carb tier 1 emission system introduction notes pages mit 1

8/11/2019 CARB Tier 1 Emission System Introduction Notes Pages Mit 1

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1

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.



S15G CARB 1 Tier 1 Emission System

2

Learning Objectives:

At the completion of this introduction and use of the servicemanual with supplemental materials, the student will beable to:

• Identify and verbally describe the function of eachcomponent in the S15G CARB 1 Tier 1 emission system.

• Demonstrate the correct use of the electric schematicand identify all wires and components on a forklift truck.

• Demonstrate the ability to use the MCFA diagnostic toolsto monitor system operation, identify faults and calibratepedal angle sensor.

• Demonstrate the ability to make required adjustments toreturn the S15G CARB 1 Tier 1 emission system toproper working order.

• Demonstrate fault identification using the servicemanual.

• Verbally explain to instructor each step to make repairsusing 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. R eproduction 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.




4

Importance Statement:

Company:

• Student understands system capabilities whendiagnosing and repairing the system.

• Equipment maintenance will be at a minimum to theend user.

• More sales and service will be available due tocustomer expectations - realities being at the samelevel 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.




5

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 newregulation 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 AgencyEnvironmental 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?




6

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 controlsystem 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 AgencyEnvironmental 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?




7

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




8

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




9(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 monitorcable to the ECU.




10

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




11

Accelerator Pedal Angle Sensor

Pedal Angle Sensor.

•Static settings should be adjusted to 45 units pedal at restand 195 units with pedal against stop bolt.




12

3-Way Catalytic Converter

3-Way Catalytic Converter.




13


• Click to edit master text


Exhaust In

Exhaust

Out

OperatingTemperature

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.




14

3-Way Catalytic Converter example

in parts book

3-Way Catalytic Converter example in parts book




15

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.




16Oxygen Sensor located in the exhaust manifold

Oxygen Sensor located in the exhaust manifold.




17

Exhaust manifold example in parts book

Exhaust manifold example in parts book




18

Check Engine LightTrans 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.




19

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.




20




S15G Functional Diagram

Vaporizer

LP

Lock

Off

LP

Tank

Check

Engine Light

Pedal

Sensor

BlockTemp.

O2

ThrottleBody

Mixer

Engine

ECU

FCVS

S15G Functional Diagram:

•Review components and the connections to the ECU



21


COBRA

Regulator

Air/Gas Mixer

Fuel Control Valve

Solenoid (FCVS)

LP Tank

Pressure

Primary

PressureGaseous 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.




22

Compare PSI to Inches of Water Column




23

Horsepower Comparison

Horsepower graph indicates:

•Horse power is maintained at mid to high engine RPM withthe S15G CARB 1 Tier 1 Emission System.

•Horsepower drops significantly 2200 RPM with a velocity

governor.




24

Operating Specifications for 2.0 L. (4G63) and 2.4 L. (4G64)

Mitsubishi Engines.

•S15G CARB 1 Tier 1 Emission System




25Wiring Schematic

Wiring schematic:

•Identify wire connections and locate on truck.




26

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 atechnician should have the ability to troubleshoot andmaintain this emission system.

• Order P/N 99729-75100 LP Supplement on MCFNET. Thisdocument has the complete description of the operatingtheory of the S15G CARB 1 Tier 1 emission system.

• On the www.mitliftdocs.com internet site you can access thefollowing 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 ScreenTroubleshooting Guide” print this document.

• The materials on the internet site are supplemental materialsto the service manual available from MCFA literature.

Summary:

This is an introduction to the S15G CARB 1 Tier 1 System. Using thispresentation 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 documenthas the complete description of the operating theory of the S15G CARB1 Tier 1 emission system.

•On the www.mitliftdocs.com internet site you can access the followingdocuments:

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 TroubleshootingGuide” print this document.

•The materials on the internet site are supplemental materials to theservice manual available from MCFA literature.




27

Summary: Warranty Statement

Only valid in California until 12/31/2003. After that Tier II for allof North America.




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Complete the following exercises on the Lift

Truck. Your Instructor will guide you.

Any Questions?

carb tier 1 emission system introduction notes pages mit 1

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