Thunder Heart - American Ironhorse Owners Organization
Transcription
Thunder Heart - American Ironhorse Owners Organization
Thunder Heart Owner's Manual SMARTLINK IV AIH DEALER AMERICAN DEALER SOFTWARE IRONHORSE@ EFI TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 General Information System Requirements Software Insta lIation Software Authorization Software Upd ates Getting Started CHAPTER 2 MAIN MENUS AND WiNDOWS ....•............•.............................. 2.1 2.2 2.3 2.4 2.5 File Menu Create aNew File o pen an Existing File Close the Current File Save the Current File Save the Current File Under a Different File Name WRITE Module Maps and Settings Exit the Software Program Gauges Toggle Monitor Gauges Reset Gauge Data Files Selecting Tuning Maps and Settings Modu Ie Configu ration Basic Settings Read Mod ule Settings Warranty Information Monitors 1 1 1 1 1 1 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 5 5 Thunder Heart Performance 615-672-8811 Corp. CHAPTER 1 1.1 www.thunder-heart.com INTRODUCTION General Information The SMARTLINK IV AIH DEALER software enables the user to monitor and diagnose the American lronhorse EFI system. 1.2 System Requirements The SMARTLINK IV AIH DEALER software is designed to run on personal computers using Microsoft@ Windows 98SETM or later operating systems. Connection to an RS232 serial port via a Thunder Heart Performance ASM2100C interface cable is required when editing the module seltings. f' .. Note: If your computer is not equipped with a serial port, you will need to purchase a USB-to-R S232 adapter from your local electronics retailer, such as RadioShack@ Note: Some computers equipped with a serial port may have difficulty connecting to the ECU. If you are experiencing such difficulty, and your computer is equipped with a USB port, use a USB-to-RS232 adapter and connect to the ECU via the USB port. 1.3 Software Installation To install the software onto your system, complete the following steps: Note: 1. Exit any programs you are currently running. 2. Insert the SMARTLINK IV AIH DEALER software into the CD-ROM drive. 3. The software will automatically If the software does not automatically begin to install, double-click on the "My Computer" icon. Then, double-click on the CD-ROM drive. Finally, doubleclick on the file named "setup.exe." 4. 1.4 begin the installation process. The SMARTLINK IV AIH DEALER installation wizard will now guide you through the rest of the installation. Software Authorization Upon initializing the software for the first time, you may be prompted to enter an Authorization Code. Contact American lronhorse for an authorization code. 1.5 Software Updates Periodically, software updates will become available. It is important that you check for updates frequently to ensure that you're using the latest version of the software. (You must be connected to the internet to search for updates.) To check for updates, follow these steps: EI7012-D.doc 1 Thunder Heart Performance 615-672-8811 Corp. 1.6 www.thunder-heart.com 1. Open the SmartLink IV Software by double-clicking it from your Windows Start menu. 2. From the Configure menu, select Update screen will appear. 3. Click the Check button to check for updates. The software will search for updates via the internet. 4. If any updates are available, click the Install button. Foliow the prompts to install the updates. If no updates are available, click the Finish button. SmartLink the icon or selecting Update. The Software Getting Started The SMARTLINK IV AIH DEALER software allows you to monitor and diagnose the American Iron horse EFI system via a commincation cable that links between the software and the motorcycle ECU. This Communication Cable is available from American Iron horse. Note: You can link to the ECU with the bike running, or not running. However, either way you must have power to the ECM. Figure 1-Module Link Button To link to the motorcycle ECU, click the Link button. The red color on the button turns to green after a link has been established. Remember: You must be connected to the module via the interface cable and have 12+ volts to the module (key "ON" and the kill switch in the "RUN" position). If you are having trouble linking to the module, try selecting a different COM port: 1. CHAPTER 2 From the Configure menu, choose Select Com Port. Pick another COM port, or choose automatic. This is a trial-and-error process. MAIN MENUS AND WINDOWS .,~ 2 EI7012-D.doc Thunder Heart Performance 615-672-8811 Corp. 2.1 www.thunder-heart.com File Menu Create a New File From the FILE menu choose NEW, or type Ctrl+N. All calibration settings will revert back to the original default state. Open an Existing File From the FILE menu choose OPEN, or type Ctrl+O. A listing of files will appear. Any files with the" .slk" extension may be opened by selecting it with the mouse. Close the Current File From the FILE menu choose CLOSE, or click the "X" icon in the upper righthand corner of the window. Save the Current File From the FILE menu choose SAVE, or type Ctrl+S. The calibration file currently displayed will be saved under the current filename. Always save files that you may want to use later. Save the Current File Under a Different File Name From the FILE menu choose SAVE AS. The calibration displayed can be saved under a different filename. file currently WRITE Module Maps and Settings From the FILE menu choose WRITE MODULE MAPS AND SETTINS, or type Ctrl+W. This function transfers calibration information from host computer to the ECU. Note: This will overwrite the current ECU settings so it may be wise to upload from the ECU and save it as another file first. Exit the Software From the FILE 2.2 Program menu choose EXIT. The program will close. Gauges Toggle Monitor Gauges From the GAUGES menu choose TOGGLE MONITOR information on Monitors for information about gauges. GAUGES. See Reset Gauge Data Files From the GAUGES menu choose RESET GAUGE DATA FILES, This resets the gauge settings to their defaults. EI7012-D.doc 3 Thunder Heart Performance Corp. 615-672-8811 2.3 www.thunder-heart.com Selecting Tuning Maps and Settings :j- SMlIV I American Iron Hor Fda Edit Gauges T0015 Cohl~ t..j T~lli~!l MlI~sl A 8- Module ConfigUiation j..~ Bas;; Settings L Warranty Figure 2-Tuning In/ormatic ~ • Maps Window In the Tuning Maps window, clicking a map will display the map in the window to the right. Note: If a plus symbol [+ J is next to a category, click it to expand your choices. The following maps can be selected: 2.4 Module Configuration Basic Settings Using the Basic Settings window, parameters such as rev limit, lAC home position, and speedometer calibration can be viewed. To view the Basic Settings stored in the ECU, click the Read Basic Settings button. Note: Some features are for reference only (do not affect the performance module), while others are not available with all products and software. Figure 3-Basic of the Settings Window Read Module Settings After a module link has been established, click on the "Read Module Settings" button to retrieve the settings stored in the module. 4 EI7012-D.doc Thunder Heart Periormance 615-672-8811 Corp. www.thunder-heart.com Warranty Information Click "Read Module" to retrieve the information from the module if it is not currently displayed. This information is helpful in analyzing the history of how the motorcycle is operated. The VIN can be recorded for future reference, and service data files can be saved and loaded. Times shown are totals of run time spent in each RPM range. 2.5 Monitors To monitor engine current engine parameters, located next to the "Link" button on the tool bar. click the "Monitor" button ~ ,1onitoring. Window _.Help ~ijJiEiEJ~i!!!<DI .•.... mtt~.t;ll. ~~~t:::;.~::~1~ Figure 4-Monilor Button Monitors are helpful for engine tuning and diagnosis. If a monitor is selected from the monitor selection window with the mouse, a stand-alone "gauge" can be configured to aid in monitoring that parameter. ;._,.~.t_!,y Figure 5-Monitors EI7012-D.doc Seleclion Window 5 Thunder Heart Performance 615-672-8811 Corp. r- www.thunder-heart.com Show In O'NN Window 1 10 1335.5392 ;0:;P/~i'[0"'it'9~ (:1~!;:6~1251'6544 YEUOW Caution stops Figure 6-Monitor RED Warning Starts Display Setup Window By checking the "Shown in OWN Window" box, a programmable "gauge" will appear. The limits for the gauge can be adjusted to suit your needs using the Monitor Display Setup window. Several gauges can be displayed simultaneously. 6 EI7012-D.doc 3-PHASE CHARGING SYSTEM COMPONENT .TESTING The 3-phase charging systems offer more current delivery over traditional single-phase systems by using a highly-efficient "series" regulator, and 33% more stator poles than a standard single-phase system. This highly efficient power conversion means more charging current is available at lower speeds for maximum battery life and easier starting-in fact, the system is already charging at 550-650 RPM, where a typical single-phase system doesn't charge until 1000-1100 RPM. Stator: Output To test if the stator output: 1. Disconnect the stator from the regulator 2. Bring engine speed up to 1,000 RPM. 3. Use a multi-meter to measure the AC voltage between any and all combinations of the stator output terminals. Output should be around 16v AC at 1,000 RPM, and increase with engine speed (Figures 2 and 3), The regulator is digitally calibrated for an optimum charging level over a wide temperature range, which is housed in a rugged, billet aluminum housing. Regulator operation is self-temperature compensated to control heat and optimize service life, and over-temperature protection prevents catastrophic heat failure under severe operating conditions. Charging System Output Figure 1-Measure the AC voltage between each stator output terminal. Testing Overall Charging System Performance To test the general performance of the 3phase charging system: With the engine running, use a multi-meter to measure the voltage across the battery terminals. Depending upon RPM range and stat of the battery, regulation voltage should be 14.3.14.7 volts. Figure 2-Voltage at each terminal should be around 16v AC at 1,000 RPM. Stator Failure Test: Shorted to Ground To test if the stator is shorted to ground: 1. Disconnect the stator from the regulator. 2. Use a multi-meter to test for continuity between any of the stator outputs to ground. There should NOT be continuity between any of the stator outputs to ground (Figure 1). Figure 3-Check for continuity between the each stator output and ground at the case. ~'. DIGITAL DASH TESTER INSTRUCTIONS a The tester comes with several harnesses and battery power clip-on leads: A. Extension harness for connecting the digital dash harness to the tester (does not require removal of the digital dash from the motorcycle). B. Harness for connecting the digital dash directly to the tester. C. Speed sensor harness for '05f06f07 motorcycles. D. Digital Dash Tester. E. 12v t012v battery harness. F. '03f04 speed sensor harness. The Digital Dash Tester, when used with the correct harness(s), will operate all 2004 and 2005 and 2006 ThunderHeari and Gill Dash Units. Some 2004 American IronHorse motorcycles were manufactured with Wire Plus Dash Units. The Digital Dash Tester (DDT) will not operate the Wire Plus Dash Unit. The Wire Plus Dash Unit can be distinguished from the ThunderHeari Dash Unit by two ways. The Wire Plus uses an orange power wire (contact #1) on the dash unit 6-pin Deutsch receptacle, ThunderHeari and Gill use a red power wire. The other difference between the two dash units, is the exposed photo cell on the bottom of the Wire Plus Dash. The Thunderhearl and Gill do not have an expcsed photo-cell. Note: On 2003 and 2004 Models the Speed Sensor Adaptor Cable must be used in conjunction with the speed sensor test harness. The '03 and '04 Adaptor Cable allows the use of the DDT by connecting the 8 contact Deutsch Receptacle on the motorcycle to the contact Deutsch Plug on the Adaptor Cable. Then, by connecting speed sensor test harness(C) to the 3 contact Deutsch Plug the speed sensors may be checked on '03 and '04 Models. 1. Supply power to the tester using the supplied battery clip harness. 2. Connect the digital dash cable to the digital dash tester using one of the supplied harnesses. The following text will appear on the display: RI H Da:=.h Te:=.t.er' PIJ::.h .:1 but.ton .--1--+ - .-t =.. .' =.1::' """I::' 1_. " +.•'t::' t.o Before any buttons are pressed, speedometer will appear as follows: the Tachometer Function 1. To test the function of the tachometer, push the "TACH" button on the digital dash tester keypad. SF'eedor'!et..er' (116r"IF'h NOTE: It is normal for the speedometer to lag a few MPH behind the tester 2. The tachometer display will begin to cycle up the RPM scale. The display value on the digital dash tester should match the display on the tachometer. Indicator Function 1. To test the function of each indicator, push its corresponding button on the keypad. T ,:ichOF!et..er' 5 i00r'pr"! 2, When each button Is depressed, the Indicator should Illuminate. Speedometer Function 1. To test the function of the speedometer, push the "MPH" button on the digital dash tester keypad. 2. The speedometer display will begin cycle to 100 MPH.The display value on the speedometer should lag behind the display on the tester by a few MPH. THIS IS NORMAL. SPEEDOMETER SENSOR TESTING The digital dash tester can also be used to test the function of the speedometersensor. 1. Supply power to the digital dash tester using one of the supplied options. 2. Disconnect the transmission sensor from the main wire hamess, and plug it into the digital dash tester using the supplied harness. 3. Jack the rear tire of the motorcycle in the air, and secure the motorcycle. 4. Put the transmission in the neutral. 5. Slowly rotate the rear tire by hand, and observe the display of the digital dash tester. 6. The digital dash tester display should flash from "PUSH A BUTTON TO SELECTTEST" to "OIL PRESSURE" with each pulse of the speedometer sensor. P'I I.-l-, ~' .1':.[ I' .::1 ~selecf.., U1 't-.~___.::..::.r.1Ito. ~_ DIGITAL DASH TESTER APPLICATION The Digital Dash Tester, when nsed with the correct harness(s), will opemte all 2004 thro 2007 ThunderHeart and Gill Dash Units. Some 2004 American Ironhorse Motorcycles were manufactured with Wire Pins Dash Units. The Digital Dash Tester (DDT) will not operate the Wire Plus Dash Unit. The Wire Pins Dash Unit can be distinguished from the ThunderHeart Dash Unit by two ways. The Wire PIns uses an orange power wire (contact #1) on the dash unit 6-pin Deutsch receptacle, whereas the ThunderHeart and Gill use a red power wire. The other difference between the two dash units, is the exposed photo cell on the bottom of the Wire Plus Dash Uuit (See attached photo #1) The ThunderHeart and Gill do not have an exposed photo-cell. HARNESS'S AND APPLICATION: (A) ExtensionHarness-easy (Refer to attached DDT Instruction Sheet) connect while Dash Unit is still on the motorcycle (B) Harness-Tester directly to DDT bezel (See attached photo # 3) (C) Speed Sensor Test Harness-This harness has been modified with a 4 contact Deutsch receptacle to check the output signal from the speed seusor to the 4 contact Deutsch Plug (located below the fuel tank, connection [2IB] on 2005 and 2006 Main Harness Print). This harness is also equipped with the 3 contact Deutsch Plug for connection directly to the 2005 and 2006 Model speed sensor (See attached photo # 4) Note: On 2003 and 2004 Models the Speed Sensor Adaptor Cable (see attached photo) mnst be used in conjunction with the speed sensor test harness (photo # 5). The '03 and '04 Adaptor Cable allows the nse of tbe DDT by connecting the 8 contact Deutsch Receptacle on the motorcycle to the contact Deutsch Plug on the Adaptor Cable. Then, by connecting speed sensor test hamess(C) to the 3 contact Deutsch Plug the speed sensors may be checked on '03 and '04 Models. NOTE: 2007 models use DTM (mini Duetch) connectors DDT Harness A and DDT Harness C will be available. (D) Digital Dasb Tester (E) 12v to 12v (clip on) battery harness-This power cable should be nsed to power the DDT (F) llOv to 12v DC adapter-Becanse of over voltage problems do not use this power snpply. 1 RELAY HARNESS CONTROLLER (RHC) .1 PIN 1 The Relay Harness Controller, or "RHC," consolidates all of the electronic functions of a motorcycle (with the exception of instrumentation and engine management) into one unit. The RHC performs all fuse, relay, and signal canceling functions in one simple package. It provides multiple flasher combinations (signal canceling, hazard lights, and tri-state indicators), running lights, brake lights, and turn signal from one bulb. RHC TESTING 3. To test the operation of each function in the RHC, a special RHC testing tool is required. Connect the power and ground leads to the appropriate terminal on the battery. This instantly powers up the tester, and the following will appear on the screen: R!HRHC Use the UP or DOWN buttons to select "Automatic Mode" or "Manual Mode." Though the RHC is not serviceable, the testing tool can be used to confirm if a certain motorcycle malfunction due to a faulty RHC. 1. Disconnect the main harness connector from the RHC. 2. Make sure the harness connector with the power leads and the red connector lock is attached to the RHC test tool. Connect the other end of the harness to the motorcycle RHC. Automatic Mode 1. To automatically test all the functions of the RHC, press the YES button on the keypad. They RHC tester will cycle through all the functions of the RHC. The RHC will either indicate "PASS" or "FAIL" briefly at the conclusion of each test before testing the next function. 2. Press the YES button on the keypad. 3. Use the UP and DOWN buttons to select the function you wish to test. Press the START button to begin testing that function. After the test is complete, the result will be displayed on the screen. 4. Press the STOP button to return to the Mode Selection screen. After the RHC tester has tested all of the functions, the test result will be displayed. If all of the functions of the RHC passed, the following will appear: Aut':1 Te:5,t.. Resl.Jlj".. flatS$ . However, if ANY ONE of the functions of the RHC failed to operate properly, this message will appear for 10 seconds: Test 2. Press the STOP button on the keypad to return to the testing mode selection. Testing Display Information FUNCTION BEING CONNECTOR TESTED USED ~ FUNCTION INDICATOR (SIGNALS ALTERNATE Manual Mode 1. To manually test an individual function of the RHC, press UP or DOWN buttons until the following appears on the display: BETWEEN "ON" AND "OFF") PINS Diagnostic Tool "Bench Testing" EFI Diagnostic Tool Instructions EC" CONNECTOR The EFI diagnostic tool provides four key testing functions: • Setup lAC fUNCTION TEST APPARJlo.TUS \ for DIAGNOSTIC MODULE CONNECTOR I Automatic testing of EFI ECU functions Manual testing of EFI ECU functions Management of Diagnostic Trouble Codes (DTCs) Monitoring of sensor outputs and engine vitals • • ,- The EFI diagnostic tool consists of the following components: • I2\'+ POWER SUPPLY CUPS diagnostic module wiring harness lAC function test apparatus • The diagnostic module also contains six status LEOs. The function of each is as follows: 1 t 2 t 3 t 4 t •••••• 1) 2) 3) 4) 5) 6) RED AMBER GREEN GREEN BLUE BLUE 5 t Power Switched Power to ECU Ignition Rear Ignition Front Injection Front Injection Rear 6 t 3. Plug the Diagnostic Module Connector of the harness into the Diagnostic Module. 4. Plug the ECU Connector to be tested. 5. Plug the Communications Connector into the communications of the ECU to be tested . into the ECU Port port ECU "Bench Tests" An ECU can be "bench tested" while either installed in, or removed from a motorcycle. 1. Supply 12V+ (either with a power supply or a battery) with the Supply Clips attached to the harness. 2. The Diagnostic Module will retrieve the following information from the ECU: • • • 3. Firmware version VIN Serial Number After the information is retrieved from the module, the following options are available: • • • • Manual Test Automatic Test Retrieve DTC ECU Monitor 4. 5. Press the UP and DOWN select a test. Press YES to begin STOP to end the test. buttons the test. to Press Manual Test 3. After the test is completed, the result ("Pass" or "Fail") will appear briefty on the screen. 4. After the test is completed, the screen will exit back to allow the user to select another test. 5. Press the STOP Manual Test. button to exit the Automatic Test 1. Press the UP or DOWN buttons on the keypad until "Automatic Test" is selected. 2. Press YES to begin the test. STOP to end the test. 3. After the test is completed, the result ("Pass" or "Fail") will appear briefty on the screen. 4. Press STOP to exit the Automatic Test. Press The following tests are available: • • • • • • • • • • • • Head Temp Sensor Air Temp Sensor TPS Sensor Bare Sensor Battery Sensor Sensor Power Engine RPM Vehicle Speed Fuel Injectors Ignition Drivers Tach Output lAC Operation Fuel Pump Diagnostic Trouble Codes 1. Press the UP or DOWN buttons on the keypad until "Retrieve DTC" is selected . 2. 1. Press the UP or DOWN buttons on the keypad to select a test function. Press the YES button. Use the UP and DOWN buttons to choose between the following options: 2. Press YES to begin STOP to end the test. • • the test. Press Get DTC Status Clear all DTCs Eeu 3. 4. CONNECTOR To get the status of the diagnostic trouble codes, press YES when the following message is displayed: I LAC fUNCTICt>l TEST APPARATUS \ DIAGNOSTIC MODULE CONNECTOR I The following message will appear: - I 12V+ PO'NER SUPPL.Y CUPS 5. 1. Plug the Diagnostic Module Connector of the harness into the Diagnostic Module. 2. Plug the Communications Connector into the communications of the ECU to be tested. Following the display of the total number of codes retrieved, the tester will display the first code: TPS Lo D Gl~r'r'ent. F.9ul t. 6. Press the UP button to cycle through the codes. 7. Codes can be cleared by pressing the YES button when the following screen is displayed: Diagnostic Tool "ECU Monitoring" Setup Monitoring Outputs Port port ECU Inputs and The ability to monitor the ECU inputs and outputs aids in troubleshooting problems with the EFI system in "real time," with the engine nunning or not running. 1. Supply 12V+ (either with a power supply or a battery) with the Supply Clips attached to the harness. 2. The Diagnostic Module will retrieve the following information from the ECU: for • • • 3. After the information is retrieved from the module, the following options are available: • • 4. Firmware version VIN Serial Number Manual Test Automatic Test Retrieve DTC ECU Monitor Press the UP and DOWN select "ECU Monitor" buttons to 6. Use the UP and DOWN buttons to scroll through the following options: • • • Eeu ~1onit.ot", • • UP .,,"DltIN VES.,,"STOF' I,,' :; .• 7. 5. Press YES. Head Temp Sensor Air Temp Sensor TPS Sensor Bro Sensor Battery Sensor Engine RPM Vehicle Speed Injection Pulse Ignition Advance Tach Output lAC Position Press the YES button inpuUoutput to monitor. to select an He d er1P Sensor' UP .....DltIN VES ..,"STOP 8. Diagnostic Tool Harness Pin and Wire Information Press the monitoring. STOP button to exit r--Diagnostic Too,l Connector Pin Function CHECK ENGINE TACH OUT SYSTEM RELAY SERIAL DATA HEAD TEMP .... AIRTEMP 02 FRONT TX" GROUND GROUND: GROUND IGNITION REAR SWITCHED POWER SENSOR POWER RX :. '" 5V FEED., lAC FEEDBACK ANALOG GROUND ANALOG GROUND INJECTOR REAR INJECTOR FRONT OZREAR ,::".' TPS MAp ...•. .. IGNITION FRONT CRANKS+ 13.8V 13:8V .... ;.Lj.. •• ., V SPEED lAC CONNECTOR.C lAC CONNECTOR 0 lAC CONNECTOR B lAC CONNECTOR A . .... .•.. 2 3 4 •. 5 6 7 8 9 10 .10 10 11 13 .'14 15 16 17 18 18 19 21 23 24 25 29 30 31 31 33 N/A N/A N/A N/A ECU Connector Pin Color N/A 21 20 N/Aj:: 13 N/A" 4 COMM3-C 7 COMM1-A 'j BLACK ALLIGATOR 18':" '.:.::',j 3 :. 11 COMM 2-B ::' lAC 1"A lAC 2-B ,Et .. lAC 3-C 14 16 17 12 5 : N/A .. ... .. .. GREYIYELLOW RED/BLUE .. . , ", 19 15 8 RED ALLIGATOR 22 1 2 9 10 :. ORANGEIWHITE ' .. .. .... :. .. ...... BLACK BLACK :: BLACK YELLOW :. REDIWHITE ... BROWN ORANGEIYELLOW PURPL:E GREEN/BLACK BLACKIWHITE BLACKIWHITE WHITE/RED WHITE BLACK/PINK ORANGE/BLACK . :: BLUEIYELLOW GREEN :. RED RED GREENIWHITE BLUEIWHITE BLUE ORANGE/BLUE BLUE/GREEN .. .: .•. PINKIYELLOW ... ....