M.T.M. s.r.l.

Via La Morra, 1
12062 - Cherasco (Cn) - Italy
Tel. ++39 0172 48681
Fax ++39 0172 488237

- handbook for the installer -

02.2001
 3

TABLE OF CONTENTS

1. PRESENTATION
1.1. GENERAL FEATURES
1.2. GENERAL LAYOUT OF THE EQUIPMENT
1.3. DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS
1.3.1. ECU AND CHANGEOVER SWITCH
1.3.1.1. Changeover function for injection cars
1.3.1.2. Changing over again in out-of-the revs threshold condition
1.3.1.3. Control function of the gas quantity
1.3.1.4. Function of injectors emulation and fuels overlapping
1.3.1.5. Emulating function of the configurable lambda oxygen sensor signal
1.3.1.6. Function of the memory management and of the signal cutting relay contact
1.3.1.7. Level gauge
1.3.1.8. Dialogue with the Diagnostic Box
1.3.1.9. Dialogue with the BRC Portable Computer
1.3.1.10. Double possibility for setting and starting operations
1.3.1.11. Self-configuration of the system to the vehicle signals
1.3.1.12. Self-adapting of the system
1.3.1.13. Check-up of the system
1.3.1.14. Troubleshooting
1.3.2. DIAGNOSTIC-BOX
1.3.3. INTERFACE PROGRAMME ON COMPUTER
1.3.4. HARNESS
1.3.5. GAS FLOW CONTROL ACTUATOR
1.3.6. REDUCER
1.3.7. MIXER
1.4. ADVANTAGES OF THE JUST SYSTEM

2. INSTALLATION OF THE SYSTEM

2.1. PRELIMINARY OPERATIONS
2.2. ECU FIXING
2.3. ECU CONNECTION
2.3.1. 5-POLE DIN CONNECTOR FOR DIAGNOSTIC BOX
2.3.2. CONNECTION TO THE BRC PORTABLE COMPUTER
2.3.3. 24-POLE HARNESS
2.3.3.1. 10-way connector for changeover switch
2.3.3.2. 4-way connector for the STEP control actuator
2.3.3.3. Connection of the gas level sensor
2.3.3.4. Startend Connector
2.3.3.5. Reset Connector
2.3.3.6. “A” Sheath
2.3.3.7. “B” Sheath
2.3.3.8. “C” Sheath
2.3.3.9. “D” Sheath
2.3.3.10. “E” Sheath
4

2.4. ASSEMBLY OF THE CHANGEOVER SWITCH

2.5. ASSEMBLY OF THE GAS LEVEL GAUGE
2.6. ASSEMBLY OF THE GAS FLOW CONTROL ACTUATOR
2.7. ASSEMBLY OF THE MIXER
2.8. ASSEMBLY OF THE REDUCER

3. CONFIGURATION AND SETTING OF THE SYSTEM FROM THE

CHANGEOVER SWITCH
3.1. THE DIAGNOSTIC BOX
3.1.1. VISUALISATION OF THE SIGNALS ON THE LED-BARS
3.1.2. NUMERIC VISUALISATIONS
3.2. PRELIMINARY CONTROLS
3.3. CONFIGURATION AND SETTING DOMAINS
3.3.1. LED READOUT ON THE CHANGEOVER SWITCH
3.4. FIRST ACQUISITION AND AUTOMATIC SELF-CONFIGURATION
3.4.1. ACQUISITION AND SELF-CONFIGURATION OF THE TPS SIGNAL
3.4.2. ACQUISITION AND SELF-CONFIGURATION OF THE R.P.M. SIGNAL
3.4.3. ACQUISITION AND SELF-CONFIGURATION OF THE LAMBDA OXYGEN SENSOR SIGNAL
3.4.4. ACQUISITION OF THE RESET POSITION OF THE STEP ACTUATOR
3.5. ADDITIONAL MANUAL SETTING AND PARAMETERS SETUP
3.5.1. ACTIONS TO BE TAKEN IN THE ADDITIONAL MANUAL SETTING DOMAINS
3.5.2. LOW LEVEL GAUGE THRESHOLD SETTING (EMPTY TANK)
3.5.3. 4/4 THRESHOLD OF THE LEVEL GAUGE (80% FILLING)
3.5.4. CHANGING OVER THRESHOLD
3.5.5. NP - NC1/NC2 RELAY CONFIGURATION
3.5.6. FUELS OVERLAPPING TIME
3.5.7. ANALOGIC - ON/OFF TPS SETTING UP
3.5.8. PARAMETERS SET-UP
3.6. DUTY CYCLE VISUALISATION AND MODIFICATION OF THE
LAMBDA OXYGEN SENSOR EMULATED SIGNAL
3.7. VISUALISATION AND MODIFICATION OF THE STEP RESET POSITION
3.8. SELF-ADAPTING
3.9. SYSTEM DIAGNOSTIC

4.

APPENDICES
"A"APPENDIX - DICTIONARY OF WORDS AND DEFINITIONS
"B"APPENDIX - MAIN TROUBLES, POSSIBLE CAUSES, SOLUTIONS
"C"APPENDIX - REFERENCE CODES
 5

1. PRESENTATION performance/price ratio and with 1.2. GENERAL LAYOUT

really considerable potentials, OF THE EQUIPMENT
able to manage manifold func-
tions by optimising times, versa- The Just system is applied on
t i l i t y a n d e ff e c t i v e n e s s o f t h e any type of engine converted to
ECU interventions. gas with a traditional BRC equip-
The long and careful road ment (LPG or CNG indifferent-
setup, with vehicles of several ly).
types and of different characteris- The ECU, with a microcon-
tics and perfomances, highlighted troller, manages the control of the
1.1. GENERAL FEATURES the remarkable potential of the whole gas equipment and adjusts
system, as well as the setup ease the fuel quantity in feedback
The Just system, destined to and the possibility to optimise the through the STEP actuator in
feed automotive explosion car working. order to obtain an optimum mix-
engines on gas (CNG or LPG), is The results attained in the ture, both in respect of pollution
the result of a long experience approval emission tests of the and consumptions, and of drive-
worked out by BRC Co. in its own product are evidence of the ability, aside from the outside
field. exceptional quality of the mixture conditions (temperature, etc.)
Indeed, this system is due to a control system. and the fuel composition.
synthesis of the best features of The approval tests from the The system setting and start-
the lambda gas control systems, point of view of the ing, widely based on self-config-
opportunely integrated by innova- Electromagnetic Compatibility uration and self-adapting proce-
tive functions and definitely in the (EMC), successfully passed by dures, present two possible
lead in the traditional gas equip- the system, highlighted its “approaches”:
ment field, thanks to the self-con- strength to the electromagnetic - complete configuration and
figuration and the self-adapting. troubles and confirmed the validi- starting of the system solely
The system core consists of a ty of the planning and realisation based on the changeover switch
microcontroller with a very high strategies. and on the BRC Diagnostic Box;

Fig. 1
General layout of
the equipment
Petrol tank
STEP ACTUATOR
BRC
PRESSURE REDUCER
MIXER

Injectors

LPG Solenoid Valve

Throttle body Multivalve LPG

STEP control
Tank
TPS
Lambda
Exhaust gas Refuelling point
oxygen sensor
Engine
Rear sol.valve
Catalytic converter Level gauge

Diagnostic
Box
Injectors
module

Lambda oxygen sensor

Ignition impulses (possible)
Vehicle BRC
portable
original computer
injection ECU JUST
Electronic Control Unit (ECU)

Changeover switch
 6

- possibility of carrying out a Fig. 2

View of the ele-
setup through the system manag- ments making up
ing interface from computer, for a the unit
dialogue in real time with the
ECU, by allowing a careful con-
trol of the equipment working, as
well as a comfortable, close and
specific setting.

The fig. 1 represents the total

layout of the equipment, in partic-
ular:
- the Just electronic control
unit (ECU);
- the changeover switch with
the level gauge;
- the connection with the BRC
Diagnostic Box;
- the possible connection to 1.3. DETAILED DESCRIP- tion, setting and diagnostic pro-
the BRC Portable Computer; TION OF THE SYSTEM cedures of the system.
- the STEP gas flow control COMPONENTS Together with the changeover
actuator; switch a sticker is supplied for its
- the reducer; 1.3.1. ECU AND CHANGEOVER upright positioning (it is sufficient
- the mixer; SWITCH to remove and replace the
- the lambda oxygen sensor. already mounted one).
Such a layout is only aimed at The Just ECU can be consid-
giving an overall view of the ered the operative unit of the The changeover switch (fig. 3)
equipment. whole gas equipment. has three positions allowing three
A lot of details can vary from a Through the special harness types of working.
vehicle to another and, for that requisite to easily reach the car
reason, please refer to the specif- different parts concerned, and a) Working on "forced petrol".
ic diagrams of each model. thanks to the inlet and outlet With the changeover switch
stages opportunely dimensioned button pressed leftwards, the
The fig. 2 represents in detail not to alter or absolutely damage two-coloured rectangular LED
the main electronic and electric the car normal running on petrol turns red, the injectors are work-
components of the system, which in time, it is able to manage the ing, the gas solenoid valves are
comprehends: whole Just system in the course closed, the gas flow control sys-
- the ECU; of its duty. tem is off.
- the changeover switch; The car regularly runs on
- the STEP gas flow control 1.3.1.1. Changeover function petrol, as if there weren’t the gas
actuator; for injection cars equipment.
- the harness.
The changeover switch con- b ) Wo r k i n g w i t h p e t r o l - g a s
sists the Just system more imme- automatic changing over.
diate interface with the user: With the changeover switch
through it the ECU supplies the button in the central position and
instructions necessary for the dri- the ignition key on, the two-
ver. coloured LED is blinking red
The Just changeover switch, (central position without revs);
even though it follows the same the car starts on petrol (two-
line of the other BRC products as coloured LED is fixed red) and
for the standard functions, pre- then it automatically changes
sents manifold additional func- over to gas (two-coloured LED is
tions reserved to the self-acquisi- fixed green), according to a suit-
 7

able changing over strategy over to gas when returning to par. 1.3.1.1).
based on the r.p.m. and on the normal conditions (par. 1.3.1.2). Both the entry threshold in
TPS signal. The threshold to out-of-the revs threshold condi-
enable the changing over is c) Working on "forced gas". tion and the one returning to
adjustable via software (Chapters With the button pressed right- acceptable working conditions
3 and 4). An orange shade of the wards and the ignition key on, the are configurable via software
two-coloured LED marks out that priming is immediately carried out from the interface programme on
the changing over enabling (timed opening of the gas sole- computer.
threshold has been get over with noid valve, to allow the car start-
the car still running on petrol (in ing). 1.3.1.3. Control function of the
such conditions, a deceleration The two-coloured LED turns gas quantity
determines the changing over to green (blinking without revs and
gas). fixed in case of priming or engine The system acts as a “closed
The automatic changing running) and the car runs exclu- loop”, by correcting the air/gas
over to gas is inhibited for a sively on gas. mixture strength in real time
short interval just after the car In this case too the system according to the information com-
ignition (approx. 5 seconds). automatically changes over to ing from the lambda oxygen sen-
Evidently, while running on petrol again in case of failed sor. As everybody knows, this
gas, the injectors are disconnect- starting or accidental stopping one produces a voltage signal
ed, because the outside cutting (safety car) and of r.p.m. above depending on the oxygen present
device and the possible emula- the threshold. in the exhaust gas and therefore
tion of the injectors are enabled, This function is to be con- supplies an indirect measure of
the gas solenoid valves are open, sidered as an emergency solu- the mixture strength (lean, stoi-
the gas flow control actuator is tion, to be used solely in case chiometric, rich), allowing the
controlled and possible further of failure of the petrol feeding ECU to act on the gas flow con-
devices, if any, are enabled. equipment and with the great- trol actuator, through a suitable
This is the recommended est care to prevent the pump power stage.
position for running on gas. f r o m r u n n i n g d r y, w i t h t h e The correction of the mixture
The system automatically empty tank. strength in real time is carried
changes over to petrol again in It is consequently advisable out both according to the infor-
case of failed starting or acci- to always keep a petrol quantity mation coming from the lambda
dental stopping (safety car) of 1/3 or 1/4 of the tank and to oxygen sensor, and through the
and such a condition is pointed renew it rather often so that it analysis of the different driving
out by a shifting lighting of a doesn’t alter. conditions of the car (maps
LED at a time from the left side based on the engine load).
to the right side and back. 1.3.1.2. Changing over again in The Just electronic card has
In a similar way, it automati- out-of-the revs threshold con- been exclusively conceived for
cally changes over to petrol dition managing the BRC STEP
again (two-coloured LED is patented actuator involved in
f i x e d r e d ) i n c a s e o f r. p . m . In case the engine is in out- the system itself and is not
above the threshold with a sub- of-the revs threshold condition, compatible with different actu-
sequent automatic changing while running on gas, the sys- ators.
tem automatically changes
over again to petrol, allowing to 1.3.1.4. Function of injectors
use the revs limiting strategies emulation and fuels overlap-
implemented in the petrol injec- ping
tion ECU.
When returning to accept- The Just ECU doesn’t have
able working conditions, the either the injectors cutting func-
ECU automatically enables the tion inside it or the injectors emu-
changing over to gas again. lator.
The changing over to gas is It is therefore necessary to
carried out as soon as the suit- install an outside module (emula-
Fig. 3
Just Changeover Switch able conditions take place (see tor, disconnector, etc.), available
 8

in different versions according to necessary to reset the memory of 1.3.1.10. Double possibility for
the injection type and the car the petrol injection ECU. setting and starting operations
specific requirements. For using the NC1/NC2 func-
By connecting the outside tion (corresponding to the relay In the Just system two possi-
emulator power-supply to the contact for cutting signal), please ble “approaches” have been con-
White/Green wire of the Just ECU refer to the specific diagrams of templated for setting and starting,
(par. 2.3.3.4), the fuels overlap- each car. to meet all the installers’ require-
ping function is obtained. ments.
The fuels overlapping time is 1.3.1.7. Level gauge It is actually possible to go
programmable via software from an essential setting-up
(Chapters 3 and 4). Inside the change over switch (Chapter 3), only based on the
there is a level gauge consisting changeover switch and on the
1.3.1.5. Emulating function of of a LED bar with four GREEN Diagnostic Box (which minimises
the configurable lambda oxy- LEDs. The low fuel warning is times and adjustments) to a tar-
gen sensor signal obtained through the first LED geted and personalised setting-
blinking. up (Chapter 4), based on the
The Just ECU incorporates a Its working can be obtained by interface programme on comput-
configurable lambda oxygen sen- connecting to the ECU one of the er (which allows the skilled
sor signal emulator which can available BRC level sensors, both installer to personalise the sys-
perform functions of both fixed of the Hall effect type and of the tem working to adjust it to the
emulation and emulation at vari- resistive type (see the Chapter 2 most varied requirements).
able richness. for installation and the “C”
The choice is associated to Appendix for the reference 1.3.1.11. Self-configuration of
the setting-up of the NP – codes). the system to the vehicle sig-
N C 1 / N C 2 r e l a y c o n t a c t ( p a r. The level gauge is preset, but nals
1.3.1.6), that is to say the emula- the indication can be improved or
tion at a variable richness is corrected via software (Chapters The Just system is able to
associated to the NP setting- 3 and 4). self-configurate to the different
up, whereas the fixed emula- types of vehicle signals (auto-
tion is associated to the 1.3.1.8. Dialogue with the matic acquisition of any type of
NC1/NC2 setting-up. Diagnostic Box TPS signal, of revs signal and
In case of emulation of the of lambda oxygen sensor sig-
lambda oxygen sensor signal at a The Just ECU provides for the nal). This makes the ECU setting
variable richness, it is possible to possibility of connection with the considerably easier, by eliminat-
programme the duty cycle of the Diagnostic Box for visualising the ing the installer’s error possibility
lambda signal emulated with a main control signals. (Chapter 3).
1% resolution (Chapters 3 and The r.p.m., the lambda oxygen
4). sensor signal and the STEP actu- 1.3.1.12. Self-adapting of the
ator position are actually visu- system
1.3.1.6. Function of the memory alised on the three LED bars of
management and of the signal the device (par. 1.3.2). Self-adapting strategies
cutting relay contact have been implemented in the
1.3.1.9. Dialogue with the BRC Just system according to the
The White and White/Orange Portable Computer changes of the car working
wires can have a double function, conditions and characteristics,
configurable via software The Just ECU (through a spe- in order to assure the constant
(Chapters 3 and 4): cial adapter) can also be con- and permanent optimisation of
- memory resetting function of nected to the BRC Portable the control potential (par. 3.8).
the petrol injection ECU (NP); Computer. A valid and powerful
- relay contact function for cut- interface programme allows to 1.3.1.13. Check-up of the sys-
ting signal (NC1/NC2). communicate with the ECU and tem
The NP function of the White to have access to its memories
and White/Orange wires is usual- and to its central processing unit Each time the board cuts out,
ly used only on cars where it is in real time (par. 1.3.3). the ECU carries out a check-up
 9

of all its parameters and of the sensor signal and the STEP actu- installations.
"state" of all the components ator position are actually visu- The Chapter 4 of this hand-
belonging to the Just system. alised on the three LED bars. book is completely dedicated to
Such a condition is pointed The Diagnostic Box is there- the interface programme on com-
out by the changeover switch fore a very useful instrument puter.
through a shifting lighting of (indispensable if the interface
couples of LEDs from the cen- programme on computer is not 1.3.4. HARNESS
tre outwards and back. used) for the system configura-
(NOTE: it is anyway possible tion and setting, as well as for the The Just ECU connection to
to break off the check-up for a starting and any future controls the system different elements can
subsequent starting in case of and adjustments of the parame- be performed with two harness
need). ters. types (see “C” Appendix for the
The combined use of the attendant codes). The main con-
1.3.1.14. Troubleshooting Diagnostic Box and the nector of the Automotive 24-way
changeover switch, particularly type gathers all the secondary
The Just system is able to allows the access to very useful pre-wired connectors and the dif-
carry out a diagnostic of its work- setting domains such as the visu- ferent wires, to which the same
ing in real time. alisation of the STEP actuator colours used for the BRC
Possible errors or troubles are reset position and the duty-cycle Lambda Gas systems have been
stored by the ECU and pointed visualisation and setting out of maintained.
out through a special encoding the lambda signal emulated (see The different wires are more-
on the changeover switch LEDs Chapter 3 for the detailed over divided into sheaths in order
as soon as they occur. description). to make the installation easier
They are also stored and and to improve the appearance.
made accessible in the interface 1.3.3. INTERFACE PROGRAMME
programme on computer. ON COMPUTER 1.3.5. GAS FLOW CONTROL
The clearance of the errors ACTUATOR
stored takes place automatical- The possibility to connect the
ly when the car stops: if their Just ECU to the BRC Portable The control of the fuel quantity
cause is removed, they won’t Computer (through a special sent to the engine is carried out
occur at the subsequent start- adapter) has been contemplated by the STEP actuator: it is a step
ing, otherwise they will reap- for a more and more practical by step engine of common use in
pear. and precise setting procedure. the automotive field, to which a
A valid and powerful interface cylindrical shutter is applied. The
1.3.2. DIAGNOSTIC-BOX programme allows to communi- stroke of this shutter provokes a
cate with the ECU and to have variation of the gas passage port
The Just ECU contemplates access to its memories and its in the pipe (fig. 4).
the possibility of connection with central processing unit in real The adjusting system is man-
the Diagnostic Box for visualising time. aged in every instant and in real
the main control signals. The interface on computer is time by the ECU which controls
The r.p.m., the lambda oxygen therefore the instrument through its work done, by valuing both the
which the installer interacts with lambda oxygen sensor response
the whole Just system and will be and the car working conditions
able to “model” the gas equip- according to special preset maps,
ment to adjust it to the car char- in case self-adapted, which can
acteristics according to the differ- anyway be handled via software
ent driving conditions. (reset position with the cold oxy-
The orderly collection of the gen sensor, stoichiometric para-
files of the different installations meters, cut-off working, at idle
performed will be real historical speed, at normal speed, at full
archives, very useful both to keep load, management of accelera-
the equipment evolution under tions and decelerations and
control in time, and to be a start- engine load).
Fig. 4
STEP Actuator ing point for new similar or critical The extreme decision-making
 10

quickness of the digital system several years of experience and Just system according to the
and its flexibility assure an easy is due to a synthesis of the best changes of the car working condi-
and effective setting for the con- features of the lambda gas control tions and characteristics, in order
stant maintenance of the correct systems, opportunely integrated to assure the constant and per-
stoichiometric ratio on every car by innovative functions and defi- manent optimisation of the control
and engine model. The actuator nitely in the lead. potential.
is designed for running extremely 2) The results attained by the 7) The two possible “approach-
well both on CNG and on LPG. system in the approval emission es” for the setting and starting
tests of the product are evidence operations have been studied to
1.3.6. REDUCER of the exceptional quality of the meet all the installers’ require-
mixture control strategies: only a ments. It is actually possible to go
The Just device is suitable modern, valid and adaptable sys- from an essential setting-up, only
both for LPG and for CNG. tem can attain such goals. based on the changeover switch
In any case, the LPG reduc- 3) The approval tests from the and on the Diagnostic Box (which
er-vaporiser or the CNG pres- point of view of the minimises times and adjustments)
sure reducer ought to be of Electromagnetic Compatibility to a targeted and personalised
BRC manufacture, according to (EMC), successfully passed by setting-up, based on the interface
the regulations in force which the system, highlighted its programme on computer (which
prohibit combinations different strength to the electromagnetic allows the skilled installer to per-
from those used during the troubles and confirmed the validi- sonalise the system working to
approval tests. ty of the planning and realisation adjust it to the most varied
strategies. requirements).
1.3.7. MIXER 4) The ECU, with a microcon- 8) The interface on computer,
troller, manages the control of the besides being the instrument
The above applies to the whole gas equipment and adjusts through which the demanding
mixer too: the mixers admitted the fuel quantity in feedback installer interacts with the whole
are only those marked ”BRC”. through the STEP actuator in system and is able to “model” the
NOTE: the use of the Just sys- order to obtain an optimum mix- gas equipment to adjust it to the
tem, through the information ture, both in respect of pollution car characteristics according to
passed on by the Diagnostic Box and consumptions, and of drive- the different driving conditions,
or rather, by the interface pro- ability, aside from the outside also allows an orderly collection
gramme on computer, allows the conditions (temperature, etc.) and of the files to the different installa-
more experienced installer to the fuel composition. tions performed, creating real his-
value possible failures of the The adjusting system is actual- torical archives, very useful both
feeding mechanical system and ly managed in every instant and to keep the equipment evolution
its best location and setting in real time by the microcontroller under control in time, and to be a
a c c o r d i n g t o t h e d i ff e r e n t c a r which controls its work done, by starting point for new similar or
models. valuing both the lambda oxygen critical installations.
sensor response and the car 9) The ECU inlet and outlet
working conditions according to stages are dimensioned so that,
1.4. ADVANTAGES OF special preset maps, in case self- by carefully following the circuit
THE JUST SYSTEM adapted, which can anyway be diagrams supplied by the BRC
handled via software. servicing and by carrying out
Yo u r a t t e n t i o n h a s b e e n 5)The Just system is able to workmanlike settings, the car
already drawn several times to self-configurate to the different original petrol system can be
the high potential of the microcon- types of vehicle signals (automat- d a m a g e d i n n o w a y. a n d t h e
troller system and of its setting ic acquisition of any type of TPS diagnostic and control systems
and starting modes. signal, of revs signal and of lamb- are kept unchanged while driving.
This paragraph resumes and da oxygen sensor signal). This 10) The system good working
sums up some of the most impor- makes the ECU setting consider- is constantly checked by the diag-
tant goals we aimed at during the ably easier, by eliminating the nostic and check-up strategies
planning, the development and installer’s error possibility. adopted and any possible anom-
the realisation of the Just system. 6) Self-adapting strategies alies are promptly reported and
1) The system is the result of have been implemented in the stored.
 11

2. INSTALLATION 2.2. ECU FIXING sheaths turned downwards and to

OF THE SYSTEM prevent the possible moisture
The Just ECU is proposed from filtering inside the connec-
with a case (though already wide- tor, by dripping on the sheaths
ly used and checked with the (fig. 5).
BRC Blitz ECU), consisting of a - try not to place the ECU near
plastic body and an aluminium the spark plug cables or near the
front which is robust, pretty coil high voltage cable.
small and watertight, therefore The solution to fix the ECU,
suitable to be installed directly where it is possible, inside the
2.1. PRELIMINARY OPER- inside the engine compartment. driver and passenger compart-
ATIONS The new 24-way connector of ment, is anyway always allowed;
the automotive type also assures in this case it is necessary to
Before physically installing the a perfect tightness and a practi- avoid little ventilated areas, e.g.
different components of the Just cal coupling system. between felts, filled carpets, etc.
system, as before any new instal- For a correct installation, it is ...
lation, it’s a good rule to check anyway necessary to carefully Use the special body tongue
the car running on petrol. follow the directions here-below: for fixing and prevent other sys-
In particular, it is necessary to - try not to fix the ECU in sight tems from deforming the case;
carefully check the status of the of the exhaust manifold: the finally check there are no vibra-
ignition electric equipment, the radiative heat propagating could tions.
air filter, the catalyst; to check damage it even at a considerable
through a multimeter or through distance; it is therefore sufficient
the instruments BRC created to have some walls interposed 2.3. ECU CONNECTION
expressly for installers (Jolly, between the exhaust manifold
Diagnostic Box, …) the correct and the ECU, avoiding like that The Just ECU connection to
behaviour of the different signals the direct radiation; the different system elements
concerning the system: positive - it is anyway always neces- ought to be carried out through
after contact, r.p.m., lambda oxy- sary to install the ECU in an area one of the two types of 24-pole
g e n s e n s o r, T P S , p e t r o l E C U of the engine compartment which harness supplied by BRC (see
storage power supply, injectors is as much protected from water “C” Appendix for the attendant
positive. It is also important to as possible; in particular, it is codes).
check that the earth power of the essential to fix it in such a way as The ECU also has a DIN 5-
different signals is stable and to have the harness with the pole connector for the connection
coincides (the acceptable gap
can be of some 10 mV) with the
one of the place where to con- Fig. 5
nect the Just ECU earth. Installation of the
Just ECU: correct
Another very important warn- positioning
ing is to carefully follow the
instructions enclosed to the BRC
products and the circuit diagrams
suggested by the Servicing,
obviously after having checked
the car model to be converted,
the production year, the engine
number, the injection and ignition
types and therefore the equip-
ment feasibility.
These are simple actions tak-
ing a few minutes which could
avoid future inconveniences and
complaints with a consequent
waste of time.
 12

to the Diagnostic Box. Portable Computer is contemplat- already used with the BRC Flying
The possible connection to the ed for a more practical and close Injection system.
BRC Portable Computer for using setting procedure. An adapter is actually avail-
the specific interface programme, A valid and powerful interface able and it can be connected to
can be carried out with a special programme allows to communi- such a cable on one end and to a
adapter (see “C” Appendix for the cate with the ECU and to have special 4-way connector placed
attendant codes), which has to be access to its memories and to its on the Just ECU card on the
connected to a connector inside central processing unit in real other (see “C” Appendix for the
the ECU body (par. 2.3.2). time. attendant codes). In order to
The connection is carried out carry out this connection it is nec-
All the connections of the on the computer serial door, even essary to open the ECU body
harness wires which are unpro- through the same interface cable (fig. 8).
vided with connector ought to
be carried out through well
done and suitably insulated Fig. 6
Just ECU
soft solderings. Do not twist (connectors side
the wires simply or use scarce- view)
ly reliable terminals.

The following instructions

have general validity and are
indispensable for understanding
the system. Please refer to the
specific diagrams for the applica-
DIN 5-pole tap 24-pole harness
tion to each car model. The 24- male connector

pole harness wires maintain the

same colours used in the other
BRC systems; the wires are
moreover divided into several Fig. 7
DIN 5-pole connec-
sheaths in order to make the tor for Diagnostic
installation as easy as possible. Box

2.3.1. 5-POLE DIN CONNECTOR

FOR DIAGNOSTIC BOX

As previously said, the Just

ECU contemplates the possibility
of connection with the Diagnostic
Box for visualising the main con-
trol signals. The r.p.m., the lamb-
da oxygen sensor signal and the
STEP actuator position are actu-
ally visualised on the three LED adapter Fig. 8
Just ECU
bars. The 5-pole DIN connector connection to the
(fig. 7) just allows the ECU con- BRC Portable
Computer
nection to the Diagnostic Box.

2.3.2. CONNECTION TO THE

BRC PORTABLE COMPUTER
PC-Fly Gas connecting cable
As already hinted in the
BRC Portable
Chapter 1, the possibility to con- Computer

nect the Just ECU to the BRC

 13

2.3.3. 24-POLE HARNESS Fig. 9

Cable for the
changeover switch
The two types of 24-pole har- connection

ness (see “C” Appendix for the

attendant codes) have on one
end a main 24-way connector
which gather all the secondary
c o n n e c t o r s a n d t h e d i ff e r e n t
wires, whose description you will
find in the following paragraphs.

2.3.3.1. 10-way connector for

the changeover switch

The 9-pole multipolar cable Fig. 10

Cable for the Step
inside the harness, ended on a actuator connection
10-way connector, is used for the
changeover switch connection
(fig. 9). It connects the ECU to
the changeover switch placed in
the driver and passenger com-
partment; in order to make its
passage through the wall open-
ings easier, the connector 90°
bending on one side is recom-
mended to make it parallel with
the wires.
The boxed changeover switch
is the one already used in the Fig. 11
Level gauge of the
other BRC systems (see “C” resistive type
Appendix for the attendant
codes). Resistive sensor

2.3.3.2. 4-way connector for the

STEP control actuator

The 4-pole multipolar cable White/Black

ended on the 4-way connector

(fig. 10) connects the ECU to the
step by step engine which is
aimed at controlling the gas flow
(par. 1.3.5 ).
Fig. 11.A
Gas level gauge of
2.3.3.3. Connection of the gas the Hall effect type
Hall effect sensor
level sensor

The connecting cable for the

sensors of the resistive type
belongs to the 24-pole harness
and is White/Black, ended with a
female faston provided with a
f a s t o n c o v e r. T h e c o n n e c t i o n Shielded cable

between the ECU and the sensor

can be carried out through the
 14

special extension cable contained The fuse on the Red wire

in the packages of sensors (fig. ought to be always correctly
11). inserted as it has the whole
For the connection of the level equipment protecting function.
gauge of the Hall effect type,
there is a type of Just ECU (see The fuses for the other two
“C” Appendix for the attendant couples of cables are housed
codes) provided with a special lit- inside the reset connector and
tle cable coming out from the ought to be inserted in case of
front with the white 3-way con- serious failure of the gas equip-
nector (fig. 11.A). ment.
For the connections, refer in By inserting the fuses and
any case to the instructions positioning the changeover
enclosed to the sensors. switch on the forced petrol posi-
tion, the car regularly runs on
2.3.3.4. Startend Connector petrol even if the Just ECU is
removed.
It is present on all the versions The installer ought to give the
of the 24-pole harness of the Just suitable directions to the car
system and consists of 3 owner on the use of this function.
White/Green, Black, Red wires,
ended on a male faston with its
cover. These connections ought
Fig. 12
to be used for linking any devices Startend connector
of the Modular family, employed and fixing of the
Modular devices
for cutting and/or injectors emula-
tion functions (fig. 12).
The devices of the Modular
family can be fixed through the
special “dovetail” on the ECU
body.
Do not feed any emulators
with the Green wire feeding the
gas solenoid valves, since that
way it shouldn’t be possible to
use the fuel overlapping func-
tion precisely managed by the
Black
Just ECU through the White/Green
White/Green wire. Red

2.3.3.5. Reset connector

It is present on a version of Fig. 13

Reset
the 24-pole harness (see “C” connector
Appendix for the attendant
codes) and consists of a 4-way
fuse-holder box (fig. 13) which
gathers the following couples of
cables:
- Yellow + Light blue
= (lambda oxygen sensor),
- White + White/Orange
= (memories),
- Red + Red
 15

2.3.3.6. “A” Sheath

Colour type (*) description
Black in engine earth
Red in battery positive(**)
Green out LPG solenoid valve
solenoid valve on LPG or CNG reducers
any safety solenoid valve on LPG tank
(any) other devices

It is important that the BLACK Fig. 14

“A” Sheath
wire is connected to the engine
earth, not to the battery negative Red
or to other bodywork parts.
+12V
Since from a point to another of the Battery

car earth the potential can change

Black
by some tenths of volt, by getting Engine earth

the negative in unfavourable points,

you risk interpreting the lambda Green
oxygen sensor signal wrongly.
(*) The “type” shows whether
Tank S.V.
the attendant signal is an inlet (in)
Reducer S.V. LPG S.V.
or an outlet (out).
(**) The RED wire ought to be
protected by a 7,5 A fuse, should
a harness unprovided with a
reset connector be used.
The loads on the GREEN wire
are to be connected in parallel each
other.

2.3.3.7. “B” Sheath

Colour type description
Brown in positive after contact
Grey in engine ignition impulses

The connection of the BROWN Fig. 15

“B” Sheath
wire absorbs very little current, so
that any positive after contact can
be chosen. What is important is
to check that it is not a point of
the electric equipment subject
to strong losses of voltage. For Engine ignition impulses Grey
Brown
Positive after contact
instance, on some cars it is neces-
sary not to use the ignition coil
positive or the injectors positive
because they are preceded by
resistances lowering the potential
by some volt.
The GREY wire ought to be able wires could be: the wire going ence to the square wave sig-
connected to a frequence impul- to the revolution counter or the nals, by choosing the connec-
sive signal proportional to the wire connecting the above ECUs tion to the “ignition coil nega-
r.p.m. It can be: with the ignition power module; tive” only as extreme possibili-
- a square wave signal findable - a signal coming from the ty.
on the injection ECU or on the "ignition coil negative". Do not twist the grey wire as
ignition one, provided that its When it is possible, we an antenna on the high voltage
amplitude is sufficient. The suit- advise to always give prefer- cables.
 16

2.3.3.8. “C” Sheath

Colour type description
Yellow in lambda oxygen sensor signal
Light blue out emulated lambda signal

The lambda oxygen sensor Fig. 16

“C” Sheath
usually supplies a signal oscillat-
i n g f r o m 0 a n d 1 V; o n s o m e
types of cars it is possible to find
oxygen sensors with signals
oscillating between 0,7 and 1,5 V
Light blue
or between 0 and 5 V; the Just Lambda Signal Emulated

ECU, with the self-acquisition Lambda Signal Yellow

procedure, is able to adjust to all

these lambda signal amplitudes
as well as to lambda oxygen sen-
sors with absorption or resistive
pull-up.
The connection of the YEL- Fig. 16.A
LOW and LIGHT BLUE wires can Read of the
Oxygen sensor signal

Lambda oxygen
be carried out directly on the sensor signal with
Injection ECU
injection ECU, or on the oxygen emulation
sensor connector; in any case it
Light blue
is necessary to carefully follow
✂ Yellow
the detailed diagrams of each
car.
If it is necessary to emulate
Lambda oxygen sensor
the lambda oxygen sensor signal,
the wiring diagram is the one of
fig. 16.A. If not, please refer to
the fig. 16.B.
Fig. 16.B
Read of the
Important: do not short-cir- Lambda oxygen
Oxygen sensor signal

cuit the oxygen sensor wire sensor signal

Injection ECU without emulation
either towards the earth, or
towards the positive.
Do not apply any load. Do not connect
Light blue

Yellow

When in doubt, the wire of the

lambda oxygen sensor signal can
be easily located through the Lambda oxygen sensor

"Jolly" code 06LB00001086.

 17

2.3.3.9. “D” Sheath

Colour type description

White in ECU memories wire (battery side)
White/Orange out ECU memories wire (ECU side)

The WHITE and WHITE/ Fig. 17

“D” Sheath
ORANGE wires can have a dou-
ble function, configurable via
software (see Chapters 3 and 4):
- Resetting function of the
ECU memories wire
White/Orange
petrol injection ECU memory (ECU side)/
NC1 relay contact
(NP);
ECU memories wire
- NC relay contact function for White
(battery side)/
NC2 relay contact
(NC1/NC2) signal cutting.

The NP function of the White

and White/Orange wires is usual-
ly only used on cars where it is
necessary to reset the petrol Fig. 17.A
injection ECU memory. Such a Memories manage-
ment (NP function)
Memories wire

memory is normally maintained

Injection ECU
through a wire connecting directly
the injection ECU with the battery
White/Orange
(see BRC specific diagrams).
This wire is generally recognis- White
able because its voltage is
always 12V, with the ignition key +
off, with the ignition key on and + 12V
Battery
with the engine running (fig.
17.A).
Thanks to these connections,
it is possible to interrupt it in time, Fig. 17.B
by also preserving determined Relay for cutting
warning light signal
functions as the self-cleaning of (NC1/NC2 function)
the hot wire, taking place some Injection ECU
seconds after the engine stop-
ping. White/Orange
For using the NC1/NC2 func-
White
tion (corresponding to the signal
cutting relay contact), please
refer to the specific diagrams of
Check light
each car (fig. 17.B).
Be careful with the connec-
tion polarity: in any case the
White/Orange wire ought
always to be connected to the
one coming from the petrol
injection ECU side.
 18

2.3.3.10. “E” Sheath

Colour type description

White/Violet in TPS (potentiometer integral with the throttle body)

The WHITE/VIOLET is to be Fig. 18

“E” Sheath
connected to the potentiometer
proportional to the throttle body
position (TPS signal).
The TPS signal can be direct
(voltage signal increasing while
the throttle opening increases), or Throttle valve White/Violet
potentiometer signal
inverted (voltage signal decreas-
ing while the throttle opening
increases). It can moreover be of
the analogic type (continuously
varying while the throttle position
varies) or of the ON/OFF type
(only assuming a minimum and a 2.5. ASSEMBLY OF THE 2.7. ASSEMBLY OF THE
maximum value). GAS LEVEL GAUGE MIXER
The Just ECU is able to recog-
nise automatically (during the Follow the instructions enclosed Follow the instructions supplied
self-configuration procedure) to the chosen transducer; regarding for each car and always use sole-
whether the signal is direct or the adjustment, also see the par. ly BRC reducers.
inverted. It is nevertheless nec- 3.5.
essary to set the TPS signal
type (analogic or ON/OFF) via 2.8. ASSEMBLY OF THE
software (Chapters 3 and 4), 2.6. ASSEMBLY OF THE REDUCER
knowing that the default con- GAS FLOW CONTROL
figuration considers a signal of ACTUATOR Follow the usual assembly
the analogic type. rules, by fixing the reducer rigidly to
The STEP actuator ought to be the bodywork and orienting it so
assembled in any point of the gas that the diaphragms are parallel to
2.4. ASSEMBLY OF THE pipe between reducer and mixer. the car longitudinal axle. Check that
CHANGEOVER SWITCH We anyway advise to assemble it no engine part hits the reducer, nei-
as near the mixer as possible . It ther when this one idles, or when it
Choose a well accessible and also ought to be mounted as is under stress. Always try to place
visible position for the driver and upright as possible, with the the reducer and the mixer in such a
fix the device through the screws connector turned upwards (fig. way as to reduce the gas pipe
supplied. By replacing the sticker 19). Check there are no exces- length as much as possible.
with the spare one, the sive vibrations and that the
changeover switch can also be engine weight doesn’t rest
assembled upright. By eliminating excessively on the pipe.
the outside body, the changeover
switch can be directly boxed in Fig. 19
Positioning recom-
the car dashboard by using the mended for the
special drilling tool code Step actuator.
90AV99000043.
YES
Special boxed changeover
switches are specifically available
for each car, to be positioned NO NO
instead of the original switch cov-
ering plates. Please refer to the
electric diagrams and to the price
list for the available models.
 19

3. CONFIGURATION and possible future controls and 0.7 to 1.5 volt or from 0 to 5 volt,
AND SETTING OF parameters adjustment. the resolution of the representa-
The combined use of the tion is obviously lower (approx.
THE SYSTEM TO
Diagnostic Box and of the 0.5 volt per LED in case of 0 ÷ 5
CHANGEOVER changeover switch also allows to volt oxygen sensors).
accede to particular setting
domains such as the visualisation c – Position of the gas flow
and setting of the emulated lamb- STEP actuator
da signal duty cycle (par. 3.6) The third (red) LED-BAR
and of the reset position of the shows the working position of the
In the Chapter 1 we told that STEP actuator (par. 3.7). gas flow STEP actuator, consist-
the Just system setting and start- ing of a step by step engine
ing present two possible 3.1.1. VISUALISATION OF THE which, partially obstructing the
“approaches”: SIGNALS ON THE LED-BARS pipe for the gas passage to the
- system configuration and mixer, allows to adjust the mix-
starting only based on the a – r.p.m. ture.
changeover switch and on the The above green LED-BAR The STEP position ranges
BRC Diagnostic Box; represents the r.p.m. from 0 (all closed) to 255 steps
- possibility to set up through When the r.p.m. signal acquisi- (all open) and the representa-
an interface programme on com- tion and self-configuration phase tion given is not of the absolute
puter, in order to communicate in is over (par. 3.4.2), the LED-BAR type, but of the relative one,
real time with the ECU, allowing a read joins the car revolution according to the reset position.
careful control of the installation counter read. The speed indica- On the LED-BAR, to have a
working as well as a close and tion supplied by the Diagnostic higher resolution, a 20-step
specific setting. Box is therefore to be considered working window is visualised. It
In this Chapter the first possi- approximate. is centred around the STEP
bility will be described in detail. actuator current reset position.
With the only use of the b – Lambda oxygen sensor The reset position is always
changeover switch (which pre- signal represented with 5 LEDs on
sents manifold functions dedicat- The second LED-BAR repre- and every more or less LED on
ed to the installation setting and sents the lambda oxygen sensor corresponds to 2 steps.
starting in the Just system, signal. Consequently, for example, an
besides the classical changing The voltage supplied by the only LED on shows that the STEP
over and fuel level gauging func- lambda oxygen sensor generally is 7 ÷ 8 steps below the current
tions) and of the Diagnostic Box it varies from zero to almost 1 volt, reset, whereas 9 LEDs on show
is actually possible to configurate every LED of this bar therefore that the STEP is 8 ÷ 9 steps
and start the whole system, corresponds to approx. 0.1 volt. It above the current reset.
thanks to special self-configurat- is possible to reckon that the ideal Obviously, if the LED-BAR is
ing and self-adapting strategies mixture corresponds to 0.4 ÷ 0.5 completely on, the actuator is in a
managed by the microcontroller. volt, that’s why around these val- position over 10 steps above the
ues some green LEDs have been current reset (considerable open-
inserted, being easy to be deter- ing condition of the STEP due, for
3.1. THE DIAGNOSTIC BOX mined, even while driving on instance, to the typically lean air-
road. The mixture anyway gas mixture strength, to an open-
The Just ECU contemplates remains excellent in the whole ing transient condition (pumping),
the possibility of connection with green field and good in the field or to a working condition at full
the Diagnostic Box for visualising marked by the yellow LEDs. load).
the main control signals. Higher voltages turn the red Otherwise, if the LED-BAR is
The Diagnostic Box is there- LEDs on. These LEDs indicate a completely off, the actuator is in a
fore a very useful instrument rich mixture, whereas voltages position ranging over 10 steps
(indispensable if the interface pro- nearly zero volt can even turn all below the current reset (consider-
gramme on computer is not used) the LEDs off. able closing condition of the
for the system configuration and In case of lambda oxygen sen- STEP due, for instance, to the
setting, as well as for the starting sors with a voltage varying from typically rich air-gas mixture
 20

strength, to a closing transient always to be a careful control of figuration of the different signals
condition, or to a cut-off working the installation of the mechani- used by the ECU (TPS, revolution
condition). cal parts (tank, reducer, mixer, signals, lambda signal) and acqui-
Step actuator, connecting pipes, sition of the STEP actuator reset
3.1.2. NUMERIC VISUALISATIONS etc.) with the empty tank. The position;
following step is to introduce no - additional manual setting with
Besides the visualisation of the more than 4 ÷ 5 litres of gas in the possibility to check and possi-
system main signals (with the the tank, which can be used bly correct the acquired values
LEDs turning on proportional to both to check whether there are and/or the default values;
the amplitude of the same signals) any leakages and to carry out - self-adapting of the system
and of the STEP position relating the first acquisition and self- while the car working conditions
to the current reset, the three configuration procedure (par. and characteristics are changing,
LED-BARS of the Diagnostic Box 3.4), whose last phase (STEP to assure the constant and contin-
are also used, all together, to actuator reset acquisition) is per- uous optimisation of the control
obtain a precise representation of formed while the vehicle is running strategies.
particular absolute numeric val- on gas. In particular, the configuration
ues. and setting domains of the Just
In these terms, both the exact ECU (the next paragraphs are
numeric value of the emulated 3.3. CONFIGURATION AND dedicated to) are the following:
lambda signal duty-cycle (par. 3.6) SETTING DOMAINS - First acquisition and automat-
and the one of the STEP current ic self-configuration;
reset position (par. 3.7) can be The Just ECU with a microcon- - Additional manual setting and
visualised on the Diagnostic Box . troller has been conceived in such parameters set-up;
The encoding adopted for this a way as to minimise the adjust- - Visualisation and modification
purpose is the following: ments necessary to start the of the emulated lambda signal
- the first LED-BAR shows installation. duty cycle;
the hundreds, namely the num- The system set-up is substan- - Visualisation and modification
ber of LEDs on starting from the tially based on three different of the STEP actuator reset posi-
left side shows the hundreds; phases: tion;
- the second LED-BAR - first acquisition and self-con- - System diagnostic.
shows the decimals, namely the
Fig. 20
number of the LED on starting
Numeric value on
from the left side shows the the Diagnostic Box
decimals; = 125

- the third LED-BAR shows DIAGNOSTIC

the units, namely the number of
1 BOX

LEDs on starting from the left

2
side shows the units. 5
The figure 20 depicts in outline,
by way of example, a reset
LED-BARS
numeric value = 125.

3.2. PRELIMINARY CON- Fig. 21

Changeover switch:
TROLS identification of the
LEDs
After the installation phase
according to the Chapter 2, in
order to start and adjust the car
running on gas, it is necessary to
configurate and set the system. 1° 2° 3° 4°
The first, indispensable step
to avoid serious failures and GREEN LEDs TWO-COLOURED LED

dangerous situations, ought

 21

3.3.1. LED READOUT ON THE

TWO-COLOURED LED Off
GREEN LED Off
CHANGEOVER SWITCH
GREEN LED Blinking TWO-COLOURED LED Blinking Yellow

During the setting the TWO-

COLOURED LED assumes differ- GREEN LED Fixed TWO-COLOURED LED Blinking Green

ent colours (Green, Red, Yellow)

TWO-COLOURED LED Blinking Red
and different working conditions TWO-COLOURED LED Fixed Green

(on, off, blinking). The GREEN Red/Green TWO-COLOURED LED

TWO-COLOURED LED Fixed Red Alternating
LEDs are also used in different
working conditions to allow a spe- Red/Green/Yellow TWO-COLOURED
TWO-COLOURED LED Fixed Yellow LED Alternating
cial encoding of the several setting
phases. In this paragraph, and
Fig. 22
more specifically in the fig. 21 and Caption for the interpretation of the changeover switch leds
22, we intend to help the installer
with the interpretation of the mes- Fig. 23
Beginning of the
sages coming from the changeover first acquisition and
switch. self-configuration
procedure
The fig. 21 depicts the
changeover switch. The GREEN G G G G
LEDs can only assume a Green
colour with a fixed or blinking turn-
ing on, whereas the TWO- the lambda oxygen sensor one. The Step actuator reset posi-
COLOURED LED can each time Before starting the procedure, tion is therefore carried out while
appear Green, Yellow, Red, fixed or we strongly recommend to put running on gas.
blinking. the changeover switch in the To make its execution easier, the
The fig. 22 contains the caption petrol position, to start the vehi- operator is informed on the work
for reading the messages supplied cle and to warm the engine up progress through a special encoding
by the changeover switch. well. With the engine warmed up based on the colours of the TWO-
it will be sufficient to put the COLOURED LED: as a general rule,
changeover switch in the central a colour is associated to each phase
3.4. FIRST ACQUISITION position to start the self-configu- and the TWO-COLOURED LED
AND AUTOMATIC SELF- ration procedure. turning on mode distinguishes the
CONFIGURATION The vehicle will keep on run- condition of the phase in progress
ning only on petrol. from the condition of the phase com-
At the first ignition, when the The first acquisition and self- pleted (see “D” Appendix for sum-
setting operations have not been configuration procedure consists of marising outlines).
carried out yet, if the changeover four phases: NOTE: It is possible to break
switch is in the central position, 1) TPS signal acquisition and off the first acquisition and self-
the GREEN LEDs blink two at a self-configuration (par. 3.4.1). configuration procedure every
time alternatively and the TWO- 2) R.p.m. signal acquisition moment and to begin all over
COLOURED LED is off (fig. 23). and self-configuration (par. again by simply putting the
In such conditions the vehicle is 3.4.2). changeover switch in the petrol
only able to run on petrol. 3) Lambda oxygen sensor sig- position and getting back to the
Before using the gas ECU, it nal acquisition and self-configu- central position.
is necessary to carry out the first ration (par. 3.4.3). Warning: should a working
acquisition and self-configura- 4) Step actuator reset position anomaly occur (TWO-COLOURED
tion procedure. With the acquisition (par. 3.4.4). LED on, alternating green - yellow
changeover switch in the petrol During the early three phases - red), in any moment of the first
position, the GREEN LEDs are the vehicle only runs on petrol. acquisition and self-configuration
off and the TWO-COLOURED At the beginning of the fourth procedure, after trying to trou-
LED is fixed red. In such condi- phase the system automatically bleshoot (par. 3.9), it is necessary
tions the vehicle normally runs changes over to gas and again to to turn the vehicle off, to discon-
on petrol and the only visible petrol when the phase is com- nect the ignition key and to begin
signal on the Diagnostic Box is pleted. all over again.
 22

3.4.1. ACQUISITION AND SELF- Fig. 24

TPS signal acquisi-
CONFIGURATION OF THE TPS tion and self-confi-
SIGNAL guration

G G R G G R
- After having warmed the
engine up well with the changeover
switch in the petrol position, leave
the engine idling and put the
Fig. 25
changeover switch in the central End of the TPS
position. signal acquisition
During this phase the vehicle
only runs on petrol. G G R G G R
- After approx. 10÷15 sec-
onds, the TWO-COLOURED LED
turns on fixed red (beginning of
the TPS acquisition phase) (fig.
24).
- Accelerate uniformly and
thoroughly 3 times
- During this phase the min. and
the max. TPS are determined and
it is possible to ascertain whether
the TPS signal is direct or inverted.
- If the operation has been
carried out correctly, the TWO-
COLOURED LED turns red blink-
ing and indicates the end of the
TPS acquisition phase (fig. 25).
Fig. 26
Acquisition and self-
3.4.2. ACQUISITION AND SELF- configuration of the
CONFIGURATION OF THE R.P.M. r.p.m. signal

SIGNAL
G G G G G G

- After the TPS acquisition

phase (red blinking TWO-
COLOURED LED), leave the
Fig. 27
changeover switch in the central End of the r.p.m.
position and the engine idling signal acquisition

(accelerator thoroughly released)

and wait. G G G G G G
During this phase the vehicle
only runs on petrol.
- After approx. 5 seconds the
TWO-COLOURED LED turns on TWO-COLOURED LED turns there is no correspondence
fixed green (beginning of the r.p.m. green blinking and indicates the between the actual r.p.m. and the
signal acquisition phase) (fig. 26). end of the r.p.m. signal acquisi- ones visualised on the
- Wait with the accelerator tion phase (fig. 27). Diagnostic Box (error factor =
thoroughly released (if the accel- - From now on, the r.p.m. indica- 1/4, 1/2, 2 or 4), it is advisable to
erator is not released thoroughly, tion on the first LED-BAR of the break off the first acquisition and
the acquisition is not carried out). Diagnostic Box is configurated cor- self-configuration procedure by
- During this phase the type of rectly (whereas so far it is likely not putting the changeover switch in
r.p.m. signal used by the ECU is to correspond to the actual r.p.m., the petrol position and to repeat
recognised. according to the vehicle type). by putting the changeover switch
- After approx. 10 seconds the WARNING: if you are sure that in the central position again.
 23

3.4.3. ACQUISITION AND SELF- Fig. 28

Acquisition and self-
CONFIGURATION OF THE LAMB - configuration of the
DA OXYGEN SENSOR SIGNAL lambda oxygen
sensor signal
G G Y G G Y
- After the r.p.m. signal acqui-
sition, the acquisition and the self-
configuration phase of the lambda
oxygen sensor starts.
During this phase the vehi-
cle only runs on petrol.
- In order to enter the acqui-
sition domain of the lambda
oxygen sensor, it is necessary
to constantly keep the engine
at 3000 r.p.m.
- If the r.p.m. is kept on a
correct value, the TWO-
COLOURED LED turns on fixed
yellow and the acquisition phase
of the lambda oxygen sensor
starts (fig. 28).
- Every time you exit (on pur-
pose or by mistake) from the
acquisition r.p.m. window, the
TWO-COLOURED LED becomes
green blinking again and the
acquisition of the lambda sig-
nal is broken off.
To s t a r t t h e a c q u i s i t i o n
again it is necessary to restore
the r.p.m. near the value wanted
(3000 r.p.m.).
- The acquisition phase of the
lambda signal has a variable
duration (from approx. 20 to 30 Fig. 29
seconds) according to the lambda End of the acquisi-
tion of the Lambda
oxygen sensor type of the vehicle. oxygen sensor
- During this phase it is possi- signal
ble to determine the amplitude of G G Y G G Y
the lambda oxygen sensor signal
(0 ÷ 1 V; 0.7 ÷ 1.5 V; 0 ÷ 5 V), the
max. and min. values of such a
signal and the lambda oxygen
sensor type (normal, with absorp- - The only operation the
tion, or with resistive pull-up). installer ought to carry out is to
- During the acquisition keep the r.p.m. around the speci-
phase the r.p.m. probably tends fied value (3000 r.p.m.).
to change and the lambda sig- - If the setting phase of the
nal on the Diagnostic Box lambda signal is successful,
remains fixedly rich or lean for the TWO-COLOURED LED turns
some seconds: this belongs to yellow blinking and indicates
the acquisition procedure and its conclusion (fig. 29).
is not indicative of any failure
of the vehicle.
 24

3.4.4. ACQUISITION OF THE

RESET POSITION OF THE STEP
ACTUATOR

- After the acquisition phase of Fig. 30

Acquisition of the
the lambda oxygen sensor (TWO- Step actuator reset
COLOURED LED blinking yel- position
low), go on keeping the engine
at 3000 r.p.m. G G GR G G GR
- After approx. 3 seconds,
the system automatically
changes over to gas and the
TWO-COLOURED LED alterna- LED or one LED on); During the searching phase,
tively turns on red and green to - the second LED-BAR shows the position visualised on the third
indicate the beginning of the the decimals, namely the number LED-BAR is continuously updated
acquisition phase of the STEP of the LED on starting from the according to the STEP shift.
actuator reset position (fig. 30). left side shows the decimals; Since every LED corresponds
- The reset search and - the third LED-BAR shows the to two steps, it is possible to visu-
acquisition are carried out only units, namely the number of LEDs alise the STEP dynamics in a win-
if the r.p.m. is outside the idling on starting from the left side dow ranging from 90 to 110 steps.
and cut-off conditions, and the shows the units. In any case, the reset defini-
permanence in the correct r.p.m. If, by way of example, the tive position acquired is exactly
for the reset acquisition is contin- reset acquired is 85, the LED- visualised on the Diagnostic Box.
uously pointed out with the TWO- BARS of the Diagnostic Box
COLOURED LED alternatively would appear like in the fig. 31. Once the reset position has
turning on red and green. been acquired, the first acquisi-
- Should the pre-established You are reminded that the tion and self-configuration pro-
working conditions be left, the step motor position ranges cedure is over and all the val-
TWO-COLOURED LED turns off from 0 (all closed) to 255 (all ues acquired and the configura-
and it is then necessary to open), with proper restrinctions tions done have been stored.
restore the suitable working on the max. possible ranges.
conditions of the engine. It is necessary to stop the
- Keep the engine inside the The search of the reset posi- engine and to turn the ignition
suitable r.p.m. window till the tion is carried out starting from an key off to get out from the
reset position acquisition is indi- actuator default reset position of domain.
cated. 100.
- While the reset position is Until the searching phase of
determined, the vehicle the reset position starts, the third
changes over to petrol again, LED-BAR constantly shows this
all the GREEN LEDs of the default reset position (100), with
changeover switch turn off and the early 5 red LEDs on.
on the LED-BARS of the
Diagnostic Box the reset posi-
tion acquired is only indicated Fig. 31
Visualisation of the
whereas respectively the r.p.m. reset acquired on
signal, the lambda signal and the Diagnostic Box

the step motor position aren’t DIAGNOSTIC

BOX
anymore, according to the
encoding already described in 8
the paragraph 3.1.2: 5
- the first LED-BAR shows the
hundreds, namely the number of
LEDs on starting from the left side
shows the hundreds (typically no
 25

3.5. ADDITIONAL MANUAL once. COLOURED LED depicted in the

SETTING AND PARAME- - The passage from a manual figures of the following paragraphs
TERS SETUP setting domain to the next one is refers to the first time the additional
obtained by changing over from manual setting domain is entered.
After the first acquisition and the central position > gas posi-
self-configuration phase, at the tion. 3.5.2. LOW LEVEL GAUGE
next ignition the system is already (If you want, for example, to THRESHOLD SETTING (EMPTY
able to run on gas. enter the fourth domain without TANK)
Before running the vehicle on setting the previous ones, three
gas, it is anyway necessary to subsequent transitions from central When entering this setting
complete the setting-up phase position to gas position are neces- domain, refer to what have been
through a series of manual set- sary). just stated in the par. 3.5.1.
ting operations, some of them - The different domains (7 The setting domain is visualised
indispensable (such as the level altogether) are indicated by a in the fig. 32 and is used for acquir-
gauging adjustment, the configura- binary code on the GREEN ing the fuel min. level.
tion of the NP - NC1/NC2 relay LEDs. Please remember that the con-
and the ON/OFF analogic TPS - Once you have got to the last dition of the TWO-COLOURED
setting), others optional (such as manual setting domain, a subse- LED quoted in the figure refers to
the changing over threshold and quent transition of the changeover the first time this setting domain is
the fuels overlapping time). switch from the central position to entered.
the gas position leads to the first The necessary operations are
3.5.1. ACTIONS TO BE TAKEN setting domain again (cyclical man- the following:
IN THE ADDITIONAL MANUAL agement). - Carry out the setting opera-
SETTING DOMAINS - The acquisition or the set- tions while the tank is empty.
ting relating to the referred - Put the changeover switch
To enter the domain dedicated domain is obtained by changing from the central position to the
to the additional manual setting, over from the central position > petrol position to acquire the
the following operations are neces- petrol position. level currently present in the
sary: - For every manual setting tank as the min. level; the TWO-
- Start the engine and leave it domain the TWO-COLOURED COLOURED LED turns fixed
idling with the changeover LED assumes the following green (showing that the datum has
switch in the central position meanings: been acquired).
and the vehicle running on - off: the current domain has - Getting back to the central
petrol (do not carry out the chang- never been set; position, the TWO-COLOURED
ing over to gas). - fixed green (or red) on: LED turns blinking green (show-
- Starting with the acquisition relating to the cur- ing the setting already carried out)
changeover switch in the central rent domain completed or in and will remain like that in the fol-
position, do 3 petrol position > progress; lowing accesses to this setting
central position transitions in no - blinking green (or red): set- domain too.
more than 3 seconds (you cannot ting relating to the current Even if the setting operation has
stop for more than half a second in domain already carried out at already been carried out, it is possi-
the same position, otherwise you least once. ble to repeat it and to acquire a
have to start the whole sequence - To exit in any moment from new value with the same acquiring
again). the manual setting domain it is process.
- After the 3 transitions the necessary to disconnect the
fourth GREEN LED blinks to ignition key.
indicate the entry in the first The detailed description of the
manual setting domain. different setting domains, of the
- The TWO-COLOURED LED attendant encoding on the
is off if the manual setting of this changeover switch LEDs and of G
domain has never been carried the parameters acquisition modes
out, whereas it blinks if the set- is presented in the following para-
Fig. 32
ting of the first domain has graphs. Low level gauge threshold setting
already been carried out at least The condition of the TWO-
 26

3.5.3. 4/4 THRESHOLD OF THE 3.5.5. NP - NC1/NC2 RELAY

LEVEL GAUGE (80% FILLING ) CONFIGURATION

When entering this setting When entering this setting

G G
domain, refer to what has been stat- domain, refer to what has been
ed in the par. 3.5.1. stated in the par. 3.5.1.
The setting domain is visualised The setting domain is visu-
Fig. 34
in the fig. 33 and is used for acquir- Changing over threshold setting alised in the fig. 35 and is used for
ing the 4/4 level of fuel. changing the contact configuration
Please remember that the condi- The setting domain is visualised of the relay coming out from the
tion of the TWO-COLOURED LED in the fig. 34 and is used for modify- White and White/Orange wires.
depicted in the figure refers to the ing the changing over threshold. - The possible functions are the
first time this setting domain is Please remember that the con- function of the “no-problem”(NP)
entered. dition of the TWO-COLOURED device, for resetting the petrol
The necessary operations are LED depicted in the figure refers to injection ECU memory, and the
the following: the first time this setting domain is function of relay contact for cutting
- Carry out the setting opera- entered. the (NC1/NC2) signal.
tions while the tank is full (4/4). The necessary operations are - The TWO-COLOURED LED
- Put the changeover switch the following: blinking green shows that there
from the central position to the - Run the engine at the r.p.m. is already a default setting and
petrol position to acquire the wanted (included between 1500 this is the NP function.
level currently present in the tank and 4500 r.p.m.) and move the - By putting the changeover
as the 4/4 level; the TWO- changeover switch from the cen- switch from the central position
COLOURED LED turns fixed tral position to the petrol posi- to the petrol position the current
green (showing that the datum has tion to acquire the current r.p.m. setting-up of the relay is
been acquired). as the revolution threshold changed, by selecting in this
- Getting back to the central above which changing over to case the NC1/NC2 function, and
position, the TWO-COLOURED gas is allowed; the TWO- the setting-up is shown by the
LED turns blinking green (show- COLOURED LED turns fixed fixed red TWO-COLOURED LED.
ing the setting already carried out) green (showing that the datum has - Getting back to the central
and will remain like that in the fol- been acquired). position, the TWO-COLOURED
lowing accesses to this setting - Getting back to the central LED turns blinking red (setting
domain too. position, the TWO-COLOURED carried out and NC1/NC2 setting-
Even if the setting operation has LED turns blinking green (show- up).
already been carried out, it is possi- ing the setting already carried out) Even if the setting operation
ble to repeat it and to acquire a new and will remain like that in the fol- has already been carried out, it is
value with the same acquiring lowing accesses to this setting possible to pass from a setting-up
process. domain too. to another of the relay function, by
Even if the setting operation has repeating the same process.
3.5.4. CHANGING OVER already been carried out, it is possi- Warning: the NP – NC1/NC2
THRESHOLD ble to repeat it and to acquire a relay setting-up ought to corre-
new value with the same acquiring spond to the configuration
When entering this setting process. adopted in the connections of
domain, refer to what has been the harness to the ECU (see par.
stated in the par. 3.5.1. 2.3.3.9).

3.5.6. FUELS OVERLAPPING

TIME

When entering this setting

G G G domain, refer to what has been stat-
ed in the par. 3.5.1.
The setting domain is visualised
Fig. 33 Fig. 35
4/4 level threshold setting Configuration of the NP - NC1/NC2 relay in the fig. 36 and is used for modify-
 27

G G G G G G G G

Fig. 36 Fig. 37 Fig. 38

Fuel overlapping time setting On/Off-Analogic TPS setting Parameters set-up

ing the fuels overlapping time while 3.5.7. ANALOGIC-ON/OFF

changing over from petrol to gas. TPS SETTING-UP
Please remember that the condi-
tion of the TWO-COLOURED LED When entering this setting
depicted in the figure refers to the G G G G
domain, refer to what has been
first time this setting domain is stated in the par. 3.5.1.
entered. The setting domain is visu-
Fig. 39
- By putting the changeover alised in the fig. 37 and is used Set-up done
switch from the central position for programming the TPS signal
to the petrol position the TWO- type (analogic or ON/OFF) pre- tions are the following:
COLOURED LED turns fixed sent on the vehicle. - Put the changeover switch
green and the current fuels over- - The TWO-COLOURED LED from the central position to the
lapping time is visualised for 3 blinking green shows that there petrol position.
seconds on the GREEN LEDs, is already a default setting con- - Remain in this position for
according to the following encod- sidering the TPS of the analog- 5 seconds at least.
ing: ic type. - Once the setup has taken
- no GREEN LED on: no over- - By putting the changeover place, all the setting operations
lapping switch from the central position carried out on the ECU have
- 1° GREEN LED on: 3 tenths to the petrol position, the cur- been completely cancelled.
of second rent TPS setting-up is changed, - The second, the third and the
- 2° GREEN LED on: 6 tenths passing to the ON/OFF type fourth GREEN LED of the encod-
of second and the selection done is ing and the TWO-COLOURED
- 3° GREEN LED on: 9 tenths shown through the fixed red LED remain fixedly on (fig. 39)
of second TWO-COLOURED LED. and the three LED-BARS of the
- 4° GREEN LED on: 12 tenths - Getting back to the central Diagnostic Box thoroughly turn
of second position, the TWO-COLOURED off.
- After 3 seconds, the overlap- LED turns red blinking (setting After this operation it is nec-
ping time is continuously carried out and TPS setting-up of essary to switch the vehicle off
increased by 3 tenths of second the ON/OFF type). and to reset the ECU complete-
each time and the visualisation Even if the setting operation ly, by repeating the first acqui-
on the GREEN LEDs is updated has already been carried out, it is sition and self-configuration
(when 12 tenths are reached, start possible to pass from a setting-up procedure too.
from the beginning and so on). to another of the TPS type, by Warning! Perform the opera-
- By putting the changeover repeating the same process. tion only if you are really con-
switch in the central position vinced!
again, the currently visualised 3.5.8. PARAMETERS SET-UP
overlapping time is acquired and
the TWO-COLOURED LED turns When entering this setting 3.6. DUTY CYCLE VISUAL-
green blinking (showing the setting domain, refer to what has been ISATION AND MODIFICA-
already carried out). stated in the par. 3.5.1. TION OF THE LAMBDA
In this case too it is possible to The setting domain is visu- OXYGEN SENSOR EMU-
repeat the setting operation and to alised in the fig. 38 and is used LATED SIGNAL
acquire a new value with the same for completely annulling any set-
acquiring process. ting already carried out on the To enter the duty cycle visuali-
system. The necessary opera- sation and modification domain of
 28

the lambda emulated signal, the cycle value it is necessary to one (and the visualisation on the
following operations are neces- disconnect the ignition key. Diagnostic Box is updated).
sary: - Putting the changeover
- Connect the ignition key switch from the central position
without starting the vehicle, 3.7. VISUALISATION AND to the petrol position, the cur-
with the changeover switch in MODIFICATION OF THE rent reset position is decreased
the central position. STEP RESET POSITION by one (and the visualisation on
- Beginning with the the Diagnostic Box is updated).
changeover switch in the cen- For entering the step reset - The reset position cannot be
tral position, carry out 3 petrol position visualisation and modifi- over the pre-fixed thresholds.
position > central position tran- cation domain, the following oper- - To acquire the new reset
sitions in no more than 3 sec- ations are necessary: position it is necessary to
onds (you cannot stop for more - With the changeover switch switch the vehicle off.
than half a second in the same in the central position, start the - During the permanence in
position, otherwise you have to vehicle on petrol and run the this setting domain, the vehicle
start the whole sequence again). engine above 1500 r.p.m., with- only runs on petrol.
- After the 3 transitions the out changing over to gas. The use of such a setting
changeover switch LEDs are all - In such conditions, begin- domain is only recommended
off, whereas the duty cycle per ning with the changeover for the reset visualisation. We
cent value (0 ÷ 100%) of the switch in the central position, actually advise you against
lambda oxygen sensor emulat- carry out 3 petrol position > “intuitively” modifying the
ed signal is visualised on the central position transitions in reset position value, since any
Diagnostic Box, according to no more than 3 seconds (you possible corrections have been
the encoding already presented cannot stop for more than half a already made by the self-adapt-
for the reset: second in the same position, oth- ing procedure (par. 3.8).
- the first LED-BAR shows the erwise you have to start the whole
hundreds, namely the number of sequence again).
LEDs on starting from the left side - After the 3 transitions the 3.8. SELF-ADAPTING
shows the hundreds; changeover switch LEDs are all
- the second LED-BAR shows off, whereas the current reset As we have already told in the
the decimals, namely the number position is visualised on the Chapter 1, particular self-adapting
of the LED on starting from the Diagnostic Box, according to strategies have been implement-
left side shows the decimals; the encoding already presented ed in the Just system while the
- the third LED-BAR shows the (par. 3.4.4). vehicle working conditions and
units, namely the number of LEDs - The accelerator can be characteristics vary, in order to
on starting from the left side thoroughly released and the assure the constant and continu-
shows the units. engine can be left running on ous optimisation of the control
- The default value at the end petrol. potential.
of the first acquisition and self- - Putting the changeover The properties and the fea-
configuration procedure is = 46 switch from the central position tures of such strategies can be
(fig. 40). to the gas position, the current summed up in two main aspects:
- Putting the changeover reset position is increased by - constant control and
switch from the central position
to the gas position, the current Fig. 40
Duty-cycle default
duty cycle value is increased value of the lambda
by one (and the visualisation on signal emulated
the Diagnostic Box is updated). DIAGNOSTIC
BOX
- Putting the changeover
switch from the central position to 4
the petrol position, the current 6
duty cycle value is decreased by
one (and the visualisation on the
Diagnostic Box is updated).
- To acquire the new duty
 29

updating of the signals used by Should any anomaly occur Problems on the TPS signal
the system, with any possible while the vehicle is running on during the first acquisition pro-
corrections in the configura- gas, this one goes on running cedure (still below a minimum
tions done during the first set- on gas, but the STEP actuator threshold or not connected cor-
ting operation; stands in the reset position rectly) (fig. 43).
- dynamism and continuous (control in the emergency con- The TPS signal control is
updating of the STEP actuator ditions). made in the first acquisition and
reset position, able to self- List of the working anomalies self-configuration phase and the
adapt according to the changes and of the attendant encoding on anomaly is a sign of an incorrect
in the car features and different the changeover switch LEDs. connection of the White/Violet
driving conditions. Lambda oxygen sensor sig- wire (par. 2.3.3.10) or of a failure
In particular, the reset self- nal transitions not detected or of the potentiometer proportional
adapting is aimed at optimising lambda oxygen sensor working to the throttle body position.
the mixture control in every situa- incorrectly (fig. 41).
tion, by assuring a greater stabili- The anomaly is pointed out if
ty of the system at normal load no oscillations of the lambda oxy-
and a high promptitude in the gen sensor are noticed for a pro-
transient conditions. longed time, both in the first
Another purpose of the reset acquisition phase and while the G G YR
self-adapting is to optimise its vehicle is normally running on
position rapidly in case a value gas.
not corresponding to the working Fig. 43 - Anomaly of the TPS signal
actual one has been acquired
during the first acquisition. In this Error or problems in the
case, the reset meets the opti- acquisition procedure of the
mum one while driving on road. STEP actuator reset position
(fig. 44).
We have already stated that
G G YR
3.9. SYSTEM DIAGNOSTIC the STEP actuator cannot move
beyond certain opening and clos-
The Just ECU is provided with Fig. 41 - Anomaly of the lambda oxygen ing limits. In particular the reset
a self-diagnosing system indicat- sensor signal acquired during the first acquisi-
ing the working anomalies with an tion phase ought to be included in
encoding on the GREEN LEDs Problems in the connection of a value window too.
and alternating the green - yellow the gas solenoid valves (fig. 42). If the anomaly is noticed, it
- red colours on the TWO- This anomaly is a sign of work- means that the STEP actuator
COLOURED LED. ing problems of the gas solenoid tries to move to an incorrect work-
Should any anomaly occur, valves (there is a trouble on at ing position, without managing to
switch the vehicle off complete- least one solenoid valve). The assure the control stoichiometry.
ly, by disconnecting the igni- problem nature is to be sought in It is necessary to check the
tion key too, and try to trou- an interrupted connection, in a equipment well and to reckon
bleshoot. damaged solenoid valve or in a whether the reducer and the
If the cause has been actually solenoid valve short-circuited mixer are damaged or wrongly
removed, at the next ignition the towards the earth. installed.
system will work correctly again.
If the cause has not been
determined or removed, at the
next ignition, the anomaly noticed
is likely to reveal itself again. G G YR G G G YR
Should you notice any
anomaly during the first acqui-
sition and self-configuration Fig. 42 - Anomaly of the gas solenoid valves Fig. 44 - Anomaly of the STEP actuator reset
acquisition
procedure, start such a proce-
dure again from the beginning.
 30

Wo r k i n g p r o b l e m s o f t h e
ECU EEPROM (fig. 45).
If this anomaly occurs, the
ECU is seriously damaged and it
is not possible to try to find a rem-
edy for the problem. Apply imme-
d i a t e l y t o t h e B R C Te c h n i c a l
Servicing.

G G G G YR

Fig. 45 - EEPROM Anomaly

TA010990/I
M.T.M. s.r.l. Via La Morra, 1 - 12062 - Cherasco (Cn) - Italy