LPG CNG Sequential injection system kits installation manual.pdf

Updated May, 2012

INSTALLATIONINSTALLATIONINSTALLATIONINSTALLATIONMANUALMANUALMANUALMANUALFor the CNG Sequential Injection System(Can be taken as reference for LPG also)

INDEXINDEXINDEXINDEX

CHAPTERCHAPTERCHAPTERCHAPTER 1111 INTRODUCTION........................................................................................................2

CHAPTERCHAPTERCHAPTERCHAPTER 2222 GENERAL INSTALLATION OVERVIEW ...............................................................3

CHAPTERCHAPTERCHAPTERCHAPTER 3333 WIRES .................................................................................................... ....................3

CHAPTERCHAPTERCHAPTERCHAPTER 4444 INJECTORS RAIL.......................................................................................................9

CHAPTERCHAPTERCHAPTERCHAPTER 5555 THE CNG REDUCER ................................................................................................11

CHAPTERCHAPTERCHAPTERCHAPTER 6666 GAS PRESSURE SENSOR ........................................................................................12

CHAPTERCHAPTERCHAPTERCHAPTER 7777 LEVEL SENSOR ................................................................................... ....................12

CHAPTERCHAPTERCHAPTERCHAPTER 8888 MONITOR...................................................................................................................13

CHAPTERCHAPTERCHAPTERCHAPTER 9999 GENERAL SET-UP .................................................................................. ..................14

CHAPTERCHAPTERCHAPTERCHAPTER 10101010 ADVANCED SET-UP .................................................................................................15

CHAPTERCHAPTERCHAPTERCHAPTER 11111111 SETUP PROGRAMMING ..........................................................................................17

CHAPTERCHAPTERCHAPTERCHAPTER 12121212 ADVANCED PROGRAMMING ................................................................................19

CHAPTERCHAPTERCHAPTERCHAPTER 13131313 SETUP LAMBDA .................................................................................................... ..20

CHAPTERCHAPTERCHAPTERCHAPTER 11114444 HOW TO MANUALLY ADJUST THE VEHICLE ....................................................22

CHAPTERCHAPTERCHAPTERCHAPTER 11115555 TROUBLE SHOOTING .............................................................................................23

CHAPTERCHAPTERCHAPTERCHAPTER 11116666 ANNEXS .....................................................................................................................29

ANNEXANNEXANNEXANNEXAAAA SET THE PORT COM ....................................................................................................29

ANNEXANNEXANNEXANNEX BBBB RAIL CONNECTION FOR 6 CILINDERS ...................................................................30

ANNEXANNEXANNEXANNEX CCCC RAIL 3 OHM CONNECTION AND WIRING3................................................................30

ANNEXANNEXANNEXANNEX DDDD FULL GROUP WIRING CONNECTION..........................................................................31

ANNEXANNEXANNEXANNEX EEEE HOW TO CONNECT 2 REDUCERS IN A 6&8 CYL. ENGINE......................................31

ANNEXANNEXANNEXANNEX FFFF CONNECTORS GENERAL INFO ....................................................................................32

ANNEXANNEXANNEXANNEX GGGG SWITCHING INDICATIONS AND LEVEL INDICATOR ON THE SWITCH............. .33

HongKongHongKongHongKongHongKong LGCLGCLGCLGC GasGasGasGas EquipmentEquipmentEquipmentEquipment Co.,Co.,Co.,Co., LtdLtdLtdLtdRm 719A, Huang Jia Centre, Dong Huan Rd 1, Long Hua Area, Shenzhen518109, ChinaTel: +86-755-81780556 Fax: +86-755-81780337 Website: www.lgc.hk

LGC copyright www.lgc.hk1

ChapterChapterChapterChapter 1111 INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

This is an electronically controlled Gas Sequential Injection System. It can be installed in nearly any petrolfuel injection vehicles, in particular in all last-generation catalytic fuel injection vehicles. The system is amulti-point sequential injection system, 100% “follower” and where no OBD emulation device is required. Itis available both for the LPG and the CNG versions.

Gas is injected through the injector rail directly into the manifold near the intake valves, thus achieving anoptimal fuel mixture and improving gas exhausts level. The gas injection timing is directly driven by theoriginal petrol signal.

The Gas Sequential Injection system is composed of the following items: an ElectronicElectronicElectronicElectronic ControlControlControlControl UnitUnitUnitUnit, amicro-micro-micro-micro- SwitchSwitchSwitchSwitch, a GasGasGasGas PressurePressurePressurePressure RegulatorRegulatorRegulatorRegulator, a GASGASGASGAS InjectorInjectorInjectorInjector RailRailRailRail.

PicturePicturePicturePicture 1111 – CNG Sequential Injection System

ChapterChapterChapterChapter 2222 GENERALGENERALGENERALGENERAL INSTALLATIONINSTALLATIONINSTALLATIONINSTALLATION OVERVIEWOVERVIEWOVERVIEWOVERVIEW

- Always disconnect the Battery when installing the Gas system.


- Never place the 15 Amp fuse in fuse housing until the system is fully installed.- Place the ECU and all cables far from heat sources and far from high voltage sources (such as battery cables,spark plugs, coils, etc.).- Place the ECU in vertical position with connectors above.- Solder and insulate all electrical connections.- Use only gas hoses specific for CNG.- Keep all Gas hoses as short as possible.- All hoses connecting the Gas injectors to the Manifold MUST have the same length.- Check the system for GAS leakage after completing the installation.

ChapterChapterChapterChapter 3333 WIRESWIRESWIRESWIRES

The wiring of the Sequential Injection System, is composed of 3 wire bundles:- TheTheTheThe GREYGREYGREYGREY wiring includes all the same connections required for every type of car, i.e. 3, 4, 5, 6, 8 cylinderscars;- TheTheTheThe BLACKBLACKBLACKBLACK wiring differs in two versions in accordance with the number of cylinders of the engine:* BlackBlackBlackBlack wiringwiringwiringwiring 4444 cylinderscylinderscylinderscylinders, to be used for vehicles until 4 cylinders;* BlackBlackBlackBlack wiringwiringwiringwiring 6&86&86&86&8 cylinderscylinderscylinderscylinders, to be used for vehicles until 6&8 cylinders

- WiringWiringWiringWiring forforforfor thethethethe socketssocketssocketssockets.Available in three versions:* Injectors with Bosh type connectors;* Bosh* Injectors with Japan type connectors;* Injectors without connectors also known as Universal type connectors.

Should the provided connectors are not compatible with the original ones of the vehicles, it is suggested to cutthe connectors and connect the wires, by welding.

The wire controlling the Petrol injectors have a different color on every cylinder, therefore, it is good practiceto check the polarity by using a multimeter. Once checked solder the wire ends and pay attention to the colorof each wire and their related sequence.

Should a mistake happen and the wrong signal be taken from the wrong wire, the following information willnot be displayed in your PC, that is; “Time of injection Petrol”, “RPM number” and “Status of the Injectors”.This information is present when viewing the screen “MONITOR”. Should this occur, check all wires andrepeat the above mentioned operation.


PicturePicturePicturePicture 2222 – The GREY wiring


PicturePicturePicturePicture 3333 – The BLACK 4 cylinders wiring


PicturePicturePicturePicture 4444 – The BLACK 6 cylinders engine wiring


PicturePicturePicturePicture 5555---- 8 cylinders engine wiring


PicturePicturePicturePicture 6666– The cylinders sockets

IMPORTANT NOTE: When performing an installation on a 6 cylinders engine, it is recommended not toconnect the injector socket indicated with the number “C3”.

The +12 volt is taken from C4 (our reference as the 4th cylinder) having wire color YELLOW,


YELLOW/BLACK and BLACK.

ChapterChapterChapterChapter 4444 InjectorInjectorInjectorInjector RailRailRailRail

3333 cylinderscylinderscylinderscylinders 4444 cylinderscylinderscylinderscylinders

PicturePicturePicturePicture 6666 -Injector Rail Types

Installation instructions:

The Injectors Rail should be installed as follows: connect the Rail outlets with the respective petrol injectorconnection, therefore follow the correct firing sequence of the engine: cable “R1” to the cylinder Nr. “1”, cable“R2” to cylinder Nr. “2”, “R3” to the cylinder Nr. “3”, cable “R4” to cylinder Nr. “4” This device should beinstalled in the engine compartment, away from heat sources and protected from water or humidity.

The hoses connecting the injectors rail to the manifold must have the same length and will be as short aspossible.

In the case of installation of a 3 or a 6 cylinders engine the following is recommended:

Important note: should you use a 4 way injector on a 3 or 6 cylinder engine we recommend NOT to connectthe injector socket C3 and on rail R3.

Note: The first rail will be connected with the grey cables to be connected with the cable N2 and which runs


the first group of cylinders ( N1 ); the second rail is to be connected with the cable N5 which runs the secondgroup of cylinders (N4 / N6 ).

Recommended injector rail nozzlenozzlenozzlenozzle sizesizesizesize ((((unit: mm) taken into consideration the Number of cylinders and theengine power, can be viewed here bellow:

CNGCNGCNGCNG withwithwithwith 3333 OhmOhmOhmOhm typetypetypetype CNGCNGCNGCNG withwithwithwith MatrixMatrixMatrixMatrix typetypetypetypeCylinderCylinderCylinderCylinder NNNN°°°° CylinderCylinderCylinderCylinder NNNN°°°°

3333 4444 5555 6666 8888 3333 4444 5555 6666 8888

Max

Max

Max

Max

Power

Power

Power

Power

inin in inKw

Kw

Kw

Kw

55555555 1,6

Max

Max

Max

Max

Power

Power

Power

Power

inin in inKw

Kw

Kw

Kw

55555555 1,865656565 1,6 1,6 65656565 1,8 1,875757575 1,8 1,8 1,6 75757575 2,0 2,0 1,885858585 1,8 1,8 1,8 1,6 85858585 2,0 2,0 2,0 1,895959595 2,0 2,0 2,0 1,8 1,8 95959595 2,2 2,2 2,2 2,0 2,0105105105105 2,0 2,0 2,0 2,0 2,0 105105105105 2,2 2,2 2,2 2,2 2,2115115115115 2,0 2,0 2,0 2,0 2,0 115115115115 2,2 2,2 2,2 2,2 2,2125125125125 2,2 2,2 2,0 2,0 125125125125 2,4 2,4 2,2 2,2135135135135 2,2 2,2 2,2 2,2 135135135135 2,4 2,4 2,4 2,4145145145145 2,2 2,2 2,2 2,2 145145145145 2,4 2,4 2,4 2,4160160160160 2,2 2,2 2,2 160160160160 2,4 2,4 2,4180180180180 2,2 2,2 180180180180 2,4 2,4200200200200 2,4 2,4 200200200200 2,6 2,6

(If for LPG, the nozzle size may be 0.2 mm less.)Important:Important:Important:Important:The above mentioned size chart, are the result of various data gathered in the laboratory. The nozzle size couldvary in accordance to the quality of the CNG. Therefore, it is recommended to verify the good performance ofthe engine during calibration by road testing the car, and change nozzles or enlarge size by a drill if needed.

TheTheTheThe nozzlenozzlenozzlenozzle holeholeholehole wewewewe provideprovideprovideprovide isisisis generallygenerallygenerallygenerally 1.4MM(Suit1.4MM(Suit1.4MM(Suit1.4MM(Suit totototo lowlowlowlow powerpowerpowerpower car),car),car),car), ifififif youryouryouryour carcarcarcar isisisis ofofofof biggerbiggerbiggerbigger outputoutputoutputoutputvolume,volume,volume,volume, ppppleaseleaseleaselease useuseuseuse biggerbiggerbiggerbigger sizedsizedsizedsized nozzles,nozzles,nozzles,nozzles, orororor DRILLDRILLDRILLDRILL thethethethe currentcurrentcurrentcurrent onesonesonesones intointointointo biggerbiggerbiggerbigger sizes.sizes.sizes.sizes.IfIfIfIf thethethethe nozzlenozzlenozzlenozzle sizesizesizesize tootootootoo small,small,small,small, itititit willwillwillwill bebebebe veryveryveryvery hardhardhardhard totototo setsetsetset anananan appropriateappropriateappropriateappropriate air-air-air-air-gasgasgasgas ratioratioratioratio duringduringduringduring calibrationcalibrationcalibrationcalibration((((““““constantconstantconstantconstant atatatat highhighhighhigh RPMRPMRPMRPM””””,,,, ““““constantconstantconstantconstant atatatat idleidleidleidle””””))))....

Chapter5Chapter5Chapter5Chapter5 TheTheTheThe CNGCNGCNGCNG REDUCERREDUCERREDUCERREDUCER


(The regulator we use now is different with the one shown above but similar, no problem to take it asreference.)- The outlet pressure of the reducer can be trimmed by acting on the screw placed on centre top of the frontcover. By turning the screw clockwise the pressure is decreased and by turning counter clockwise the pressureis increased.

- It is recommended that the outlet pressure of the reducer is trimmed as per the table here bellow

EngineEngineEngineEngine SizeSizeSizeSize IfIfIfIf :::: MapMapMapMap PressurePressurePressurePressure ThenThenThenThen :::: ReducerReducerReducerReducer PressurePressurePressurePressureUp to 140 Hp 30KPa 80 - 90KPa

Up to 210 Hp 35KPa 90 - 110KPa

- The reducer can be installed in any position but it is recommended that the coil of the lock off is positionedupward. None the less, the reducer must be secured by fitting on to the bracket.

- It is not a good practice to connect the water circuit in series to the water flow, if set in series the water flowwill be limited to the engine and may create damage. Therefore, always fit the reducer in parallel to the waterflow and always bellow the radiator’s water level.

- The NTC or temperature sensor is fitted to the side of the alloy block of the reducer. When screwing thesensor take care and DO NOT apply excessive torque. The only function of the sensor is to measure thetemperature of the reducer. Always use the NTC provided with the given ECU and connect as per themanufacturer instruction.

- In the case the reducer is placed in a “big” size engine it is recommended to use an oversize CNG lock offand a steel pipe having 8x1mm in size.

- Connect the vacuum port placed on the side of the top cover of the front part of the reducer to the pressuresensor or ECU as recommended by the manufacturer or follow the indications provided in the “MAP SENSORCONNECTION SCHEME”.

Pressure setting screw

Incr. (+)


ChapterChapterChapterChapter 6666 GasGasGasGas PressurePressurePressurePressure SensorSensorSensorSensor

The sequential injection system uses a gas pressure sensor to assure a good performance of the engine and toallow the best possible carburetion of the engines. The sensor is to be connected, using a rubber hose to theGas injector rail, to the manifold and to the vacuum port located on the cover of our reducer.

This device allows measures the following signals:- The MAP value (MAP: Manifold Absolute Pressure)- The gas pressure inside the injector Rail

•

Chpter7Chpter7Chpter7Chpter7 LEVELLEVELLEVELLEVELSENSORSENSORSENSORSENSOR

With this system it’s possible to make use of different types of level sensor, it is simple and easy to use, simpleselect the right sensor type from the screen “GeneralGeneralGeneralGeneral SetupSetupSetupSetup” and then selecting “LevelLevelLevelLevel SensorSensorSensorSensor TypeTypeTypeType”.

Go to “GeneralGeneralGeneralGeneral SetupSetupSetupSetup” screen and click on “SetSetSetSet SwitchSwitchSwitchSwitch LevelsLevelsLevelsLevels”, open the window with manual regulation ofthe levels limits. We can select two types of data input:

SIMPLESIMPLESIMPLESIMPLE: normally used for the LPG. Hold the multivalve in your hand with the level sensor connectedcorrectly. Move the float to the desired level and click on the arrow next to the level you wish to set. Doing this,we’ll decide at which exact LPG level will the led light up (When red light shown on the micro-switch, itmeans LPG is going to use out, it’s time to refill the tank with LPG).


ADVANCEDADVANCEDADVANCEDADVANCED: Normally used for the CNG. Select the 4 desired Voltage levels at which the exact CNGpressure will the led light up. Click on SEND to save all chosen values.

ChapterChapterChapterChapter 8888 MONITORMONITORMONITORMONITOR

- Connect the Interface from the PC to the ECU Mach PRO.

- Select “MONITORMONITORMONITORMONITOR”.

- See on bottom left of the screen above the switch, make sure the light shows a GREEN color and that the

word CONNECTED is shown. This indicates that the PC is connected to the ECU:

- Check the bottom right screen and see that all injectors are ALWAYS GREEN in color:

- MAP Pressure should indicate a value between 35KPa to 45KPa:

- The temperature of the reducer should be no less than 65°C before proceeding with the trimming/


programming:- When engine is on Petrol you can switch to Gas by clicking on the screen switch above the LGC logo:

- The GASGASGASGAS PRESSUREPRESSUREPRESSUREPRESSURE (reducer pressure indicated when idling) should be 75 to 95KPa when trimming onCNG (NGV).

- Even though it is not necessary, we do advise to connect the lambda 1. The lambda is useful to visualize if the

air/fuel ratio indicated a rich or lean mixture:

ChapterChapterChapterChapter 9999 GENERALGENERALGENERALGENERALSET-UPSET-UPSET-UPSET-UP

- Select “GENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP”- SETUPSETUPSETUPSETUP SWITCHINGSWITCHINGSWITCHINGSWITCHING, this function is used to select the way to switch from Petrol to Gas. Normally weadvise to switch in Deceleration when using manual gears and Acceleration with automatic gear box and fullgroup

- Select the “MAPMAPMAPMAPTHRESHOLDTHRESHOLDTHRESHOLDTHRESHOLD” or leave as per our suggestion (Best).

- “THRESHOLDTHRESHOLDTHRESHOLDTHRESHOLD PRESSUREPRESSUREPRESSUREPRESSURE VALUEVALUEVALUEVALUE” This value will be selected to modify the pressure value in which


the switching will happen, (keep as per suggested by the manufacturer but change if required).

- “AUTOMATICAUTOMATICAUTOMATICAUTOMATIC SWITCHINGSWITCHINGSWITCHINGSWITCHING TOTOTOTO PETROLPETROLPETROLPETROL” When “ActivatingActivatingActivatingActivating” this function, the system willautomatically switch to Petrol when the gas tank is empty. If activated select a value between 10KPa and20KPa. Default value is 20KPa.

- “MINMINMINMIN TEMPERATURETEMPERATURETEMPERATURETEMPERATURE OFOFOFOF VAPORIZERVAPORIZERVAPORIZERVAPORIZER” Keep the temperature “Switching to GAS” at 36°C in coldclimates and no less than 32°C on hot climates.

- AUTOMATICAUTOMATICAUTOMATICAUTOMATIC SWITCHINGSWITCHINGSWITCHINGSWITCHING TOTOTOTO PETROLPETROLPETROLPETROL, If activated the system will automatically switch the systemback to Petrol in the event of low temperatures within the reducer. This phenomenon can happen duringnormal and when having a vapor lock in the water system or in case of low water level in the radiator. Ifactivated select a temperature value between 6°C to 10°C.

- LEVELLEVELLEVELLEVELSENSORSENSORSENSORSENSOR TYPETYPETYPETYPE. Select the level sensor type in accordance to the sensor type, or signal used.

- SETSETSETSET FUELFUELFUELFUEL LEVELSLEVELSLEVELSLEVELS: Click on this function in order to modify the level ranges of the level sensor. Thisfunction will allow you to set and personalized level thresholds. For more details see the installation manual orAnnex B here included.

- SOUNDSOUNDSOUNDSOUND: Click on this function to activate the beeper or the talking kit (optional to be ordered separately andcould be programmed with different languages)

ChapterChapterChapterChapter 10101010ADVANCEDADVANCEDADVANCEDADVANCED SET-UPSET-UPSET-UPSET-UP


- You can decide to return to petrol when the vehicle is working at idle and/or at high RPM. When it happenthe display inside the driver's cabin will always indicate running on Gas, without any variation.

- When the engine is working at idle, the vehicle could run:* TOTOTOTOGASGASGASGAS: normally to GAS;* REENTERREENTERREENTERREENTER TOTOTOTO PETROLPETROLPETROLPETROL: the vehicle changes over to petrol as soon as it’s under the set engine rpm;* TOTOTOTO PETROLPETROLPETROLPETROL: The vehicle switches over to petrol after 3 seconds that the rpm are below the set ones;* The vehicle automatically switches over to Petrol as soon as the engine rpm exceed the set re-turn values.

If this function is selected, it consents to modify the configuration of the system during certain situations,allowing the automatic switching from Petrol to Gas or from Gas to petrol automatically at a given RPM,temperature or Time of injection.

WORKINGWORKINGWORKINGWORKINGATATATAT IDLE:IDLE:IDLE:IDLE:- When selecting TOTOTOTOGASGASGASGAS, the engine will work on GAS at idle.- When selecting RERERERE ENTERENTERENTERENTER TOTOTOTO PETROLPETROLPETROLPETROL, a small window with an RMP will pop up and you must selectan RMP setting. Basically, when reaching the selected RPM limit the engine will run on Petrol and it willautomatically switch to GAS mode once accelerating over the selected RPM setting.- When selecting TOTOTOTO PETROLPETROLPETROLPETROL, same as RERERERE ENTERENTERENTERENTER TOTOTOTO PETROLPETROLPETROLPETROL, but it will switch to Petrol after idlingfor some seconds.

NOTE: This operation is done and managed by the gas ECU, no action is required by the driver.

WORKINGWORKINGWORKINGWORKINGATATATATHIGHHIGHHIGHHIGH RPM:RPM:RPM:RPM:- When selecting TO GAS, the engine will work on GAS at all high RPM range.- When selecting TO PETROL, and after selecting the limit of RPM and the Injection time, the LGC ECU willallow the engine to work on Petrol and will automatically come back to GAS when at lower than selectedvalues.


Other Options: QUICKQUICKQUICKQUICK GASGASGASGAS CHANGECHANGECHANGECHANGE OVEROVEROVEROVER WITHWITHWITHWITH WARMWARMWARMWARM ENGINEENGINEENGINEENGINE, if activated the engine willchange over to Gas soon after ignition, provided it reach set Pressure in the system and there is a suitableswitching temperature.

EXTERNALEXTERNALEXTERNALEXTERNALEMULATOREMULATOREMULATOREMULATOR: to be used only with the 5, 6 and 8 cylinder model

TIMETIMETIMETIME OFOFOFOFOVERLAPOVERLAPOVERLAPOVERLAP: is used to select the time of overlap by using the two fuels (Petrol 68mode.

RETURNRETURNRETURNRETURNTOTOTOTOGENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP clicking here you will return to GENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP....

ChapterChapterChapterChapter 11111111 SETUPSETUPSETUPSETUPPROGRAMMINGPROGRAMMINGPROGRAMMINGPROGRAMMING (Trim(Trim(Trim(Trim Setup)Setup)Setup)Setup)


ATTENTION:ATTENTION:ATTENTION:ATTENTION: BeforeBeforeBeforeBefore startingstartingstartingstarting totototo programprogramprogramprogram,,,, setsetsetset inininin thethethethe typetypetypetype ofofofof injectorinjectorinjectorinjector usedusedusedused withwithwithwith thethethethe system.system.system.system.

““““PROGRAMMINGPROGRAMMINGPROGRAMMINGPROGRAMMING””””

- “ENGINEENGINEENGINEENGINE DATADATADATADATA”; Always input the vehicle engine data. The information is VERY important and it issimple to insert.

- “PARAMETERSPARAMETERSPARAMETERSPARAMETERS OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION”: BeforeBeforeBeforeBefore proceeding with the “PROGRAMMING IDLE”, make sure toselect the correct “TYPETYPETYPETYPE OFOFOFOF INJECTORINJECTORINJECTORINJECTOR”.

- “MINIMALMINIMALMINIMALMINIMAL IMPULSEIMPULSEIMPULSEIMPULSE”: Select an impulse of 2.0ms when using Matrix rails and 3,4ms when using 3.0Ohms rails.

- Select “PROGRAPROGRAPROGRAPROGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE” and follow the indications. NOTE: DURING THIS PROCEDURE DONOT ACTIVATE THE “MAP CORRECTOR” OR THE “SET MAPPING”.

- After PROGRAMMING IDLE is completed, you can adjust the system by making small corrections on theCONSTANTCONSTANTCONSTANTCONSTANTATATATAT IDLEIDLEIDLEIDLE for idle and CONSTANTCONSTANTCONSTANTCONSTANTATATATAT HIGHHIGHHIGHHIGH RPMRPMRPMRPM for accelerations.

- In case accelerations are not satisfactory, ACTIVATE the MAPMAPMAPMAPCORRECTORCORRECTORCORRECTORCORRECTORThe MAP CORRECTOR works just like a BOOSTER. It works just for a few milliseconds only duringacceleration. Always select the smallest number (1) to work, then next number ex. 1, 2, 3 etc…until reachingthe desired acceleration output. On each number change stop the car and make your acceleration test on eachacceleration.

- “SETSETSETSET MAPPINGMAPPINGMAPPINGMAPPING”, this function is used only for emissions tests or in very rare situations in which the carneeds to be mapped. See Annex C for details.


MAPPINGMAPPINGMAPPINGMAPPING If activated it allows the change of the time of injection at any given RPM in function to thepressure MAP. This function is to be used with CARE and ATTENTION.* Absolute Values: It modify a fuel gas injection value as a net value in the selected MAP-RPM area.* Relative: The selected value will add or subtract from a base value in the selected MAP-RPM area.

ChapterChapterChapterChapter 12121212ADVANCEDADVANCEDADVANCEDADVANCED PROGRAMMINGPROGRAMMINGPROGRAMMINGPROGRAMMING


In this area we can manage every and each single injector and can be done as follows:

- Activating the Gas Injector will start working or Deactivating the petrol injector will start working

The percentage given will give the option to increase or decrease the opening gas time of the gas nozzle for thegiven cylinder.

Chapter 13 SETUP LAMBDA


- This section of the Software is useful when performing emission tests. We advise not to make use of it forevery day application, unless required. Reason is, that in time, the lambdas will become slow or die off. Whenthis happen the system will no longer work on gas unless this function will be deactivated or a new lambda isused. This function allows you to make a better control of the exhaust gasses.

- If in need, then make sure to connect Lambda Nr. 1.

- Activate the Fast Lambda corrector by clicking and selecting a value from 1 to 16. The values are from 1 lessimportant to 16 most important.

- The slow lambda can be activated as well, and is referred to the average calculation of a “X” number ofcycles. Basically works on its average.

- Click on SETUP LAMBDA for the programming process and acquisition of the same.

- LAMBDA PROBE it allows to fix the vehicle’s lambda signal.

- LAMBDA THRESHOLD it fixes the medium value of the Lambda Probe signal.

- SLOW LAMBDA CORRECTOR this parameter can be activated only if lambda is connected, will correctthe Gas air fuel ratio utilizing and ideal average of the Lambda signal.

- FAST LAMBDA CORRECTOR this parameter, if selected and if the lambda is connected, will allow tocorrect the fuel-air ratio utilizing the instant value provided by the system.

- LAMBDA MAPPING THRESHOLD it allows the emulation of the lambda signal, if connected thru the


signal wire. It works in function of the engine RPM and the MAP of the engine.

- HIGH EMULATION VALUE allows to fix in mVolts the maximum value of the emulated signal.

- LOW EMULATION VALUE allows to fix in mVolts the minimal value of the emulated signal.

- LAMBDA SETUP is an automatic procedure to acquire the lambda type signal, provided that lambda probeis connected

Note: If is necessary to utilize the LAMBDA CORRECTORS it is a must to connect the lambda 1 to the ECUwiring as indicated here bellow :


ChapterChapterChapterChapter 14141414 HOWHOWHOWHOWTOTOTOTOMANUALLYMANUALLYMANUALLYMANUALLYADJUSTADJUSTADJUSTADJUST THETHETHETHEVEHICLEVEHICLEVEHICLEVEHICLE

1. It may happen the vehicle cannot be trimmed by the automatic programming mode. This situation mayhappen when the engine is unstable at idle or when the A/C is on or when the vent goes on very often. In suchcases, follow the listed steps to trim manually.

2. “ENGINEENGINEENGINEENGINE DATADATADATADATA”: Always input the vehicle engine data. The information is VERY important and it issimple to insert.

3. “PARAMETERSPARAMETERSPARAMETERSPARAMETERS OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION””””: BeforeBeforeBeforeBefore proceeding with the “PRPGRAPRPGRAPRPGRAPRPGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE” (TrimmingTrimmingTrimmingTrimmingIdleIdleIdleIdle), make sure to select the correct “TYPETYPETYPETYPE OFOFOFOF INJECTORINJECTORINJECTORINJECTOR”.

4. “MINIMALMINIMALMINIMALMINIMAL IMPULSEIMPULSEIMPULSEIMPULSE”: Select an impulse of 2.0ms when using Matrix rails and 3.4ms when using 3.0Ohms rails.

5. VERYVERYVERYVERY IMPORTANTIMPORTANTIMPORTANTIMPORTANT:::: Write down the TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION OFOFOFOF PETROLPETROLPETROLPETROL

(((( )))) when the engine is RUNNING ON PETROL.

6. Select “TYPETYPETYPETYPE OFOFOFOF INJECTORSINJECTORSINJECTORSINJECTORS” click on “PPPPRRRROGRAOGRAOGRAOGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE”, select “suggested values”. Writedown the suggested values related to the ENGINEENGINEENGINEENGINE CONSTANTCONSTANTCONSTANTCONSTANT and the OFFSET INJECTOR. Once writtenthe values exit the procedure.

7. Set in the written values in the area of the CONSTANTCONSTANTCONSTANTCONSTANT ENGINEENGINEENGINEENGINE and the OFFSETOFFSETOFFSETOFFSET INJ.INJ.INJ.INJ. VALUESVALUESVALUESVALUES givenon point 14.6.

8. Click on the Lo. Gas Logo located on left bottom side once the reducer temperature reaches 65°.

9. Change the OFFSETOFFSETOFFSETOFFSET INJECTIONINJECTIONINJECTIONINJECTION VALUESVALUESVALUESVALUES (at IDLE), by viewing the lambda on “MONITOR”--see iffuel air ration is rich or lean, and modify accordingly. Then change the ENGINE CONSTANT (at high RPM),by viewing the lambda on “MONITOR” --see if fuel air ration is rich or lean, and modify accordingly. Followthis process until the “TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION of PETROLPETROLPETROLPETROL” WHENWHENWHENWHEN RUNNINGRUNNINGRUNNINGRUNNING ONONONON PETROLPETROLPETROLPETROL as per point14.5 is the same or near to the TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION OFOFOFOF PETROLPETROLPETROLPETROLWHENWHENWHENWHEN VEHICLEVEHICLEVEHICLEVEHICLE ISISISIS RUNNINGRUNNINGRUNNINGRUNNING ONONONONGASGASGASGAS.


ChapterChapterChapterChapter 11115555 TROUBLETROUBLETROUBLETROUBLE SHOOTINGSHOOTINGSHOOTINGSHOOTING

DEFINITIONDEFINITIONDEFINITIONDEFINITION CAUSECAUSECAUSECAUSE CHECKCHECKCHECKCHECK //// SOLUTIONSOLUTIONSOLUTIONSOLUTION

AAAA. PC does not connect 1.1.1.1. Interface.

2.2.2.2. ECU

1.1.1.1. Check if interface is working

2.2.2.2. Check all Cables

3.3.3.3. Set the Port Com on

UTILITY** See annex A to set the Port

Com

4.4.4.4. If 12 volts under key has been set

on a coil, then the ECU is probably

burnt

BBBB. PC connects but it does not

show any pressure values

Pressure sensor burnt or wet Change pressure sensor.

CCCC. Values of pressure both the

MAP and Gas pressure exceed

100KPa

Pressure sensor not

connected

1.1.1.1. Check Electrical connection

2.2.2.2. Change pressure sensor

DDDD. Values of the MAP pressure

and/or Gas pressure are fixed

Pressure sensor not working Change pressure sensor

EEEE. Temperature value is 0 or not

shown

Temperature sensor not

working or disconnected

1.1.1.1. Check Electrical connection.

2.2.2.2. Change the temperature sensor.

3.3.3.3. Note: InInInIn casecasecasecase ofofofof emergencyemergencyemergencyemergency

groundgroundgroundground thethethethe sensor.sensor.sensor.sensor. ThisThisThisThis waywaywayway thethethethe

systemsystemsystemsystem willwillwillwill inininin anyanyanyany casecasecasecase changechangechangechange overoveroverover

totototo gas.gas.gas.gas.

FFFF. Some or all Injectors lights are

White.

Wiring Check Connections

GGGG. MAP Pressure is lower or

higher than 35Kpa / 45KPaMAP

Wrong positioning of the

MAP port

Change the vacuum port.

Note: keep away from the throttle

butterfly.

HHHH. Temperature of the reducer is

cold

or does not increase

1.1.1.1. Lack of water.

2.2.2.2. Air lock in reducer

1.1.1.1. Add water to the radiator.

2.2.2.2. Purge the system/reducer for

possible air locks.


IIII. Engine does not switch to gas 1.1.1.1. Low water temperature.

2.2.2.2. Empty Gas Tank.

3.3.3.3. Solenoid valves do not

4.4.4.4. Lambda SET UP has been

activated but the Lambda’s

have not been connected.

1.1.1.1. Add water to the radiator.

2.2.2.2. Purge for air locks.

3.3.3.3. Check gas level in tank.

4.4.4.4. Check if solenoid valves open and

its wires.

5.5.5.5. Check the fuse.

6.6.6.6. + 12 volts may not be well

connected.

7.7.7.7. Check all electrical connections,

specially the injector plugs.

8.8.8.8. Connect Lambda! If the Lambda

Corrector is activated.

JJJJ. Engine does not switch to gas

when clicking on the switch

1.1.1.1. Gas pressure.

2.2.2.2. Temperature too low

1.1.1.1. System must be filled with Gas and

must have the pressure indicated in

point 1.8.

2.2.2.2.Make sure the system has reached

the temperature of 65°C.

3.3.3.3. Check if “SETUP SWITCHING” has

been set correctly.


KKKK. Engines Switches to Gas but

return back to petrol

1.1.1.1. Low Gas pressure.

2.2.2.2. Low Temperature.

3.3.3.3. Electromagnetic interference

1.1.1.1. Check the Pressure on the rail.

2.2.2.2. Check the switching temperature.

3.3.3.3. Check that the Pressure of the

automatic switching to petrol is not

over 20KPa.

4.4.4.4. Check the spark Plugs, and change

if used for over 20,000Km.

5.5.5.5. Check if the cable bundles and

ECU are far away from high tension

cables.

6.6.6.6. Check if there is a loss of tension on

the 12 volts

7.7.7.7. Check that the “Automatic switching

to petrol” is set between 10 to 20KPa.

If already 20KPa then reduce to

10KPa.

LLLL. When clicking on the switch the

led shows red and it is no longer

possible to switch to gas

System is not ready for

switching

1.1.1.1.Wait until temperature is reached.

2.2.2.2. Check the pressure, as it may be

too low.

3.3.3.3.When this happens, manually click

on the real switch and wait for the

temperature and pressure conditions

are met.


MMMM. The Trimming Idle does not

finish.

1.1.1.1.Wrong Engine data.

2.2.2.2. Nozzles too large or too

small

3.3.3.3. Injectors used differ from

those selected on the TYPE OF

INJECTOR.

4.4.4.4. Constant Engine and Offset

Injector Values are far from the

working point.

5.5.5.5. Bad wiring connections

1.1.1.1. Check Selected Injectors with those

actually used.

2.2.2.2. Set engine values in the unlikely

event of having Engine Constant at or

near the 200 value, you are required

to change nozzles to a bigger size.

Should the engine Constant be at the

50 value then change to a bigger size

nozzle.

3.3.3.3. Check that the minimal impulse is

as per the indicated in 3.2

4.4.4.4. In the case of ECU manufactured

before September 2007, Check that

the under key +12volts is constant.

Make sure it is not temporized.

NNNN. Engine Dies off when switching

to Gas.

1.1.1.1. Fuel/Air ratio too Lean or too

Rich.

2.2.2.2. High Gas pressure.

3.3.3.3. No fuel in the Tank.

4.4.4.4. Injector wires.

1.1.1.1.Manually Adjust the Constant

Engine or the Offset Injector Values.

2.2.2.2. Reducer is leaking, change the

reducers Shutter Valve.

3.3.3.3. Check the injector polarity and

wiring.

4.4.4.4. If reducer’s pressure is too high or

too low. See point 1.8

OOOO. Engines looses power during

acceleration

1.1.1.1. Fuel/Air mixture too lean or

too rich.

2.2.2.2. Injector signal is lost during

acceleration.

3.3.3.3. Gas filter dirty.

1.1.1.1. Check the Gas pressure set the

values as per point 1.8.

2.2.2.2. Increase or decrease the

CONSTANT ENGINE.

3.3.3.3.Make sure that the injector signal is

present during acceleration (see the

green lights on MONITOR bottom

right of the screen. The lights should

become white only during cut off.

4.4.4.4. Change Gas filter if dirty.

5.5.5.5. Check spark plug cables.


PPPP. Engine does not run linearly or

has some vibration.

1.1.1.1. Air Fuel ratio too rich or too

lean.

2.2.2.2. One or more cylinder is not

working.

3.3.3.3. Hose between Rail and the

manifold too long or with

different lengths.

4.4.4.4.Wrong rail and cylinder

correspondence.

5.5.5.5.Multivalve placed up side

down or low gas level.

1.1.1.1. Change or modify the ENGINE

CONSTANT and or the OFFSET

INJECTOR VALUES.

2.2.2.2. Check the injector wiring and

correspondence between the cylinders

and the rail outlet.

3.3.3.3. Check if coils are working and if

there is gas flows from the nozzles.

4.4.4.4. Check for the right positioning of the

M/V and if there is enough gas in the

tank.

5.5.5.5. Check that all hoses going from the

rail to the cylinders have the same

length.

NOTENOTNOTENOTNOTENOTNOTENOTE:E:E:E: If intake valves are far

from the manifold nozzles then use

LGC GAS Extension.

QQQQ. Illogical values are shown on

the ECU

Engine has been washed or

water has penetrated in the

ECU

Change the ECU

RRRR. Level Indicator indicates always

reserve or always full

1.1.1.1.Wrong wiring connections.

2.2.2.2. Level sensor type is different

from the sensor used.

3.3.3.3. Level sensor wrongly

installed.

1.1.1.1. Check the wiring connections.

2222.... Check the sensor signal and match

with the one selected in the software

(see ““““PROGRAMINGPROGRAMINGPROGRAMINGPROGRAMING”, “LevelLevelLevelLevel SensorSensorSensorSensor

TypeTypeTypeType”).

3.3.3.3. Install and check the installation of

the sensor by checking the

instructions provided with the level

sensor.

4.4.4.4. Check that the float in the tank is

free to move, in the unlikely situation

that they may get stock.


SSSS. Vehicle with high fuel

consumption.

1.1.1.1. Gas leakage.

2.2.2.2. High reducer pressure

1.1.1.1. Check for gas leaks

2.2.2.2. Reduce the pressure of the reducer.

TTTT. Vehicle uses both Gas and

Petrol at the same time

Emulator 1.1.1.1. Check that the wires of the emulator

are well connected.

2.2.2.2. If vehicle is a full group there may be

a new for a specific wiring diagram.

UUUU. The switch’s led with reduced

intensity.

1.1.1.1.Wire contacts.

2.2.2.2. Electromagnetic Interference

1.1.1.1. Check cables of switch

2.2.2.2. Check for high voltage

interference.

VVVV. Lambda always rich or poor 1.1.1.1. Too much or not enough gas.

2.2.2.2. High Gas pressure

1.1.1.1. Check and adjust the reducer

pressure.

2.2.2.2. Change the Constant Engine and

adjust the Offset Injector Values.

3.3.3.3. Check the nozzle diameter.

4.4.4.4. Check if lambda is working

WWWW. LAMBDA 1 is connected but

LAMBDA 2 is shown

Wrong wires have been

connected

Check wiring Diagram

ChapterChapterChapterChapter 11116666ANNEXSANNEXSANNEXSANNEXS

ANNEXANNEXANNEXANNEXAAAASETSETSETSET THETHETHETHE PORTPORTPORTPORTCOMCOMCOMCOM1. Go to the Control Panel2. Select “System”3. Select “Hardware”4. Select “Management Peripheral”5. Open PORT (COM&LPT)6. See the port used may be from 1 to 97. Go to the Mach Pro and enter into UTILITY set the PORT COM found in point 6.8. Now the PC should connect, but wait a few moments after inserting the new Port Com.


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LPG CNG Sequential injection system kits installation manual.pdf

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Transcript of LPG CNG Sequential injection system kits installation manual.pdf