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KMS MD35 manual

Version 4.16

WARNING:

Disconnect the battery cables when you’re doing electrical work.

Disconnect the KMS ECU from the wiring harness connector when

welding on the vehicle.

Make sure there are no fluid leaks and all connections are secured

and/or tightened.

Wiring and fuel system components must be mounted away from

heat sources or shielded if necessary.

Do not use a batterybooster or a 24V charger. Do not reverse the

polarity of the battery or the charging unit. Do not change the

battery with the engine running. The peak power supply could

severely damage the KMS ECU and other electrical devices.

Avoid open sparks and flames near flammable substances.

Do not use unsuppressed spark plugs and leads. They cause

electromagnetic interference.

Summary of Contents for MD35

Page 1: ...MD35 Manual V4 16 ...

Page 2: ... 3 46 3 2 4 1 14 External Dashboard 47 3 2 4 1 15 Remarks 47 3 2 4 1 16 Speed settings 48 3 2 4 1 17 Traction control settings 49 3 2 4 1 18 Communication port 51 3 2 4 2 Output test 52 3 2 4 3 Crankshaft sensor test 52 3 2 4 4 Motor system diagnostics 53 3 2 4 4 1 Runtime 53 3 2 4 4 2 Over revving of the RPM limiters 53 3 2 4 4 3 Crank sensor 54 3 2 4 4 4 Oil pressure 54 3 2 4 4 5 Water temperatu...

Page 3: ...The communication bar 63 4 Programming 65 4 1 Manual changing 65 4 2 Bar charts 65 4 3 3D graph changing 67 5 Hardware installation 68 5 1 Fitting the ECU 68 5 2 Connecting the communication cable 68 6 Fault tracing 69 7 Specifications 70 8 Wiring diagram MD35 71 Appendix 1 Trigger wheel drawings 72 ...

Page 4: ...ignition spreadsheet can be setup By modifying these values while monitoring the exhaust gas composition best way is using a wide band lambda sensor you can see if the engine runs rich or lean This way you can find the optimal amount of fuel and optimal ignition moment needed for all possible combinations of RPM and throttle position manifold absolute pressure This process can be best carried out ...

Page 5: ...ng and fuel system components must be mounted away from heat sources or shielded if necessary Do not use a batterybooster or a 24V charger Do not reverse the polarity of the battery or the charging unit Do not change the battery with the engine running The peak power supply could severely damage the KMS ECU and other electrical devices Avoid open sparks and flames near flammable substances Do not ...

Page 6: ...ly when the CD is inserted The program KMS FIRMWARE DOWNLOADER can be used to update the ECU When there are new options available they can be downloaded as a zip file from the Van Kronenburg website The zip file consists of 3 files and a readme text file see figure below Unpack the zip file on your computer in the KMS Firmware downloader folder This is the location where you installed the Firmware...

Page 7: ...stalled the program is set to work via communication port COM1 If this port is already being used or not available another communication port can be used For the procedure to change the communication port see 3 2 4 1 17 Communication port USB connections have the most various numbers of communication ports so make sure you ve got the communication port right For settings and finding the right comm...

Page 8: ...s use function key F11 The spreadsheets are two dimensional diagrams showing engine speed against engine load The engine speed range can stretch from 500 rpm to 20 000 rpm Standard the screen stretches from 500 rpm to 12 500 rpm This however can be changed see 3 2 4 1 1 RPM pickup The RPM range is divided over 25 boxes The engine load range is sub divided into 16 boxes dividing the range that has ...

Page 9: ... 3 2 4 1 4 Injection settings by clicking on the buttons that are marked in the drawing below These groups can be set for different kind of injector banks For more settings look at the hardware configuration and the injection settings see 3 2 4 1 7 Hardware configuration and 3 2 4 1 4 Injection settings 3 1 2 The ignition characteristic diagram In the ignition spreadsheet figures can be entered th...

Page 10: ... Acrobat reader 4 0 can be found on the installation CD ROM 3 2 2 Function key F2 This function key enables a previously saved file to be opened from the hard disk CD ROM USB memory key etc The files can be recognised by a floppy icon MD35 files have the extension M04 3 2 3 Function key F3 This function key is used to save modified files The names of these files automatically receive the extension...

Page 11: ...KMS MD35 manual Version 4 16 11 3 2 4 1 Options If Options is selected a menu appears which lists several possible settings These settings are described below ...

Page 12: ...left figure below If your engine doesn t make more than 6 500 rpm you can devide the 25 rows over this 6 500 rpm example see right figure below So the mapping will be more fine tuned for this engine rpm range 3 2 4 1 1 1 Crank pickup Users can enable the crank pickup and set the references Sensor type Here you can select if your connected sensor is hall or inductive Hall sensor a current runs thro...

Page 13: ...e crank or camshaft and choose to make the reference point 1 or 2 missing tooth Note It s still only possible to use one reference point When using the User defined trigger wheel the number of coils ignition outputs used on the MD35 and odd fire TDC s see chapter 3 2 4 1 1 3 must be defined Note When using a 60 2 trigger pattern the maximum engine speed is limited to 12 500 rpm When using a Hall s...

Page 14: ...ompression stroke for direct fire Active The cam reference can be set between 180 and 180 degrees TDC of the compression stroke Select the kind of pickup signal high or low There is a easy way to find out whether the signal is high or low Just apply power to the KMS system engine not running with the cam sensor connected Right below in the main screen in the communication bar of the KMS software y...

Page 15: ...nect the cam sensor to make this work With dis coil it is a wasted spark Separate coils per cylinder is requiered for this sequential ignition Make sure that the connections of the KMS ECU to the single coils are in the right igniting order For example a 4 cylinder inline engine with firing order 1 3 4 2 The coil outputs get activated in the order 1 2 3 4 For direct firing coil output 1 fires cyli...

Page 16: ...in and 90 degrees further which gives 480 90 570 degrees Cyl 1 Cyl 4 Cyl 3 Cyl 6 Cyl 2 Cyl 5 0 90 150 90 150 90 0 90 240 330 480 570 In the software you can fill in a maximum of 360 degrees after TDC cylinder1 So this would mean that cylinder 2 and 5 can t be set up Every value above 360 you need to subtract 360 degrees Which result for cylinder 2 in 480 360 120 degrees and cylinder 5 in 570 360 2...

Page 17: ...tting the number of teeth before TDC at which an ignition impulse is given under 500 rpm Keep this number as low as possible to prevent backfiring when the engine is started For engines with a high compression ratio it is recommended not to set this to a number higher than 1 ...

Page 18: ...ettings gives the possibility of setting a fixed ignition moment between 54 degrees before and 54 degrees after TDC After TDC is indicated by a negative number fixed fuel enrichment and fixed PWM boost for several ascending engine speeds This enables a high boost pressure to be built up in turbocharged engines without further increasing the engine speed Additional fuel enrichment can be set when l...

Page 19: ...ween the available gears Note that a gearposition sensor must be present on the transmission housing for the use of these features When 0 is entered in one of the cells it will not be taken into effect Cut time ignition Here you can set the desired ignition cut time for each gear change position The ignition will be interrupted for the time set here Cut time injection You can set the desired injec...

Page 20: ...V In the top row the various gears from reverse to 8th gear can be selected The second row contains the corresponding sensor output voltages to the various gears The gearposition sensor output voltages can be set manually or automatically For automatic calibration of the voltages please select Automatic calibration gearposition The software will tell the user which gear to select and to press ok t...

Page 21: ...arged engines is higly recommended Some settings in the software are always related to TPS and some to the MAP sensor However there is the possibility to select on which sensor TPS MAP combination TPS MAP the main load tables are linked to In the picture above you can see all the possible combinations The possible combinations are explained below Main Load is TPS All the load tables included lambd...

Page 22: ...um the injection value will be 50 of 10 ms 5 ms With the boost correction table set on 25 this will result in an extra 25 enrichment So if MAP pressure raises with 100 kPa the enrichment will not be 100 but 100 25 125 which results in an injection time of 22 5 ms at 200 kPa 1 bar boost and 35 ms at 300 kPa 2 bar boost In theory an engine runs on lower loads lambda 1 00 A F 14 7 on pump gas to meet...

Page 23: ... engine running smooth with changing the complete fuel map all cells at once with positive or negative percentage using the edit menu If lambda control is active and the engine is at normal operating temperature you can start programming the separated cells in the fuel map with the boost pressure set as low as possible After the injection table is mapped at low boost the next step is to raise the ...

Page 24: ...e throttle positions will now be shown A warning will appear if automatic calibration cannot be finished correctly For possible causes see Fault tracing Manual calibration When a map sensor or an air mass sensor is used automatic calibration is not easy because the minimum and maximum output signals of the sensor are not known before the engine has run We recommend filling in the figures by hand m...

Page 25: ...ided in proportion to the signal MAP sensor Logarithmic At lower loads the load signal is divided over a smaller number of steps and at higher loads it is divided over a larger number of steps Air mass sensor e log The action is opposite to that of the logarithmic parabola Single Throttle body setup ...

Page 26: ...PM and below x TPS Injection driver 2 If you have selected enabled the second injection driver in the hardware configuration see section 3 2 4 1 7 Hardware configuration you will be able to configure the type banked or staged of injection here depending on the kind of injector configuration TIP Mapping a banked V engine can be easily done by disabling banked injection and selecting the first lambd...

Page 27: ... long as the engine speed is lower than 500 rpm the quantity of injected fuel shown in the first row applies Proper firing of the engine often requires more fuel depending on coolant temperature than the quantity needed when the engine is already running at the same engine speed This extra enrichment can be entered in the table for the duration of a certain amount of crankshaft rotations There are...

Page 28: ...cceleration type2 However type 2 can be combined with type 1 for some engines useful Acceleration enrichment type 2 is always linked to main engine load The initial burst is one pulse that is directly injected when needed no matter what crank position and will intervene to avoid a short lean mixture The sensitivity is linked to opening speed of the throttle A low value for sensitivity means that t...

Page 29: ... communication bar change to the values for map 1 or map 2 when switching However the injection map has to be uploaded from the ECU if you want to change those values Analog Aux2 input For this input the 5V gearpostion and map selector are the same as the first input but there are three different options At this input you can t connect a second Oxygen sensor but you can connect a KMS EGT sensor a ...

Page 30: ...or banked V engine injection is not possible Vice versa it s not possible to use ALS if you use staged or banked injection See also section 3 2 4 1 4 Injection settings and 3 2 4 1 10 A L S Warning When connecting the injectors do not allow the engine to flood make sure the fuel pump is switched off and the Power output2 is set to Injection driver 2 and not to A L S Oil pressure sensor You can use...

Page 31: ...c for the UEGO display Always check if the output type is the same as selected in this software Type a of the KMS UEGO Display controller has the same output curve as the KMS UEGO controller When using the KMS UEGO CAN controller the lambda controller type must be set up correctly When the UEGO CAN controller operates by CAN communication you must set the lambda controller type to KMS UEGO control...

Page 32: ...equency becomes dependent on the value set under Idle Sample delay while the A F ratio adopts the desired value of the Idle A F mix Recommended value 0 5 2 0 TPS value Idle mix RPM When the engine speed decreases under the threshold set here this is considered as idle In other words the sampling or measurement frequency becomes dependent on the value set under Idle Sample delay while the A F ratio...

Page 33: ...e conditions it is therefore preferable to deactivate the air fuel ratio control loop When the throttle position is less than this value TPS input here the air fuel ratio feedback control will be deactivatedd Make sure this value is always set higher than the Fuel Cut Off value For example a value between 0 5 1 5 depending on your FCO value Overrun RPM turn on In case of overrun TPS overrun thrott...

Page 34: ...aximum negative injection compensation between two samples as a percentage If 0 0 is set in here this function is not active For example if the sample rate is set on 10 samples per second The maximum decrease in 1 sample is set on 0 5 Then the lambda control can only compensate 10x0 5 5 fuel decrease per second Up to main load Above this main load value there is no limit on the compensation betwee...

Page 35: ...o maximum negative correction After this time span the lambda control will shut down If set to 0 0 this function will not be active Recommendeed time 3 10 sec If Error on A F sensor inc Fuel by Here you can input a compensation value as a percentage in case of lambda shut down due to error This can be used as a protection for the engine against running a too lean mixture Recommended value 3 10 3 2...

Page 36: ...correction map and press OK twice There are 2 correction maps to work with Depending on which lambda sensor s you have selected and the specified correction on the selected injection group These correction maps will adjust the injection group corr map1 injection group 1 corr map2 injection group 2 There are some exceptions 1 with correction on injection group 2 1 correction on injection group 1 an...

Page 37: ...entered here Recommended 1 or 2 Advanced settings If the use advance settings control box is selected the advanced settings menu must be set You can set here different sample rates for various RPM Engine load ranges In general with higher engine speeds and engine loads the sample rate can be set higher due to more combustions per second and higher exhaust gasflow If the sample rate is set too low ...

Page 38: ... or maximum pressure depending on the connection of the solenoid valve Here you need to select the correct control boxes Boost control on off Here you can decide to switch the boost control on or off If the boost control is activated in the hardware configuration the boost pressure will be regulated by the PWM percentages in the PWM table Boost PID control Here you can activate the control to not ...

Page 39: ...and the sample rate determine the duration of the PID on delay Start RPM Here you can enter the rpm at which the control may activate This helps avoid unnecessary operation of the solenoid valve at low revs Boost Limit ignition cut off In case the boost pressure exceeds the target value risk of engine damage you can specify a limit with this parameter When the boost pressure reaches this limit ign...

Page 40: ...ion of the boost pressure to its target value The gain factor can be entered here 3 2 4 1 9 2 Boost target map Via this menu you can enter target boost pressures for separate engine speeds 3 2 4 1 9 3 Boost PWM map In this field you can specify for each throttle opening and rpm a fixed duty cycle percentage PWM for operating the control solenoid valve In other words you can ensure that boost press...

Page 41: ...PWM map If overboost is active the system will use the overboost PWM map The values in the boost PWM map can be easily copied to the overboost PWM map by selecting the cells and choose copy boost to overboost map So the values in the overboost PWM map can easily be increased by a percentage over the boost PWM map values 3 2 4 1 9 4 2 Enable window for activation Here you can set the margins within...

Page 42: ...row contains ten boxes where speeds can be entered the first box is fixed at 0 In the second row the boost correction in percentages can be entered for each corresponding speed interval In the example below the first speed interval ranges from 0 to 10 km h and has a boost reduction of 80 The second speed interval ranges from 10 to 20 km h and has a boost reduction of 75 etc 3 2 4 1 9 4 5 Boost red...

Page 43: ...so a fixed PWM value can be set The fuel enrichment and PWM boost are both percentages If using variable A L S by connecting a potentiometer signal you can vary the PWM value from 0 to the value set here in the A L S settings The potentiometer must be in the range of 1 kΩ 47 kΩ The variable signal from the potentiometer must be connected analog aux2 input on pin 25 or analog aux3 input on pin 24 T...

Page 44: ... and deactivates off at at 85 Celsius 3 2 4 1 11 3 Mode 1 Mode 1 functions a lot like mode 0 except for two things The aux output will deactivate when the criteria parameters exceed the preset off at values It s also possible to set a hysteresis for both criteria This means that the aux output can also be deactivated when the criteria parameters drop below the hysteresis and on at values The advan...

Page 45: ...h will be activated when the criteria aux result that have been set for mode 0 or mode 1 are met fullfilled and the timer has expired finished As soon as the aux result drops below the criteria the timer is reset and the aux output expires Delay without reset The aux output aux pin in the graph will be activated when the criteria aux result that have been set for mode 0 or mode 1 are met fullfille...

Page 46: ...ph will be activated as soon as the timer has expired However the timer is reset each time the criteria aux result that have been set for mode 0 or mode 1 are met fullfilled or expire 3 2 4 1 12 AUX 2 See section 3 2 4 1 11 AUX 1 3 2 4 1 13 AUX 3 See section 3 2 4 1 11 AUX 1 ...

Page 47: ...channels design your display and transmit the configuration to the AIM logger Connect TX pin 2 of the KMS MD35 connector to the RX input from AIM Not all channels are working from KMS this depends on which sensors are connected to KMS You can see this on line and disable these channels in your configuration Please contact your AIM dealer for more details and information 3 2 4 1 14 1 CAN protocol T...

Page 48: ...nce between the driven and non driven wheels It s only possible to separately calibrate the speed sensors on the front and rear axle of the vehicle This means that if there are two sensors on one axle these sensors must be mounted in the same way and have the same trigger wheel to prevent an incorrect measurement of the speed on one side of the vehicle For example sensor 1 front left sensor 2 fron...

Page 49: ...ction control starts at a speed difference percentage of 10 front speed sensors at 100 km h and rear speed sensors at 110 km h 10 difference in speed and ends with a speed difference percentage of 40 front speed sensors at 100 km h and rear speed sensors at 140 km h 40 difference in speed with an initial retard of 5 deg and maximum retard of 20 deg the traction control is set to the ignition retar...

Page 50: ...nition reduction to gear position Ignition can be reduced for each separate gear only possible after the gear positions are calibrated shown in the first row The second row contains the corresponding reduction in ignition for each gear ...

Page 51: ...s You will now see a screen with some tabs Select the tab compatibility and set the compatibility mode in this screen to Windows XP SP2 Don t forget to click the box above it to select the compatibility modes The KMS software will now see the different communication ports and you will be able to connect the ECU to the computer If this is not the case another communication driver should be installe...

Page 52: ...ched off 3 2 4 3 Crankshaft sensor test The crankshaft sensor function is used to check whether the crankshaft position sensor registers the correct number of teeth The number of teeth shown should be 60 for a 60 2 toothed wheel and 36 for a 36 1 version If another reading is shown check whether the sensor is correctly connected and properly mounted Electronic interference can occur when the leads...

Page 53: ...e Runtime ECU Indicates how long the ECU was powered Runtime 500 rpm 1 Indicates the running time of engine above 500 rpm Runtime 500 rpm 2 Indicates the running time of engine above 500 rpm Under reset runtime 500 rpm 2 the runtime 500 rpm 2 can be reset The runtime 500rpm 1 as well as runtime ECU cannot be reset 3 2 4 4 2 Over revving of the RPM limiters In this part you can see how many crank t...

Page 54: ...ave the changes you made when you close the system diagnostics screen If the oil pressure is below the in the rpm range specified oil pressure time will start counting until the specified oil pressure is reached The lowest oil pressures measured for the different rpm ranges are shown 3 2 4 4 5 Water temperature sensor This part is for the diagnostics of the water temperature sensor or measurements...

Page 55: ...e when you close the system diagnostics screen The maximum air temperature that was reached is shown 3 2 4 4 7 Throttle Position Sensor This part is for the diagnostics of the throttle position sensor or measurements from the sensor The time a short circuit or a open circuit is detected will be shown here When the TPS value reaches a lower value than the minimum load 0 steps from 0 until 255 the p...

Page 56: ...emperature injection time overflow can occur when the injector flow is to narrow 3 2 4 4 12Lambda control The total time that the maximum increase or decrease in fuel has been reached is recorded here as MaxIncLambda or MaxDecLambda The values for maximum increase in fuel or maximum decrease in fuel are set in Lambda Control see section 3 2 4 1 8 Lambda control The time behind MaxIncLambdaError or...

Page 57: ...d to the CANbus really communicate with the ECU If a connected device or multiple devices are not found please check the CANbus for correct connection and power supply When more than one UEGO CAN controller is connected to the CANbus the lambda controllers have to be designated to a function lambda 1 to lambda 16 Lambda 1 has the highest priority and will be selected first for the lambda control L...

Page 58: ...As a result the mix becomes too weak so that the engine will hesitate To compensate for the loss of fuel at low engine temperatures more fuel will have to be injected There is also an option to completely cut off the injection so no fuel will be injected If you insert exactly 100 in the water temp correction fields fuel will cut off In the ignition correction table you can enter percentages for mo...

Page 59: ...ltage decreases with the risk of engine damage In this table this effect can be compensated for by matching the injector opening time to the battery voltage The correction values are indicated in ms per injection For instance 0 68 ms will be added to the duration of injection when the battery voltage is 12 6V The table is suitable for injectors with a resistance of 12Ω 15Ω Atmospheric pressure cor...

Page 60: ...ening You can set up 3 different temperatures between the increase takes place Airco settings The system can compensate extra air and fuel when air conditioning system is activated Tick the box when the airco switch is normally closed The airco activating signal from the pump needs to be connected on the powershift input pin For the MD35 this is pin 22 The maximum current on the powershift input p...

Page 61: ... will be lost when the power supply to the system is broken 3 2 8 Function key F8 This function key allows temporary activation deactivation of the air fuel ratio feedback control However the control will resume if the system has been without voltage or if the F8 key is pressed again 3 2 9 Function key F9 With this key the interpolation between the boxes can be switched on or off When the interpol...

Page 62: ...reaking the communication again Warning Make sure that the battery of the vehicle supplies more than 10V If the battery doesn t exceed 10V the changes you made to the ECU will not be saved Tip On vehicles with an ignition lock switched in such a way that the power supply to the system is cut off when the engine is started always download the data from the PC to the system as in the PC the modified...

Page 63: ...OM or USB port of the PC and the power supply to the system is on function key F10 can be used to activate the communication There are nine check lights in the communication bar which indicate the status of the relevant outputs The following readings will show These readings can be used to check whether the right sensors are being used and all settings are correct ...

Page 64: ...KMS MD35 manual Version 4 16 64 There is an option to get an enlarged picture of the lambda sensor reading by clicking on the display bar An extra reading window will appear at the top of the screen ...

Page 65: ...s will appear when an engine speed or engine load value is clicked If an engine speed is clicked a bar chart will appear showing all the values related to that engine speed If an engine load value is clicked a bar chart will appear showing all the values related to that engine load value Access to the bar charts can also be obtained by pressing the ALT C keys or the ALT R keys simultaneously The t...

Page 66: ...o go automatically to the relevant value in the bar chart matching the current situation of the engine even when this value is at another engine speed or engine load To go to another engine speed or engine load use the Page Up Page Down keys The correction tables can also be shown in the form of a bar chart if a correction figure is clicked And here can also the arrow keys be used to change the va...

Page 67: ... speed engine load by moving the yellow spot using the arrow keys When the Ctrl key is pressed simultaneously with upward or downward arrow key the value will go up or down 1 00 with each touch of the key If the Shift key is pressed simultaneously the value will change 0 10 per touch and if instead of the Shift key the Alt key is pressed the value will change 0 01 per touch ...

Page 68: ...d in a dry and not too hot place When fitting it make sure that the cover is readily accessible for easy removal Removal is necessary for the connection of a communication cable 5 2 Connecting the communication cable There is a cover at the front of the ECU Removing this cover gives access to the communication connector A standard USB cable A male B male can be connected to this connector This cab...

Page 69: ...mp effect menu Check whether the engine load indicated on the dashboard changes evenly when the accelerator is slowly depressed See paragraph 3 2 4 1 3 Engine load sensor Temperature reading gives incorrect value Temperature reading gives in the communication bar Wrong type of NTC temperature sensor Sensor not connected or short circuit in sensor wiring Fit the correct temperature sensor see the A...

Page 70: ... mA at 12V 5V supply to sensors can have maximally 100 mA Inputs Inputs are protected up to 50V Input for coolant and air temperature is suitable for an NTC sensor as standard 2 2 kΩ at 25 Celsius Input for engine load is suitable for potentiometers air mass meters and map sensors with an output between 0 5V Outputs Injector output can deliver at most 7A at 12V for instance 6 injectors with a resi...

Page 71: ...ion output 2 15 purple Ignition output 3 16 pink Ignition output 4 17 blue Ignition output 5 18 red black Tacho output 19 black Sensor ground water air MAP TPS etc 20 yellow 5V sensor supply 21 yellow black Launch control 22 green red Powershift Airco 23 black ECU ground 24 orange red Analog aux 3 A L S launch gearpos map selector EGT 1 25 purple red Analog aux 2 A L S launch gearpos map selector ...

Page 72: ...KMS MD35 manual Version 4 16 72 Appendix 1 Trigger wheel drawings ...

Page 73: ...KMS MD35 manual Version 4 16 73 ...

Page 74: ...KMS MD35 manual Version 4 16 74 ...

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