TA01Z001I 1

"STEP HS"DOSER

ENGINE

REDUCERVACUUM

SYSTEMECU

PressureSensor

Code DE802045 orCode DE802041

MAP P1

Code DE810000-0001

Primary cableelectrical connections

SecondaryCable

Code 06LB50010058To the Personal

Computer

TemperatureSensor

THE NEW JUST HEAVY SYSTEM1. INSTALLATION

1.1. UPDATING OF VEHICLES EQUIPPED WITH THE OLD SYSTEM

Mechanical verifications:

• Genius HS Reducer: verify that the batch number, written near the pressure adjusting screw, is equal to orhigher than 2DA;

• Step HS Actuator : verify that the batch number, written on the lower part circumference (gas outlet), is equalto or higher than 2-DE.

In both cases, if the batches are before the above mentioned ones, the replacement of the part is recommended.

Electronic verifications:

Just Heavy ECU : verify on the white tag on the ECU side that the code is DE810000-0001. If the code is correct,check the software version, that has to be 0104X00. If it is different, update the ECU with such a software version.If the ECU code is not correct, replace the ECU.

Updating process:

After the above mentioned verifications, it is advisable to install the “P1 JUST HEAVY UPDATING KIT ” code30JH99000001 containing, besides the small items, the MAP-P1 sensor code DE802045 (“Sensore di pressione2,5 – 4 bar” on the red label) or the sensor DE802041 (“Sensore di pressione GPL turbo – Metano SEQUENT”),the P1 taking connection and the secondary cable code 06LB50010058.

1.2. NEW INSTALLATION

To install the new Just Heavy system it is important not to use materials in stock, but to order the new kit, includingall the parts for the correct installation.

New Just Heavy installation general diagram

Fig. 1

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2. CALIBRATION PROCESS OF THE NEW SYSTEM

CAREFUL!!!Calibrate the Just Heavy system only after the installation of the 01.03 version of the interface software on the PC.The new interface software allows to tune up the ECU’s equipped with the old software version, but it does notallow to save the configuration, in order to prevent from mixing up the old and new EEprom files.

2.1. FIRST ACQUISITION PROCESS: 1 st STEP

- Calibrate the signals;- Select the basic cartography depending on the engine size and the fuel type;- Click on Store in the screenshot of figure 3, even without acquiring points;- Go on with the remaining screenshots;- Store

Chronological list of the screenshots:

- Input signals configuration- Max. MAP acquisition (ambient pressure)- RPM signal calibration- Min. MAP acquisition (engine steady in idle condition)- Min. TPS acquisition- Max TPS acquisition- Lambda oxygen sensor acquisition- Basic cartography choice- First acquisition cartography window- Changing over- Level control- Lambda emulation

Novelties compared to the old system:

The screenshot of fig. 2 (configuration of input signals configuration) depicts the possibility to select the P1correction, strategy that considers pressure at the reducer outlet to change the Step HS actuator position.

This strategy ought to be enabled (selecting YES) only if the MAP–P1 sensor has been installed and afterconnecting both pressure taking pipes; otherwise, it ought to be configurated on NO.

Fig. 2

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N.B.A similar screenshot can be drawn from the parameters menu but, in this case in the section “M.A.P. – P1PRESSURE SENSOR” (identified by the novelties arrow in fig. 2) the item Sensor Type appears instead ofP1 Correction, to give the possibility to select the sensor model subsequently. This operation ought to beperemptorily carried out in case of sensor replacement, that is when the new sensor is not equal to theprevious one (DE802041 instead of DE802045 or vice versa).

In the screenshot of fig. 3, the “Store” button appears; it is now possible to choose the interruption of the resetacquisition in any moment, also without acquiring points.

A great novelty of the calibration phase is the elimination of the data loss should the vehicle switch off whileacquiring the seven spots indicated in fig. 3.

It is sufficient to cut off the communication between the ECU and the PC by switching off for approx. 10 sec., switchon again and wait that the PC rereads the EEprom. After reading, the screenshot of fig. 4 will appear.

By clicking on the “YES” button, the acquisition of the spots of figure 3 will start where it left off.By clicking on the “NO” button, the calibration will start from zero.

The other possible way is not to cut off the communication, but to Store from the screenshot of fig. 3, by keepingthe previously acquired one and having like that the possibility to go on with the calibration screenshots.

Fig. 3

Fig. 4

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2.2 QUICK SELF-LEARNING: 2 nd STEP

The installer ought only to drive the vehicle on the road and let the self-learning work: a strategy that manipulatesthe configuration in order to obtain a ContStec value very near to zero.

The self-learning is initially configurated quick, to have a sufficiently quick cartography self-learning, but werecommend to configurate it before delivering the vehicle to its owner, at an average or even slow speed.

Configuration description: (refer to figure n°5)

- Bold-edged cells: they are cells that are not self-learnt, but only changed by the self-learning in order to alwayshave distance respected by the resets beside them. Basically, distance is 5 steps between the 1st and the 2nd

column and the 1st and the 2nd line;- Thin-edged cells: they are recommended to self-learn immediately after the calibration of signals;- Coloured cell: it shows the current running condition that therefore can be self-learnt;

- “Enable manual modification” button: it allows to manually change every value of the cartography, including theMAP and RPM references. Of course, the manual modification of the resets is used in case the self-learning isdisabled;

- “Distribute” button: it automatically calculates the resets included between the 2nd and the 8th line, marked byarrows on the left side (option used only when the manual modification is enabled);

- “Store” button: it is used to save on the ECU the manual modifications carried out on the cartography (optionthat is only used when the manual modification is enabled).

The first self-learning phase:

As referred in the cartography description, the essential points to quickly adjust the cartography during the firstphase of self-learning are the bold-edged cells of figure 5, even if it is always true that the more points are self-adapted the better the result is.

Three steps can be distinguished:

Self-learning of the 2nd line: it is recommended to keep the accelerator slightly stepped on with a low speed (2nd) inorder to guarantee a RPM slow variation and a low MAP.

Self-learning of the 8th line: it is recommended to keep the accelerator completely stepped on with a sufficientlyhigh speed (3rd or 4th) in order to guarantee a RPM slow rise and a high MAP.

Idling self-learning: it is sufficient to keep still for some seconds with the vehicle in neutral, first without engine loadand later with load (air conditioner, headlights, heated rear window, complete steering power).

1st column 16th column

Fig. 5

1st line

8th line

Bold-edgedcell

Thin-edgedcell

Colouredcell

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N.B. The self-learning to work needs sufficiently stable RPM and MAP, approx. three continuous seconds of thecoloured lighted cell of fig. 5 in normal working area condition.

2.3 LONG-TERM SELF-LEARNING: 3 rd STEP

Before delivering the vehicle, reduce the self-learning speed in normal load, with the configurations behind the Setup window under self-learning (see figure 6).

Selecting one of the two items, the screenshot of fig. 7 will appear enabling us to change the self-learning speed.Make sure you do not confuse the screenshots!

Running the bar rightwards, you can visualise Personalized that, if it is configurated by the installer, gives a veryslow speed to self-learning, but, if it is configurated by a BRC engineer, allows modifying some parameters notvisible with the installers’ software.

Fig. 6

Fig. 7

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2.4 NOVELTIES IN THE TUNE-UP SCREENSHOTS

Lambda control in normal load:

Description of parameters:

Speed Control: it is the speed of the ContStec change. It normally corresponds to 6 steps/s for LPG and 4 steps/sfor CNG.

It is advisable to reduce this parameter by basing on the response times of the lambda oxygen sensor; on vehicleswhere the oxygen sensor is decidedly slack or where a Memory 5 is installed, the parameter isn’t therefore over 3or 4 steps/s (both for LPG and for CNG), while where it works well the standard parameter is left.

Cut–Off and return from cut-off:

Description of parameters:

Cut-off entry speed: It is the speed of the STEP HS closure in the cut-off area.

NOVELTY

Fig. 8

Fig. 9

NOVELTY

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This parameter is normally raised when there are troubles in the slow RPM drop after a sudden acceleration in idleconditions.

Full Load:

Description of parameters:

Full-load step correction: it is basically configurated on none: that is, when you are in the full load area, thecartography is used, whereas, if it is configurated on additive, an enrichment can be configurated.

Full-load correction steps: number of steps added to the configuration only in full load conditions. This strategy israrely required and is used in case of need to make the acceleration smoother. It is indicated on the turbo vehicles.

Transient conditions:

Description of parameters:

Transient deactivation T.P.S. threshold: TPS threshold (in U.C.) over which the transient condition strategy is notcarried out;Duration: duration of the pumping (ms).

NOVELTY

Fig. 10

NOVELTY

NOVELTY

Fig. 11

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2.5. NOVELTIES OF THE PARAMETERS SECTION

Control of anomalies: (new screenshot)

Description of parameters:

Solenoid valve anomaly enabling: if it is configurated on YES the ECU recognises the solenoid valve anomaly,otherwise it doesn’t. NO ought to be normally configurated on two-ECU installations;

High P1 threshold: pressure value over which the P1 anomaly is recognised;

High M.A.P. threshold: pressure value over which the MAP anomaly is recognised;

Lambda oxygen sensor diagnostic enabling time: time that ought to pass after changing over so that the systemstarts diagnosing the oxygen sensor anomaly;

Lambda oxygen sensor diagnostic time: time for which the lambda anomaly is indicated, if there are no oxygensensor oscillations.

NOVELT

Fig. 12

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2.6. “ EVENTS HISTORY” NEW SECTION

Self-learning history:

This new section allows visualising the self-learnt cells that will be marked by a 1.The above table shows a non self-learning condition because the cells are all to zero.

2.7. NOVELTIES OF THE PROGRAMMING SECTION

Software files deletion:

To delete the file it is necessary to select the software version by clicking on the side-on square (1) and later clickon Clear (2) (see screenshot of figure 14).

1

2

Fig. 13

Fig. 14

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2.8 NOVELTY OF THE UTILITIES SECTION

Deletion of basic configurations:

To delete the file it is necessary to select the configuration by clicking on the side-on square (1) and later click onClear (2) (see screenshot of figure 15).

2

1

Fig. 15