Troubleshooting Guide For Doctor Portable Series
Contents
1. Clogged Thompson Adapter In very exceptional circumstances the Thompson Adapter may become clogged This is most likely to be due to incorrect storage may be clogged with melted plastic for example if placed on plastic surface when hot Faulty extension lead Check lead for continuity and for shorts If any problems are found it is likely that a replacement will be needed No power to pressure sensor Faulty pressure sensor Check on the TNC connector on the EPU for 24V between the inner contact and the outer thread on the connector If the voltage is found to be significantly lower than this the instrument should be returned for investigation The pressure sensor can be visually inspected for damage Removal from the Thompson Adapter using the supplied tube spanner may assist this It cannot be electrically checked If the sensor is suspected to be the cause of lack of readings after other tests it should be returned to Icon for repair or replacement 2 1 CHAPTER 2 Problems with Taking Readings 2 2 Checking Operation of the Crank Pickup s In the EPU press UTIL and select CRANK SETUP from the menu This utility checks the crank pickups for the engine type selected in the MAIN screen Connect the instrument to the pickup s on the engine and press ENT to start the test For a TDC ONLY pickup a steady RPM should be found and the RPM should be the correct value for the engine For a DU2. AL pickup the RPM should be steady for both TDC and FLYWHEEL and the MAX TOOTH DEVIATION should be under 10 Note that the deviation should be under 4 to get acceptable readings however operation is possible up to 10 CHAPTER 3 Inductive Pickups The most common faults found are 3 1 TDC ONLY Operation CHAPTER 3 Inductive Pickups RPM is double expected RPM too low or unsteady RPM too high No reading Two TDC markers on flywheel Unreliable signal check gap pickup and marker Pickup too close to flywheel Check that the engine selected has TDC ONL Y selected in the SET screen 3 2 DUAL Operation RPM is double expected RPM too low or unsteady RPM too high RPM steady but number of teeth low and or unsteady RPM steady but number of teeth too high and or unsteady Max tooth variation gt 5 and RPM and No of teeth steady RPM correct but tooth reading fails at higher RPM s RPM very high Two TDC markers on flywheel Unreliable signal check gap pickup and marker Pickup too close to flywheel Pickup too far from flywheel teeth Check that target diameter is machined and there is no run out on the flywheel Pickup too close to flywheel teeth Check target diameter is machined and free of burrs or dents Teeth probably worn or damaged move pickup to a more uniform diameter on teeth or revertto TDC ONLY operation The gap between the tooth readings is in
3. Troubleshooting Guide For Doctor Portable Series Revision 1 5 May 2007 eon ERESEARCH 3 Raw Holdings East Calder West Lothian EH53 OHY UK T 44 1506 885000 F 44 1506 885501 W www iconresearch co uk NOTICE Information contained in this document is believed to be accurate and reliable However due to ongoing product developments and revisions Icon Research Ltd cannot guarantee the accuracy of this document after the date published nor can it accept responsibility for errors or omissions This document and the software and or hardware which it describes is subject to change without notice Icon Research Ltd acknowledges that various products or trademark names referred to in this document are subject to copyright and or trademark by their respective registered holders CONTENTS CHAPTER 1 Instrument Operativa 1 1 1 1 Battery and Power AAA 1 1 CHAPTER 2 Problems with Taking ReadingS occccococcccnnnoccccnonnnccccnnnancancconanancnnnnnna 2 1 2 1 Checking the Pressure Sensor scooters 2 1 2 2 Checking Operation of the Crank EIG 2 2 CHAPTER S Inductive Se aA 3 1 3 1 TDG ONLY Operation coda 3 1 3 2 DUAL Operations ceda Rate 3 1 CHAPTER 4 Full Diagnostics for Inductive PiCkUPS rrura 4 1 4 1 Single Pickup No RPM indication at EPU ss 4 1 4 2 Dual Pickup No RPM indication at EELren 4 3 CHAPTER 5 Downloading Issues AAA 5 1 5 1 Cable specification AEE 5 1 5 2 No Egiako iaia azaiera 5 1 5 3 Ti
4. V faults found With LED NOT lit no metal in front of pickup x Replace pickup check voltage on terminal 2 in junction box signal wire after resistor pack This should be OV Y Check for continuity and no shorts back to PinA x Repair or replace CIC 3 cable of CIC 3 cable at EPU end Check for 5V here with LED lit and for OV with LED not lit Y Rotate flywheel on engine slowly and check LED x Check pickup gap and that the on pickup goes on when target is in front of pickup is far enough away pickup and off when not from flywheel surface when target is not in front of pickup Y Check that the engine selected in the EPU has x Alter EPU SET screen setting TDC ONLY set in the SET screen to TDC ONLY CHAPTER 4 Full Diagnostics for Inductive Pickups Y With the engine running and EPU connected to crank pickup enter UTILS screen Select CRANK SETUP and follow on screen instructions to test TDC ONLY pickup RPM should be correct and steady If OK on other engines review above If problems persist contact Icon for advice Y Crank pickup is operating correctly CHAPTER 4 Full Diagnostics for Inductive Pickups 4 2 Dual Pickup No RPM indication at EPU Check for 24V at pin E on Mil spec connector on x Check EPU operates normally EPU otherwise and if so return EPU to Icon for investigation Y C
5. an es e shifted to the right 70 04 60 04 50 0 40 0 gt r 30 0 10 0 10 0 30 0 50 0 Crank Angle degrees 6 1 CHAPTER 6 6 5 Faulty indicator cocks Pressure bar Pressure bar Issues with Results Incorrect Power Results If a cock has a damaged seat inside the results often look like the ones shown below The cylinders affected will show much higher power than is actually present in the cylinder 160 0 Traces Faulty Indicator Cocks z El A a Jar Jaz as Tas Tas Jao Jar Jae o1 Joz Jeo EO 60 67 ns 140 0 mr EAE EA IV lv lv lv lv lv lv lv E lv lv lv E Engine Trace Selection 120 0 4 100 04 Faulty cocks can cause readings like these They are quite severe in this example Crank Ang 0 90 0 180 0 270 0 360 0 e degrees Faulty Cocks One Severe and One Only Slight 70 0 50 0 Mar Variation 3 EN BEL 20 0 10 0 Spill Valve Closes OI Cylinder 6A has a faulty cock resulting in a bad reading UA Cylinder 1 has the _ Inlet Opens _ Exhaust Opens same problem to a lesser extent Crank Angle degrees CHAPTER 7 Database Setup Issues CHAPTER 7 Database Setup Issues 7 1 Firing order incorrect Incorrect entry of the firing order can result in traces like this A similar effect is seen if readings are taken starting at the wrong end of the en
6. e under 4 If OK on other engines review above If problems persist contact Icon for advice V Crank pickup is operating correctly 4 4 CHAPTER 5 Downloading Issues CHAPTER 5 Downloading Issues 5 1 Cable specification A download from the Doctor EPU to the Doctor software in a PC is made using an RS232 crossover cable The pin out of the connector on the instrument is shown below 12345 ATE Eee E 3 TX 6 7 89 5 GND For connection to the 9 pin connector on a PC an industry standard PC AT AT DB9 cable is recommended Alternatively a cable as shown in the diagram below can be used 9 way 9 way D connector D connector socket socket 2 S 2 ba 3 5 5 For connection to a PC fitted with USB ports a USB to serial converter will work quite adequately with the RS232 cable supplied 5 2 No serial number entered Check that the RS232 cable is connected at both ends and that the instrument is switched on From your database click on the Yellow Box Button and you should see the dialogue for transfer of results If the programme requests a serial number this can be found on the cover of the CD that was used to install your software Software Registration You will only be able to download data using a fully licensed copy of the Doctor software The ESO first time you download the following window ere of the co box ths sofmare nes appears Enter your serial number to continue EEE
7. further the following tests can be made To test RS232 operation of EPU cable and PC the unit displays a short message on start up If you connect HyperTerminal using the following settings you will get a message on the PC saying I m Alive when you switch on the EPU 5 2 CHAPTER 5 Downloading Issues To use HyperTerminal use Start All Programs Accessories Communications HyperTerminal Use the Set up a New Connection option this will appear automatically the first time you use HyperTerminal Enter a name for your connection e g Doctor From the drop down list choose COM1 or the COM port number you are testing Set up the following e 9600 Bits per Second e 8 Data Bits e No Parity e 1 Stop Bit e No Flow Control Click OK and HyperTerminal is ready to use Connect up to the EPU and then switch on the EPU If you get the message I m Alive then the correct port has been selected and communication is established HyperTerminal must be closed before a transfer with the Doctor software 5 6 Further tests If the computer has only one serial port an additional computer will be required to perform all of the tests Firstly using HyperTerminal connect to the suspected faulty serial port using the settings of e 9600 Bits per Second e 8 Data Bits e No Parity e 1 Stop Bit e No Flow Control If HyperTerminal states that it cannot connect it may be due to one of the following e The serial
8. g leave for 30 secs and try again 2 Keep an eye on the unit for the first 10 to 20 mins of charging If the CHARGING light goes out during this time repeat step 1 A full charge from a flat battery condition will take 2 to 3 hours 3 Ideally after a deep discharge the battery should be cycled by fully charging it fully discharging it and then fully charging it again To discharge leave the unit switched on and make sure the BATTERY LEVEL selection in the UTIL screen is set to 5 90 When the BAT warning appears in the top right of the screen the unit is quite close to being discharged and can be charged up again 4 The batteries in the Doctor are Ni Cad batteries and these should be allowed to discharge before being charged up in normal operation of the system Failure to do this or constant topping up of the batteries can induce a memory in the battery that results in reduced battery capacity 5 If the battery still fails to power the unit or only powers the unit for a short time the battery should be replaced In most Doctor units the battery is fitted with a quick change connector lf this is the case then a new battery should be ordered from Icon If there is no connector present the EPU must be returned to Icon for fitting of a connector and replacement of the battery To check inside the unit for a connector Before starting switch on the instrument and go to the SET screen and take a note of any settings you
9. gine Firing Order Reversed If the firing order is enterediin reverse or readings are taken starting at the wrong N of the engine traces will app A Mu Ee 140 0 120 0 alike this A 80 04 Pressure bar 60 04 40 0 200 4 A N a AN q e d E N bu o Tb gt a EA E aar Ed EA pr F ade ed aan wt Ti ar T ea ee ee N 0 0 T T T T T T T 1 180 0 135 0 90 0 45 0 0 0 45 0 90 0 135 0 180 0 Crank Angle degrees 7 2 Bank angle on V configuration engine incorrect The graph below shows the effect of an incorrectly entered bank angle for a V engine V Engine with wrongly set V Angle in Engine Data 160 0 i o TD Exhaust Closes _Inlet Closes 140 05 Spill Valve Closes When the V Lingle i is set wrongly in the Engine Details the traces will appear ZA like this BESS e Engine Trace Selection 120 04 100 04 Pressure bar 00 The separation of the 2 groups is the error in SN the V angle 20 04 00 E 360 0 270 0 180 0 90 0 0 0 90 0 180 0 270 0 360 0 Crank Angle degrees 7 1
10. have made in the instrument for your engines Battery changing will not affect the memories in the instrument 1 1 Chapter 1 Instrument Operation Switch the instrument off and remove the 10 screws holding the front panel Lift the panel slightly and move it towards you before tilting the back up to remove the chassis from the case Turn the panel over and place it in the case as a convenient support Note that newer units do not have the internal power supply fitted lower right in picture Check to see if a connector is fitted to the battery 1 2 CHAPTER 2 Problems with Taking Readings CHAPTER 2 Problems with Taking Readings If the unit fails to take a reading but the screen is operating normally it is best to determine if the pressure sensor and the crank pickups are functioning correctly 2 1 Checking the Pressure Sensor From the UTILS screen in the EPU select READ PMAX In this mode the instrument acts as a peak pressure gauge independent of the crank pickups With the engine running attach the pressure sensor to an indicator cock on a running engine open the cock fully and press ENT This will start peak pressure measurement If a normal pressure reading is obtained the pressure sensor and lead are OK If the pressure sensor gives a reading but it is too low or too high check that the sensitivity that has been entered for the sensor is correct If not the following can be checked
11. heck 24V at Junction boxes on terminal E of Mil x Check CIC 3 cable for Spec connector and to all power connections continuity and shorts If faulty brown wires either repair or replace Check pickups for physical damage x Damage normally impairs operation Replace pickup Y Check that each LED is lit when metal is present x Replace pickup Note that the in front of the pickup system can be re configured for TDC only operation as a stand by until a replacement is available Y Check that the LED is NOT lit when metal is NOT x Check wiring and if correct present in front of each pickup replace pickup Y With LED lit metal in front of pickup check x Replace pickup voltage on black wire from each pickup This should be 24V Y With flywheel LED lit metal in front of pickup x Check resistor values and check voltage on terminal 2 in junction box connections Remedy any signal wire after resistor pack This should be faults found 5V Repeat for TDC pickup and terminal 6 Y With flywheel LED NOT lit no metal in front of x Replace pickup pickup check voltage on terminal 2 in junction box signal wire after resistor pack This should be OV Repeat for TDC pickup and terminal 6 Y Check for continuity and no shorts on the green Repair or replace connecting and yellow wires back to the junction box with the cable or make connections Mil spec connector good Y Check for continui
12. int the box below Serial Number you must first register this software 5 1 CHAPTER 5 Downloading Issues 5 3 Timing Issues On a very few older PC s the timing for the RS232 may be incompatible with the EPU For such cases the EPU has a SLOW transfer mode To select this in the EPU enter the UTILS screen and select the SLOW option for SERIAL TRANSFER 5 4 Incorrect Com Port Selected The COM port that is selected by default is COM 1 If this is not the one you are using it is possible to change the port If you know the COM port number for the socket you have used you can enter it however if you don t know you can keep trying until one works There are 8 COM port selections to choose from Note that if you are using a USB to serial adapter you will always need to change from the default setting of COM 1 If connection is unsuccessful you will see the following window 1 Communication with the Engine Processor Unit failed Please check your connections and try again E From the drop down menus select Download Comms Setup and choose the COM port you need Click on OK and try downloading again Comms Port Port Cancel Click on the a button after the correct COM port has been selected 5 5 Problems with the PC s RS232 connection As an initial test it may be easiest to install the Doctor programme on another PC and test downloading If this works then the cable and the EPU are OK To check
13. ith Results Incorrect Power Results CHAPTER 6 Issues with Results Incorrect Power Results 6 1 TDC Offset By far the most common reason for unacceptable results is that the TDC offset has not been correctly adjusted A 1 error in TDC adjustment will give an error in power of 7 or so The manual for the software fully covers how this adjustment may be made Alternatively Icon provides a service for initial results free of charge To use this service just send an archived database to doctor iconresearch co uk 6 2 Sensitivity of sensor incorrectly entered The sensitivity of the pressure sensor must be correctly entered into the database in the software on the PC The default value is 20mV bar and all sensors supplied today are close to this value Older sensors had a sensitivity of 25mV bar and if the two are confused a 20 to 25 error in pressure and power values can result 6 3 Incorrect dimensions in the database The values for bore stroke and con rod length all need to be correct in the database to provide correct power values 6 4 Clogged or restricted indicator passageways Pressure bar Partial clogging of the indicator cock or passageways will affect the results Restricted Indicator Cock or Passageway 120 0 Restricted flow to the pressure sensor can cause a slugged reading The gradient changes are slower the whole curve is 110 04 100 04 90 0 6 30 04 03 1 80 04 EES cs
14. ming Issues ek A ena 5 2 5 4 Incorrect Com Port GSren 5 2 9 5 Problems with the PC s RS232 connection rra 5 2 5 6 FUN era Ian 5 3 CHAPTER 6 Issues with Results Incorrect Power Results rss 6 1 6 1 A A eatea baaa egiazta 6 1 6 2 Sensitivity of sensor incorrectly entered raa 6 1 6 3 Incorrect dimensions in the database rra 6 1 6 4 Clogged or restricted indicator passageways rr 6 1 6 5 Faulty indicator COCKS pri id 6 2 CHAPTER 7 Database Setup ISSUCS na ee 7 1 7 1 Firing rderiincorrett ee be 7 1 7 2 Bank angle on V configuration engine incorrect rr 7 1 Chapter 1 Instrument Operation CHAPTER 1 Instrument Operation 1 1 Battery and Power Issues The EPU screen should illuminate and show text indicating a test sequence on switching the instrument on If this does not happen it is likely that there is no power in the battery Try switching on with the battery charger connected lf the instrument switches on the battery may either have been deep discharged or it may require replacement If the Doctor is left switched on for an extended period or occasionally on new units the battery charging circuit may switch off before a full charge is reached If the battery seems to be losing charge quickly when in use this may be the cause To remedy this the following procedure should be used 1 Connect the charge lead to the mains and check that the POWER light comes on The CHARGING light should also come on however if not unplu
15. port does not exist Check using the Windows Device Manager which is found in the Control Panel System Tools 5 3 CHAPTER 5 Downloading Issues e The hardware driver for the serial port is faulty Check using the Windows Device Manager e Another application is currently using the serial port this must be closed before it can be used by the Doctor Software If the computer has another serial port repeat the process above using a second copy of HyperTerminal or else use a second computer Connect your RS232 cable between the serial ports and type a message on each of the HyperTerminal windows The message should be displayed on the other HyperTerminal window If it does not it may be due to one of the following e The cable is not actually connected to the correct serial port on the computer e The cable is not a crossover cable or is faulty e One or other of the serial ports if faulty If the message only appears on one of the HyperTerminals it may be due to one of the following e The cable is not a crossover cable or is faulty e One or other of the serial ports is faulty If the serial port works correctly HyperTerminal can also be used to check the workings of the DK 2 unit Firmware Version 3 xx only To do this e Start HyperTerminal in the same manner as above e Connect the DK 2 to the computer using the serial cable e Switch on the DK 2 and observe a single line message displayed 5 4 CHAPTER 6 Issues w
16. sufficient Move the tooth pickup to a larger diameter where the gaps are larger or use a smaller diameter pickup with a higher response Check that the engine selected has DUAL selected in the SET screen 3 1 CHAPTER 3 Inductive Pickups 3 2 CHAPTER 4 Full Diagnostics for Inductive Pickups CHAPTER 4 Full Diagnostics for Inductive Pickups 4 1 Single Pickup No RPM indication at EPU Check for 24V at pin E on Mil spec connector on x Check EPU operates normally EPU otherwise and if so return EPU to Icon for investigation Y Check 24V at Junction boxes on terminal E of x Check CIC 3 cable for Mil Spec connector and to all power connections continuity and shorts If faulty brown wires either repair or replace Check pickup for physical damage x Damage normally impairs operation Replace pickup Y Check that the LED is lit when metal is present in x Replace pickup front of the pickup Y Check that the LED is NOT lit when metal is x Check wiring and if correct NOT present in front of pickup replace pickup Y With LED lit metal in front of pickup check x Replace pickup voltage on black wire from pickup This should be 24V Y With LED lit metal in front of pickup check x Check resistor values and voltage on terminal 2 in junction box signal wire connections Remedy any after resistor pack This should be 5
17. ty and no shorts back to pins A x Repair or replace CIC 3 cable and B of CIC 3 cable at EPU end Check for 5V here on each with LED lit and for OV with LED not lit 4 3 CHAPTER 4 Full Diagnostics for Inductive Pickups Y Check that pin A on the CIC 3 connector at the EPU end corresponds to the Flywheel pickup monitors the teeth on the flywheel and that pin B corresponds to the TDC pickup monitors bolt in the flywheel Swap connections for pickups at junction box nearest to flywheel Rotate flywheel on engine slowly and check LED on pickup goes on when target is in front of pickup and off when not Check that the flywheel pickup flashes each time that a tooth is in front of the pickup Check pickup gap and that the pickup is far enough away from flywheel surface when target is not in front of pickup Note that flywheel pickups should have at least twice the pickup diameter as free space between each tooth If not move pickup to achieve this or replace with smaller pickup Y Check that the engine selected in the EPU has DUAL set in the SET screen Alter EPU SET screen setting to DUAL Y With the engine running and EPU connected to crank pickup enter UTILS screen Select CRANK SETUP and follow on screen instructions to test DUAL pickups RPM should be correct and steady The MAX TOOTH DEVIATION should be under 10 as a maximum note that for good readings this should b
Download Pdf Manuals
Related Search