Engine Service Manual : 2001
Contents
1. that it encounters during operation The RECEIVE Fault s From ECU button enables you to read the codes the ECU is currently encountering Most faults reported by the system can be corrected by examining the connector attached to the device or by tracing the continuity between the ECU connectors and the device connector NOTE Obtain the vehicle s wiring diagram before attempting any testing 1 Connect the data cable to the computer and vehicle 2 Open the Cannondale Diagnostic Tool software on your PC 3 Power up the vehicle When the vehicle is powered up the LED on the data cable block with be lit 4 Click the RECEIVE Fault s From ECU button If the ECU is reporting any faults they will be displayed POSSIBLE FAULT s Fault Report Fuel pump fuel short Fuel pump open short Sensor power supply fault Ai temp sensor high fault Battery voltage low fault Cooling Fan open fault Battery voltage high fault Coil short fault Cooling fan short fault ATV only Cooling fan open fault ATV only Injector A short fault Injector A open fault Injector B short fault Injector B open fault Throttle sensor low fault Throttle sensor high fault Stepper motor fault Crank tooth synch fault Air temp sensor low fault Air temp sensor high fault Engine temp sensor low fault Engine temp sensor hi fault NOTE The Fault Report window sample above was taken while the Cannondale Diagnostic Tool was connected to an 2002 X440s m2. the Cannondale Diagnostic Tool software on your PC 3 Power up the vehicle ECU 4 Click the MONITOR ECU Parameters button The ECU monitor window will be displayed Click CANCEL to exit and close the monitor ECU Monitor This displays the engine RPM This displays the percentage that the throttle plate is open This value may not RPM be 0 even with the throttle plate completely Throttle Position closed ECU Parameters Battery Voltage This is the battery system voltage as measured by the airbox air pressure Airbox Pressure kPa sensor Engine Temperature degC This is the airbox pressure reading as measured by the ECU sensor IACV Stepper Position This is engine temperature reading as measured by the coolant temperature senso Run Mode Continuous This is the position of the Idle Air Control Valve IACV The ECU moves or steps the valve between 0 255 depending on the current engine and air temperature Select Continuous to view live data Select Hold to take a snap shot and hold the values displayed NOTE While this window is open constant communications between the ECU and PC are occurring the ECU will not power itself down The moment you click CANCEL the two minute power down timing will start if no other communication is attempted P N 912 5001985 Printed 11 8 01 7 RECEIVE FAULTS FROM ECU The vehicle ECU will record and maintain faults
3. Cannondale Diagnostic Tool Manual ve For vehicles ATV amp Motorcycles equipped with the MC1000 Engine cannondale Management System Software CD P N 971 5001983 Data Cable P N 971 5001984 Cs A DANGER POTENTIAL HAZARD Running the engine indoors Breathing exhaust gases WHAT CAN HAPPEN Running the engine indoors will expose you to dangerous exhaust gases Breathing carbon monoxide gas leads to poisoning asphyxiation and death This will happen rapidly and without notice HOW TO AVOID THE HAZARD Never operate the vehicle indoors even for brief periods Cannondale Diagnostic Tool Manual fm P N 912 5001985 2001 Cannondale Corporation All Rights Reserved Printed 11 8 01 Safety Alerts e FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH e Keep this Assembly manual in a safe place Messages with the Safety Alert Symbol Ay e Pay special attention to all messages preceded by the Safety Alert Symbol The Safety Alerts symbols means ATTENTION BECOME ALERT YOUR and YOUR CUSTOMER S SAFETY IS INVOLVED Indicates that severe personal injury or A DANGER death WILL result if instructions are not followed A WARNING Indicates a potential hazard that COULD result in serious injury or death CAUTION Indicates a potential hazard that could result in vehicle damage if instructions are not followed NOTE Provides helpful information Cannondale D
4. RUN position Then press the green start button and release it without starting the engine When the system is powered up the green LED on the data cable block will light After 2 minutes of inactivity the ECU will power down automatically except with the ATV the data cable block green LED will not go out It will remain lit as long as the ATV ignition is in the ON position CONNECTING THE DATA CABLE Serial connector female to PC Serial connector male to Pocket PC LED Cable connector to vehicle Motorcycle harness connector on this model 2002 X440s ATV harness connector located under the right front fender the connector is secured to the relay mounting plate on the near the main fuse frame spar Components have been removed for this photo Cap Cap Main fuse holder Data interface connector Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved FAILED TO UNLOCK SYSTEM 125 Failed to Unlock System 145 This message means that the Cannondale Diagnostic Tool was not able to communicate with the vehicle ECU If you see this message check one or more of the following Make sure that both the vehicle harness connector and data cable are undamaged pins not bent or broken and the connectors are properly locked together Make sure the vehicle battery is fully charged Make sure the vehicle ECU is powered up See page 3 Make sure the data cable is plugged sec
5. d from a saved file or received from the vehicle ECU In addition to the ID number each calibration file is assigned a 128 character description Although Cannondale assigns a Numeric Cal ID and description to authorized files a calibration file is like most other kinds of computer files Its possible to changes to the Numeric Cal ID and description through third party software applications A WARNING WARNING Do not experiment with calibration files Sending unidentified altered or third party calibration files can result in severe damage to the vehicle or affect the safe operation of the vehicle You could be severely injured or killed in a resulting accident Always consult the Cannondale website www cannondale com for calibration files authorized for a specific vehicle identification number VIN The ECU for each ATV and Motorcycle leaving the Cannondale factory is loaded with a specific calibration file All calibration files developed by Cannondale are assigned a Numeric Cal ID code Refer to Numeric Cal ID Coding starting on page 8 The code identifies the model and sequence of the calibration file issued The calibration files SHOULD NOT be interchanged between model VINs or models A database of calibrations files is maintained on the Cannondale website so that service technicians have ready access to the correct factory authorized calibration files for a particular vehicle VIN Vehicle s equipped with a third party afterma
6. ds the calibration file open in the Cannondale Diagnostic Tool software to the vehicle ECU Whenever you send a calibration file to the vehicle ECU you have to keep the following points in mind e The software will automatically retrieve the vehicle specific variables throttle positions min max throttle body offset injector flow rate injector offset from the vehicle s current calibration file if specific values have not been entered manually and send the retrieved values with the open file The process is automatic e Anytime the throttle body is serviced you will have to reset or teach the ECU the new values before the new calibration file is sent to the ECU In the case of a replaced throttle body or injector set you will have to enter the throttle body offset and injector flow rate and injector offset variable values that are supplied with the components in the main screen before sending the calibration file to the vehicle Refer to 8 Updating calibrations starting on pa ge15 1 Connect the data cable to the computer and vehicle 2 Open the Cannondale Diagnostic Tool software on your PC 3 Power up the vehicle When the vehicle is powered up the LED on the data cable block with be lit 4 Open a calibration file or receive a calibration 5 Click the SEND Calibration File to ECU button The file that is open will be sent to the vehicle ECU It will over write the current calibration file stored in the ECU Wh
7. en the send has been completed the vehicle ECU will automatically power itself down The LED on the data cable block will turn off indicating the ECU power is now off The calibration file just sent will remain open in the Cannondale Diagnostic Tool software program until the program is exited or another calibration file is opened or received Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved 5 SET THE THROTTLE POSITION CAUTION Set the throttle position with the vehicle off This SET Throttle Position button enables you to teach the ECU the fully closed and fully open throttle body plate positions Teaching the ECU these positions assures that the ECU is calculating fuel and timing on the information arriving from the Throttle Position Sensor TPS mounted on the throttle body Slight variations in different vehicles necessitate this teaching step When a calibration file is opened or received the TPS fully closed and fully open voltage values are displayed at the TPS Sensor Closed volts and the TPS Sensor open volts in the main screen 1 Make sure the throttle plate on the vehicle is completely closed Closed does not mean at the idle position rather it means the idle adjustment screw is backed out until the throttle plate is completely shut Pay attention to any tension present in the cable Tension will hold the plate open While you can t see inside the instal
8. ese calibrations into the calibration file manually If either the throttle body or fuel injectors are replaced the variables are supplied by factory analysts and would be packaged with the parts 1 Connect the data cable to the computer and vehicle 2 Power up the ECU 3 Click the UPDATE Calibrations button The following menu will display Update Calibrations E Throttle Offset lo Injector Flow Rate 2600 _ Type in values and __ click OK Injector Offset 0 7488 Lancel Click Cancel to exit without updating P N 912 5001985 Printed 11 8 01 4 Type in the values in the corresponding fields and click OK The new values will display in the main screen 5 Now you have to send these values to the ECU for them to take effect Click the SEND Calibration File to ECU button 9 PROGRESS INDICATOR Whenever data is being transferred between the vehicle ECU and PC a progress indicator displays in the upper right area of the main screen RECEIVE UPDATE Fault s Calibrations from ECU Data transfers should take no more than 1 minute If the progress indicator freezes for a long time close the Cannondale Diagnostic Tool software and try again making sure the cables are connected properly and that the vehicle battery is fully charged RETRYING CHECKSUM Data is transferred between the vehicle and PC in small packets or chunks During the transfer process checks are performed by the diag
9. his button functions the same way as if you click File Open 3 RECEIVING A CALIBRATION FILE FROM THE VEHICLE ECU The RECEIVE Calibration File from ECU button allow you to receives the calibration file from the vehicle s ECU to the Cannondale Diagnostic Tool It works just like opening a saved calibration file but unlike opening a saved calibration file on your computer the calibration file will be received from the vehicle ECU across the data cable NOTE The received calibration file is not removed from the ECU it is merely copied into the Cannondale Diagnostic Tool program 1 Connect the data cable to the computer and vehicle 2 Open the Cannondale Diagnostic Tool software on your PC 3 Power up the vehicle s ECU 4 Click the RECEIVE Calibration File from ECU button After you click the button the data transfer will start While the data is copied from the ECU to the PC the progress indicator in the upper right of the menu will display and the LED on the data cable block may appear to flicker The time required for the transfer could vary It should take place within 1 minute When the entire data transfer process is complete you will see the Receive complete message 5 Click OK The vehicle calibration file has now been copied to the Cannondale Diagnostic Tool program P N 912 5001985 Printed 11 8 01 4 SEND CALIBRATION FILE TO ECU The SEND Calibration File to ECU button sen
10. iagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved Basics WHAT IS THE CANNONDALE DIAGNOSTIC TOOL The Cannondale Diagnostic Tool is a Windows based software program and special data cable that enables you to connect and communicate with vehicles using the MC1000 Engine Management System The software is installed on a PC or Pocket PC then the PC or Pocket PC is connected to the vehicle wiring harness via the special data cable Once the software is installed in the PC and communication with the vehicle ECU Is established here s what the tool can do e Send a calibration file from the PC to the vehicle ECU e Receive a calibration file from the vehicle ECU to the PC e Set the vehicle throttle body and injector variables e Monitor the vehicle ECU operating parameters e Read system faults INSTALLING THE SOFTWARE To install the Cannondale Diagnostic Tool in your PC insert the installation CD in your computer CD ROM drive Use the Windows explorer and open the program Setup exe on the software CD Follow the step by step instructions When the installation is complete go to the security set up See next heading SECURITY SET UP After the software has been installed on your PC click on the Windows START button in the lower left corner of your desktop go to Cannondale Dlagnostic and Maintenance Program group and open securityCode exe Follow the instructions that are displayed in program window When the
11. led throttle body checking the position of the throttle set plate position can confirm that the plate is fully closed Connect the data cable to the computer and vehicle Open the Cannondale Diagnostic Tool software on your PC Power up the vehicle Use the OPEN button to open a calibration file that is saved on your PC or use the RECEIVE button to open the calibration file that is currently stored in the vehicle ECU When the calibration file is opened or received successfully click the SET Throttle Position button The following prompt will display Read Min Throttle Voltage X Click OK when ready to read MINIMUM Throttle Voltage Cancel P N 912 5001985 Printed 11 8 01 6 Since you already made sure the throttle plate was completely closed click OK to continue Next the following prompt will display Read Max Throttle Voltage X x Click OK when ready to read MAXIMUM Throttle Voltage j Cancel 7 When the prompt above displays have an assistant fully open the throttle and hold it While the throttle is held in the fully open position click OK Immediately after you click OK you will see the following prompt Send Calibrations to ECU Bed x Click OK to send new Throttle Calibration to ECU i Cancel 8 Tell your assistant to release the throttle Click OK and the Cannondale Dealer Tool will send the open calibration file which now includes the new values for fu
12. lly closed and fully open throttle to the vehicle ECU When the send is completed the vehicle ECU will automatically power itself down the green LED on the data cable block will go out Communication from the software to the ECU is now shut down To re communicate with the ECU you will have to power up the vehicle once again 9 Power up the vehicle ECU and click on the MONITOR ECU Parameters button You are looking for the Throttle Open value Now make sure the ECU parameters display is in the Continuous mode Adjust the idle adjustment screw so that the Throttle Open value increases by 3 For example if the value was 2 3 with the throttle plate fully closed you need to adjust this to approximately 5 3 to ballpark the throttle plate position enough to achieve idle Start the engine and allow the vehicle to reach operating temperature 70 C and fine tune the vehicle idle setting as specified for the vehicle NOTE Refer to 6 ECU Monitor starting on page 13 Cannondale Diagnostic Tool Manual fm 12 2001 Cannondale Corporation All Rights Reserved 6 ECU MONITOR The MONITOR ECU Parameters button enables you to monitor selected ECU parameters with the vehicle engine running or with the vehicle engine off It can be operated in Continuous live or Hold Snap shot mode You can start the vehicle with the monitor running 1 Connect the data cable to the computer and vehicle 2 Open
13. nostic tool software to ensure that the data is not damaged during the transfer Each small packet is checked during the transfer If data errors are detected in the packet the message Retrying Checksum will display in the progress indicator Retrying Checksum Typically this is due to electrical noise or other interference during the process The diagnostic tool will keep trying automatically 10 VERSION INFORMATION The Cannondale logo in the top right corner of the main menu is a link to the Cannondale Tech Center website The site includes all factory issued calibration files The file can be downloaded via the link Follow the link for more details Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved
14. otorcycle This vehicle does not have a cooling fan The Cooling Fan open fault will report when the tool is connected to a motorcycle however it can be disregarded Also for the sample fault report above we temporarily disconnected the air temperature sensor notice the Air temp sensor high fault that was reported Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved 8 UPDATING CALIBRATIONS The UPDATE Calibrations button enables you to calibrate the Throttle Body Leakage also called Throttle Body Offset the Injector Flow Rate and Injector Offset The current values for an open or received calibration file are displayed in the main screen oO Received ECU Cal Cannondale Diagnostic Tool File OPEN RECEIVE SEND SET MOHITOR RECEIVE UPDATE Calibration File Calibration File Calibration File Throttle ECU Fault s Calibrations saved from EGU to ECU Position Parameters from ECU PS sensor closed volts a Fuel injector flowrate 2600 lt Instr offset 0 75 lt Mecerintion These calibrations compensate or correct for slight manufacturing variations in the vehicle s throttle body and or fuel injectors Anytime these components are serviced or changed these values must be calibrated The values are loaded to the calibration file when the vehicle is dyno tested and are determined at the factory The Cannondale Diagnostic Tool enables you to input th
15. rket map select interface can toggle maps and other fueling features while the engine is running to meet changing performance demands v 00200 Cannondale Diagnostic Tool MOHITOR ECU Parameters RECEIVE Fault s from ECU Calibration File from ECU to ECU UPDATE Calibrations 00200 2002 X440s 082801 lt This is the Cal ID description up to 128 characters is not retained by ECU P N 912 5001985 Printed 11 8 01 NUMERIC CAL ID CODING MODEL CODE 2 DIGIT YEAR SEQ 2 DIGIT MODEL CODES ee es a NOTE Reset every 10 years 00 thru 99 NOTE The two digit SEQ number is assigned sequentially When a calibration file is updated the SEQ number increases However due to continual product evolution the updated calibration file for the model may not be authorized for use in vehicles produced previously Always consult the Cannondale website for the compatibility of calibration files for a specific vehicle VIN number Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved 2 OPENING A CALIBRATION FILE The OPEN Calibration File saved button opens the Windows explorer so that you can look for and open a calibration file that is saved on your PC or Pocket PC A saved calibration file might be one that you have received via e mail downloaded from the Cannondale website or one that is stored on a diskette or CD T
16. security code is entered after you call Optimum Power to get it you can begin using the software ALWAYS MAKE SURE THE VEHICLE BATTERY IS FULLY CHARGED Before performing any diagnostic work on the vehicle make sure the battery is at full charge If the battery voltage is low the ECU power relay may drop out and shut off the ECU If the battery is not fully charged the ECU power relay can drop out while the engine is cranking over Why During crank over the battery voltage could drop below the needed latch voltage of 10 volts ALWAYS MAKE SURE THE ECU IS POWERED UP The vehicle s ECU operates on a relay controlled power source which is separate from any lighting or starting electrical systems The relay latches in the ECU when the crankshaft sensor detects flywheel movement If the ECU senses inactivity no engine start or communications between the PC and ECU for two minutes it powers down If you try to communicate with the ECU when it is powered down or off the Failed to Unlock System 125 message will display POWERING UP MOTO ECU S On motorcycles power up is relatively simple Press the green start button and release it without starting the engine When the system is powered up the green LED on the data cable block will light P N 912 5001985 Printed 11 8 01 POWERING UP ATV ECU S To power up the ECU on ATVs you have to switch the ignition switch to the ON position then switch the engine switch to the
17. urely into the PC Click OK and start again P N 912 5001985 Printed 11 8 01 MAIN SCREEN 1 2 3 4 5 6 7 8 9 10 J 00200 Wfannondate Didgnostie Toot re File OPEN RECEIVE RECEIVE Calibration File Calibration File Fault s saved from ECU from ECU PS sensor closed volts 0 36 5 PS sensor open volts 4 47 hrottle Body Leakage 8 lt Fuel injector flow rate 2600 njector offset T5 Be Description l l l 00200 X440s 082801 Calibration file identification Opens a saved calibration file Receives a calibration file from the vehicle s ECU Sends the current calibration file to the vehicle ECU Used to set the vehicle s throttle body min max values Used to monitor ECU parameters rpm throttle body offset battery voltage airbox temp airbox temp engine temp IACV Receives faults from the vehicle ECU Used to update throttle body leakage fuel injector flow rate injector offset Progress indicator 0 Used to display Cannondale DiagnosticTool version info Se ee eS Cannondale Diagnostic Tool Manual fm 2001 Cannondale Corporation All Rights Reserved 1 CALIBRATION FILE ID On the top left corner of the Cannondale Diagnostic Tool main screen there will be a Numeric Cal ID number for the calibration file that is open If Untitled is displayed in this area of the screen no calibration file has been opene
Download Pdf Manuals
Related Search