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GROUP 02(EFI)
SECTION 1
Specifications .........................................................................................1
Definition of Terms................................................................................4
Ignition Timing....................................................................................17
Troubleshooting ...................................................................................25
SPECIFICATIONS:
Fuel Pressure:
Gasoline 10 psi measured at idle
LPG 24 psi with lock-off energized, engine off.
Ignition Timing: 0 deg. BTDC with engine running and Clark harness # 929713
connected. (See page 5:4)
Sensor Resistance:
Air & Coolant 2106-2393 ohms @ 30 deg. F
265- 516 ohms @ 70 deg. F
182-199 ohms @ 100 deg. F
Procedure Allow engine to idle for 2 1/2 minutes at or above 161 deg. F.
ECT Use Clark connector (See page 5:2)
Propane has an excellent safety record, but just like other hydrocarbon fuels, injury can occur when
mishandled. The physical properties of propane are somewhat different than gasoline, thus requiring
different handling and safety procedures.
NFPA 58 chapter 8: 6 lays out the basic procedures for garaging and repairing propane powered ve-
hicles.
Vehicles with LP-Gas fuel systems shall be permitted to be serviced or stored inside garages, provided
that:
(a) The fuel system is leak-free and the container is not filled beyond the limits specified.
(b) The container shutoff valve is closed when vehicles or engines are under repair except when
engine is operated.
(c) The vehicle is not parked near sources of heat, open flames, or similar sources of ignition, or
near inadequately ventilated pits.
Carbon Monoxide. Carbon monoxide (CO) is a colorless, tasteless, and odorless gas and gives no
warning of its presence. Those exposed to it do not realize it is present until symptoms begin to de-
velop.
The exhaust emissions from internal combustion engines can increase through the lack of mainte-
nance. This can cause the carbon monoxide inside a building to climb above the OSHA maximum limit
of 50 ppm during an eight-hour period.
Procedures to vent the exhaust to a safe environment should be carried out during maintenance and
repair procedures.
Levels of Effects of
Carbon Monoxide Exposure Carbon Monoxide Exposure
400 PPM (0.040%) Frontal headache within 1-2 hours. Life threaten-
ing
after three hours. The maximum allowable
Concentration according to the US EPA and AGA
Figure 3.3
LEANER RICHER
MIXTURE MIXTURE
SAME INTERVAL
BETWEEN PULSES
Figure 3.5
Fuel injectors are sensitive to contaminants and Figure 3.6 - Gasoline Injector
require filters in the 20 - 30 micron range. Both
the gasoline and propane systems use a 20 micron
filter.
Fuel Pump:
To supply gasoline to the injector, ZEEMS uti-
lizes a high capacity (16 gallons / hour) fuel pump
mounted in the fuel tank Figure 3.10 - Gasoline Fuel Pump
11
4
5
8 12
6 11
10
13
6 9
3 2
3. From the shut off valve, fuel enters the pri- Water Jacket
mary vaporizer regulator (converter). Gas
pressure is reduced to 28 PSI and changes Heat Exchanger
from a liquid to vapor state. Engine coolant
flows through this device to aide fuel va- Figure 3.11 - Gasoline Regulator
porization. Fuel then enters the secondary
pressure regulator where gas pressure is re-
duced to 24 psi for delivery to the injector.
Because no two machines are exactly alike, the ECU has the ability to learn and adjust the throttle
stop for improved idle quality and governing. After a period of extended, uninterrupted engine idle at
normal operating temperature, the ECU will reprogram idle parameters to correct idle speed and im-
proved decelerations. After the initial factory installation, it is unlikely that the ECU will need to
learn its base setting.
Failsafe Modes:
If any electrical failure to the throttle control occurs, the throttle will return to the mechanical idle stop
position.
If for any reason engine RPM exceeds the maximum limits, fuel delivery is interrupted.
The gasoline fuel pump or LPG lock-off will disengage in 2 - 4 seconds if the ignition key is on and
there is no secondary ignition pulse to the ignition coil.
There is no need to depress the throttle pedal to set the choke or provide fuel for cold start. Depress-
ing the throttle pedal has no effect until the engine is running. The ECU opens the throttle to a prede-
termined position for starting.
Note:
Turn service valve on slowly. This will prevent
premature excess flow valve operation, if fuel line
is empty.
Relief Valve:
The relief valve is preset by the manufacturer to
activate at 375 psig. Tank pressure will rise when
the liquid expands. This can be caused by over-
filling the tank, an external heat source eg. fire
etc. The valve will close when pressure drops be-
low 375 psig.
Outage Valve:
This valve is also called the 80% liquid level valve. Plug
This device when opened, allows gas (vapor) to
escape as the tank is being filled. When the liquid Restricting
Orifice
level reaches 80%, liquid spills out the valve, in-
dicating that the tank is filled to the correct level.
Body
Dip Tube
Float
Quick Disconnect Couplings:
Figure 3.21
To aid in connection and disconnection the liquid
service valve has a male ACME quick connect
coupling. This coupling and its female counter-
Knurl
part, that is attached to the fuel supply line, are
equipped internal check valves. When connected Hose Check
the checks open and allow gas to flow. Valve
External
Threads
Check
Valve
H-MSTS Module
Malfunction
Diagnostic Lamp
Deutsch Connector
Harness
1. Be sure engine coolant temperature is a mini- Note: When working on a truck equipped with
mum of 161 deg F. ( If coolant temperature the dual fuel system, set the mechanical idle with
is below 161 deg F. or falls below 161 deg. truck operating on LPG fuel.
F. governor self learn will not start or be
complete.) 1. Disconnect the throttle actuator wire harness.
NOTE:Machines equipped with ECU revision 2. Start engine and set the mechanical idle
level G or higher will idle at 1200 RPM until screw to 500-550 RPMS.
coolant temperature reaches 161 deg.F. 3. Reconnect the throttle actuator wire harness.
4. Apply a silicone type sealer to the top of the
2. Set parking brake. Do not engage brake adjustment screw to prevent moisture from
pedal, steering or any other hydraulic entering the throttle actuator motor.
funcfion.
3. Disconnect the 12 pin connector from the
wiring harness and install the self learn pro-
gramming connector Clark P/N ******
This procedure is to be carried out when the ECU The following steps are required to allow the elec-
and or the throttle body is replaced. It may also tronic control unit to self learn the correct throttle
solve poor low speed governor performance. stop position
Note: Machines equipped with ECU revision level Note: Do not connect the Self Programming Con-
G or higher will idle at 1000-1200 RPM until nector jumper leads when operating on gasoline.
coolant temperature reaches 161 deg.F. Connect jumper leads only when operating on
LPG.
2. Set parking brake. Do not engage brake
pedal, steering or any other hydraulic func- 4. The ECU will self learn after 3 minutes of
tions. running. During this period, let the engine
3. Disconnect the 12 pin connector from the idle with no external hydraulic load applied.
wiring harness to the ECU and install the: 5. After three minutes, disconnect the self learn
programming connector and reconnect the
vehicle harness. The ECU self learning pro-
cess is complete.
6. For dual fuel machines, repeat steps 1
through 5 with machine operating on LPG
after connecting the blue jumper wires to-
gether on the self learn programming con-
nector.
Special Tools
There is a service kit available for troubleshoot-
ing the fuel injection system.
X-MIT.
SIGNAL
GO.
tlmdc +12vclc
I
6h 7 a*
Cl2 +12
Vdc
+12 a>
-1 +12
3.OL GM D U A L FUEL
Vdc VdC Vdc
r
E.C.
POWER
-
8h
1I
ZXTERNAL ELECTRICAL CONNIK!TIONS
-8 7 8
8 ENGINE GROUND.
I - - CONNECTOR
CLARK 8 PIN
3 DISTRIBUTOR LEAD
(TACA INPUT)
T
(THERMOSTAT HOUSING
F O R 3.OL)
--
- A
EXTERNAL ELECTRICAL CONNECTIONS
0 ENGINE QROUND.
0 DISTRIBUTOR LEAD
(TACR INPUT)
0 COO- TEMP. S E N S O R .
(CYLINDER - 4.3L)
0 12 PIN CONNeCTOR TO
V E H I C L E HARNESS.
+12
0 V8 EPIN CONNECTOR TO
N I C L E NARNESS.
Vdc
0 ENGINE GROUND.
GROUP 02(EFI)
TROUBLESHOOTING
The pedal position sensor used on fuel injected fork lift trucks can be thought of as an electronic
version of a conventional adjustable resistor or rheostat. Because it is electronic, however, it must be
checked with voltage applied instead of being checked as a separate component.
1. Locate the 12 pin connector in the harness from the throttle body ECU. This procedure is done
with ignition switch on, engine does not need to be running.
2. Voltage across Pins 7, 8 and 9 may be checked by back probing the connector with a voltmeter
(preferably an analog type). Ref. electrical schematic in service manual. NOTE: Do not perfo-
rate wire insulation.
5. Voltage between Pin 7 and Pin 8 should vary between approx. 1 volt and approx. 4 volts as the
pedal is depressed.
If the voltage between Pin 7 and 9 is not approx. 5 volts, suspect harness to ECU or ECU. If pedal
sensor has 5 volts input with no output (Pin 7 and 8) replace pedal sensor.
I YES
Repair
wiring or
YES
voltage
rl Replace
fuel press.
regulator
I YES
I I
Check
ground or
replace ECU
I NO
YES
YES
/ v
\
Replace
injector or
o-rings
\ ,
I OK
YES
SEE operating
suecifications
Qip=JT]
1 YES
1 YES
I Check throttle
plate rotation
/ \
Correct NO
charging 13.5 - 14.7 volts
system fault
.
r %
Repair NO
ground
L /
1 NO
/ .
SEE engine YES
diagnostics
L /
/ Y
c 3 / \ / b
Check MAP Check MAP Check coolant and
OK OK
sensor sensor with ) air temperature
connections alternate sensor sensor connection
\ J \ / L /
OK
+
r \ f \
1 NO
/ \
Adjust/replace NO
primary 4
regulator
\ /
1 YES
f \
NO Adjust / replace
k secondary
regulator
\ /
r \
Adjust timing NO
or repair
harness / module
\ /
/ , /
I
v
OK
\
OK Check MAP
Check for
sensor with
leaky injector
alternate sensor
J \ J
in fuel return
1 NO
/ \
Adjust timing NO
or repair
harness / module
L /
NO
1
I YES
NO
YES
LP Lock-off Valve
I NO
I
YES
1 OK
I Go to gasoline
no start
diagnostic
NO GAS
b
LPG YES
\
Go to LPG
no start
diagnostic
1 Neither
fuel starts
Go to gasoline
no start
diagnostic
1 NO
/
Check wiring
fuel selector
switch
L
NO
o - 6 :
/ \
Is injector
clogged?
/
/ \
Replace NO
MAP 4
sensor
\ /
/ \
Set ignition timing NO
SEE engine service (
manual
L /
r >
Replace NO
module
\ /
Continued
< t i m i n g >zA S e t i g n i t i o n t i m i n g 1
Adjust pressure
or I
replace regulator
1 YES
Continued
/ 3
Check vacuum leaks:
Intake manifold
Throttle adapter
Throttle body
k PCV valve 2
OK
P .
NO Replace
b MAP sensor
. a
YES
/ I
NO Replace
b module
. 2
YES
r I .
Tune
engine
. /
OK
GROUP 02(EFI)
SECTION 2
HYBRID MICROPROCESSOR
SPARK TIMING SYSTEM
3 Wire Sensor
2 Wire Sensor
The illustration below shows a schematic repre- Binary code is used inside the ECM and between
sentation of a 2-wire sensor. This sensor is basi- a computer and any electronic device that under-
cally a variable resistor in series with a stands the code. By stringing together thousands
known-fixed resistor within the ECM. By know- of bits, computers can communicate and store in-
ing the values of the input voltage and the voltage finite varieties of information. To a computer that
drop across the known resistor, the value of the understands binary, 11001011 might mean that it
variable resistor can be determined. The variable should turn an output device ON at slow speed.
resistors that are commonly used are called ther- Although the ECM uses 8-bit digital codes inter-
mistors. A thermistors resistance varies with tem- nally and when talking to another computer, each
perature. bit can have a meaning.
Service Mode
CLARK test harness part #929713 will allow
you to:
Display the DTC 12 by flashing the test har-
ness light indicating that the system is func-
A closed throttle on engine coastdown would pro-
tioning correctly.
duce a relatively low MAP output voltage, while
Display any stored DTCs by flashing the test
a wide open throttle would produce a high MAP
harness light. Each DTC will be flashed 3
output voltage. This high output voltage is pro-
times. DTC 12 will then flash indicating that
duced because the pressure inside the manifold is
there are no other fault codes.
almost the same as outside the manifold, so you
The ignition timing is controlled to a fixed tim-
measure almost 100% of outside air pressure.
ing degree programmed in the ECM. This will
allow base timing to be adjusted.
MAP is the opposite of what you would measure
on a vacuum gauge. When manifold pressure is
Reading Diagnostic Trouble Codes (DTCs)
high, vacuum is low, causing a high MAP output
Once the test harness is properly connected, the
voltage. The MAP sensor is also used to measure
ignition switch must be moved to the key ON,
barometric pressure under certain conditions,
engine OFF position. At this point, the test har-
which allows the ECM to automatically adjust for
ness light should flash DTC 12, three times con-
different altitudes.
secutively. This would be the following flash se-
quence: flash, pause, flash-flash, long pause,
The ECM sends a 5 volt reference voltage to the
flash, pause, flash-flash, long pause, flash, pause,
MAP sensor. As the manifold pressure changes,
flash-flash.
the electrical resistance of the MAP sensor also
changes. By monitoring the sensor output volt-
DTC 12 indicates that the ECMs diagnostic sys-
age, the ECM knows the manifold pressure. A
tem is operating. If DTC 12 is not indicated, a
higher pressure, low vacuum (high voltage) re-
problem is present within the diagnostic system
quires different spark timing than lower pressure,
itself, and should be addressed by consulting the
high vacuum (low voltage). The ECM uses the
Diagnosis section.
MAP sensor to control ignition timing.
H-MSTS Module
Malfunction
Diagnostic Lamp
Deutsch Connector
Harness
DTC Problem