STRUCTURE AND FUNCTION

CARB T ier 1
Emissions C ontrol S ystem
The California Air
The California AirResources
Resources Board
Board (CARB)
(CARB) is the state’s
is the state’s environ-
mental regulatory
environmental agency. agency.
regulatory CARB hasCARB issued emissions
has issued regulations
emissions
for certain types
regulations of industrial
for certain typesequipment not already
of industrial equipment covered
not by exist-
already
ing EPAcovered by existing
regulations. This newEPAregulation
regulations. This new
impacts regu- using
vehicles
lation spark-ignited”
“large impacts vehicles usingabove
engines “large25spark-ignited” engines forklift
horsepower, including
above 25
trucks. Thehorsepower, including
term “sparkignited” lift trucks.
includes The term
all engines “spark-
using gasoline,
ignited” includes all engines using gasoline, LP, and
LP, and related fuel types, such as Compressed Natural Gas. The related
fuel types, applies
regulation such asonly
Compressed Natural Gas.
to new equipment, The regulation
starting with units pro-
applies only to new equipment, starting with units produced
duced in year 2001, and does not require existing equipment to be
in year 2001, and does not require existing equipment to be
modified to meet the new emissions standards.
modified to meet the new emissions standards.
The
The CARB
CARB regulations
regulations require
requireforklift truck
lift truck manufacturerstoto modify
manufacturers
a percentage of the trucks sold into California,
modify a percentage of the trucks sold into California, beginning in year
2001,
beginningto incorporate
in year 2001, an emissions
to incorporate control
an system
emissions(ECS) which will
control
system (ECS)
achieve exhaustwhich will achieve
emissions levels exhaust emissions
defined within levels
the regulations. In
defined
the within
following the regulations.
years, the percentage In theoffollowing
trucks soldyears,
withthe
emissions
percentage of trucks sold with emissions reduction
reduction technology must increase each year until 2004, when the technology
must increase
entire eachengine
sparkignited year until 2004,be
line must when the entire
emissions spark-This ini-
compliant.
ignited
tial engine
phase-in line is
period must be emissions
designated compliant.
“Tier 1”, Thisexhaust
and defines initial emis-
phase-in period is designated “Tier 1”, and defines
sions standards which must be achieved by the manufacturer at the exhaust
emissions
time standards
of shipment. which“Tier
In 2004, must2” be achievedwill
regulations by take
the manu-
effect, with a
facturer at the time of shipment. In 2004, “Tier 2” regulations
proposal by the EPA to adopt this as a nationally-legislated standard.
will take effect, with a proposal by the EPA to adopt this as a
The emissions standards
nationally-legislated and phase-in
standard. percentages
The emissions standardsare and
shown in
the chart below.
phase-in percentages are shown in the chart below.

Tier 1 CARB Tier 2 CARB

Effective Date Jan 2001 to Jan 2004 to
Dec 2003 Dec 2006
Emissions Limits CO 37 37
(g/hp-hr) HC + NOx 3 3
Useful Life / Durability Testing 3500hr/5yr
Emissions Limits (g/hp-hr) N/A 50 CO
4 HC + NOx
Warranty Period- Components
< $400 1500hr / 2yr 2500hr / 3yr
> $400 1500hr / 2yr 3500hr / 5yr
2001 25% CA Sales
Phase-In % 2002 50% CA Sales 100% USA
2003 75% CA Sales
Production Line Testing Required Required
In-Use Testing N/A Required
System Adjustment Tampering Resistant Tamper-Proof

37
 STRUCTURE AND FUNCTION

1. Outline of CARB Tier 1 LP-gas system

Function of components

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 STRUCTURE AND FUNCTION

2. CARB Tier 1 LP-gas layout (2001-2002 Model Year)

Mixer

Throttle Body

FCSV LP Filter

Fuel Lock 0ff

Vaporizer

Location of components on truck

CARB Label

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STRUCTURE AND FUNCTION

3. Main Component Illustrations

3.1 Electronic Control Unit (ECU)

Identification of ECU is shown in examples below

version 1 version 2

3.2. Electronic Control Unit (ECU)

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 STRUCTURE AND FUNCTION

3.3. Oxygen sensor mounted in exhaust manifold

3.4. Pedal Sensor

3.5 Engine Block Temperature Sensor

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STRUCTURE AND FUNCTION

3.6. Mixer and Throttle Body Illustration

LP GAS VALVE CARBURETOR INTERNAL GAS FLOW
PART LOAD METERING
VALVE NON ADJUSTABLE

Pressure Transfer holes

Metering Spring
Diaphragm
FCSV
Air Measuring Valve
Fuel Metering Valve
Air
LP Gas (Vapor)
From Regulator

IDLE AIR ORIFICE

NON ADJUSTABLE

Vacuum Advance Port

Map

Electronic Throttle body

3.7. Three Way Catalytic Converter

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 STRUCTURE AND FUNCTION

3.8 Dash Light Illustration

Transmission Fluid level Low Oil Charging System Check

Oil Temp Brake Pressure Engine

43
STRUCTURE AND FUNCTION
3.9. Exploded view for use with Pneumatic type models

1 LPG Converter 5 Mixer

2 Fuel Lock Filter 6 Oxygen Sensor
3 Fuel Control Solenoid Valve 7 Throttle Body
4 ECU 8 Vacuum Lines
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 STRUCTURE AND FUNCTION
3.10 Exploded view for use with cushion type models

1 LPG Converter 5 ECU

2 Vacuum Lines 6 Throttle Body
3 Fuel Lock Filter 7 Mixer
4 Fuel Control Solenoid Valve 8 Oxygen Sensor

45