Fuel Induction Manual

HYOSUNG MOTORS AMERICA INC.
w w w. h yo s u n g m ot or s u s a . c om
HYOSUNG MOTORS AMERICA INC.
5815 BROOK HOLLOW PKWY. SUITE-B, NORCROSS, GA 30071
FUEL INDUCTION SYSTEM
All text, graph and other content appearing in this Manual are the property of Hyosung Motors
America, 5815 Brook Hollow Parkway, Suite B, Norcross, GA 30071. You may not copy, print,
reproduce, or distribute any portion, in whole or in part, of this manual in any way. All Rights
Reserved ®.
Reasonable care is taken to ensure the accuracy of information and related materials provided by
Hyosung Motors America in this Manual; however Hyosung Motors America is not responsible
for misprints, out-of-date information, technical or pricing inaccuracies, typographical or other
errors appearing in this Manual or any other Manual. Information and related materials are
subject to change without notice. By using this Manual, you assume the risk that the information
and materials in this Manual may be incomplete, inaccurate, out of date, or may not meet your
needs and requirements.
Under no circumstances will Hyosung Motors America be liable for damages of any kind,
including without limitation any special, indirect, incidental or consequential damages.
Hyosung Motors America reserves the right without prior notice to discontinue models, parts,
accessories, clothing and other items or change specifications at any time without incurring any
obligations.
©2010 HYOSUNG MOTORS AMERICA
INTRODUCTION
HYOSUNG
This manual is designed to provide Hyosung dealer technicians with a complete understanding of
the construction and operating principles of motorcycle fuel induction systems.
The manual starts with a description of the basic principles of motorcycle fuel injection systems.
Subsequent sections describe specific fuel and induction system circuits and operation, adding
technical detail as the reader’s comprehension grows.
Special care has been exercised in preparing clear, simple illustrations as an aid in visualizing the
fuel and induction systems described in this text.
The variety of fuel and induction systems in use and frequent design changes preclude the listing
of service and repair specifications. Refer to the Service Manual for service information on
specific system models.
For additional information or questions contact Hyosung Motors America.
HYOSUNG MOTORS AMERICA INC.
SERVICE TEAM
HYOSUNG MOTORS AMERICA INC.
Table of Contents
Abbreviations Used In This Manual ……………………………………………………… 1-1
The Basics of Electronic Fuel Injection Systems ………………………………………… 2-1
Component Overview ……………………………………………………………………… 3-1
Malfunction Codes & Defective Conditions ………………………………………………. 4-1
Service Data Chart …………………………………………………………………………. 5-1
Location of Relays & Fuses ………………………………………………………………... 6-1
Electronic Control Modules ……………………………………………………………….. 7-1
Wire Color Codes ………………………………………………………………………….. 8-1
Special Tools ……………………………………………………………………………….. 9-1
Diagnostic Program ……………………………………………………………………….. 10-1
Diagnostic Tool Screen Overview ………………………………………………………. 11-1
Diagnostic Tool Operation Manual ………………………………………………………. 12-1
ABBREVIATIONS USED IN THIS MANUAL
HYOSUNG
1-1
THE BASICS OF ELECTRONIC FUEL INJECTION SYSTEMS
HYOSUNG
For most of the existence of the internal combustion engine, the carburetor has been the device
that supplied fuel to the engine. On many other machines, such as lawnmowers and chainsaws, it
still is. But as motorcycles have evolved, the carburetor gets more and more complicated trying
to handle all of the operating and emission requirements. For instance, to handle some of these
tasks, carburetors have five different circuits:
Main circuit - Provides just enough fuel for wide open throttle
Mid-Range circuit - Provides just enough fuel for fuel-efficient cruising
Idle circuit - Provides just enough fuel to keep the engine idling
Accelerator pump - Provides an extra burst of fuel when the throttle is first twisted,
reducing hesitation before the engine speeds up
o Choke - Provides extra fuel when the engine is cold so that it will start
o
o
o
o
In order to meet stricter emissions requirements, a fuel induction system that carefully controls
the air-to-fuel ratio was introduced. Hyosung’s fuel injection system uses oxygen sensors that
monitor the amount of oxygen in the exhaust. The ECU uses this information to adjust the air-tofuel ratio in real-time. This is called closed loop control – it was not feasible to achieve this
precision of control with carburetors.
A microprocessor inside the Engine Control Unit (ECU) makes hundreds of changes per second.
Each adjustment allows precise fuel and ignition mapping to the engine for the current
environmental conditions. This results in maximum fuel economy and performance because each
cylinder is given only the fuel it needs.
The Electronic Fuel Injection system uses several sensors to provide feedback about external and
internal operating conditions to the electronic “brain” of the system, the ECU.
These operating conditions include:
o
o
o
o
Rider Input (throttle position)
Engine Load
External Environmental Conditions (outside air temperature and pressure)
Internal Engine Environmental (cylinder head temperature)
When the rider twists the throttle, the throttle valve opens more, letting in more air. The ECU
"sees" the throttle valve open and increases the fuel rate in anticipation of more air entering the
engine. It is important to increase the fuel rate as soon as the throttle valve opens; otherwise,
when the throttle is twisted, there may be a hesitation as soon as air reaches the cylinders without
enough fuel in it.
Each of these conditions must be known in addition to the information already “memorized” by
the ECU. This is necessary for the ECU to perform the calculations necessary to deliver the
optimum spark advance and fuel amount for each cycle for maximum performance as well as to
meet government regulations for emissions.
2-1
Fuel Injector
The method of how the required amount of fuel is calculated is based on the EFI system. The
ECU calculates and delivers spark and fuel on a set of predetermined spark and fuel “maps.”
These “maps” provide the base information necessary to run the engine with only minor
adjustments for external / internal environmental conditions, as well as, feedback from the
exhaust gas oxygen (O2) sensor to continually adjust the amount of fuel delivered to the engine.
This offers the advantage of “learning” the behavior of the engine over time, as well as,
responding to a wider variety of conditions encountered while riding. The EFI system then
continuously “tunes” the performance of the engine to compensate for changing conditions and
provide maximum performance by using the O2 sensors input.
Fuel Injector
When the ECU receives all of its input from the various sensors and calculates this information,
it then sends an electronic signal to the fuel injector. A fuel injector is nothing but an
electronically controlled valve. It is supplied with pressurized fuel by the fuel pump, and it is
capable of opening and closing many times per second.
Inside the Fuel Injector
2-2
Fuel Injector
______________________________________________________________________________
When the injector is energized, an electromagnet moves the plunger that opens the valve,
allowing the pressurized fuel to squirt out through a tiny nozzle. The nozzle is designed to
atomize the fuel – to make as fine a mist as possible so that it can burn easily.
A Fuel Injector Firing
The amount of fuel supplied to the engine is determined by the amount of time the fuel injector
stays open. This is called the pulse width, and it is controlled by the ECU.
The injectors are mounted in the intake manifold so that they spray fuel directly at the intake
valves. This is called multi-port fuel injection. The fuel pump supplies pressurized fuel to all of
the injectors.
In this picture (650 model), you can see both front and
rear injectors mounted in the intake pipe.
2-3
Engine Sensors
______________________________________________________________________________
In order to provide the right amount of fuel, the ECU is equipped with a whole lot of sensors.
Engine Sensors
In order to provide the correct amount of fuel for every operating condition, the ECU uses six (6)
different sensors to monitor rider demands and changing engine conditions to determine the
correct fuel and spark requirements. These sensors are:
1.
2.
3.
4.
5.
Throttle Position Sensor (TPS)
Pick-Up Coil
Intake Air Temperature Sensor (IAT)
Intake Air Pressure Sensor (IAP)
Engine Temperature Sensor (ET) )(250cc) or Water Temperature Sensor
(WTS)(650cc)
6. Oxygen Sensor (O2)
2-4
2-5
Throttle Position Sensor
______________________________________________________________________________
The TPS monitors the throttle valve position (which determines how much air goes into the
engine) by how far the throttle is open, whether it is opening or closing, and how fast it is
opening or closing so the ECU can respond quickly to changes, increasing or decreasing the fuel
rate as necessary.
Throttle Position Sensor
The Pick-Up Coil determines the exact position of both cylinders in the combustion cycle and
engine speed by picking-up the signal from the magneto rotor and sending this signal to the ECU
to calculate ignition timing and fuel injector pulse width.
2-6
Intake Air Temperature Sensor
______________________________________________________________________________
The IAT is located in the air box and measures the temperature of the air entering the engine.
The ECU then determines how long the fuel injector pulse width will be and how much to
advance or retard ignition timing.
Intake Air Temperature Sensor
The IAP is located in the intake pipe and measures the pressure or density of the air entering the
engine. The ECU compares absolute pressure (sea-level) with the IAP readings, and then
analyzes the air volume indirectly and adjusts accordingly.
Intake Air Pressure Sensor
The ET/WTS provides the ECU the current engine temperature. Proper fuel and spark delivery
are dependent on the temperature of the engine. When the engine is cold the ECU will provide a
richer fuel mixture and a higher degree of spark advanced. As the engine warms up to operating
temperature the fuel mixture will lean and spark advance will decrease.
Engine Temperature Sensor
2-7
Oxygen Sensor
______________________________________________________________________________
The O2 sensor monitors the amount of oxygen in the exhaust so the ECU can determine how
rich or lean the fuel mixture is and make adjustments accordingly.
Oxygen Sensor
2-8
HYOSUNG
COMPONENT OVERVIEW
ECU (Engine Control Unit)
The computer that controls the fuel injection system is referred to as the engine control unit
(ECU). The ECU is the central brain which contains the computerized fuel quantity maps. The
main function of the ECU is to gather information from the various sensors, analyze their input,
and activate the fuel injectors. The ECU is also equipped with some fail-safe functions. In the
unlikely event of a component failure, the ECU will utilize input from the other sensors and in
most cases override the failed component. The ECU is located under the seat and in front of the
battery.
Ignition Coil
3-1
Electric Fuel Injector
______________________________________________________________________________
EI (Electric Fuel Injector)
The Fuel Injectors are mounted on the intake pipe. Fuel injectors are electrically opened on/off
solenoid valves. They are either fully closed or fully open. The amount of fuel injected is
dependent on how long the injector is kept open. Each injector is opened by a signal from the
ECU. Fuel is only injected when it is needed – during each cylinder’s intake stroke.
Inside the injector there’s a spring-loaded plunger that closes against a valve seat. Once seated,
the flow of fuel is blocked. When the solenoid coil within the injector assembly lifts the plunger,
the pressurized fuel sprays into the cylinder. The battery supplies the power for the solenoid coil.
The injector solenoid coils are a switch to ground circuit. The ECU provides an electrical ground
when it determines the injector should be opened.
The injector tip’s opening is designed to provide a spray pattern that atomizes the fuel to help it
mix with incoming air.
MS3250
GV/GT650-250
3-2
Engine Temperature Sensor / Water Temperature Sensor
______________________________________________________________________________
ET/WT Sensor (Engine Temperature Sensor / Water Temperature Sensor)
The engine temperature sensor senses the temperature of the engine and sends the perceived
temperature reading to the ECU. When the engine is cold the ECU will provide a richer fuel
mixture and a higher degree of spark advance. As the engine warms up to operating temperature
the fuel mixture will lean and spark advance will decrease. The engine temperature sensor, for
250cc models, is mounted on the front cylinder head below the intake pipe. The water
temperature sensor, for 650cc models, is mounted on the rear side of the thermostat case.
3-3
Gear Position Switch
______________________________________________________________________________
GP Switch (Gear Position Switch)
The Gear Position switch is located below the final drive pulley/sprocket and mounted on the
engine case. The Gear Position switch provides the input to the ECU of what gear the motorcycle
is in. The ECU only utilizes the Gear Position switch at start-up. If the motorcycle is not in
neutral the ECU will not allow the bike to start.
CODE
3-4
Intake Air Pressure Sensor
______________________________________________________________________________
IAP Sensor (Intake Air Pressure)
The IAP is mounted to the bottom side of the air box. The IAP measures the pressure or density
of the air entering the engine. The ECU compares absolute pressure (sea-level) with the IAP
readings, then analyzes the air volume indirectly.
The following example assumes the same engine speed and air temperature.
•
Condition 1:
An engine operating at WOT (wide open throttle) on top of a very high mountain has a
MAP of about 15" Hg or 50 kPa (essentially equal to the barometer at that high altitude).
•
Condition 2:
The same engine at sea level will achieve 15" Hg of MAP at less than WOT due to the
higher barometric pressure.
The engine requires the same mass of fuel in both conditions because the mass of air entering the
cylinders is the same.
If the throttle is opened all the way in condition 2, the manifold absolute pressure will increase
from 15" Hg to nearly 30" Hg (~100 kPa), about equal to the local barometer, which in condition
2 is sea level. The higher absolute pressure in the intake manifold increases the air's density, and
in turn more fuel can be burned resulting in higher output.
Anyone who has driven up a high mountain is familiar with the reduction in engine output as
altitude increases.
MS3250
GT/GV 650-250
3-5
Intake Air Pressure Sensor
______________________________________________________________________________
3-6
Intake Air Pressure Sensor
______________________________________________________________________________
IAT Sensor (Intake Air Temperature Sensor / IATS)
The IAT sensor is mounted to the bottom side of the air box. The IAT senses the temperature of
the air entering the engine and sends this information electronically to the ECU. The ECU uses
the information received from the IAT to adjust the air/fuel mixture.
MS3250
GV/GT 650-250
3-7
Idle Speed Control Solenoid
______________________________________________________________________________
ISC Solenoid (Idle Speed Control Solenoid)
The ISC is mounted on the right side of the motorcycle beneath the fuel tank. The ISC is
controlled by the ECU. When first starting the motorcycle the ISC closes off an air passage that
leads to the intake pipe. As the motorcycle begins to warm up the ISC slowly backs out of the air
passage, thus allowing more air to enter the engine. ECU controls the ISC to allow more or less
air to enter the engine.
3-8
Oxygen Sensor
______________________________________________________________________________
O2 Sensor (Oxygen Sensor)
The oxygen (O₂) sensor measures the percent of oxygen in the exhaust gas. The Fuel Injection is
continuously adjusted to inject more or less fuel, keeping the amount of oxygen consistently at a
level where the lowest amount of toxic gases is produced.
This air/fuel is called the stoichiometric ratio. (Theoretically, this is the A/F ratio for complete
combustion.) With the air/fuel ratio controlled around this point by the oxygen sensor, the
remaining toxic compounds in the exhaust gas are more efficiently converted to non-toxic
compounds.
The oxygen (O2) sensor is mounted on the exhaust pipe just after the cross-over.
3-9
Pick-Up Coil
______________________________________________________________________________
Pick-Up Coil
The Pick-Up Coil is mounted to the inside of the magneto cover. The Pick-Up Coil determines
the exact position of both cylinders in the combustion cycle and engine speed by picking-up the
signal from the magneto rotor and sending this signal to the ECU to calculate ignition timing and
fuel injector pulse width.
CODE
3-10
Roll Over Switch
______________________________________________________________________________
RO Switch (Roll Over Switch)
The Roll Over switch provides the input to the ECU that the motorcycle is not leaning greater
than a 60 degree lean angle. If the vehicle exceeds a 60 degree lean angle the Roll Over switch
will interrupt the operation of the ignition system and the fuel supply. The Roll Over switch is
located under the rider’s seat beneath the seat lock.
MS3250 / 2010 &UP GT/GV 650-250
2009 GT/GV 650-250
3-11
Secondary Air Valve Solenoid
______________________________________________________________________________
SAV Solenoid (Secondary Air Valve Solenoid)
The SAV is located on the left side of the motorcycle next to the thermostat housing on 650cc
models and under the fuel tank on the right side of the motorcycle on 250cc models. The SAV is
an electronically controlled solenoid that is operated by the ECU. The purpose of the SAV is to
supply fresh air to the exhaust system to reduce exhaust gas emissions.
3-12
Throttle Position Sensor
______________________________________________________________________________
TP Sensor (Throttle Position Sensor / TPS)
The TPS is mounted to the rear intake. The TPS monitors the throttle valve position (which
determines how much air goes into the engine) by how far the throttle is open, whether it is
opening or closing, and how fast it is opening or closing so the ECU can respond quickly to
changes, increasing or decreasing the fuel rate as necessary.
All MS3250 / 2010&UP GT/GV 650-250
2009 GT/GV 650-250
3-13
Fuel Pump
______________________________________________________________________________
Fuel Pump
The fuel pump is located in the fuel tank and submerged in the fuel itself. When the engine is
running the fuel pump operates continuously, thus exerting a constant 48-53 psi of pressure
which supplies the maximum fuel demands of the engine.
3-14
MALFUNCTION CODES & DEFECTIVE CONDITIONS
HYOSUNG
4-1
Malfunction Codes & Defective Conditions
______________________________________________________________________________
4-2
SERVICE DATA CHART
HYOSUNG
5-1
Service Data Chart
______________________________________________________________________________
5-2
Service Data Chart
______________________________________________________________________________
5-3
LOCATION OF RELAYS & FUSES
HYOSUNG
6-1
Location of Relays & Fuses
__________________________________________________________
(1) Head Lamp Relay
(2) Fuel Pump Relay
(3) Main Relay
(4) Turn Signal Relay
(1) Main Fuse
(2) Head Lamp Fuse
6-2
ELECTRONIC CONTROL MODULE
HYOSUNG
(650cc wire color change (G), (B), (GR), (B))
7-1
Electronic Control Module
__________________________________________________________
7-2
Electronic Control Module
__________________________________________________________
7-3
WIRE COLOR CODES
HYOSUNG
8-1
SPECIAL TOOLS
HYOSUNG
Mode Select Switch – Part # 09900-27000
Fuel Pressure Gauge – Part # 09915-54510
Diagnostic Scanner Kit – Part # 09900-27035
9-1
DIAGNOSTIC PROGRAM
HYOSUNG
I. Installing the CARMANSCAN LITE program (Diagnostic Scan Tool Program).
a. Install the download CD in your computer.
b. Double click the SETUP File and follow the procedures in the box’s.
c. When finished installing the program, you can see the CARMANSCAN LITE
download program’s icon on your desktop.
10-1
DIAGNOSTIC PROGRAM
______________________________________________________________________________
II. Installing New Download Updates into the Diagnostic Scan Tool.
1. Move New Download file into you’re (C) Local Disk file. ((C) Local Disk is located
in My Computer file under Hard Disk Drives.)
2. Attach power cord to the Diagnostic Scan Tool and press the power up button.
3. From the Initial Screen
a. Select 05. S/W DOWNLOAD
4. Install the USB cable between Diagnostic Scan Tool and Computer
5. Double-Click on the Carmanscan Lite Icon, that’s installed on your desk.
6. Click on the Data Folder dropdown button and select (C) Local Disk.
10-2
DIAGNOSTIC PROGRAM
______________________________________________________________________________
7. Select File to be Downloaded
8. Select Copy and file will begin to download.
9. When file finishes downloading the Diagnostic Scan Tool Screen will display as
follows:
10. New Download Update is complete.
10-3
DIAGNOSTIC PROGRAM
______________________________________________________________________________
III. Installing New Download Update into Motorcycle.
1. Connect Diagnostic Scan Tool to Motorcycle using:
Note: Only install 4-Pin connector to motorcycle at this time.
2. Turn Ignition Switch On and place the Engine Cut-Off switch in the on position.
3. Select 02. REPROGRAMING
4. Select 01. GV250GIN7050
10-4
DIAGNOSTIC PROGRAM
______________________________________________________________________________
5. Follow instructions on the screen
a. Turn Ign. Off
b. Connect Mode Select S/W (2 Pin)
c. Turn Ign. On
d. Press ENTER on the key pad
6. CAREFULLY FOLLOW INSTRUCTION ON SCREEN OR DAMAGE WILL
OCCUR TO ECU.
7. Press YES on the key pad.
10-5
DIAGNOSTIC PROGRAM
______________________________________________________________________________
8. Scanner will begin erasing program installed on ECU.
9. Scanner will begin to reprogram ECU.
10. When reprogramming is complete press enter.
10-6
DIAGNOSTIC PROGRAM
______________________________________________________________________________
11. CAUTION: FOLLOW PROCEDURES BELOW IN ORDER.
a.
b.
c.
d.
Disconnect Mode Select S/W (2 Pin)
Turn Ign. Off
Wait 1 Minute
Turn Ignition Switch On and place the Engine Cut-Off switch in the on
position.
e. Verify Motorcycles is running properly.
f. Finished
10-7
DIAGNOSTIC TOOL SCREEN OVERVIEW
HYOSUNG
0. INITIAL SCREEN
01. VEHICLE DIAGNOSIS
02. Flight Record Review
MEMORY 1
11-1
01. Vehicle Diagnosis
01. Vehicle Diagnosis
01. Diagnostic Trouble Codes
11-2
Vehicle Diagnosis
______________________________________________________________________________
02. Current Data
FIX
FULL
SCRN
GRPH
11-3
Vehicle Diagnosis
03. Flight Record
RCRD
CALL
04. Actuation Test
05. Identification Check
11-4
02. Reprogramming
0. INITIAL SCREEN
02. REPROGRAMING
11-5
03. System Setup
______________________________________________________________________________
0. INITIAL SCREEN
03. SYSTEM SETUP
01. SYSTEM CONFIGURATION
02. DATA SETUP
04. SCREEN CONTRAST ADJUST
03. KEY PAD SETUP
05. BATTERY STATUS
11-6
04. Screen Capture View
0. INITIAL SCREEN
04. SCREEN CAPTURE VIEW
N/A
11-7
S/W Download
______________________________________________________________________________
05. S/W DOWNLOAD
11-8
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
MS3250 ONLY
0. INITIAL SCREEN
01. VEHICLE DIAGNOSIS
02. Flight Record Review
MEMORY 1
11-9
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
01. Vehicle Diagnosis
01. Diagnostic Trouble Codes
02. History Diagnostic Trouble
11-10
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
03. Current Data
FIX
FULL
SCRN
GRPH
11-11
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
04. Flight Record
RCRD
CALL
05. Actuation Test
11-12
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
06. Idle CO Adjustment
07. TPS Resetting
11-13
01. Vehicle Diagnosis (MS3250 ONLY)
______________________________________________________________________________
08. STEP Motor Initialization
09. Identification Check
11-14
HYOSUNG
DIAGNOSTIC SCAN TOOL OPERATION MANUAL
CAUTION : Any changes or modifications in construction of this device which is not expressly approved by the
party responsible for compliance could void the user’s authority to operate the equipment.
NOTE : This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. The limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in commercial environment. This equipment generates, uses,
and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may
cause harmful interference to radio area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
TABLE of CONTENTS
SAFETY
UNPACKING
I. GENERAL INFORMATION
1. GENERAL FEATURES ………………………………………......
10-5
2. SPECIFICATIONS ………………………………………………..
10-5
3. PARTS DESCRIPTION ….……..…………………………………
10-3
II. VEHICLE DIAGNOSIS
1. VEHICLE AND SYSTEM SELECTION………………………….
10-6
2. DIAGNOSTIC TROUBLE CODES……………………………….
10-7
3. CURRENT DATA….……………………………………………...
10-8
4. FLIGHT RECORD…..…………………………………….…….…
10-11
5. ACTUATION TEST ………………………………………………
10-16
6. IDENTIFICATION CHECK…...…………………………….……
10-18
III. FLIGHT RECORD REVIEW
1. OPERATION FLOW ………………………………………….….
10-19
2. MODE APPLICATION ……………………………………….….
10-20
IV. SYSTEM SETUP
1. CONNECTION METHOD …………………………………….…
10-21
2. SYSTEM CONFIGURATION …………………………………...
10-21
3. DATA SETUP ………………………………………………….…
10-22
4. KEY PAD TEST …………………………………………………. .
10-23
5. SCREEN CONTRAST ADJUST …………………………………
10-24
APPENDIX
A. IMPORTANT MESSAGE DESCRIPTION
B. TROUBLESHOOTING
12-1
Safety Precautions
______________________________________________________________________________
Safety Precautions
This equipment described in this manual is intended for use only by qualified personnel. Safe and
effective use of this equipment is dependent upon the operator following normally accepted safety
practices and procedures in conjunction with the special requirements detailed in this manual. Specific
warning and cautionary statements will be found, where applicable, throughout this manual.
Where necessary, the WARNING statements and ICON will be described in this guide.
WARNING identifies conditions or actions which may damage DIAGNOSTIC TOOL or the vehicle.
IMPORTANT WARNING MESSAGES FOR SAFETY ARE
AS FOLLOWS :
DO NOT DROP DIAGNOSTIC TOOL MAIN BODY. AND
DIAGNOSTIC TOOL MUST ALWAYS BE COVERED BY
THE SHROUD.
STRONG ELECTRO-MAGNETIC INTERFERENCE CAN
DAMAGE DIAGNOSTIC TOOL.
A STRONG SURGE OR ELECTRONIC SHOCK IN THE
POWER SUPPLY LINE CAN DAMAGE HISCAN ACE
POWER SUPPLY. DO NOT USE DIAGNOSTIC TOOL
UNDER THESE HARSH ENVIRONMENT.
12-2
Diagnostic Tool Kit
______________________________________________________________________________
DIAGNOSTIC TOOL KIT
The DIAGNOSTIC TOOL kit comprises the following standard along with the option kit where ordered.
The kit contents should be checked upon receipt and damage or shortages reported to the supplier
immediately.
[ Figure 0.1 :DIAGNOSTIC TOOL KIT ]
12-3
Icon
12-4
General Information
______________________________________________________________________________
I. GENERAL INFORMATION
1. General Features
DIAGNOSTIC TOOL offers the following functionality:
- On board diagnostic communication
- Special vehicle test emulation
This combination provides for easy and comprehensive diagnosis of the electronically controlled systems used on all
vehicle range.
DIAGNOSTIC TOOL feature include :
Diagnostic communication with S&T Motors
High resolution LCD display
Soft touch key
Shock protecting leather shroud
PC communication facility
PC software download with USB
2. Specification
12-5
Vehicle Diagnosis
______________________________________________________________________________
II. VEHICLE DIAGNOSIS
1. VEHICLES AND SYSTEM SELECTION
1-1. OPERATION FLOW
[FLOW II.1 : VEHICLE AND SYSTEM SELECTION SUB-MENU IN/OUT FLOW ]
12-6
Vehicle Diagnosis
______________________________________________________________________________
1-2. BASIC APPLICATION
Having connected and turned on DIAGNOSTIC TOOL, the vehicle and systems 1 and 2 selections must be made
from the [ 1.0 VEHICLE DIAGNOSIS] screen.
The support functions differ from vehicle to vehicle and therefore the correct selection must be made. Selection can
be made by scrolling up or down the screen and pressing ENTER.
Selection is made in the order of VEHICLE, SYSTEM 1, and SYSTEM 2.
2. DIAGNOSTIC TROUBLE CODES
2-1. OPERATION FLOW
[FLOW II.2 : DIAGNOSTIC TROUBLE CODES IN/OUT FLOW]
12-7
Vehicle Diagnosis
______________________________________________________________________________
2-2. MODE APPLICATION
At this level, diagnostic trouble codes (DTC) are displayed for the selected ECM
Whenever the screen is opened or refreshed, the cursor moves to the beginning of the display and an audible
warning will be given along with the number and description of the component from which the code has been
generated.
By using the UP / DOWN key, the display may be scrolled.
This soft function key will clear the DTC currently held in the memory of the selected ECM. If
this option is selected, a message requesting confirmation of the ERAS request will be displayed.
The ENTER or ESC key should be used to confirm or cancel the request to clear the current DTC.
3. CURRENT DATA
3-1. OPERATION FLOW
[ FLOW II.3 : CURRENT DATA MODE IN/OUT FLOW ]
12-8
Vehicle Diagnosis
______________________________________________________________________________
3-2. MODE APPLICATION
The sensor values and the ON/OFF state of the system switches of the selected ECM are displayed.
Scrolling up and down the data is possible by means of the UP / DOWN keys and more detailed data is available by
Using the soft function keys as follows :
Executing the [Figure II.1 FIX ITEM] function that moves the item in inverted text to the top of
the display. This item is held and does not move when the cursor keys are used to page through
the display and therefore allows specific items to be compared directly to one another.
[ Figure II.1 : FIX ITEM ]
A fixed item may be released by depressing the
key again.
In the example, illustrated by figure 1, is fixed as denoted by the asterisk to the left of the item number.
Pressing this key will change the number of displayed sensors or switch state which are ‘active’
from 8(MAX), 4, or 2(MIN). Where only 2 items are ‘active’, the rate at which DIAGNOSTIC
TOOL update the display data will be faster than where a higher number of ‘active’ items are
selected.
In the example illustrated by [Figure II.2 Split screen], only 2 ‘active’ data items are selected
[Figure II.2 : Split screen]
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Vehicle Diagnosis
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Use of this key will cause maximum 22 data value to be displayed on the screen as illustrated in
figure 3. The component description displayed will be abbreviated when this mode is used. The
date may be scrolled by use of the UP / DOWN key.
[ Figure II.3 : DISPLAY ALL ITEMS ]
Where more 2 ‘active’ data items have been selected using the FIX key, pressing the GRPH key
will cause the data for those items to be displayed in the form of a graph as illustrated in
[Figure II.4].
Holding one item of two. When the UP / DOWN keys are used to scroll up and down the display,
the item selected by FIX key does not move.
[Figure II.4 : CURRENT DATA (GRPH)]
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Vehicle Diagnosis
______________________________________________________________________________
4. FLIGHT RECORD
4- 1 OPERATION FLOW
[ FLOW II.4 : FLIGHT RECORD MODE IN/OUT FLOW]
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Vehicle Diagnosis
______________________________________________________________________________
4-2 . MODE APPLICATION
The FLIGHT RECORD mode allows for the display and recording of data generated by the ECM as determined by
the user of DIAGNOSTIC TOOL.
By using the UP / DOWN key, the display may be scrolled.
The function of the FLIGHT RECORD is determined by the following soft function keys :
This soft function key selects or releases the items for which data is to be recorded. The fixed are
identified by means of an asterisk to the left of the item number on the DIAGNOSTIC TOOL
screen. The maximum number of items, which may be selected for FLIGHT RECORD functions,
is 8.
The data sampling time interval is displayed at the center of the bottom line of the screen.
This function is used to replay the recorded data. Stored data is only overwritten when recording
and therefore the same data can be viewed more than once/without being over written provided
that no recording takes place.
If the stored file to be viewed relates to vehicle or system, which differs from the current vehicle
and system selection, or if no recording data, the following message will be displayed.
The message is displayed on the screen as shown in Figure 5. The user can select one of the items to read.
[Figure II.5 : FLIGHT RECORD (CALL) ]
MEMORY 1 and MEMORY 4, each memory indicates built-in memory of DIAGNOSTIC TOOL.
If data is in the selected memory, stored data will be displayed , But the following message will be displayed if the
ID of the stored record is different from that of current vehicle and system selection or if no recorded data.
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Vehicle Diagnosis
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end when either the END or ESC key is depressed. During the recording function,
the screen takes the appearance of that illustrated in [ Figure II.6 ]
If the quantity of data being recorded exceeds the capacity of the DIAGNOSTIC TOOL memory,
the first recorded data of the current session will be progressively overwritten as recording
continues
[ Figure II.6 FLIGHT RECORD (RECORDING) ]
The message is displayed on the screen as in the following figure.
[ Figure II.7 : FLIGHT RECORD (RCRD) ]
MEMORY 1 and MEMORY 4, each memory indicates internal memory of DIAGNOSTIC TOOL.
If user selects memory, [ Figure II.7 ] is display. If this key is pressed without selected items, the following message
is displayed.
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Vehicle Diagnosis
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This key is used to set trigger point in this recording process.
When TRIG key is depressed more than twice , only the latest TRIG key handled as trigger at
trigger point.
If END key or ESC key is depressed before TRIG key , that time becomes the trigger point and
recording will be ended.
After finishing the recording, screen will display stored data values in a numeric data form. The
screen example is as follows:
[ Figure II.8 : FLIGHT RECORD (NUMERIC) ]
In this numerical data display, GRPH key is used to see Graphic views for the items recorded by FIX key
operation.
If the two items are selected, a graphical view is as follows.
[ Figure II.9 : FLIGHT RECORD (GRAPH) ]
[ T+5 ] MEANS SAMPLED TIME INDEX, AND CURRENT SCREEN DISPLAY THE TIME AFTER
5TH SAMPLING INDEX FROM TRIGGER POINT.
You can change sampled time index by LEFT(◄) or RIGHT(►) key. In graphic display, current sampled
time index position is displayed as vertical line cursor. If this cursor is arrived end of screen, screen will be moved
as half page.
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Vehicle Diagnosis
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5. ACTUATION TEST
5-1 OPERATION FLOW
[ FLOW II.5 : ACTUATION TEST MODE IN/OUT FLOW ]
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Vehicle Diagnosis
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5-2 MODE APPLICATION
The ACTUATION TEST mode allows certain actuators to be forcibly driven by DIAGNOSTIC TOOL but this
mode can only be supported according to the selected vehicle. The illustration of a typical screen is shown in
[ Figure II.10 ] .
The actuator to be driven can be changed by using the UP / DOWN key to scroll through the list.
[ Figure II.10 : ACTUATOR DRIVING ]
The test must be performed with the vehicle in the state indicated by the CONDITION statement on the screen. In
this illustration given, for example, the ignition key must be turned “on”, and the engine must be running.
The duration of the test will either be fixed by DIAGNOSTIC TOOL and indicated on the screen or the duration
dialogue will indicate
To begin an actuator test, the STRT key should be pressed. For fixed duration test, the message
will be display after an acknowledged code has been received from the vehicle. For tests of no fixed duration, the
message
will be displayed once an acknowledged code has been received from the vehicle and until the STOP key is pressed.
In both types of test, the message
will be displayed if no acknowledge code is received from the Vehicle. The messages will be displayed for 0.5
seconds and then disappear.
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Vehicle Diagnosis
______________________________________________________________________________
6. IDENTIFICATION CHECK
6-1. OPERATION FLOW
[ FLOW II.6 : IDENTIFICATION CHECK ]
Right after IDENTIFICATION CHECK mode is accessed, Part number and Software Version number will be
displayed automatically.
12-18
Flight Record Review
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III. FLIGHT RECORD REVIEW
1. OPERATION FLOW
Choose VEHICLE DIAGNOSIS to operate the FLIGHT RECORD REVIEW function.
In this mode, you can review recorded Flight Record data. The screen will be displayed by frame
unit that is determined by data update.
[ FLOW III.1 : FLIGHT RECORD REVIEW MODE IN/OUT FLOW ]
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Flight Record Review
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2. MODE APPLICATION
After finishing the recordings, screen will display stored data values in a numeric data form. The
example screen is as follows:
[Figure III.1 : FIGHT RECORD (NUMERIC) ]
In this numerical data display,
operation.
key is used to see graphic views for the items recorded by
key
When two items are selected, a graphical view is as follows.
[ Figure III.2 : FLIGHT RECORD (GRAPH) ]
[ T+5 ] MEANS SAMPLED TIME INDEX, AND CURRENT SCREEN DISPLAY THE DATA AFTER
5TH SAMPLING INDEX FROM TRIGGER POINT.
You can change sampled time index by UP or DOWN key. In graphic display, current sampled time index position
is displayed as vertical line cursor. When this cursor is reached at the end of screen, the screen will be moved by
half-a-page.
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System Setup
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IV. SYSTEM SETUP
1. CONNECTION METHOD
The following four kinds of power supply methods can be used.
(1) DLC cable
(2) AC/DC adapter
2. SYSTEM CONFIGURATION
2-1. OPERATION FLOW
[FLOW IV.1 : SYSTEM CONFIGURATION MODE IN/OUT FLOW]
2-2. MODE APPLICATION
This mode displays data for the following items.
1) SERIAL NUMBER
: Display product serial number of your DIAGNOSTCI TOOL
2) MAIN PROGRAM VERSION
: Display software version of DIAGNOSTIC TOOL
3) USED MEMORY SIZE
: Display Software internal memory size
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System Setup
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3. DATA SETUP
3-1. OPERATION FLOW
[ FLOW IV.2 : DATA SETUP MODE IN/OUT FOLW ]
3.2 MODE APPLICATION
The operating parameters of DIAGNOSTIC TOOL may be set prior to vehicle testing. The following list details
items which are user configurable.
1) SOUND : Determines whether or not the internal beep sounds at each key depression.
2) LANGUAGE : Determines whether or not a local language is used.
3) UNIT CONVERSION : The units of measure used by DIAGNOSTIC TOOL may be selected from either of the
following :
Speed : Km/h, MPH
Temperature : Fahrenheit, Centigrade
Pressure : kPa, mmHg, inHg, psi, mbar
Angle : degree, percent
Airflow Volume : gm/s , Ib/m
Items are selected by using the LEFT / RIGHT key, and values may be changed using the UP / DOWN key.
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System Setup
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4. KEY PAD TEST
4-1. OPERATION FLOW
[ FLOW IV.3 : SYSTEM TEST MODE IN/OUT FLOW ]
4-2. MODE APPLICATION
User can perform DIAGNOSTIC TOOL self-test.
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System Setup
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5. SCREEN CONTRAST ADJUST
5-1. OPERATION FLOW
[ FLOW IV.4 : CONTRAST ADJUST SCREEN ]
5-2. MODE APPLICATION
This mode is for contrast adjust screen because LCD’ brightness will change according to the temperature.
Contrast settings will be saved when exiting the screen.
12-24
Appendix A
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APPENDIX
App. A IMPORTANT MESSAGE
DESCRIPTION
This message occurs when the external power supply is Not connected or is lower than 7.0V. The user must supply
sufficient external power.
The DIAGNOSTIC TOOL cannot perform the Communication.
Because the system status is abnormal. The user must inspect the system.
A communication error occurs when the DIAGNOSTIC TOOL.
Displays data which is received via communication. After checking the system, press the
key.
This message occurs after opening the communication, when the system is different from the system selected by the
user. After checking the system, the user should select the correct system again.
This message occurs when there is no recorded data or there is a different system data in the FLIGHT RECORD
mode.
This message occurs when the user selects an item that has no
.
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Appendix A
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This message occurs when the user presses the TIPS key, but there is no DTC in the DIAGNOSTIC TROUBLE
CODES mode.
This message occurs when the
key is pressed without any item selected in the CURRENT DATA mode, or
key is pressed without any item selected in the FLIGHT RECORD mode. In these cases, you must select
an item with the
key.
This message occurs when an error occurs in the ROM(Read Only Memory) of the DIAGNOSTIC TOOL. If you
are having a problem with the DIAGNOSTIC TOOL, please try the procedures in appendix B.
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Appendix B
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App.B TROUBLESHOOTING
1. START-UP TROUBLE
(1) Symptom
1) No BEEP sound after power ON key is pressed
2) Blank screen is displayed
(2) Causes Assumption and Recommended Trial
Causes Assume. 1: No power is supplied to the DIAGNOSTIC TOOL
Trial 1-1 : If power is supplied by DLC cable, check that the DLC cable is connected. If there is no
problem with the DLC cable, change the power supply method.
Trial 1-2 : If power is supplied by AC/DC adapter, check that the AC/DC adapter voltage is over
12.0 volt. If there is no problem in the AC/DC adapter voltage, change the power supply
method.
2. POWER SUPPLY TRIP MODE
To protect the DIAGNOSTIC TOOL and power supply from Harmful electrical shock-such as a surge in the power
supply line-, there is a trip function in the DIAGNOSTIC TOOL power supply.
When the power supply has been tripped, the power supply status is still ON but the power supply has been halted.
So this status can be mis-understood to be OFF status by the user, but the power supply is still alive. To release the
trip mode, you must reset the power supply by pressing the ON/OFF key for more than 2 seconds (power OFF) and
pressing the ON/OFF key for about 0.5 second (power ON).
A description of this trip function’s symptom and recommended trial is described below.
(1) Symptom
1) LCD suddenly OFF, and no key operation can be performed in the power ON mode.
(2) Causes Assumption and Recommended Trial
Cause Assume. 1: The DIAGNOSTIC TOOL power supply has entered the trip mode for surge
protection.
Trial 1-1 :
a. Press the ON/OFF key for more than 2 seconds to turn the power supply OFF.
b. Press the ON/OFF key for more than 0.5 second to turn the power supply ON.
c. In normal mode, the power supply can be restarted by the reset trip.
d. If a severe or continuous surge is sent to the DIAGNOSTIC TOOL power supply,
physical recovery may be needed for the power supply of DIAGNOSTIC TOOL. This
recovery may take a full day.
3. BLANK SCREEN DISPLAYED
(1) Symptom
1) BEEP sound after power ON key is pressed and a blank screen is displayed.
(2) Causes Assumption and Recommended Trial
Causes Assume. 1: LCD Contrast misadjusted
Trial 1-1 : Press the Left+F5 key or Left+F6 key after power ON if this problem is caused by
maladjustment of the screen.
Causes Assume. 2 : Flash memory or ROM misinstalled.
Trial 2-1: Check the main board status.
12-27
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