Daytona Twin Tec LLC. ETC Test System Manual

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Imogen Gaines
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1 Daytona Twin Tec LLC ETC Test System Manual

2 Acronyms used: ETC Electronic Throttle Control (also called drive-by-wire) ECM Electronic Control Module (also called ECU, or TCFI) TGS Twist Grip Sensor (rider throttle input) TCA Throttle Control Actuator (throttle dc motor) TPS Throttle Position Sensor (throttle motor position) DUT Device Under Test Overview The electronic throttle control (ETC) test system is intended for testing Harley- Davidson throttle control actuator (TCA) units and twist grip sensors (TGS). The user is presumed to be generally familiar with the Harley-Davidson TCA including the functions of the dual rising and falling twist grip sensors (TGS) and throttle position sensors (TPS). The ETC test system hardware consists of a test system wire harness which connects the twist grip and the throttle actuator to an electronic control module. The twist grip and throttle actuator can remain installed on the bike, or individual components can be bench tested. The test system includes an isolated power supply for this. The bike is to remain off. The TCFI Gen 6 ECM, twist grip sensor assembly and throttle body assembly are available separately. The ETC test program software (for Windows PC) provides two test options: 1. Manual test. TCA throttle position follows TGS command. This option is useful for a quick check of the ETC system operation. When the twist grip commands 100%, the throttle will open just as when the engine is running. The onscreen TGS & TPS values can be monitored while performing the manual test. TGS and TPS are displayed as a percentage, and the four corresponding input voltages are also displayed. 2. Characteristic curve. The system plots out the characteristic curve of TCA throttle position versus TCA motor pulse-width modulated (PWM) drive. This option allows detection of defects such as excessive friction, incorrect or noisy TPS signals, and broken gear teeth. Optional Bench Setup Harley-Davidson A Throttle Jumper Harness is useful to connect a bench mounted TGS assembly to the ETC Test harness. The twist grip assembly may be conveniently mounted in a custom built table mount, as pictured on the cover. Revision 1.1 ETC Test System Manual Page 1 3/23/2018

3 Quick Start: 1) Do not connect the computer to the USB Interface. 2) Download and install the latest software from our website. 3) Bike is to remain OFF. Connect TGS, TCA, and USB Interface together with the TCFI using the supplied harness and various extensions. 4) Plug in AC/DC 12V power adapter into wall outlet. 5) You should hear the TCFI complete a quick power-up movement of the TCA motor. 6) Plug in USB cable to the computer. 7) Using the Device Manager, check the COM port number and the Latency Timer is set to 2ms. 8) Start the ETC Tester software 9) Change the COM port to the number that was in the Device Manager. 10) Begin your testing of the twist grip and throttle actuator. PC Requirements We recommend running the ETC Test program under Microsoft Windows XP/Vista7/8/10. Can use either 32-bit or 64-bit operating systems. Older PCs running anything less are not recommended. The PC requires minimum 1600 x 900 pixel display resolution. The PC should have an Internet connection or CDROM drive for program loading. The PC must have an available USB port. ETC Test includes print commands to print downloaded data. We recommend using a color inkjet or color laser jet printer. Software Installation The software is supplied in the form of a compressed executable file, downloaded from our website. The installation process uses InstallShield. This industry standard installer is based with the Microsoft Windows Installer service that greatly reduces potential problems such as version conflicts and allows for application self-repair. Before proceeding with installation, shutdown any other applications that may be running. For Windows Vista, you must disable the User Account Control (UAC) during installation. If you are not familiar with the UAC, please refer to the Vista UAC Tech Note on our website's Tech FAQ for details. If installation fails, turn off anti-virus program and try again. For installation help on Windows 10, check here: Run the downloaded ETC_Tester_v2.x_setup.exe file downloaded from our website. InstallShield will install the software in a Daytona TwinTec folder under Program Files, Revision 1.1 ETC Test System Manual Page 2 3/23/2018

4 or under Program Files (x86) if on a 64-bit computer. It will also install ETC_Tester.cfg file to your user AppDat/Roaming/Daytona TwinTec folder. After InstallShield has completed the installation, ETC Tester will appear on the Windows Start Menu. You can then launch it just as you would any other Windows program. Tester USB Driver Installation The tester uses our USB interface, P/N , is used for communication with the TCFI6 module. No additional hardware for communication is required. The USB interface connects to the four terminal Deutsch data link connector that is part of the ETC Test harness. The USB Interface has a switch that selects the operating mode. For communication with the TCFI6, you must use the TC88A And All Others switch position. The USB interface is based on FTDI FT232R chip and drivers that allow the unit to emulate a standard Windows RS-232 COM port. Updated Windows drivers, installation instructions and troubleshooting tips are available on the FTDI website at Additional information, latest driver and troubleshooting tips can be found on the downloads page on our website at After installation of the program and the driver installation is complete, turn on power to the tester and connect it to the PC with the supplied USB cable. The Windows Found New Hardware Wizard will appear and complete the installation of the USB drivers. COM Port Configuration After completing the installation steps outlined above, you must configure the new COM ports using Device Manager. This procedure is very simple and only requires a few clicks. Follow the next six steps: 1. Windows XP/ Vista/ 7/8/10: Click Start, and type into the search bar device manager, then click on Device Manager from the list of programs. 2. In the Device Manager, scroll down to Ports (COM and LPT). The tester will appear as a USB serial port. In most cases the wizard will have installed the new usb device at COM2. 3. Double click on the new port to open the properties window. Click on the Port Settings tab. 4. Click on Advanced. In most cases the wizard will have installed the new usb device at COM2, but you can change it here. Make sure it is less than For optimum performance, you must change the BM Options Latency Timer to 2 msec as shown in Figure Click Ok, then Click OK again, then you can close the Device Manager. Once you have configured COM port number for the new tester, make sure that you use the same starting COM port selection in the test. Please note that when the program has Revision 1.1 ETC Test System Manual Page 3 3/23/2018

5 the wrong COM port selection (or USB not installed), several errors such as Invalid port number will occur. Click on Abort until the program screen appears, then scan for device or manually select the correct port. If you are not sure what COM port the USB interface has been assigned to, you can click on the Scan button to automatically detect and select the correct port. Before you do so, make sure that the USB interface has been connected to your PC and the TCFI module, with the power adapter plugged in. After the test system has been properly configured once, the COM port setup is remembered and should not change. Figure 1 COM Port Configuration Revision 1.1 ETC Test System Manual Page 4 3/23/2018

Manual Test Figure 2 ETC Test Program Throttle control actuator (TCA) throttle position follows twist grip sensor (TGS) command. This option is useful for a quick check of TCA operation.

6 Using the ETC Tester 1. Start the ETC test program. 2. Connect the throttle control actuator DUT using the supplied harness. 3. Connect the twist grip sensor DUT using the supplied extension. 4. Plug in TCFI power. 5. Select the desired test option to start. Start Manual Test or Start Characteristic Test. Manual Test Figure 2 ETC Test Program Throttle control actuator (TCA) throttle position follows twist grip sensor (TGS) command. This option is useful for a quick check of TCA operation. Click the "Start Manual Test" button to enable ETC manual test mode or "Stop Manual Test" to disable. The Start Manual Test will allow you to view real-time TGS and TPS data. Figure 3 Live Data using Manual Test Revision 1.1 ETC Test System Manual Page 5 3/23/2018

Characteristic Curve The system plots out the characteristic curve of TCA throttle position versus TCA motor pulse-width modulated (PWM) drive.

A typical characteristic curve for a properly functioning throttle body is shown in Figure 4. The red trace shows the primary rising sensor (TPS1) voltage level versus TCA motor PWM drive.

7 Characteristic Curve The system plots out the characteristic curve of TCA throttle position versus TCA motor pulse-width modulated (PWM) drive. This option allows detection of defects such as excessive friction, incorrect or noisy TPS signals, and broken gear teeth. A typical characteristic curve for a properly functioning throttle body is shown in Figure 4. The red trace shows the primary rising sensor (TPS1) voltage level versus TCA motor PWM drive. The green trace shows the sum of the rising and falling sensors (TPS1 and TPS2) versus TCA motor PWM drive. Test parameters including TPS1 levels corresponding to zero, limp back and wide open position are also reported. Figure 4 - TCA Characteristic Curve Interpreting Characteristic Curve Data The red trace shows the hysteresis loops caused by friction and spring tension in two regions, above and below limp back position (refer to Figure 5). Each test cycle starts at zero PWM with the TCA at limp back position (approximately 0.75V). TCA PWM is stepped to 40%. At approximately 15% PWM, motor torque is sufficient to overcome spring tension and friction and the throttle starts to open. TPS1 rises to approximately 4.75V (wide open throttle) at approximately 30% PWM. Next, PWM is stepped back down to zero. As PWM drops down below approximately 12%, friction effects are Revision 1.1 ETC Test System Manual Page 6 3/23/2018

8 overcome and spring tension closes the throttle back to limp back position. TCA PWM is then stepped in the negative direction to -40%. At approximately -20% PWM, motor torque is sufficient to overcome spring tension and friction and the throttle starts to close. TPS1 falls to approximately 0.5V (closed throttle) at approximately -23% PWM. At the end of each test cycle, TCA PWM is stepped back to zero and the throttle returns to limp back position. The traces for multiple test cycles should overlap closely. The green trace showing the sum of TPS1 and TPS2 should always be very close to 5.0V. The resistive TPS elements can wear out and become noisy, like a scratchy volume control on an old radio. This noise will appear as wiggles or jumps in the green trace. Figure 5 - TCA Characteristic Curve Hysteresis Loops A broken gear tooth near limp back position is a common failure mode. Figure 6 shows the effect. Figure 6 - TCA Characteristic Curve with Broken Gear Tooth Revision 1.1 ETC Test System Manual Page 7 3/23/2018

During either testing, if you see the ECU Status has P1512 ETC Limp Back Mode, this means that the TCFI6 ECU has detected a major problem with the TGS, motor driver, or TPS.

9 Comment You can add a comment by using the Comment command from the Edit menu. This is useful when printing the chart data to a printer. Troubleshooting If you do not hear the electric motor whine when either test is started, check that the TFCI6 is connected properly and that the power is plugged in. During either testing, if you see the ECU Status has P1512 ETC Limp Back Mode, this means that the TCFI6 ECU has detected a major problem with the TGS, motor driver, or TPS. During the Manual Test, the software will give you the option to Reset TCFI. After checking cables and connections, click the Reset TCFI button, and the TCFI will reboot. If the error goes away, you can continue with testing. ETC Tester requires the Monospace 821 BT fixed pitch printer font in order to properly align columns when printing. The Monospace 821 BT font is included in the distribution media and automatically copied to your Windows Fonts folder during installation. The software installs a configuration file, ETC_Tester.cfg into the users AppData/Roaming folder. This is the recommended Windows location for files that may be modified without admin privileges. When the program starts, the splash screen will notify you if this file cannot be found. If the file cannot be installed, an extra copy is available in the folder c:\program Files (x86)\ Daytona TwinTec\ETC Tester\files Copy the file to C:\Users\your_user_name\AppData\Roaming\DaytonaTwinTec\ETC_Tester.cfg. Revision 1.1 ETC Test System Manual Page 8 3/23/2018

CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR SALE OR USE IN CALIFORNIA OR ON ANY POLLUTION CONTROLLED VEHICLES.

Twin Tec User Instructions for Software CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR SALE OR USE IN CALIFORNIA OR ON ANY POLLUTION CONTROLLED VEHICLES. OVERVIEW software runs under