HMC S Eng V6

HMC 2.
4L LPG ENGINE
&
FUEL SYSTEM
HMC
Table of Content Juniper Fuel System
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS
• JUNIPER FUEL SYSTEM
• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
• TROUBLE SHOOTING
• DIAGNOSTIC SERVICE
TOOL
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Confidential, proprietary and trade secret Clark Europe GmbH, KK, Page 2
information. Do not copy or disclose to anyone!
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
C35 trucks use 70 hp HMC engine
HMC-S-ENG-V6 / 30.04.2012
HMC
MODELS Juniper Fuel System
• C15-20s SE Pneumatic or Solid (SE) tyres with DSL or LPG engine
TYPE Capacity Load centre Wheel base Diesel Engine LPG Engine
C15 L/D 1500 kg 500 mm 1400 mm Yanmar 4TNE88 MMC 4G63*
C18 L/D 1800 kg 500 mm 1400 mm Yanmar 4TNE88 MMC 4G63*
C20s L/D 2000 kg 500 mm 1400 mm Yanmar 4TNE88 MMC 4G63*
*OPTION: HMC Theta 2,4
• C15-20sC Cushion tyres with LPG engine only
gasoline
TYPE Capacity Load centre Wheel base LPG engine
engine
C15C L 1500 kg 500 mm 1220 mm HMC Theta 2,4
C18C L 1800 kg 500 mm 1220 mm HMC Theta 2,4
C 20sC L 2000 kg 500 mm 1220 mm HMC Theta 2,4
HMC-S-ENG-V6 / 30.04.2012
HMC
MODELS Juniper Fuel System
C20-35 Pneumatic or Solid (SE) tyres with DSL or LPG/G engine

Wheel
TYPE Capacity Load centre Diesel engine LPG engine
base
C20 D/L/G 2000 kg 500 mm 1620 mm Yanmar 4TNE98 MMC 4G64
C35 D/L/G 3500 kg 500 mm 1700 mm Yanmar 4TNE98 HMC Theta 2,4
C20-35 Cushion tyres with LPG engine
Wheel
TYPE Capacity Load centre LPG engine
base
C20C 2000 kg 500 mm 1400 mm MMC 4G64
C25C 2500 kg 500 mm 1400 mm MMC 4G64
C30C 3000 kg 500 mm 1400 mm MMC 4G64
C32C 3200 kg 500 mm 1400 mm MMC 4G64
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Where does it come from?
• Designed in Novi, Michigan
• Joint development effort by
Chrysler, Hyundai, and Mitsubishi
• Current production since 2006 in
Mitsubishi Gallant, Dodge Strata, Hyundai Sonata
• Over 900,000 engines built
• Similar technology to GM Ecotec, Ford Duratec
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Main Features
• High compression ratio-10.5 : 1
• Low friction design
– “Diamond Like” coating on cam & lifters
– Low friction piston rings
– 5W-20 Lube oil
• Dual overhead camshafts
• 4-Valves per cylinder
• Timing chain with tensioner
• Multipoint Sequential Fuel Injection
• Distributor-less Ignition with individual “coil packs” for each

cylinder
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Main Benefits
• Increased power
• Improved fuel economy
• Improved durability
• Long life—20,000 hour design life
HMC-S-ENG-V6 / 30.04.2012
Industrial 2.4L HMC Engine HMC
Juniper Fuel System
Modifications from Automotive Engine

Piston & ring set redesigned for greater durability Water cooling system
Valve and valve seat material changed Higher water cooling capacity
Aluminum intake manifold Take-off for vaporizer / heater
Exhaust manifold re-designed Starter capacity increased
Variable valve system removed Interface with industrial applications
Camshaft Fan drive added – v-belt off

crank pulley with tensioner
Profile and timing dedicated to
low speed range operation Bell housing & flywheel
Maximize volumetric efficiency Engine mounting
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Specifications
Base Engine Clark HMC 2.4 L
Cycle 4-Stroke
Cylinder Arrangement In-Line 4
Counter-clockwise rotation as
Rotation viewed from flywheel side
Displacement 2.359 L
Dry Weight 170 Kg / 375 lb.
Length 648 mm
Dimensions Width 603 mm
Height 696 mm
Compression Ratio 10.5:1
Rated Output 70 hp @ 2650 rpm
Performance, full power
(C20/30) Max Torque 190 Nm @ 1600 rpm
Derated Output 52 hp @ 2650
Performance, Derated
(C15/20) Derated Torque 156 Nm @ 1300 rpm
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Specifications
Diagnostics Integral fault diagnostics
Throttle Control Electronic throttle body
ECU interface Keyword Protocol 2000
Closed loop with O2 sensor &
Emission control
3 way catalyst
EPA 2007 Tier 3 off-road LSI
Engine
North America
Emission CARB 2010 Off-road LSI
regulations Regulations (Tier 4)
Blow-by gas
Closed crankcase system
ventilation
Idle speed 750 rpm
Governed speed 2650 rpm
Starting system 12V-1.4kW
Type Water cooled-2.2L
Cooling system Thermostat
Wax type (open 82℃-95℃)
type
Type Oil pan 5.2L
Lubrication Maximum
system running 135°C
temperature
Alternator 13.5V-70A
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Cylinder Block and Head
• Aluminum Block & Head

• Both expand and contract at equal rates, reducing gasket stress
• Cast in place steel liners provide long life
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Cylinder Head and Valves

– Hardened valve seat inserts and valve faces provide long life on LP and “dry” fuels
– DOHC 16 Valve head improves volumetric efficiency, improves power and fuel economy
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Cylinder Head HMC
Juniper Fuel System
• Dual overhead cam
• Direct-acting shim-less
mechanical bucket tappets
• Bucket tappets have

diamond-like carbon (DLC
coatings for low friction
• Designed to no adjustments
required for 20,000 hours
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Timing Chain
•“Silent chain” designed for improved endurance
• Much longer service life than rubber timing belt.
• Enclosed in engine front cover, not external
• Chain tensioner keeps chain accurately adjusted for close valve timing
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Ignition System
•Uses Distributorless Ignition, individual “Coil Packs” for each cylinder
•Crank Sensor and Cam Sensor determine spark timing.
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Valve Tappets
•Top of Tappet Coated with DLC (Diamond Like Carbon)
• Provides lower fuel consumption by reducing friction losses
• Provides long life with no adjustments
• Non-adjustable “Solid lifters” reduce maintenance, prevent plugging and wear common with
hydraulic lifters
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Engine Cooling System HMC
Juniper Fuel System
W/Outlet Housing
HEAD
VAPORIZER
RADIATOR
BLOCK
W/PUMP
BY-PASS
THERMOSTAT
Coolant path with closed thermostat
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Fuel System
• MPI (Multipoint Injection) fuel system consists of the fuel rail,
ECU (Electronic Control Unit), Regulator
• Positive pressure (15 psi) 1 bar vapor injection
• The Electronic Control Unit [ECU] was developed specifically for industrial
applications
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Fuel System
List Mixer System LPG Hyundai Multipoint Solution
Compact system design
Layout Large mixer and reducer
(Simple injectors / nozzles)
Fuel induction Mixer Sequential multipoint injection
Power & Torque Limited by airflow pressure losses through Optimal torque curve
capability mixer system at mid/higher engine speeds. Due to better volumetric efficiency
Slower air/fuel toggling due to longer

Emissions Cylinder individual injection allows precise
transport path between mixer and O2
capability and quick lambda toggling control
sensor
Better emissions control allow for smaller
Catalyst An expensive catalyst is required to reduce
catalyst volume and lower precious metal
requirements emissions
loading
Risk of back-fire Possible Not Possible
(through intake (Large combustible volume in intake (Minimal combustible volume with port
system) manifold) injection)
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Clark HMC 2.4 HMC
Juniper Fuel System
Fuel System
– Injector body is connected to
individual nozzles with hose
– Injector assembly is separate
serviceable unit
HMC-S-ENG-V6 / 30.04.2012
Industrial 2.4L HMC Engine HMC
Juniper Fuel System
Cam position
sensor Blow-by outlet
Water
temp
Coolant outlet
sensor
Water
T-MAP sensor outlet
O2 sensor
Water
inlet
Coolant inlet
(thermostat)
Crank sensor
Oil pressure switch
Confidential, proprietary and trade secret

24
Clark Europe GmbH, KK, Page 24
HMC-S-ENG-V6 / 30.04.2012
Engine Emissions HMC
Juniper Fuel System
• The Juniper fuel system is designed to meet and exceed EPA 2007 and CARB 2010
exhaust emissions requirements – commonly known as Tier 4
• Low emissions are achieved through:

– Use of a 3-way catalytic converter
– Closed loop fuelling control using an oxygen sensor
– Transient pressure estimating algorithm
– Engine mapping and tuning

Tier 4 Engine Label
HMC-S-ENG-V6 / 30.04.2012
California ARB Emissions Requirements HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Certificate HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Service
• Fuel System
• Fuel System problems can be diagnosed with flash

codes, (check engine light) and service manual
• Software upgrades and in-depth problem solving can be

done with cable and laptop.
• Engine Mechanical
• Short Block and Cylinder Head serviced as sub-

assemblies
HMC-S-ENG-V6 / 30.04.2012
Clark HMC 2.4 HMC
Juniper Fuel System
Summary
• Latest Technology Engine
• Increased power and improved fuel economy
• Multipoint Sequential Fuel Injection
• Improved durability (no timing belt)
• DIS ignition system with coil packs
• Long life, 20,000 hour engine
• Best engine in the industry!
• Surpasses Nissan K25, Toyota 4Y, GM 2.5
HMC-S-ENG-V6 / 30.04.2012
HMC
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS

• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
TOOL
main menu:
- Quit presentation
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System: Components HMC
Juniper Fuel System
• OMVL Fuel Vaporizer/Regulator: Vaporizes LPG, and provides fuel

rail with a regulated supply of propane
• OMVL Fuel Rail/Injectors: Provides multi point sequential propane

injection, fuel is metered by duration of injection pulse
• Valtek Fuel Filter: Filters gaseous propane, providing clean fuel to

injection rail
Filterkit 935 964 Filter with 2 Clamp‘s
935 959 Tool for crimping the Clamps 1 242 770
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
• Magneti Marelli Throttle Body: Electronically controls

intake manifold pressure
• MTA Engine Control Unit (ECU): Monitors engine sensors,

controls engine speed and load, fuel injection, and
ignition
• Umicore Emissions Catalyst: 3 way catalyst which

reduces NOx, CO, and HC. (Option for Tier 4 only)
HMC-S-ENG-V6 / 30.04.2012
Fuel Injection HMC
Juniper Fuel System
• The Juniper fuel system uses a speed density algorithm to determine the injector pulse required to
deliver the appropriate amount of fuel to each cylinder
• Sensors Used
– Foot pedal informs ECU of operator demand
– TMAP and Crank Position Sensor informs ECU of the amount/rate of air entering cylinders
– Physical models in the ECU calculate the fuel required per cylinder cycle
– Fuel Rail Sensor provides fuel pressure and temperature, ECU calculates injection duration
– Cam Position Sensor is used for sequential injection timing
– Pre-Catalyst Oxygen Sensor provides feed back for control of air fuel ratio, ECU adjusts
injection duration to suit
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
LP GAS
Electrical Signal
Pressure control pipe Lock-Off Valve
Fuel / Temperature Sensor
Fuel Injection Drive
Key-Switch Coolant Temperature
CAN
Pre-CAT O2 Sensor
MIL
Post-CAT O2 Sensor
Accelerator Pedal
Oil
pressure
Oil Pressure Sensor

Camshaft Sensor
Crankshaft Sensor
Ignition / Coil Drive
TMAP Sensor
HMC-S-ENG-V6 / 30.04.2012
Ignition Control HMC
Juniper Fuel System
• The Juniper fuel system has complete electronic control of engine spark timing, this varies
with engine speed, load, and temperature
• Sensors Used
– TMAP informs ECU of engine load
– Crank Position Sensor provides engine RPM
– Calibrated spark table determines ideal spark timing
– Cam Position Sensor provides base engine timing; spark signal is sent from ECU to
, which fires Coil-Over-Plug system
– Coolant Temperature Sensor provides engine temperature used for spark advance
addition (when cold) or advance subtraction (when hot)
• NOTE: The HMC 2.4 has a fixed base engine ignition timing, setting the base ignition timing
is therefore never necessary
HMC-S-ENG-V6 / 30.04.2012
Engine Load and Speed Control HMC
Juniper Fuel System
• The Juniper fuel system electronically controls both the engine RPM and engine load
• The electronic foot pedal informs the ECU of the operator’s demands
• The ECU filters this signal and provides the electronic throttle body with a commanded
throttle angle
• Tuned PIDs control the throttle angle to limit engine RPM and vehicle speed
• In the unlikely case of an RPM over rev, the engine is protected by cutting the ignition
signal until the RPM is reduced
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System Sensors HMC
Juniper Fuel System
Cam Sensor Crank Sensor TMAP Rail P/T Sensor
Coolant T Sensor
Pre Cat O2 Sensor Vehicle Speed Sensor Oil P Sensor
(Option Only)
HMC-S-ENG-V6 / 30.04.2012
Sensor Locations HMC
Juniper Fuel System
Rail P/T Throttle Body

Cam Position
Sensor Connector
Sensor
Ignition
Coolant Coil
Temperat
ure
Sensor
Pre Cat Oil P

O2 Switch
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Juniper Fuel System
Injector Rail P/T Sensor
TMAP
Crank Position Sensor Cam Position Sensor

(hidden)
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
Ignition
Coil
Rail P/T
Sensor
Coolant Temp Pre Cat O2

Sensor Sensor
HMC-S-ENG-V6 / 30.04.2012
Fuel System Components: ECU HMC
Juniper Fuel System
• The Juniper mono-fuel ECU has on-board diagnostics that monitor and detect:
– electric failures or malfunctions of all input sensors
– electric failures or malfunctions of all output actuators
– electric failures of most wiring connections
– most electric failures of ECU itself
– fault conditions that negatively impact emissions
• The specified on-board diagnostics are compliant with:
– SAE J 1979: E/E Diagnostic test modes.
– ISO 14230-4 Keyword Protocol 2000, Part 4: Requirements for emission-related

systems.
– Proprietary KWP2000 ISO14230 protocol over CAN-bus protocol
HMC-S-ENG-V6 / 30.04.2012
ECU Key Features HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
ECU Key Features HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
HMC
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS
• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
TOOL
main menu:
- Quit presentation
HMC-S-ENG-V6 / 30.04.2012
Fuel System Components: Fuel Rail HMC
Juniper Fuel System
Fuel Rail and Injectors
– Manufactured by OMVL
– Common rail houses 4 individual plunger type injectors
– Rail houses a Sensata fuel pressure/temperature sensor
HMC-S-ENG-V6 / 30.04.2012
Fuel Rail Key Features HMC
Juniper Fuel System
• OMVL gas injectors are integrated into a single aluminum injection rail: the single injectors
inject the gas into the intake manifold through aluminum nozzles and injection hoses
(indirect injection).
– Coil resistance (at 20°°C): 2.9 - 3.4 Ohms
– Interface: IP54, Tyco SuperSeal 2-way connectors
– Opening time: 2.7 ms (driven at 13.5 Vdc, gas @ 200KPa, 20°°C)
– Speed-up current: 1.8A (for 3.24 ms at 13.5 Vdc, gas @ 200 kPa, 20°°C)
– Hold current: 1A (driven at 11 kHz, 13.5 Vdc, gas @ 200

kPa, 20°°C)
– Static flow rate per injector: 2.47g/s ± 5% (air at 200 kPa, 20°°C)
– Max working pressure: 600 kPa
– Burst pressure: 1000 kPa
– Working temperature: -40 to 120°°C
HMC-S-ENG-V6 / 30.04.2012
Fuel Rail: Details HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Fuel Vaporizer/Regulator HMC
Juniper Fuel System
Fuel Vaporizer/Regulator
– Manufactured by OMVL
– High volume
– 2 stage
– Referenced to intake manifold

pressure
HMC-S-ENG-V6 / 30.04.2012
Fuel Vaporizer/Regulator Key Features HMC
Juniper Fuel System
• Technical Specifications:
– Working temperature: -30 - 120 °C
– Input pressure: 300 - 3000 kPa
– Input Connection: ¼” NPT
– Gas outlet pressure: 120 ± 10% kPa (13 – 18 psi)
– Output Connection : D12 mm
– Maximum flow rate (propane @ 300 KPa): 25 kg/h
– Pressure relief valve operating pressure: < 202 kPa
– Weight: 1.6 kg
– Diaphragm maintenance: Indicated by OBD trouble code
HMC-S-ENG-V6 / 30.04.2012
Regulator Schematics HMC
Juniper Fuel System
Pressure equalization
MAP with inlet manifold
LPG Liquid In
LPG
Vapour
Out
Water Circuit
State 1: LPG Liquid Shutoff Valve Closed
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
MAP
LPG Liquid In
High-pressure Seat
LPG
Vapour
Out
LPG Vaporizer Tube
State 2: LPG Shutoff Valve Open – Engine Not Running
When the shut off valve is opened liquid LPG passes through the vaporizer pipe and through the pressure
diaphragm. The reduction in pressure vaporizes the LPG. Circulating hot water provides the heat required
to increase the maximum vaporization rate and to prevent freezing of the vaporizer.
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
MAP
LPG Liquid In
LPG
Vapour
Out
State 3: LPG Shutoff Valve Open – Engine Not
Running (2)
Once the liquid starts to flow and vaporize the gas the system immediately achieves equilibrium.
The resultant gas output pressure is a function of the manifold pressure and the spring setting.
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
MAP
LPG Liquid In
Low-pressure
Seat
LPG
Vapour
Out
State 4: Shutoff Valve Open and Engine Running
Once the engine starts and is running there is a flow of gas through the injectors reducing the pressure after
the second stage reducer. Therefore the pressure on top of the membrane is lower and the membrane
moves up. Gas will then flow through the low pressure seat to maintain the intended pressure.
HMC-S-ENG-V6 / 30.04.2012
Vaporizer/Regulator Service HMC
Juniper Fuel System
• Both the first and second stage membranes of the regulator are serviceable, as are
the springs and other internal components
• Detailed instructions on the break down, replacement of parts, and reassembly of

the regulator are given in the Juniper Service Manual
FIRST STAGE
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Vaporizer/Regulator Service HMC
Juniper Fuel System
Second Stage
HMC-S-ENG-V6 / 30.04.2012
Electronic Throttle Body HMC
Juniper Fuel System
Electronic Throttle Body (36 mm)
– Manufactured by Magneti Marelli
– Default (un-powered) throttle angle is 11% (not

fully closed)
– 2 throttle position sensors (redundant) for

safety concerns
– 350 kg/hr air rating 500
450
– High volume (automotive)
400
350
Air Flow [Kg/h]

300
250
200
150
100
50
0
500 1500 2500 3500 4500
TPS1 [mV]
HMC-S-ENG-V6 / 30.04.2012
Fuel Filter HMC
Juniper Fuel System
Key Features
– LPG/CNG gaseous phase filter, Class #2
– Flow rate: 55Kg/hr (air) @ 160KPa
– Max working pressure: 450 KPa (compliant to ECE110,
class #2)
– Burst pressure: >7000KPa
– Temperature range: -40 to 120°°C (compliant to ECE110)
– Material: zinc plated steel, FeP04 (UNI5866-66)
Filtering Element:
Paper cartridge (un-serviceable)
Minimum filtering size: 7µm
Filtering surface: 327cm2
Particle filtration efficiency:
Particles smaller than 3µm: 30-50%
Bigger than 3µm, smaller than 30µm: 85-

98%
Particles bigger than 30µm: 98%
HMC-S-ENG-V6 / 30.04.2012
HMC
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS
• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
TOOL
main menu:
- Quit presentation
HMC-S-ENG-V6 / 30.04.2012
MAINTENANCE SCHEDULE HMC
Juniper Fuel System
Hour Intervals
every 400 every 2000
Category Item Action Daily hours or hours or
3 months 1 year
General MIL Check MIL lamp at key-on. Repair any faults as indicated X
Fuel System Fuel Tank / Shutoff Verify proper mounting & valve function X
Fuel Hose & Fittings Inspect for cracks, leaks, abrasion X
Regulator / Injector rail Inspect for leaks X
Fuel lock-off Verify functionality X
Air Intake Air filter Inspect indicator, replace if neccesary X

Air inlet system Inspect X
Intake manifold & vacuum hoses Inspect for leaks X
Electronic throttle body Inspect for oil deposits from flow reversion X
Ignition Wiring to control modules Inspect for cracks, abrasion X

Coil-over-plug units Inspect for cracks, abrasion X
Spark plugs Change X
HMC-S-ENG-V6 / 30.04.2012
MAINTENANCE SCHEDULE HMC
Juniper Fuel System
Hour Intervals
every 400 every 2000
Category Item Action Daily hours or hours or
3 months 1 year
Exhaust Exhaust manifold & piping Inspect for cracks, leaks, abrasion X
Pre-Catalyst Oxygen sensor Check wire is not damaged / burnt X
Post-Catalyst Oxygen sensor Check wire is not damaged / burnt X
PCV valve Check for leaks X
PCV vent hose Inspect for cracks, leaks, abrasion X
Engine - General Coolant Check level, top-off if necessary X change

Additional engine maintenance listed
in engine manual
Coolant hoses, fittings Check for cracks, looseness, swelling, deterioration X
Engine oil Check level, top-off if necessary X change
Oil filter Change X
Vehicle Electrical Battery & main cables Inspect connections, check for corrosion X
Starter & cables Inspect connections, check for corrosion X
Foot pedal Check that travel is clear of interferences X
ECU Inspect mounting bolts X
Harnesses Check for looseness, proximity to exhaust X
HMC-S-ENG-V6 / 30.04.2012
HMC
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS
• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
TOOL
main menu:
- Quit presentation
HMC-S-ENG-V6 / 30.04.2012
Diagnostic Trouble Codes HMC
Juniper Fuel System
• The Juniper fuel system has active diagnostic troubleshooting to assist a technician in
locating an issue
• There are over 80 diagnostic trouble codes (DTCs) that are monitored at startup, while
running, and some after shutting engine down
• If a DTC is present the MIL on the dashboard will illuminate
• DTCs can be retrieved using the Juniper Service Tool, or as flashes of the MIL
HMC-S-ENG-V6 / 30.04.2012
DTC Retrieval HMC
Juniper Fuel System
• To display the numeric code for a DTC on the MIL the operator must:
– Turn Key On
– Cycle accelerator pedal from 0 to 100 % 3 times within 5 seconds of Key On
• The MIL will flash the code of present DTCs using short pauses between digits, and long
pauses between different DTCs
• The flash cycle will continue to repeat itself until the key is turned Off
• A code of 12 (one flash, short pause then 2 flashes) starts the DTC sequence
6 sec 2 sec
Time
5 6 + 9
DTCs Present: 0005 and 0069
HMC-S-ENG-V6 / 30.04.2012
DTC Retrieval HMC
Juniper Fuel System
To display the numeric code for a DTC on the MIL the operator must:
Turn Key On
Cycle accelerator pedal from 0 to 100 % 3 times within 5 seconds of Key On
The MIL will flash the code of present DTCs using short pauses between digits, and long
pauses between different DTCs
Zeros are represented using a single, 3 second long flash. All DTCs are 4 digits
The flash cycle will continue to repeat itself until the key is turned Off
A code of 12 (one flash, short pause then 2 flashes) starts the DTC sequence
6 sec 2 sec
0+0+6+9
6 sec 2 sec
Time
5 6 + 9
DTCs Present: 0005 and 0069
HMC-S-ENG-V6 / 30.04.2012
Clearing DTCs HMC
Juniper Fuel System
• An operator may clear all present and stored DTCs by clicking the “Clear” button on the
DTC tab of the Juniper Service Tool
• If the issue is corrected, the MIL will automatically go out after the engine has been started
and stopped 3 times
• If the issue is properly fixed, the MIL will go out on the 4th start
• Note: To crank and clear DTCs, the engine must be running for a minimum of 30 seconds
each time, and the key must be turned off for a minimum of 30 seconds
HMC-S-ENG-V6 / 30.04.2012
Possible DTCs HMC
Juniper Fuel System
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Possible DTCs HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Possible DTCs HMC
Juniper Fuel System
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Possible DTCs HMC
Juniper Fuel System
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Possible DTCs HMC
Juniper Fuel System
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Possible DTCs HMC
Juniper Fuel System
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Possible DTCs HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Sensor Pin-Outs HMC
Juniper Fuel System
• The OBD Troubleshooting Guide makes many references to sensor and harness pin-
outs, along with nominal connector voltages when disconnected
• Below are pin-out diagrams for troubleshooting reference
HMC-S-ENG-V6 / 30.04.2012
Sensor Pin-Outs HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
Sensor Pin-Outs HMC
Juniper Fuel System
HMC-S-ENG-V6 / 30.04.2012
DTC Troubleshooting HMC
Juniper Fuel System
• A complete troubleshooting guide for every DTC is provided in the Service Manual
• As an example of using the guide, imagine that a technician is troubleshooting a vehicle

that was displaying the check engine light
• The technician discovers DTCs 107 and 117 using either the Juniper service tool or the MIL
DTC display procedure
• When consulting the service manual the technician finds the following information:
HMC-S-ENG-V6 / 30.04.2012
DTC Troubleshooting: EXAMPLE 1 HMC
Juniper Fuel System
DTC 107: Manifold absolute pressure circuit low input
This diagnostic checks to see if the MAP sensor voltage is within the expected range. It issues
a code if the apparent voltage is too low.
Possible Causes
A. Manifold pressure sensor disconnected
B. Harness is shorted to ground
C. Harness wires are broken/damaged
D. MAP Sensor is defective
E. ECU defective
1. Is the MAP sensor connected?

-Yes: Go to 2.
-No: Reconnect and test again
2. Test for continuity between connector Pins and Chassis Ground

-Only Pin 4 is continuous: Go to 3.
-Pins 1, 2 or 3 are continuous: Locate and rectify short in harness
3. Test harness continuity.

-Continuities are T-MAP Connector Pin 1 --- ECU C1
T-MAP Connector Pin 2 --- ECU C3
T-MAP Connector Pin 3 --- ECU C2
T-MAP Connector Pin 4 --- ECU C4 : Go to 4
-Anything other than above: Locate and Rectify harness damage
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
4. Test ECU voltage outputs at Key On.

-Connector T-MAP Connector Pin 1 is 5 +/- 0.5V
T-MAP Connector Pin 2 is 5 +/- 0.5V
T-MAP Connector Pin 3 is 5 +/- 0.5V
T-MAP Connector Pin 4 is 0 +/- 0.5V: Go to 5.
-Voltage outputs out of specification: Replace ECU to see if problem can be
eliminated
5. Test manifold pressure sensor output.

-If the manifold pressure not equal to atmospheric* +/- 50 mbar pressure at Key
On: Replace MAP sensor
- *For reference, check barometric pressure sensor value with reader.
• Although the troubleshooting procedures are not always performed in order of

ease or probability of cause, they are designed to prevent the unnecessary
replacement of functioning parts.
• For example, while it may be easier and more likely that the DTC is caused by a
faulty T-MAP, it is important to rule out an ECU issue (providing the wrong
supply voltages) before reading the manifold pressure to determine T-MAP
functionality.
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
DTC 117: Engine coolant temperature circuit low
This diagnostic senses an out of range error (low voltage) for the engine coolant temperature
(ECT) sensor.
Possible Causes
A. Coolant temperature sensor disconnected
B. Harness is shorted to ground
C. Harness wires are broken/damaged
D. Temperature Sensor is defective
E. ECU defective
1. Is the coolant temperature sensor connected?

-Yes: Go to 2.
-No: Reconnect and test again
2. Test for continuity between connector Pins and Chassis Ground

-Only Pin 1 is continuous: Go to 3.
-Pin 2 is continuous: Locate and rectify short in harness
3. Disconnect ECT connector and test harness continuity.

-Continuities are ECT connector Pin 1 --- ECU L3
ECT connector Pin 2 --- ECU D2: Go to 4
-Anything other than above: Locate and Rectify harness damage
HMC-S-ENG-V6 / 30.04.2012
Juniper Fuel System
4. Test ECU voltage outputs at Key On with sensor disconnected.

-Connector ECT connector Pin 1 is 0 +/- 0.5V
ECT connector Pin 2 is 5 +/- 0.5V: Go to 5.
-Voltage values out of specification: Check for shorts to battery voltage, replace
ECU if none
5. Test coolant temperature sensor output with Juniper service tool.

-If reported coolant temperature is less that ambient or greater than 125 degrees
Celsius at Key On: Replace Coolant temperature sensor
HMC-S-ENG-V6 / 30.04.2012
HMC
• BASE ENGINE
DESCRIPTION &
SPECIFICATIONS
• FUEL SYSTEM
COMPONENT DETAILS
• MAINTENANCE
TOOL
main menu:
- Quit presentation
HMC-S-ENG-V6 / 30.04.2012
Introduction HMC
Juniper Fuel System
- Communication between the Engine Control Unit (ECU) and a computer is established by
using the Juniper Tool.
-The tool allows for a wide range of diagnostic functions and for easier identification of engine
problems
-Simple to use and easy to read screens
Juniper Tool - Clark Nr. 935 958

Parts of the Juniper Tools
USB Connect
USB Cable A to B
Cable RS232 to CAN
Software Version 1.0.0.3
Minimum Software Requirements

PC with Windows 2000, XP or Vista
Minimum of 800 x 600 screen resolution
CD – ROM or DVD-ROM Drive required
HMC-S-ENG-V6 / 30.04.2012
Starting and Logging in HMC
Juniper Fuel System
Start the Program by pushing the Juniper Icon . The logo screen will prompt you for a
language, login level, and password (if needed)
Login levels
1. Basic (no Password)
- Read Data
- Clear DTCs
- Perform diagnostic routines
2. Advanced (password required)
- all Basic functions
- Edit ECU parameters
- Load new Software und Calibrations
3. EOL (password required)
- End-of-line access for Juniper factory use only
Further information to installing the software and passwords you can find attached to the Juniper Software CD 446 99 13.
HMC-S-ENG-V6 / 30.04.2012
Connecting to the ECU HMC
Juniper Fuel System
-To connect to the ECU, connect the Juniper Tool to the computer using the USB cable,
then use the RS-232 to CAN cable to connect the other end to the harness
-You must connect the 3-pin connector to the CAN1 connector on

the harness, NOT CAN2. Currently, the CAN2 connector is
not enabled.
-The program will be connected as soon as the ignition

is turned on, and up to one minute after the ignition
ECU Plug behind the engine hood at
is turned off the left rail (inside the harness)
HMC-S-ENG-V6 / 30.04.2012
Connecting to the ECU HMC
Juniper Fuel System
LED red
Juniper Tool not connected and ECU not linked to

computer
LED red
Juniper Tool connected with computer but ECU not

linked with tool
LED green
Juniper Tool connected and ECU linked to computer
HMC-S-ENG-V6 / 30.04.2012
GAUGES Tab: Main Screen (not connected) HMC
Juniper Fuel System
The software after Startup / not connected
HMC-S-ENG-V6 / 30.04.2012
GAUGES Tab: Main Screen (not connected) HMC
Juniper Fuel System
- When logging commences, “REC” button changes from a

blue Button with a triangle to a red button with a square.
- To stop logging, click on the red button. A prompt will ask

for confirmation to end the acquisition.
- The log file is in Comma Separated Value format, or CSV
- This format is easily opened by Microsoft Excel, Open Office Calc or any other spreadsheet program
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS Tab HMC
Juniper Fuel System
- The “Parameters” tab allows the user to see various real-time engine parameters
- You can pause the automatic refreshing of the screen by using the pause button.
- The logging function is exactly like the “Gauges” tab
- A print function is also available to print a snapshot of the values of the current page
directly to an attached printer
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS Tab – Engine 1 HMC
Juniper Fuel System
Basic real-time parameters from ECU and Engine sensors
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS Tab – Engine 2 HMC
Juniper Fuel System
Basic real-time parameters from ECU and Engine sensors
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS – Calculated and Learned Values HMC
Juniper Fuel System
These values are calculated or estimated by the ECU based on look-up data or previous operation
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS Tab – Diagnostic Values HMC
Juniper Fuel System
These are values that are relevant to the On-Board Diagnostic (OBD) system of the forklift
HMC-S-ENG-V6 / 30.04.2012
PARAMETERS Tab – Calibrated Parameters HMC
Juniper Fuel System
These are parameters that are determined by manual calibration or by ECU calibration routines
HMC-S-ENG-V6 / 30.04.2012
ECU ID Tab HMC
Juniper Fuel System
These are parameters that provide identification information of the ECU and vehicle
HMC-S-ENG-V6 / 30.04.2012
DTC Tab HMC
Juniper Fuel System
- allow you to save you

to save the current DTC to a text
file
- all PRESENT and

STORED DTCs from memory of
the ECU
- to ensure all
present and stored DTCs are
shown on the screen
- DTC MAUNU open a

document that describes all DTC
in detail
Allows for viewing of the current DTCs that are present and stored on
the ECU. (Automatically refreshed every 5 seconds)
HMC-S-ENG-V6 / 30.04.2012
DTC Tab: Snapshots HMC
Juniper Fuel System
Double Click to show

snapshot
Snapshot
HMC-S-ENG-V6 / 30.04.2012
DIAGNOSTICS Tab – Voltage Inputs HMC
Juniper Fuel System
Diagnostic values can only be accessed with key-on and when the engine is not running
Voltage Inputs show detailed voltage inputs that are relevant to the OBD system
HMC-S-ENG-V6 / 30.04.2012
DIAGNOSTICS Tab – Active Diagnostic HMC
Juniper Fuel System
These allow for manual setting of various actuators for easier troubleshooting
HMC-S-ENG-V6 / 30.04.2012
DIAGNOSTICS Tab – Diagnostic Routines HMC
Juniper Fuel System
To start the diagnostic

routine, double click on
circle
These routines allow for throttle self-calibration, and fuel leakage checking
No Test active (LED grey)
Test in progess (LED yellow)
Test complete (LED green)
HMC-S-ENG-V6 / 30.04.2012
EDIT PARAMETERS Tab (Advanced) HMC
Juniper Fuel System
This page allows for editing of ECU and vehicle identification parameters
HMC-S-ENG-V6 / 30.04.2012
DOWNLOAD Tab HMC
Juniper Fuel System
File Extension
Software files = .mot

Calibration files = .cal
- This page allows for updating of software and calibration

- Calibration update MUST be performed immediately after software update. Calibration version
must match software version
- Key-off for at least 20 seconds after calibration update to allow for proper software updating
(or key-off until program loses connection to ECU)
HMC-S-ENG-V6 / 30.04.2012
DOWNLOAD – Calibration file HMC
Juniper Fuel System
The HMC engines are distinct in four different types. The calibration file is regulated by emission and
torque. The label on the top of the engine tells you the needed version.
Actual used Version 09/2010
HY24_100813_0217_LPGCLKS20T0HT_A.cal
HY24_100813_0217_LPGCLKS10T0LT_A.cal
HY24_100813_0217_LPGCLKS20T4HT_A.cal
HY24_100813_0217_LPGCLKS10T4LT_A.cal
Tier 0 with high torque
HY24_100813_0217_LPGCLKS20T0HT_A.cal T0HT = Tier 0 high torque

T0LT = Tier 0 low torque
T4HT = Tier 4 high torque
Software version Engine specification T4LT = Tier 0 low torque
HMC-S-ENG-V6 / 30.04.2012

HMC S Eng V6

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HMC 2.

C35 trucks use 70 hp HMC engine

• C15-20s SE Pneumatic or Solid (SE) tyres with DSL or LPG engine

• C15-20sC Cushion tyres with LPG engine only

C20-35 Pneumatic or Solid (SE) tyres with DSL or LPG/G engine

C20-35 Cushion tyres with LPG engine

Where does it come from?

• Designed in Novi, Michigan

• Joint development effort by

Chrysler, Hyundai, and Mitsubishi

• Current production since 2006 in

Mitsubishi Gallant, Dodge Strata, Hyundai Sonata

• Over 900,000 engines built

• Similar technology to GM Ecotec, Ford Duratec

• Low friction design

– “Diamond Like” coating on cam & lifters

– Low friction piston rings

– 5W-20 Lube oil

• Dual overhead camshafts

• 4-Valves per cylinder

• Timing chain with tensioner

• Multipoint Sequential Fuel Injection

• Distributor-less Ignition with individual “coil packs” for each

• Improved fuel economy

• Long life—20,000 hour design life

Modifications from Automotive Engine

Aluminum intake manifold Take-off for vaporizer / heater

Exhaust manifold re-designed Starter capacity increased

Variable valve system removed Interface with industrial applications

Camshaft Fan drive added – v-belt off

Maximize volumetric efficiency Engine mounting

Cylinder Block and Head

• Aluminum Block & Head

Cylinder Head and Valves

• Dual overhead cam

• Bucket tappets have

Coolant path with closed thermostat

Fuel induction Mixer Sequential multipoint injection

Slower air/fuel toggling due to longer

– Injector body is connected to

individual nozzles with hose

– Injector assembly is separate

Confidential, proprietary and trade secret

• Low emissions are achieved through:

– Closed loop fuelling control using an oxygen sensor

– Transient pressure estimating algorithm

– Engine mapping and tuning

• Fuel System problems can be diagnosed with flash

• Software upgrades and in-depth problem solving can be

• Short Block and Cylinder Head serviced as sub-

• Latest Technology Engine

• Increased power and improved fuel economy

• Multipoint Sequential Fuel Injection

• Improved durability (no timing belt)

• DIS ignition system with coil packs

• Long life, 20,000 hour engine

• Best engine in the industry!