le domande presentate dalla Officine LOVATO S p A Vicenza in data 06 11 2003 successiva in data 10 12 2003 intese ad ottenere l omologazione del Complessivo di trasformazione G P L ai sensi della circolare U di G MOT n B54 del 27 07 2000 rispondente alle Direttive 1999 102 CE 2001 1 CE 2DOMADO CE 2002 80 CE Fase B tipo STIL SLAVE Fascia di cilindrata 900 2250 em Vista la documentazione allegata Visto il verbale n 1006 1 03 RM in data 17 02 2004 redatto dal C S R P A D di ROMA SI DICHIARA OMOLOGATO Il Complessivo di trasformazione a G P L ai sensi della circolare U di G MOT n B54 del 27 07 2000 rispondente alle Direttive 8B 68 CE 1999 102 2001H CE 2001 TOO CE 2002 B0 CE Fase B tipo STIL SLAVE Fascia di cilindrata 900 2250 marchio di fabbrica LOVATO Gli
11. fuel supply is sequenced and phased by the lock off valves con trolled by the electronic control unit FAST 4 LOVATO LPG filter This device is installed upline from the injector assembly and pro tects it from the impurities in the LPG FAST service bag The service bag contains the nozzles to install on the inlet manifold next to the combustion chamber fuse holders with relative fuses screws supports and the hardware required to install the KIT In particular the aluminium or galvanized steel supports can easily be cut and or bent to size in order to properly secure the reducer and injector assembly to the car Rubber hosing There are four types of rubber hosing in the Kit water circuit hosing for heating the reducer vaporizer with the fluid in the engine cooling circuit only air hosing connects the pressure tap downline from the butterfly valve y to the MAP sensor and the reducer vaporizer It also connects the overpres sure valve of the reducer to the air filter of the engine intake system the various sizes of LPG E67R1 hoses are class 2 approved ac cording to European Regulations E67 R01 and connect the re ducer to the injector assembly and the lock off valve outputs to the corresponding ducts on the inlet manifold coil of copper piping for compressed air connections between the valve of the tank and the LPG lock off valve in the engine compartment and between the lo
12. Approved E67 R01 4x10 hose for connecting the nozzles of the injector assembly to the nozzles fixed to the inlet manifold 010 3 12 3 hose clamps for securing the hosing to the nozzles Select the nozzles to install on the injector assembly according to the power of the car There are two sizes of nozzle 2 4 for cars with power outputs equal to or less than 65kW 2 7 for cars with power outputs from 65 to 85 kW To install the Injector Assembly proceed as follows 1 Fix the nozzles 2 chosen according to the kind of car being converted to the Injector assembly 1 2 Bend and shape the supports 3 as required 3 Fix the supports 3 to the engine 4 Fix the Injector Assembly 1 to the supports 3 with the washers 4 the two M5 screws 5 and the nuts 6 if required 5 Make sure that the Injector Assembly 1 with the wiring harness mounted does not prevent the bonnet from being closed 6 Cut one of the lengths of hose G to size in order to connect one of the lateral nozzles on the manifold to the corresponding outlet on the injector assembly 1 The hose must be cut so that the connection is as short as possible and to avoid sharp bends 13 T O LOVATO Fi D 7 the other lengths of hose 7 to the same length 8 Attach the four cut lengths of hose 7 to the nozzles on the ducts of the inlet manifold and to the outlets of the injector assembly 1 using the supplied clamps 8 and secure them with
13. Multipliers Map Press Apply ECU to transfer the 8X10 Map to the control unit 9 10 Diagnostics in Diagnostic managment Values Diagnostic counter Gen DP Timer Petrol Runnig Pmap Gas Running Oh he Reducer Gas InJectors Error Petrol Injectors Error INJGASA 0 0 INJ GAS B INJ B ECU Software INJGASC 0 110 INJGASD 0 INJGASE INJGASF 0 INJGASG INJGASH 0 After clicking on Diagnostics you are asked whether to load the data from the control unit or view those already present in the memory of the PC The counters relative to internal system diagnostics are displayed Values displayed Gen 1 if a fault is found Timer gas and petrol operating time counters in hours DP signals when reducer pressure Is too low and for too long com pared with the pressure measured during calibration This hap pens when the gas runs out and the car is automatically switched to petrol Pmap this is the MAP sensor fault counter 43 FAST O LOVATO Trail gas temperature sensor fault counter Trid reducer temperature sensor fault counter Prail gas pressure sensor fault counter Gas injector problems series of fault counters on each gas injector Petrol injector problems series of fault counters on each petrol injector Control unit software shows the version of the software installed in the FAST electronic control unit
14. Press Reset Diagnostics to reset the counters apart from the Timers 9 10 1 Diagnostics flag window Diagnostic Flags _ Fetral Injectors Diagnostic Gas Injectors Diagnostic Check Enabling Injector Injector B Injector Injector Injector E Injector Injector B Injector Injector Injector E Enabl Petrol Inj Enabl Gas Inj Enabl Delta P Enabl T reducer Enabl T rail Injector F Injector F Enabl P map Injector G Injector H Injector G Enabl F rail Cold Reducer Injector H Enabl Cold Reducer 10 pae ad Relay Close The red LED s signal faults on injectors and sensors in real time LED ON means that fault is present Use the selection boxes in the Enable controls section to enable or disable individual controls When the car is stopped the faults are reset but the relative counters are memorised cf Diag nostics on previous page The LED s can also be commanded with the Reset flags button It is also possible to set the threshold under which the reducer cold diagnostic trips with conse quent switching to petrol Sensor Diagnostic o DE o Trail o Frail Tred o Cold 9 11 Logger Signal Plotting Show Points Log File 7 ime iv Tpetrol Prail Date Time Pmap e Tgas ef Rpm Trail Add Overwrite gt Lambda LogSensori bd Leaf __ Startt
15. and carefully verify that no leaks can be perceptable both from the body of rail and the outlet seals kz D G LOVATO Annex 2 Routine maintenance Similarly to any other vehicle parts maintenance of Lovato equipment is vital for guaranteeing system efficiency and safety Use of the maintenance vouchers extends the lifetime of all the equipment thereby helping to reduce operating costs Inspection vouchers Inspections are programmed every 15 000 km and allow the system to be kept in perfect working order These vouchers do not replace the maintenance vouchers issued by car makers of course which must be performed at the established intervals In this regard the gas delivery system should be controlled immediately after maintenance operations required by the car makers in order to prevent the repetition of certain operations 53 UOIEINQUEI o4juoo eunsseJd weds pue uoipub 183 eansseJd OND Jo eunsseJd 94110 JO AeA JJO 420 sjoxsebD jo uonoedsulr wa sAs eJeuac FRASI 4 LOVATO Annex EU RADAN SS IE TECA DELLO E 3 L 18 10 77 an DIPARTIMENTO PER I TRASPORTI TERRESTRI E PER SISTEMI INFORMATIVI E STATISTICI
16. be connected to the electronic control unit these components must all be in stalled near to each other the high pressure LPG is supplied from underneath the gaseous LPG outlet at injection pressure must point towards the FAST injector assemblies at a fairly close distance the reducer must be fed with engine cooling fluid through the relative adjustable pipes the overpressure valve must be connected to the engine intake circuit the reducer must be positioned so that it can be easily accessed from above after assembly it must also be easy to reach the adjustment screw located on the top of the cover and read its serial number during its MOT test after making all compressed air hydraulic and electrical connections the reducer must not touch or lie dangerously close to moving or hot parts of the car 10 9 LOVATO Top Pressure adjustment screw T Union connecting the Overpressure valve reducer to the engine Fo O l cooling circuit 7 II i Gaseous LPG outlet LT Bottom Temperature sensor 4 3 Locating the installation area for the LPG Lock off valve After deciding on the assembly area for the reducer locate the position for mounting the on off lock off valve on the high pressure LPG line place the valve as close as possible to the reducer but far away from accident impact zones Mount the lock off valve vertically with the coil at the top 44 Mounting the nozzles Mount th
17. connect the lock off valve to the reducer fixing it to the lock off valve and then to the reducer with the double cone and the relative galvanised connector Screw for fixing the LPG lock off valve to the car bodywork ge gt Gas outlet union LPG lock off valve a n e Gas inlet connector 15 4 7 Installing the FAST reducer vaporiser Reducer Reducer fixing stud bolts Reducer fixing spacers Reducer fixing bracket Wide M6 washers Hex nut MG Screw M10 x 20 Hex nut M10 Double cone 8 9 9 Galvanised connector M10x1 To fix the reducer proceed as follows Mount the two studs 2 in the relative holes on the reducer body 1 and fix them with an M3 Allen key Insert the brass bushes 3 into the studs with the widest part lying on the reducer body 1 Bend the steel bracket 4 to size and insert the shorter slot into the two studs 2 16 i 4 LOVATO Position the wide M6 washers 5 Fix the bracket to the reducer using the M6 nuts 6 Before fixing the reducer bracket assembly to the car connect the gas inlet tube from the lock off valve using the double cone 9 and M10 connector 10 Fit the reducer bracket assembly to the bodywork of the car in the chosen position using the M10x20 screw 7 and the M10 hex nut 8 see figure 11 Suitably shaped _ Bolt for fixing the bracket for fixing
18. injector assembly 1 FAST injector assembly 1LPG filter 1 FAST service bag 1 length of 15x23 rubber water hosing 2 lengths of 5x10 5 rubber only air hosing 1 length of 12x19 EG7R1 rubber hosing 2 lengths of 4x10 E67R1 rubber hosing 1 coil of 4x6 copper piping FAST electronic control unit EMU FAST injector cutter control unit for emulating the petrol injection signal gas Temperature and Pressure sensor FAST wiring harness EMU FAST emulator wiring harness microswitch acoustic signal use and maintenance manual I I n 3 2 Description of parts LPG lock off valve This electromagnetic device interrupts the flow of LPG when the en gine is stopped or when the fuel supply is switched to the petrol mode Reducer vaporizer The reducer vaporizer provides the heat required to vaporize the liquid LPG from the tank and reduces and adjusts the pressure of the LPG in its gaseous phase according to the pressure in the engine Intake system downline from the butterfly valve MAP short for Mani fold Absolute Pressure This component is fitted with a temperature sensor for the petrol LPG switching procedure an overpressure valve and an adjustment screw for modifying the gas reduction pres sure FAST injector assembly This component delivers the quantity of gaseous LPG determined for each cycle by the electronic control unit to each cylinder The
19. supply Dedicated Bosch and Japan wiring har nesses are available Switch This electronic device allows the driver to switch the fuel supply from pet rol to gas and vice versa and to view the operating status and gas level in the tank Buzzer This device is directly controlled by the FAST control unit It sounds when switching from petrol to LPG when the LPG level in the tank reaches reserve and when automatically switching to petrol if the LPG runs out For further information on the buzzer please consult chapter 8 0 User information and the use and maintenance manual F O LOVATO 4 0 Installation sequence The sequence of operations for installing the system is shown below 1 Installing the tank multivalve and high pressure line to the engine compartment Consult the specific manual for each product 2 Locating the installation area for the FAST Injector Assembly 3 Locating the installation area for the FAST Reducer Vaporiser Assembly 4 Locating the installation area for the LPG lock off valve 5 Installing the nozzles 6 Installing the FAST Injector Assembly 7 Installing the LPG lock off valve 8 Installing the FAST Reducer Vaporiser 9 Installing the FAST control unit 10 Installing the EMU FAST control unit 11 Installing the switch and buzzer 12 Electrical connections 13 Connection between PC and control unit 14 Checking and configuring sensors 15 Calibration 16 Diagnostics 17 Road test Before st
20. the relative tool LPG hose from reducer supporting the in jector assembly Bolt and suitably 1 E shaped bracket L Injector assembly E67 RO1 hosing for connecting the nozzles mounted on the inlet manifold to the nozzles on the injector assem bly 4 6 Installing the LPG lock off valve TTTTTTTTY er LPG lock off valve 2 4 8x16 self tapping screws for fixing the LPG lock off valve to the chassis or bodywork of the Car 3 Ferrule 6 4 M10x1 galvanised connector 5 4x6 copper pipe 6 Z 8 car hose clamp 7 3 9x9 5 self tapping screw 14 E O LOVATO Fit the LPG lock off valve 1 before installing the reducer to do this use the bracket built into the valve and the two self tapping screws 2 Connect the multivalve mounted on the tank to the LPG lock off valve 1 with a suitable length of copper piping 5 Fix the pipe to the multivalve with the double cone 3 and the galvanised connector 4 supplied with the multivalve Fix the pipe to the bottom of the car in as protected a position as possible from heat sources and or accidental impact as this may cause it to deteriorate or break using the car hose clamp 6 and the self tapping screws 7 until it reaches the engine compartment Fix the pipe to the gas inlet of the LPG lock off valve using the double cone 3 and the galvanised connector 4 Also prepare a section of copper piping that will
21. to the petrol mode simply press the switching button the green gas LED turns off and the red petrol LED turns on Emergency operation In case of emergency the engine can be started in the gas mode as shown below press the switching button with the engine off turn the key and release the button after 3 seconds The switch will show the RED LED on and the GREEN LED flashing Now you can start the engine Automatic switching to petrol The system automatically switches from the LPG mode to the petrol mode when the amount of LPG inside the tank is no longer able to maintain the pressure required to power the car correctly When the car is switched to petrol due to the lack of LPG the buzzer emits long repeated sounds which only stop after pressing the switching button Switching to LPG will only be permitted again after filling up the tank Car safety condition The car safety condition occurs when the number of revs measured by the electronic gas control unit falls under a set safety threshold In this condition all the gas delivery valves are closed and the car reverts to the petrol mode This feature is required by current legislation in order to keep the system safe in case of an accident The car safety condition can also occur for example when the engine stalls or breaks down The gas and petrol LED s both flash and the level LED s turn off To reset the system simply restart the engine In the event of a faul
22. LOVATO ignition circuit mount the control unit in an area where the temperature is not normally very high do not position it near the engine exhaust manifold do not fix it to the engine assembly even though the control unit is airtight do not fix it in a position where it can be directly sprayed by water to ensure the MAP tap connection is not too long install the FAST control unit as near as possible to the reducer and butterfly valve body Generally speaking it should be positioned near the engine battery Electronic control unit bracket Electronic control unit 4 9 Installing the EMU FAST electronic control unit 1 EMU FAST control unit 2 4 8x16 self tapping screw for fixing the EMU FAST con trol unit to the chassis or bodywork of the car Position the control unit 1 in the chosen point and fix it with the self tapping screw 2 supplied with the kit Position the control unit in the engine compartment taking care to respect the following require ments mount the control unit as far away as possible from the spark plug wires and the high voltage ignition circuit mount the control unit in an area where the temperature is not normally very high do not position it near the engine exhaust manifold do not fix it to the engine assembly donot fix it in a position where it can be directly sprayed by water 21 LOVATO Generally speaking it should be positioned near the engine battery
23. N 277777777777777777777777777777777777777777777777777 w 80915 NdH ug MOV1d ONAN K quuesse oddnJc 61815 105095 UDSIXO epquie epuos o pusog 3lIHAJ LE aJOUNPIY 9A EA Dd 1 Josues uolss id pue eunjejeduje 149 4 euoissaJd e eJosueg cq 5 o 277777777777777777777777777777777777777777777777777777777777777777777777777 o 7 0 3 4 X gt N3390 AGHI N3389 3QHHA Lm lel 3NOHHVIN MOV1d OMAN 3018 484 05504 I 0 OMG 2 Was AO MA LSV4 OLNVIdWI OOIHSN3O VIN3HOS B 103joefu yun 5 gt dr E l 5 Ip me wu Odi 210 OIN d 70 Z0 SZ UOISIAGI 158 J 00 oss 90012910 Bnjd sisouBbelp 6 0 W 25 9 LOVATO 7 0 Pneumatic diagram SCHEMA PNEUMATICO IMPIANTO FAST 1 revision last revision date file name 25 02 04 F j Pag
24. amming the FAST control unit page 31 9 5 Data management in the FASTCOM programme page 32 9 6 Explanation of the drop down menus in the FASTCOM programme page 33 9 7 Sensor and COMMON ees E page 36 EE i i gii EET page 37 22 RES mm page 38 9 9 1 Advanced calibration page 42 9 10 HVAC IO SUG S e e page 43 9 10 1 Diagnostics flag window 4 page 44 Sil s E 44 92 WAS page 45 9 12 1 Map management Multipliers directory eese page 45 9 12 2 Map management Petrol times directory page 46 lt 1 6 0 i it page 46 I d rc A page 47 ANDOK CARRO page 53 ANNI lc page 55 PT Cal gt LOVATO 1 0 General recommendations Before installing the gas system disconnect the battery earth cable unless specified to the contrary by the car maker Attention this may delete the car radio and telephone memories and jam the centralised door locking and anti theft systems In this case you may connect the battery temporarily Always smooth holes after drilling and apply
25. anti rust to the edges Apply silicon to each cable through hole to prevent water from entering the interior Always soft solder connections without connectors to prevent the formation of false con tacts Always observe the current laws and or regulations in the State where the LPG system is mounted Remember that as per the relative standards all the assembly instructions refer to the driving position Before assembling the FAST control unit make sure the relative fuses are disconnected Do not wash the engine after installation ATTENTION FAILURE TO OBSERVE THE INSTRUCTIONS CONTAINED IN THIS MANUAL MAY CAUSE THE FAST SYSTEM TO WORK INCORRECTLY OR NOT WORKAT ALL THIS MAY CAUSE DAMAGE TO LOVATO COMPONENTS AND INVALIDATE THE WARRANTY FAST G LOVATO 2 0 FAST gas injection system features 2 1 System description The system comprises Tank Multivalve Safety lock off valve Reducer vaporiser Injector assembly Electronic control unit Compressed air connections Gas temperature and pressure sensor Wiring harnesses Smart injector cutter control unit Switch Buzzer 2 2 Operating principle The liquid LPG 15 stored in equilibrium with the vapour phase in a tank fitted with a multivalve Storage pressure depends on the composition and temperature of the fuel The LPG 15 collected in its liquid phase and delivered to the reducer vaporiser along the pressurised p
26. arting to mount the components locate the areas where the FAST devices can be in stalled inside the engine compartment according to the following instructions 41 Locating the installation area for the FAST Injector Assembly Secure the FAST injector assembly to the car using the two steel supports supplied in the kit Locate fixing points for the supports bearing in mind that the injector assembly must be positioned as near as possible to the ducts on the engine inlet manifold in order to minimise the length of the connecting hoses the hoses connecting the outlet nozzles of the assembly to the nozzles mounted on the mani fold ducts must all have the same length and have no sharp bends ATTENTION THERE ARE NO CONSTRAINTS TO THE INSTALLATION POSITION OF THE INJECTOR ASSEMBLY WE RECOMMEND INSTALLING THE ASSEMBLY WITH THE NOZZLES POINT ING DOWNWARDS IN ORDER TO PREVENT POSSIBLE DEPOSITS OF OIL AND DIRT THAT MAY COMPROMISE LONG TERM SYSTEM PERFORMANCE G LOVATO D 4 2 Locating the installation area for the FAST Reducer Vaporiser Fix the FAST reducer vaporiser to the car with the relative steel support making sure to observe the following requirements the reducer must be mounted in the position indicated in figure 2 the hose connecting the MAP tap on the reducer cover to the pressure tap on the inlet fold downline from the butterfly valve must be as short as possible Considering that MAP tap must also
27. bility between the versions of the serial connection and the SW on the control unit is also checked In the event of any discrepancies an error message is displayed Possibili problemi di compatibilita ECU ver 11 1 Attenzione La centralina collegata non ha una versione pienamente compatibile con FASTCOM 10 0 A communication symbol is located on the status bar to the left of the main window A red cross over the symbol means that communication is inactive 9 4 Programming the FAST control unit If your FAST control unit has a different programme from the one loaded in the computer update the software in the FAST control unit as shown below Select the BootLoader command from the Tools menu The window shown in figure 24 appears s FastCom ER File visualize Data Tools Settings Window Sensors Corrector Diagnostic Logger Diagnostic Calibration Open Save Exit Calibration Advanced Calibration The programme will show a connection with control unit failed message Remove the fuses and 31 O LOVATO IU put them back again After restoring power reactivate the buttons on the Coded BootLoader Software for Control Unit window that were deactivated see figure 24 Click on Select File cpt to open the window shown in figure 25 ECU firmware selection Documenti recenti Desktop Documenti Risorse del computer e Risorse direte Nome file Fastinjection CryptV2 0 ad file Pr
28. ck off valve and the reducer Electronic control unit This microprocessor controlled electronic system processes the sig nals from the sensors in real time and calculates optimum gaseous LPG injection times on the basis of the operating conditions of the engine It is fitted with a hose connecter for reading the absolute pressure signal of the inlet manifold M A P EMU FAST injector cutter control unit This control unit prevents the petrol injection system from working while the engine is running in the gas mode The control unit also checks the polarity of the petrol injector and selects the negative injector sending the signal to the control unit for processing 7 LOVATO Gas Temperature Pressure Sensor Reads gas pressure and temperature in real time near the injector as sembly The control unit uses this information to calculate gas density and corrects the opening time of the injectors FAST wiring harness The universal wiring harness supplied with the FAST Kit connects the electronic LPG sensor to the sensors required to determine the operating conditions of the engine and the FAST system compo nents In particular it connects the electronic control unit to the EMU FAST injector emulator control unit EMU FAST emulator wiring harness This wiring harness connects the EMU FAST control unit to each petrol injector in order to interrupt petrol operation and transmit the injection signal for correct engine
29. e nozzles by dismounting the inlet manifold and the air filter box of the car This will allow you to make sure the manifold is perfectly clean Gas injector nozzles 6 pieces in service bag To install the nozzles proceed as follows 1 drilla 4 7 mm hole in each of the four ducts of the inlet manifold taking care to centre the hole in the width of the manifold and as near as possible to the engine intake valve 2 drill a 4 7 mm hole in the stretch of the inlet manifold just downline from the butterfly valve in the point previously located for the pressure tap on the manifold 11 LOVATO 3 drill a 4 7 mm hole in the air filter box or if the car is fitted with hot wire air flow meter immediately downline from it 4 thread each hole with a male M6 tapper 5 fit the six nozzles into the relative holes after applying a drop of thread retainer Loctite 638 to each thread M A P signal delivery nozzle A L a a L kam LPG injection nozzles 6 clean the inside of the inlet manifold before remounting it 12 A LOVATO 4 5 Mounting the FAST injector assembly Injector assembly Nozzles for injector assembly these must be sized according to the capacity of the car being converted Injector assembly supports 6 washer M5 x 25 screws for fixing the supports to the injector assembly Nuts for creating a gap between the injector assembly and the support 000060 OO
30. esemplari pradotti dovranno essere canformi al tipo omologato le cui caratteristiche sono riportate nel prospetto mod DGM 405 munito del timbro a secco del Dipartimento dei Trasporti Terrestri che costituisce parte integrante del presente certificato Ciascun esemplare dovr portare impresso il marchio di fabbrica LOVATO e la dicitura DGM 59534 GPL 1 10 marzo 2004 VO 04 STIL SLAVE GEL 55 C LOVATO mut ee d MOD 99109 DIPARTIMENTO PER TRASPORTI TERRESTRI na GT E PER 1 SISTEM INFORMATIVI E STATESTICI 0 MB R 2004 Direzione Generale della Motorizzazione e della Sicurezza del Trasporto Terrestre MOT 2 Prot r 88B MOTZ2 P 213 All amp eyat vari Alla Officne LOVATO 5 Strada Casale 175 38100 Vicenza Aj d ROMA Rit n 8508 7265 03 in data 18 62 2004 Oggetto Dilta Officine LOVATO S p A Vicenza Omologazione complessivo di trasformarione a GPL ai sensi della circolare Lidl G B54 del 27 07 2000 rispondente alle Direttive 1889 102 2001 1 2001 100 2002 BONCE Fase B Fascia di cilindrata 900 2250 cm Per il complessiva in oggetto si dato corso al seguente provvedimento di omologazione STIL SLAVE VC 0O4 ETTL SLAVE 5FL 56 Officine Lovato S p A Strada Casale 175 36100 Vicenza LOVATO ___ DGM 59534 GPL _ SISTEMA GPL STIL SLAVE
31. f LOVATO Installation manual Ys 7e Q9 ag E roe LOVATO Index 12 General recommendations irritati page 4 2 0 FAST gas injection system features page 5 2 1 System descripto E 5 2 2 Operating principle 5 2 Precautions Tor MOTS u uuu uuu ete ae page 5 3 0 FAST system components u page 6 3 1 FAST kit components page 6 3 2 Description of 6 4 0 Installation sequence as page 9 4 1 Locating the installation area for the FAST injector assembly page 9 4 2 Locating the installation area for the FAST reducer vaporizer page 10 4 3 Locating the installation area for the LPG Lock off valve page 11 4 4 Mounting the nozzles 8 page 11 4 5 Mounting the FAST injector assembly page 13 4 6 Installing the LPG lock off page 14 4 7 Installing the FAST reducer vaporizer
32. fers Change its value by setting a variation percentage and pressing Enter All map values are modified by the set percentage 9 12 2 Map management Petrol times directory 3 Calibration managment Multiplier Calibration Constant Modifica mappa K Start Stop cursor 2 64 New value K Tar alJ 2 Insert Row 2 Col 2 8222 R2C2 Access the Petrol times directory from the maps management window To modify a cell or group of cells 1 block the cursor by clicking on start stop cursor 2 select the cell or group of cells by dragging the mouse 3 enter the new value and press new value Use the enter command to work on an individual cell during operation and capture the displayed petrol time 9 13 Vectors 5 Correction Vectors managment RPM Vector Value must be in growing order Ce Ca Nc CE CB cy C10 R1 455 59 1414 2069 2724 3373 4034 4689 5344 000 New Value vector value must be in growing order my Ce 59 4 CE n RI 18 30 41 5e 63 4 85 100 New Value Read vectors After clicking on Vectors you are asked whether to load the data from the control unit or view those already present in the memory of the PC Ranges RPM and MAP are displayed The RPM and MAP vectors establish the reference points of the multipliers map These values are also shown in the first row and the first column of the maps window respectively To modi
33. fy one or more cells 1 Select the cell or group of cells by dragging the mouse 2 enter the new value and press new value 46 D G LOVATO Annex 1 MAINTENANCE OF INJECTORS XJ5XX The injectors rail is a high precision device that in normal operating conditions needs no maintenance Particular conditions of use non complying fuel exhaust or non fitted filter may require the disassembly and cleaning of the rail to be done with care by skilled technicians It is particularly recommended to ensure the most careful cleaning of the workbench Foreign matters even of small dimensions accidentally introduced inside the rail can generate functional defects The use of solvents or chemical products to clean the internal or external parts of the rail is expressly vorbidden Tools setscrew wrench 2 5 setscrew wrench 5 Allen wrench 13 small dimensioned tweezers or screwdriver Cleaning material blotting paper or equivalent little brush Equipment pneumatic system Remove the front flange acting on the 4 screws by the setscrew wrench 2 5 Clean this part particularly on the inlet side and control that the seals aren t occluded Remove the 4 sealing o rings placed on the flaps support by means of the Fig 1 tweezers Remove the two locking screws of the flaps support by means of the setscrew wrench 2 5 keeping the support in position on the rail Fig 2 47 4 LOVATO FARASI Overtur
34. gt ra S f 4 N LI y 7722 4 Y 44 i3 Pi 2 Corpo farfallato Pood Throttle body P 224 7 0 7 RSs QU 9 ENI E SS ET Riduttore 2 51 Reducer mr me RSs 5 Lidi AN EVI o Per vetture con sistema a filo caldo SS ONS 0 PH PCV LV 9 Uscit In Dispositivo misurazione portata aria C m 2 C 42 i o Air mass metering device 8 5 7 3 9 Attacco carica 9 d Fill in plug S a Filtro ari Elettrovalvola GPL gt d LPG lock off valve Air filter 2 o Z i E Ce O 2 Multivalvola n 7 2 O gt 7 77 7 7 Multivalve N N Per vetture con sistemi diversi dal filo caldo E Z i a gt lt gt A gt gt 6 O lt gt u 3 I I I I IN c N Z Tubo rame 6 x 8 4 Tubo gomma 5 x 10 5 Codice 135035 6 x 8 copper pipe 5 x 10 5 rubber pipe Part number 135035 Tubo rame 4 x 6 Codice 434004 s Tubo gomma 15 x 23 Codice 135036 4 x 6 copper pipe Part number 434004 15 x 23 rubber pipe Part number 135036 Tubo gomma 4 x 10 Codice 135031 IIR Tubo gomma 12 x 19 Codice 135130 4 x 10 rubber pipe Part number 135031 12 x 19 rubber pipe Part number 135130 26 ros LOVATO 8 0 User informa
35. he reducer and the FAST control unit and then attach the free end to the Y union 3 connect two lengths of only air hose and fix them with two hose clamps to the free ends of 19 4 LOVATO a the union Taking care to keep them as short as possible connect one to the M A P tap on the FAST control unit and the other to the reducer pressure delivery nozzle M A P signal JA a ae M A P signal delivery nozzle on E W CAT B delivery nozzle on inlet manifold and I a 23 Y union ri u ES M A P signal delivery nozzle on control unit 4 8 Installing the Electronic control unit Bracket for fixing the electronic control unit Electronic control unit M6 x 30 screw for fixing the bracket to the control unit M6 washer M6 nut 4 8x16 self tapping screws for fixing the control unit supports to the chassis or bodywork of the car 9 5 2 0 2 C2 Cut two pieces from the fixing bracket 1 and shape them so as to be able to fix the control unit 2 in the required position Fix the two brackets to the control unit using the screws 3 washers 4 and nuts 5 Fit the control unit to the bodywork of the car using the self tapping screws 6 Position the electronic control unit in the engine compartment Make sure to respect the following requirements mount the control unit as far away as possible from the spark plug wires and the high voltage 20 ff O
36. hift from the petrol mode to the LPG mode with two short sounds Subsequent switching If the car was turned off in the petrol mode when the dashboard is turned on the switch shows the amount of gas in the tank the gas LED is off and the petrol LED is on When the engine is turned on the switch remains unchanged and the car works on petrol To switch to gas press the switching button the green gas mode LED flashes the car still works on petrol and the FAST system waits to be enabled by the FAST electronic control unit to switch to gas As soon as it receives the enable switching takes place the green gas mode LED turns on and the petrol mode LED turns off The buzzer sounds If the car was turned off in the gas mode when the dashboard is turned on the switch shows the amount of gas in the tank the gas LED is off as is the petrol LED When the engine is turned on the green gas mode LED flashes the car works on petrol and the FAST system waits to be enabled by the FAST electronic control unit to switch to gas As soon as it re ceives the enable switching takes place the green gas mode LED turns on and the petrol mode LED turns off 27 LOVATO The engine therefore is normally turned on in the petrol mode in order to keep the petrol injection system efficient the system automatically switches to the gas mode when the engine reaches the set temperature Switching from LPG to petrol Switch
37. iping to which the LPG lock off valve is fitted The reducer vaporiser is heated by the engine cooling water vaporises the fuel and adjusts its pressure Known as injection pressure to a value that is propor tional to the pressure in the inlet manifold downline from the engine butterfly valve M A P The gaseous LPG then reaches the injector assembly controlled by the electronic control unit The LPG is batched by the injection time and phasing signal This is determined by the electronic control unit according to the signals from the engine and petrol supply system 2 3 Precautions for fitters The vehicle must be fitted with a four 4 cylinder engine with a capacity ranging between 900 and 2 250 cm and a maximum power of 85kW ATTENTION MAKE SURE THE ELECTRONIC PETROL INJECTION MANAGEMENT SYSTEM ESPE CIALLY THE LAMBDA PROBE IS IN PERFECT WORKING ORDER ANY IRREGULARITIES OR FAULTS MAY BE TRANSFERRED TO THE GAS INJECTION SYSTEM AND CAUSE IT TO WORK INCORRECTLY Check the general condition of the car Check the signals required for conversion especially the Lambda probe Follow the instructions in this manual with care LOVATO 3 0 FAST system components 3 1 FAST kit components The LPG 4 cylinder FAST Kit comprises the following components 112 Volt E67R1 LPG lock off valve 1 FAST reducer complete with guarantee certificate 1 galvanized reducer support 2 aluminium brackets for control unit and
38. jectors belong to The same 37 4 LOVATO EREET number on more than one injector indicates that these injectors belong to the same assem bly For example injectors A B C D marked 1 2 3 4 describe a phased 4 cylinder injection system 1 1 1 1 instead describes 4 cylinder full group injection as all the injectors belong to assembly 1 Values displayed modifiable RPM threshold this is the threshold over which switching may take place if the other condi tions temperature of reducer change delay RPM lt 4 000 and MAP pressure lt 60KPa are satisfied Change delay this is the minimum delay in sec between starting the engine and switch ing Trid threshold this is the temperature threshold for switching Change type this is the window for selecting the type of switching sensor type this is the window for selecting the type of Sensor for indicating residue gas RPM factor this is the window for selecting the type of RPM input Injector type chooses between Lovato and Matrix injector piloting Compar threshold sets the parameter for reading the RPM input stage depending on whether the input signal is low 0 5V or 0 12V high 6 12V or average The set thresholds are either low 2 5V or average 6 0V or high 8 0V 9 9 Calibration Do not open other windows in the programme during the calibration procedure The sensors window can be used After running the calibration procedure with the relative butt
39. liers after switching the car to the gas mode Calibration System Managment The system is switched automatically to gas to apply calculated time ATTENTION WHEN SWITCHING TO GAS DURING THIS PHASE THE CAR MAY STOP IN THIS CASEA WINDOW WILL BE DISPLAYED TO ALLOW THE PROCEDURE TO CONTINUE Calibration System Managment Engine Stopped Engine Stop detected For going on with calibration from the stopped step start the engine and push Going on with calibration otherwise push Stop calibration Calibration Repeat Stop Calibration riS H LOVATO After identifying a more or less correct work point the procedure continues with a detailed control Calibration System Managment Gas Times Fine Tuning in progress It takes some minutes Times Sampling in progress After this detailed control the multipliers map is updated and the car is switched to the petrol mode Calibration System Managment Gas Injector Drive Time Map Calculation in progress The Engine 15 switched to petrol During this initial calibration phase if the gas pressure is too high or too low a warning window will be displayed at the end Adjust the pressure within the range 85 map pressure at minimum and recalibrate Calibration System Managment Step 1 Calibration Procedure Ended Warnig Reducer Pressure Out of Adjusting Range G LOVATO 85 Calibration System Managment S
40. load all the data from the FAST control unit overwriting the data on the computer screen open the sensors and flags view window open the map of the multipliers and petrol times open the corrective factor vector window open the operating setting parameters window open a window of parameters to attach to the mappings when they are saved to file 34 L 4 LOVATO Fu Tools menu s FastCom File visualize Data hme Settings window i 1 Bootloader 2 Data Logger Sensors Corrector 3 Diagnostic Logger Diagnc 4 Calibration 5 Advanced Calibration The items in the Tools menu are used to access BootLoader for programming the FAST control units if they require reprogramming Data Logger for tracing and memorising the values transmitted by the sensors diagnostics window basic calibration procedure optional advanced calibration procedure N Settings Menu s FastCom File Visualize Data Tools EES Window 1 FastCom Parameters S say Sey Sensors Correctors Vectors Farameters Logger Diagna The Settings menu accesses the Fastcom parameters Window menu Tools Settings 1 Fall CTRL D 2 Place horizzontally side by side s vectors Par Place vertically side by side 35 4 LOVATO The items the Window menu allow the various open windows t
41. ls The Switch button changes the display to gas or petrol The indicative values of a car at minimum heat regime are shown below Trail 30 C Trid 75 90 C Prail 110 120 kPa 85 M A P value at minimum MAP 30 40 kPa Q 3 RPM 600 800 Level Depends on the quantity of LPG in the tank Tbenz 4 5ms Lambda 0 2 0 9 V oscillating for 0 1V probe Molt 15000 18000 Tgas 4 5 5 5 Ms 9 8 Parameters 32 Parameter Managment Value Bead Parameter inj Group Injector State Switching Deceleration Save parameter inj Group E 0 RPM Threshold 2000 RPM Sensor Type Lovato std __Save parameter inj Group Switch Relay 3 5 RPM Factor 3 gp inj Group D Tred Threshold 40 C Interpalation m injGroupE 0 Pick up Type none gt inj Group F Injector Type inj Group G Compar thres Low inj Group H 0 After clicking on Parameters you are asked whether to load the data from the control unit or view those already present in the memory of the PC The system operating parameters are displayed Some parameters can be modified to change the way the system works To access the parameters managed in the Tbenz min and Offset Tar items click twice on the word values in the top left hand corner Values displayed Inj assembly A H indicates the injector assembly the single in
42. m the petrol mode to the LPG mode The red status LED will shine and the green status LED will flash on the switch 5 2 Lambda probe signal before catalyser The Lambda probe signal 15 not required for the FAST signal but it may be useful when calibrating the system Check the Lambda probe works properly in the petrol mode before connecting it to the FAST system To prevent electromagnetic disturbance do not lay the sheath with the WHITE wire near the ignition coil The Lambda probe signal is captured by pinning the WHITE wire of the FAST cable harness to the Lambda probe signal wire the BLACK wire of the probe is generally the signal wire ATTENTION THE COLOURS OF THE LAMBDA PROBE WIRES IN THE EXPLANATIONS AND THE ELEC TRICAL DIAGRAM REFER TO THE SECTION FROM THE PROBE TO THE CONNECTOR AS THE SIGNALS ARE ALWAYS CAPTURED AFTER THE PROBE CONNECTOR AND THE COLOURS OF THE WIRES OFTEN CHANGE MAKE SURE TI REFER TO THE CORRE SPONDING WIRE BEFORE THE CONNECTOR 5 3 Connecting the reducer temperature sensor The FAST system uses the reducer temperature signal for various purposes The temperature of the reducer is one of the variables that govern switching from the petrol mode to the LPG mode Switching from petrol to LPG is only allowed with the temperature of the reducer reaches the set switching temperature Connect the temperature sensor by attaching the GREY BLACK wire of the cable harness to one of the two sensor terminals on the red
43. male connector located on the coil of the LPG lock off valve 5 6 Connecting the injector power connector Connect the male connector on the FAST wiring harness to the corresponding female connector on the FAST injector assembly 5 7 Connecting the power supply When using the car FAST system parameters are temporarily updated in a temporary memory on the control unit and then saved to the to the memory of the control unit whenever the car is turned off Connect the RED BLACK wire to the positive battery terminal interposing a 7 5A fuse and the BROWN wire to the negative battery terminal Connect the RED wire to the 12V key on circuit not timed interposing a 5 A fuse ATTENTION ALL CONNECTIONS WITHOUT CONNECTORS MUST BE SOFT SOLDERED IN ORDER TO PREVENT RUSTING AND FALSE CONTACTS 24 VIOIA Asayeg gt eueneg dau 05504 T Jozzng J 9JO eSelAA V vi C uo Ady A CI vS asna f S2 ISNI J 03305 A CT 93 OSSO OHSN OSSOH 3NOHWVI
44. mporary memory Serial interface 9 6 Explanation of the drop down menus in the FASTCOM programme File menu Visualize Data Tools Settings Window Load data From database Save data on database Communication check CTRL C eters Logger Diagn Periodic Read Timer CTRL T Reset centralina Stop Communication Motes ESC CTRL amp A The items in the File menu are used to 1 load data mappings from a mass memory unit 2 save data mappings to a mass memory unit 33 A LOVATO 4 reactivate periodic reading of sensors the event of problems 5 reset the FAST control unit 6 force the interruption of serial communication in order to work only locally open the integrated block notes for writing saving loading and printing notes 8 exit the programme View menu 55 FastCom File Data Tools Settings Window H4 1 Add sensor detail F 2 Remove sensor detail P Sensors vectors Parameters Logger Diagn The items in the View menu are used to 1 Add graphics to the sensors window 2 Remove graphics from the sensors window Data Menu 5 FastCom File Visualize EEE Tools Settings Window Download all data on ECU Upload all data From ECU P Logger Diagn Sensor and flags correctors Other correctors Parameter Other parameters The items in the Data menu are used to download all screen data to the FAST control unit
45. n the rail keeping the flaps support in position and lay it on the workbench avoiding the internal components to come out Pict 3 Remove the rail as well as the sealing lid by means of the Allen wrench 5 or the eventual pressure tube by means of setscrew wrench 13 Fig 5 Clean with compressed air the inside of rail pipelines removing eventual oil deposits or foreign matters Carefully clean the contact surfaces with absorbent not abrasive material then with compressed air Clean and carefully tighten the sealing cap the eventual pressure inlet Fig 6 48 O LOVATO Delicately remove the magnetic gap from the flap support by means of tweezers or little screwdriver avoiding to bend or deform the component Fig 8 Clean the surfaces by means of absorbent material The highest attention is recommended to avoid the bending or deformation of magnetic gap Take off the flaps by means of tweezers or little screwdriver and place them the workbench according to the original sequence Pict 10 11 LOVATO Clean the flaps by means absorbent material Verify that on the rubber surfaces no foreing matters are present Take off the external seal the linear o ring and metal lamina underneath by means of tweezers or little screwdriver Carefully clean the flaps support by small brush and compressed air Check if outlet nozzles arent obstructed
46. o be arranged the screen various ways 2 menu Tools Settings Window 29 1 FAST Installation manual 2 Information about actors Vectors Parameters The items in the menu are used to access 1 Visualisation of the FAST system installation manual 2 Fastcom programme information 9 7 Sensor and status control FF Sensors and flags Value Trail Prai o EJE Level 100 2 Lambda 041 stas rio gt PPM 758 EY vor rafici TRed tPetrol Level Trail Prail Lambda Sfas 40 a ms A 100 X RPM i sensor OK Cut off 5 Gas state Ps Satety car From the View menu you can expand the sensors window to obtain a graphic display of system values and statuses Values displayed Trail gas temperature in Rail Trid temperature of reducer Prail gas pressure in MAP pressure in intake duct Q gas flow parameter RPM engine RPM Level quantity of fuel in tank Tbenz petrol injector open time 36 4 LOVATO Lambda lambda probe value Molt multiplier applied Tgas gas injector open time Statuses displayed sensors OK LED on if sensor data is significant Cut off LED on if in cut off mode Gas status LED on if in gas mode Safety car LED ON if in safety car mode gas injectors closed if car stal
47. ogram cpt Annulla Select the coded control unit programming file cpt and click on Open The window shown in figure 26 appears wi ECU Encrypted Software Bootloader ECU alligned Bootloader 2 0 kian RETE CE TI D apps yp select file cpt Click on Enter The programme begins to transfer the data from the computer to the FAST control unit Download progress is displayed on the status bar under the file selection window After downloading has finished remove the fuses put them back again and reset the control unit from the file menu to implement the modifications ATTENTION BEFORE UPDATING THE SOFTWARE OF THE FAST CONTROL UNIT SAVE A COPY OF THE RESIDENT DATA WITH THE FOLLOWING COMMANDS SEE EXPLANATIONS OF THE DATA AND FILE MENUS 32 2 E EPI LOVATO 9 5 Data management in the FASTCOM programme Two types of data are contained in the mappings permanent data which is saved to a permanent memory on both the computer mapping file and the FAST control unit flash memory and vola tile data which is saved to RAM memory on both the computer and the FAST control unit All the mapping modifications made when calibrating the car are temporarily saved in tte RAM memory and are then transferred to the permanent memory when the file is saved on the computer and 30 seconds after disconnecting the 12 V key on power supply in FAST control unit Te
48. on various boxes showing calibration progress are automatically displayed in sequence Calibration System Managment Step Start Engine in Petrol mode and stay at idle When the Forward gt gt button shines green you can move on to the next step In any case you are automatically moved on to the next step after a few seconds 38 LOVATO iz Wait Tria 89 3E Calibration System Managment Shep 3 Wait for injectors acquisition e Injector pu Injectar E Group of A 5 S ey Injector B ey Injector F Group of B ey Injector ey Injector G Group of C 2 Group of G F ey Injector D ey Injector H Group of D Group of E Group of F Group of H During calibration the number of petrol injectors connected is established LED ON and the type of grouping is checked full group semi full group or sequential injection Calibration System Managment Verify the right rpm indication select right multiplier factor 3000 4000 2000 5000 0 6000 F000 RPM factor Adjust the RPM factor to synchronise RPM visualisation with the RPM counter of the car Press Forward to continue 39 1 m LOVATO Calibration System Managment Petrol Time Sampling on progress It takes more or less 90s Time Sampling in proggress The petrol injection time is acquired as it is used to calculate the multip
49. racing Show Logfile Close G LOVATO The Data Logger window shows the progress of the parameters selected in the bottom left hand box It is possible to save the graph to a file choosing whether to reset the file before writing the data Overwrite add the data to that already existing in the file Add The View points shows the exact points sampled in the graph the continuous trace is con structed by interpolation between these points The View Log File button shows the associated values in tabular format at the moment they are sampled text 9 12 Maps FASTCOM 3 Load all Data from ECU CIF ves all data actually loaded at screen will be overwritten by ECL data __ _ After clicking on Maps you are asked whether to load the data from the control unit or view those already present in the memory of the PC The map is established during auto calibration 9 12 1 Map management Multipliers directory 5 Calibration managment 59 2724 3379 6000 15153 15163 15038 15604 16483 15429 15163 15038 15604 16483 15429 15474 15474 15980 16168 15961 15992 15432 15432 16166 16420 16107 16255 17688 17688 16416 16022 16150 16790 Suggestion 17225 17225 16345 15990 16060 18234 15941 15941 16188 16236 16738 10882 14946 14946 16853 18227 18312 13825 Calibration Constant Modifica mappa 0 K 26 Start Stop cursor 2 64 New value
50. ration procedure and terminate it with the Stop button During calibration each cell displays the average Petrol Time acquired during an 8 second inter 42 4 LOVATO val in which the position of the cursor remains in the centre of the 9X9 grid red symbol The Gas Time green symbol is also shown if the car is running on gas as well as the average calculated Multiplier indicated with the symbol 7 If you exit the cell centre during acquisition padlock active the samples memorised up to that point are maintained Acquisition is automatically started for each operating status Gas petrol when the cell centre is maintained for over 2 seconds If the reducer temperature is too low the whole window is disabled The Switch button changes to gas or petrol The current status is shown by the symbol above the button In the Modify box you may block the update status and edit the previously calculated Theoreti cal Multiplier The Reset button resets all the boxes in the Map With the car in the petrol mode the Acquire button forces the acquisition of the Petrol Time while in the gas mode it forces the acquisition of the current time and calculated multiplier After terminating Advanced Calibration by completely acquiring Gas and Petrol mode a suffi cient number of cells press the Calculate Map button to find the Theoretical Multipliers of each cell and interpolate the results on the main 8X10
51. re has finished remove the CD from the drive and run the programme 9 2 Connection between PC and control unit The PC and the control unit are linked with the Code 540011 serial connection Connect the RS232 serial connector on the interface harness to the relative socket on the computer If you have a last generation computer without a serial port fit a standard USB to serial port adaptor Connect the 4 pin female AMP connector on the interface harness to the corresponding 4 pin 29 9 LOVATO AMP male connector on the FAST harness The following figure shows an example of a connec tion between the computer and the FAST system Serial port on PC Connection between Serial interface RS232 serial interface and PC connector Serial interface code 540011 Personal computer 4 pin female AMP Connection between 4 pin AMP male connector on serial serial interface and connector on FAST interface harness FAST wiring harness harness with protector 9 3 Start window A LOVATO ir LruEx Injection System Diagnostic Interface English gt Copyright 2004 Officine Lovato S p A 30 L DU m D H LOVATO The start window shows the version of Fastcom and contains a language selection option When the programme is run the serial connection with the FAST control unit is checked and a message is displayed both if the connection fails and if the connection is regular Communcation Problem E The compati
52. t or an acci dent contact an Authorised Lovato Fitter A table summarising the various signals given by the buzzer is shown below Switching to gas Entering on LPG reserve Low reducer pressure detected no fuel Starting in gas mode ATTENTION DO NOT TRAVEL IN THE GAS MODE WITH THE PETROL TANK EMPTY PREVENT THE PETROL PUMP FROM RUNNING DRY BY KEEPING THE PETROL TANKAT LEAST AQUAR TER FULL O LOVATO 9 0 FASTCOM calibration and diagnostics software To install FASTCOM you must first obtain the FAST installation CD code 512 9 1 Programme installation guide To install FASTCOM insert the installation CD and follow the instructions on the screen If the autoinstall procedure doesn t run install the programme as follows 1 insert the CD in the drive 2 click on START and then on SETTINGS and CONTROL PANEL the following window opens 15 Pannello di controllo fos tig ni Me Z 3 click on INSTALL APPLICATIONS irm nin mes rr Ps ier ge kar r ee Nan a m cme ae sassa eee ee eee RIT E H 4 click on INSTALL and then FORWARD 5 make sure that d setup exe appears on the command line and click on end If d setup exe does not appear click on browse and look for the file setup exe manually 6 follow the instructions on the screen 7 after the installation procedu
53. tep 11 Calibration Procedure Ended After calibration the maps and parameters are saved to the RAM memory on the control unit The data may be deleted if the battery positive is disconnected To memorise it permanently simply switch off the panel and wait about 30 secs until the window signalling that the permanent memory EEPROM is being updated appears This permanent memorisation procedure is also valid for modifications made manually by modifying other inter face data ATTENTION ALWAYS WAIT 30 SECONDS AFTER TURNING OFF THE CAR BEFORE DISCONNECTING THE POSITIVE BATTERY AS WELL AS LOSING ALL THE DATA MODIFIED AFTER THE LAST TIME THE CAR WAS TURNED OFF ALL THE MEMORISED DATA MAY ALSO BE LOST IN THIS CASE THE CONTROL UNIT WILL START WITH FACTORY SET DATA 9 9 1 Advanced calibration Advanced Calibration Aquired Petrol Times m3 Cursor Position T39 2069 4034 6000 3 080 gt 3 1 0 3331144937 2 711 14957 0 0 0 0 0 0 Acquisition Type Theoretical M ___ Thenz E Petrol State Start Stop cursor 3 4 21 Manual Calibration Legenda Aquired tPetral Dai Hessi Acquired tGas Calculate Map Apply ECU i Calculated Theoretical Multiplier Mean Aquired Multiplier Close This procedure can improve if required the mapping obtained from the auto calibration process Press Start to begin the Advanced Calib
54. tion The MICRO switch is the interface between the end user and the FAST system This component displays the operating status of the car the gas level in the tank and allows various operations to be performed such as setting the gas or petrol modes and in case of emergency starting the car directly in the gas mode Spie di funzionamento P Pulsante di commutazione Indicatore di livello The operating LED s display the power status of the car the green LED at the top left refers to gas the red LED at the top right refers to petrol The button with the Lovato logo is used to manually switch from petrol to gas and vice versa and to force engine ignition in the gas mode Lastly there are five level indicator LED s at the bottom Indicating the quantity of gas in the tank The amount of fuel in the tank is measured by the relative indicator LED s as shown below 1red LED on reserve 1 green LED on tank full 2 green LED s on tank 72 full 3 green LED s on tank full 4green LED s on tank full Operation Initial switching to LPG To switch from the petrol mode RED LED on press the button The GREEN LED starts flashing gas enabled In this condition the car is still working in the petrol mode When all the conditions required for switching have been satisfied the control unit switches from the petrol mode to the LPG mode The RED LED switches off the GREEN LED switches on and the buzzer confirms the s
55. ture Pressure Sensor Hose clamp O 12 22 LPG filter Supply the LPG to the FAST injector assembly as shown below fig 12 1 install the LPG filter 4 and the gas temperature pressure sensor 2 in series between the reducer and the injector assembly cut the 12x19 E67 R01 approved hose 1 into three sections install and tighten the compressed air circuit using the six hose clamps D 12 22 3 ATTENTION MOUNT THE LPG FILTER HORIZONTALLY 18 FAST 4 LOVATO LPG inlet hose from reducer 6 1 Only air hose C 2 Y shaped union O 3 Hose clamp Install the overpressure discharge circuit as follows fig 13 1 fix a section of only air hose to the reducer overpressure valve hose connector using the hose clamp 2 cut the hose to length and attach it to the nozzle fixed to the air filter or downline from the airflow meter if fitted 3 fix the hose with the hose clamp u Overpressure Overpressure dl gt 4 discharge discharge hosing nozzle in air e filter overpressure discharge hose connecTor Reducer Air filter Install the inlet manifold pressure measurement circuit as follows fig 14 1 mount a length of only air hosing to the manifold pressure delivery nozzle fitted downline from the butterfly valve and secure it with a hose clamp 2 cutthe hose so that it can reach the immediate vicinities of t
56. ucer and earthing the other If the temperature sensor does not work correctly is not connected the system will not allow you to switch from petrol to LPG The red status LED will shine and the green status LED will flash on the switch 23 ma i E 4 LOVATO gt 5 4 Connecting the level indicator The FAST system includes a digital fuel level indicator located in the MICRO switch The wiring harness of the FAST system is fitted with a level sensor connecting wire Install Lovato level sensor by connecting the green wire of the level sensor mounted on the multivalve to the green wire of the FAST cable harness and the purple wire of the sensor to the red wire of the FAST cable harness 12 V key on Specific connections for other kinds of sensor are shown in the following table PURPLE Black wire Lovato 12V key on Harness GREEN wire Sensor GREEN wire 0 900 Toearth Harness GREEN wire Sensor GREEN wire 0 950 Toearth Harness GREEN wire Sensor GREEN wire 90 00 Toearth Harness GREEN wire Sensor GREEN wire AEB Toearth Harness GREEN wire Sensor GREEN wire Reserve Harness GREEN wire Sensor GREEN wire 5 5 Connecting the LPG multivalve and lock off valve Connect the sheath with the BLUE and BROWN wires to the multivalve coil power wires Connect the BLUE wire to the RED wire from the multivalve and the BROWN wire to the BLACK wire Connect the two way male connector to the corresponding fe

Installation manual - Medic-car

Contents

Download Pdf Manuals

Related Search

Related Contents