MI-07 Integrated Engine Control System for 3.0L …

1 Service Manual MI- 07 integrated engine control system for KEM Engines LP & Bi-Fuel Systems 2007 Emission-Certified Systems Manual 36553. WARNING DANGER OF DEATH OR PERSONAL INJURY. WARNING FOLLOW INSTRUCTIONS. Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. WARNING OUT-OF-DATE PUBLICATION. This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: If your publication is not there, please contact your customer service representative to get the latest copy.

2 WARNING OVERSPEED PROTECTION. The Engine , turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover Control System . An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. WARNING PROPER USE. Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i). constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings.

3 CAUTION POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY. CAUTION BATTERY CHARGING. To prevent damage to a Control System that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the System . CAUTION ELECTROSTATIC DISCHARGE. Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts. Discharge body static before handling the Control (with power to the Control turned off, contact a grounded surface and maintain contact while handling the Control ). Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards. Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. IMPORTANT DEFINITIONS. A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

4 A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property. A NOTE provides other helpful information that does not fall under the warning or caution categories. Revisions Text changes are indicated by a black line alongside the text. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken. Woodward 2007. All Rights Reserved Manual 36553 MI-07 Engine Control System for Engines Contents REGULATORY V. EPA / CARB Emissions North American Compliance ..v SPECIAL CONDITIONS FOR SAFE USE .. VI. Electromagnetic Compatibility (EMC).

5 Vi Electrostatic Discharge vii CHAPTER 1. LPG System OVERVIEW .. 3. MI-07 General Description ..3. MI-07 System Key Components ..4. MI-07 System Features ..5. Bi-Fuel System ..6. Customer-Supplied Components ..6. LPG Fuel System Operation ..7. MI-07 LP Fuel Filter ..8. MI-07 Fuel Lock-Off (Electric)..8. N-2007 Pressure Regulator/Vaporizer ..9. CA100 Mixer ..11. Fuel Trim Valve (FTV) ..14. Electronic Throttle System ..16. MI-07 Electronic Throttle ..16. Ignition System ..18. General Motors (GM) High Energy Ignition (HEI) System ..18. Exhaust Catalytic Muffler ..20. SECM ..22. Fuel Throttle Management ..23. Engine Speed Governing Ignition Management ..26. SECM Electrical Mounting SECM / Sensors ..27. Analog Frequency/Position Inputs ..27. Digital Inputs ..27. Outputs ..28. SECM-48 Wiring Diagram ..29. CHAPTER 2. GASOLINE ENGINES.

6 33. Gasoline Fuel System ..33. Gasoline Fuel System Specifications ..33. CHAPTER 3. SPECIFICATIONS .. 34. LP Fuel System Environmental / Electrical Specifications ..34. N-2007 Pressure Regulator Specifications ..35. CA100 Mixer Specifications ..36. Electronic Throttle System Specifications ..36. SECM Specifications ..37. Fuel Trim Valve (FTV) Ignition System System Control Performance Power /Torque ..38. Exhaust Emissions ..38. Woodward i Manual 36553 MI-07 Engine Control System for Engines Drivability / Transient Low Idle Maximum Speed / High Idle ..38. CHAPTER 4. RECOMMENDED MAINTENANCE .. 39. Maintenance Tests & Inspections ..39. Test Fuel System for Inspect Engine for Fluid Leaks ..39. Inspect Vacuum Lines and Fittings ..39. Inspect Electrical System ..39. Inspect Foot Pedal Check Coolant Level ..40. Inspect Coolant Hoses.

7 40. Inspect Battery Inspect Ignition System ..40. Replace Spark Plugs ..40. Replace LP Fuel Filter Testing Fuel Lock-off Operation ..42. Pressure Regulator/Converter Inspection ..42. Fuel Trim Valve Inspection (FTV)..42. Inspect Air/Fuel Valve Mixer Assembly ..42. Inspect for Intake Leaks ..42. Inspect Throttle Assembly ..43. Checking the TMAP Sensor ..43. Inspect Engine for Exhaust Leaks ..43. Maintenance CHAPTER 5. INSTALLATION 46. Hose Connections ..47. Removal and Installation of N-2007 LP Regulator/Converter ..48. Removal and Installation of CA100 Mixer ..49. CHAPTER 6. TESTS AND ADJUSTMENTS .. 52. N-2007 Regulator Service Testing ..52. Break-Off Test ..52. Pressure Test ..53. AVV (Air Valve Vacuum) Testing ..55. Ignition Timing Adjustment ..55. Connection of MI-07 Service Tool ..56. Idle Mixture Adjustment ..57.

8 CHAPTER 7. BASIC TROUBLESHOOTING .. 61. Preliminary Basic Intermittent Faults ..62. Surges and/or Stumbles ..63. Engine Cranking but Will Not Start / Difficult to Start ..64. Lack of Power, Slow to Respond / Poor High Speed Performance /. Hesitation During Acceleration ..67. Detonation / Spark Dieseling, Run-on ..70. Rough, Unstable, Incorrect Idle, or Cuts Out, Misses ..73. Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust High Idle Speed ..75. Excessive Exhaust Emissions or Diagnostic Aids for Rich / Lean Operation ..77. Chart T-1 Restricted Exhaust System CHAPTER 8. ADVANCED DIAGNOSTICS .. 79. Woodward ii Manual 36553 MI-07 Engine Control System for Engines Reading Diagnostic Fault Displaying Fault Codes (DFC) from SECM Clearing Fault (DFC) Fault Action Fault List Definitions ..82. Table 1. Fault List Definitions.

9 82. Table 2. Diagnostic Fault Codes (Flash Codes) ..91. CHAPTER 9. PARTS DESCRIPTION .. 109. LP Fuel System Components for Engines ..109. CA100 Mixer ..110. N-2007 Regulator ..112. APPENDIX .. 114. LPG & LPG Fuel Tanks ..114. LPG Fuel Installing LPG Fuel Tanks ..116. LPG Fuel Tank Components ..117. Fuel Gauge ..117. Pressure Relief Valve ..118. Service Quick Disconnect Coupling ..120. Filler Valve ..120. Woodward iii Manual 36553 MI-07 Engine Control System for Engines List of Figures Figure 1. MI-07 Bi-Fuel System for Engines ..3. Figure 2. MI-07 Closed Loop Fuel Figure 3. Inline LP Fuel Filter ..8. Figure 4. Electric Fuel Lock Assembly ..8. Figure 5. N-2007 Figure 6. Parts View of N-2007 Regulator ..10. Figure 7. CA100 Figure 8. CA100 Mixer Attached to Throttle Figure 9. Parts View of CA100 Mixer ..12. Figure 10. Bottom View of Air Valve Figure 11.

10 CA100 Mixer Installed with Electronic Throttle ..13. Figure 12. Idle Mixture Adjustment Screw ..14. Figure 13. Fuel Trim Valves Connected to MI-07 System ..15. Figure 14. Bosch Electronic Throttle Figure 15. Throttle Body Assembly Exploded View ..17. Figure 16. HEGO (O2) Figure 17. Foot Pedal ..23. Figure 18. Throttle Position Sensor (TPS) on DV-E5 Throttle ..23. Figure 19. Peak Torque and Power Available with MI-07 Figure 20. Drive-By-Wire Signal Flow Process ..25. Figure 21. SECM Wiring Diagram for Bi-Fuel System ..30. Figure 22. SECM Wiring Diagram for LP System ..31. Figure 23. SECM Wiring Diagram for Gasoline System ..32. Figure 24. MI-07 System Installed on GM Engine ..42. Figure 25. Hose Connections for Engines ..47. Figure 26. N-2007 Regulator Installed on Engine ..48. Figure 27. CA100 Mixer Installed on Figure 28.