CARB Tier 1 Emission System Introduction Notes Pages Mit 1

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Technician Factory Qualification
Introduction to
S15G CARB 1 Tier 1
Emission System
Ask each student what they want out of this course.
Write their objectives on the board or flip chart.
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S15G CARB 1 Tier 1 Emission System
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Learning Objectives:
At the completion of this introduction and use of the service
manual with supplemental materials, the student will be
able to:
Identify and verbally describe the function of each
component in the S15G CARB 1 Tier 1 emission system.
Demonstrate the correct use of the electric schematic
and identify all wires and components on a forklift truck.
Demonstrate the ability to use the MCFA diagnostic tools
to monitor system operation, identify faults and calibrate
pedal angle sensor.
Demonstrate the ability to make required adjustments to
return the S15G CARB 1 Tier 1 emission system to
proper working order.
Demonstrate fault identification using the service
manual.
Verbally explain to instructor each step to make repairs
using electric schematic and service manual.
All registered trademarks herein are the property of their respective owners.
The information set forth herein is confidential and is not for distribution beyond MCFA and its authorized Mitsubishi Forklift Trucks and Cat Lift Trucks
dealer network.
Copyright 2003 by MCFA. All rights reserved. Reproduction of this material in any form is prohibited without written permission of MCFA.
Read this slide to students.
Give each a copy of the slide.
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Importance Statement:
Personal:
Student will be confident with the system.
Student will be qualified to maintain this system.
Student with show customer professionalism when
repairing this system.
Personal:
Student will be confident with system.
Student will be qualified to maintain this system.
Student will show customer professionalism when repairing
this system.
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Company:
Student understands system capabilities when
diagnosing and repairing the system.
Equipment maintenance will be at a minimum to the
end user.
More sales and service will be available due to
customer expectations - realities being at the same
level as the dealership.
Company:
Student understands system capabilities when diagnosing
and repairing this system.
Equipment maintenance will be at a minimum cost to the end
user.
More sales and service will be available due to customer
expectations-realities being at the same level as the
dealership.
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Effective January 1, 2001, the California Air Resources
Board (CARB) introduced Emissions regulations
for certain types of industrial equipment not
already covered by the EPA regulations. This new
regulation impacts vehicles using large spark-
ignited engines above 25 horsepower, including
forklift trucks. The U.S. Environmental Protection
Agency has also announced a proposal to
introduce similar controls, across the U.S., starting
in 2004. Mitsubishi Forklift Trucks are among the
first to achieve engine Certification to meet the new
emissions standards and phase-in percentages as
required by the State of California. Mitsubishi
Forklift Trucks have developed an emissions-
compliant emissions control system (ECS).
This slide states the emission regulations put into effect
January 1, 2001 by the (CARB) California Air Resources
Board. It states the emission control system in the current
MCF K series 15-35 capacity models.
When this slide is presented refer to the following web site:
www.epa.gov/otaq/regs/nonroad/proposal/f01028.htm
United States Environmental Protection Agency
Environmental Fact Sheet
Subject: Frequently Asked Questions: Emission Standards for
Industrial Spark-ignition Engines
Question: As an owner of a Large SI engine, what must I do?
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The first release of this system is on LP fuel
configurations of the 4G63 and 4G64 engines in the
FGC-FG15K-35K series of forklift trucks. The
Mitsubishi Forklift Trucks emissions control
system is a closed-loop system with a 3-way
catalytic converter as standard. It utilizes electronic
fuel delivery with drive-by-wire accelerator
control. The key system component is the
Electronic Control Unit (ECU) that monitors various
sensors on the forklift truck, and controls engine
performance.
The benefit to the user is a vast improvement in
indoor air quality, engine drivability and
performance, maintenance and fuel economy.
This slide states the emission regulations put into effect
January 1, 2001 by the (CARB) California Air Resources
Board. It states the emission control system in the current
MCF K series 15-35 capacity models.
When this slide is presented refer to the following web site:
www.epa.gov/otaq/regs/nonroad/proposal/f01028.htm
United States Environmental Protection Agency
Environmental Fact Sheet
Subject: Frequently Asked Questions: Emission Standards for
Industrial Spark-ignition Engines
Question: As an owner of a Large SI engine, what must I do?
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Vaporizer
Mixer
FCVS
Fuel Lock Off
LP Filter
Throttle Body
S15G CARB 1 Tier 1 Component
Identification
Introduction to S15G CARB 1 Tier 1 Components:
Throttle Body
Fuel Control Valve Solenoid (FCVS)
LP Fuel Lock Off
COBRA LP Regulator (Vaporizer) not serviceable
LP Fuel Filter
IMPCO Model 60 LP Fuel Mixer not serviceable
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Component location examples in parts book
ECU
LP Vaporizer
LP Mixer
Throttle Body
Component location examples in parts book:
1. ECU (Electronic Control Unit)
2. LP Regulator (Vaporizer) COBRA not serviceable
3. IMPCO Model 60 LP Mixer not serviceable
4. Throttle Body
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(ECU) S15G CARB 1 Tier 1 Electronic Control Unit
Diagnostic
Monitor
Connection
(ECU) S15G CARB 1 Tier 1 Electronic Control Unit
Remove rubber plug before connecting diagnostic monitor
cable to the ECU.
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Program Version #1 Program Version #2
Identification of S15G CARB 1 Tier 1 Electronic Control Units
(ECU) by part number.
P/N 91165-05800 ECU has the Part # S15G-2-N018-001 on
the decal. Version #1
P/N 91165-15800 ECU has the Part # S15G-2-N039-002 on
the decal. Version #2
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Accelerator Pedal Angle Sensor
Pedal Angle Sensor.
Static settings should be adjusted to 45 units pedal at rest
and 195 units with pedal against stop bolt.
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3-Way Catalytic Converter
3-Way Catalytic Converter.
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Click to edit master text
Exhaust In
Exhaust
Out
Operating
Temperature
Operation of the 3-way catalytic converter at operating
temperature.
Click on mouse. Exhaust gas enters 3-way catalytic
converter.
Click on mouse. Exhaust enters catalyst at operating
temperature.
Click on mouse. Clean exhaust leaves 3-way catalytic
converter.
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3-Way Catalytic Converter example
in parts book
3-Way Catalytic Converter example in parts book
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Engine Block
Temperature Sensor
Sensor should be located
on the bolt identified by
the arrow.
Engine Block Temperature Sensor
Sensor should be located on the bolt identified in the picture.
If found mounted on the intake manifold stud. Relocate to
correct position as indicated by the arrow.
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Oxygen Sensor located in the exhaust manifold
Oxygen Sensor located in the exhaust manifold.
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Exhaust manifold example in parts book
Exhaust manifold example in parts book
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Check Engine Light
Trans Oil
Temp
Brake
Fluid Level
Low Engine Oil
Pressure
Charging
System
Check Engine Light located in the operator display
Check Engine Light located in the operator display.
Note: Identify the rest of the warning lights and their function.
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Exhaust
Manifold
O2 Sensor
Inputs in and outputs from the
Electronic Control Unit
EGOS
Input to and outputs from the ECU
INPUTS to:
RPM (TACH signal from the ignition distributor)
MAP (Manifold vacuum to the ECU)
ET (Engine Block operating temperature sensor input)
Pedal Position (45 units to 195 units)
EGOS (Exhaust Gas Oxygen Sensor)
OUTPUTS from:
Commanded Engine Speed (Voltage output to throttle body)
LPG Lock-off (over speed protection) Engine is at 3100 RPM
for more than 2 seconds. LP fuel lock off will be deactivated.
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S15G Functional Diagram
Vaporizer
LP
Lock
Off
LP
Tank
Check
Engine Light
Pedal
Sensor
Block
Temp.
O2
Throttle
Body
Mixer
Engine
ECU
FCVS
S15G Functional Diagram:
Review components and the connections to the ECU
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COBRA
Regulator
Air/Gas Mixer
Fuel Control Valve
Solenoid (FCVS)
LP Tank
Pressure
Primary
Pressure
Gaseous Propane
Gaseous Propane Out To Mixer
Filtered Intake Air
To Throttle Body
Control Vacuum
A. Primary Pressure LP F. Check Valve
B. Secondary Pressure LP G. Fuel Solenoid
C. Controlled Vacuum/Pressure H. Air/ Gas Mixer
D. Diaphragm I. Diaphragm/ Metering Valve
E. Restrictor
Vaporizer/Regulator diaphragm movement controlled by FCVS
Secondary
Valve
(1-1.5 psi)
Primary
Valve
(- 1-1.5 in. W.C.)
Start on the Left Side! Fuel at tank pressure enters the
regulator. The primary valve drops the LP fuel pressure to 1.0
-1.5 psi. The secondary valve drops LP pressure to negative
1.25 -1.5 W.C. Gaseous fuel is drawn through the hose to the
carburetor.
The ECU pulses the fuel control valve solenoid (FCVS) at
36%-38% on time (dwell) causing control vacuum to work on
the secondary diaphragm of the regulator. A high dwell
percentage causes vacuum to pull the diaphragm enough to
close down the secondary orifice and lean out the mixture.
The throttle body opens to draw more air into the engine. This
causes the air/gas valve to lift and maintains the air/fuel ratio
at higher engine speeds.
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Compare PSI to Inches of Water Column
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Horsepower Comparison
Horsepower graph indicates:
Horse power is maintained at mid to high engine RPM with
the S15G CARB 1 Tier 1 Emission System.
Horsepower drops significantly 2200 RPM with a velocity
governor.
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Operating Specifications for 2.0 L. (4G63) and 2.4 L. (4G64)
Mitsubishi Engines.
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Wiring Schematic
Wiring schematic:
Identify wire connections and locate on truck.
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Summary:
Tools: P/N 90467-00100 Laptop Diagnostic Kit
P/N 93060-06400 Hand Held Diagnostic Unit
P/N 90467-00200 PDA Diagnostic Kit
This is an introduction to the S15G CARB 1 Tier 1 System.
Using this presentation and the following materials, you as a
technician should have the ability to troubleshoot and
maintain this emission system.
Order P/N 99729-75100 LP Supplement on MCFNET. This
document has the complete description of the operating
theory of the S15G CARB 1 Tier 1 emission system.
On the www.mitliftdocs.com internet site you can access the
following documents:
Click on the Training header.
Click on Service Publications under library categories.
Click on S15G CARB 1 Tier 1 print this document.
Click on S15G CARB 1 Tier 1 Computer Screen
Troubleshooting Guide print this document.
The materials on the internet site are supplemental materials
to the service manual available from MCFA literature.
Summary:
This is an introduction to the S15G CARB 1 Tier 1 System. Using this
presentation and the following materials, you as a technician should
have the ability to troubleshoot and maintain this emission system.
Order P/N 99729-75100 LP Supplement on MCFNET. This document
has the complete description of the operating theory of the S15G CARB
1 Tier 1 emission system.
On the www.mitliftdocs.com internet site you can access the following
documents:
1.Click on the Training header.
2.Click on Service Publications under library categories.
3.Click on S15G CARB 1 Tier 1 print this document.
4.Click on S15G CARB 1 Tier1 Computer Screen Troubleshooting
Guide print this document.
The materials on the internet site are supplemental materials to the
service manual available from MCFA literature.
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Summary: Warranty Statement
Only valid in California until 12/31/2003. After that Tier II for all
of North America.
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Complete the following exercises on the Lift
Truck. Your Instructor will guide you.
Any Questions?

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