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BUDS dongle ECU download error code messages reference

  • PaulHamilton
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2 months 2 weeks ago #19923 by PaulHamilton
Ok I had some lane lights come on and a bought a dongle and downloaded the errors.events. Warnings faults and failures. Where is the reference for all the error codes to troubleshoot/figure out what is happening?

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2 months 2 weeks ago #19925 by Neville
you must attend the Rotax maintenance school to have access to the interpretation to the decoding of the down loaded data. Run the engine with the dongle pluged in and look at the health page. I had a lane light and the active heath page reported the number one cylinder EGT was defective.

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2 months 1 week ago #19972 by PaulHamilton
Yes Neville I did fly with it live and no faults at the time. Pretty bad service policy to sell expensive dongles with no instructions on how to analyze/use it. Basically leaves me with no solution. I would think Rotax would like its customers to be able to service the engines in the field with a simple decoding/troubleshooting document. I was told by a Rotax service center there is no decoding document just trial and error in the field. Sadly this is overall pitiful support of the 912iS Rotax product. Knowing this I am starting to recommend people stick with the carb engines when making the decision of fuel injected or carbs.

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  • Bill Hertzel
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2 months 1 week ago - 2 months 1 week ago #19973 by Bill Hertzel
What error code are you seeing?

You may find Pages 8 and 9 of the attached PDF helpful.

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Last edit: 2 months 1 week ago by Bill Hertzel.

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2 months 1 week ago - 2 months 1 week ago #19975 by PaulHamilton
Faults are shown in the attachment. First and second downloads.

First I had the Lane A light come on solid, two out of three flights. When this happened in flight I did a quick reset (Lane A) off and back on (typically within gliding distance of a safe landing area) that would clear it. Sometimes I had to do this twice in a flight. This could not go on and had to be diagnosed. From my first dongle download Bryan determined that the ignition coils might be at fault with the SPARKS MISSED "Failure" from cylinder 3/4 (first Download). He suggested I clean/tighten the electric connections on the ignition coils which I did. This helped greatly but did not completely solve the problem.

Now I get a blinking Lane A, one flight every four flights (improvement from solid Lane A two out of three flights). Big improvement but still not acceptable. So now I am trying to figure out the blinking lane A with the new error code analysis with the "second download" NEW circled Faults from the second download.

Again, I am VERY irritated with this dongle download lack of information from Rotax. This fault/data key should be in the maintenance manual just like all the other maintenance items.

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Last edit: 2 months 1 week ago by PaulHamilton. Reason: had to many of the same attachment included in post

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  • Bill Hertzel
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2 months 1 week ago - 2 months 1 week ago #19976 by Bill Hertzel
I am not sure what more you would like to see. ???

I see faults all over the board that do not point to anything specific.
It looks like an electrical problem.
Is this engine more than 2 years old?
Was this engine involved in the Generator/Stator replacement Service Bulletin in 2016?
Were the Stators replaced?

This is a crazy batch of fault where it looks like it just about everything is going bad.
This brings my old troubleshooting mantra to mind.

"If it absolutely makes no sense, and it appears that Magic is at play, It is a Problem with the Grounds!".
Last edit: 2 months 1 week ago by Bill Hertzel.

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2 months 6 days ago #19978 by PaulHamilton
I get similar gobbely goop on another 912iS engine that I downloaded via dongle that is running like a top. Yes both engines have had all the required stater updates.

The simple point is that if we had a tool to understand/decode all the specific Rotax messages they designed into the ECU to pop up, then we could make an informed decision as to what is going on.

Knowing what the messages are would explain allot.
Which ones would cause a solid Lane light, which ones would cause flashing Lane lights. Which are typically startup or run up faults, such as doing a run up and switching the Lanes off and back on.

The maintenance/service procedures for the dongle need to be in the Rotax engine maintience/service documents.

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2 months 6 days ago #19979 by Neville
The tool needed is the software titled BUDS log viewer software, On the Rotax site under ECU software is a list of which version is available for 3 types of operating systems. The listing states that training is required to obtain the appropriate software.

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2 months 6 days ago #19980 by PaulHamilton
Since all other maintenance/service procedures for rotax engine are in the Rotax engine maintenance/service documents to maintain the engine properly to ROTAX standards, why are the 912iS doggle maintience/service documents not provided? Why the secret? I do not understand. Rotax needs to change improve this policy it does not make sense. Every single procedure/process for installing/servicing and maintaining is in the rotax documents, why hold back needed information? Who at ROTAX can fix this? It is a much needed improvement in customer service.

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2 months 3 days ago #20001 by porterjames
Paul,
I can't enlarge the report you posted to the point I can read it, but it appears that it is a list of all the faults recorded during the last downloaded operational time period.
I think the system may record faults detected during the start up and shut down phase so it could be that many are really not germane to your in flight engine warnings.
The analysis of the time the fault is recorded should be correlated to an actual in-flight warning light and give you more insight into the problem.
Again, since I can't read the posted document, I am only offering it as a suggestion. You may have already distilled the faults during the in-flight time period.

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  • Bill Hertzel
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2 months 2 days ago - 2 months 2 days ago #20004 by Bill Hertzel
James,

It is hard to read and low resolution.
The Yellow highlights indicate that the second print is 44 hours after the first.
The circled entries are the only ones that have changed.

There were 10 New Generator select faults of two varieties.
There were 6 New eTPU (enhanced Time Processing Unit) Faults. (Crank Position Sensor???)
There were 11 New Cylinder #3 EGT Sensor Faults.

For a total of 27 Logged Faults in 44 hours.

I would work on that list from the bottom up.
The EGT faults are the most likely and easiest to resolve.
Swap the #3 EGT Probe with another cylinder and see if the problem moves (Intermittent Probe) or is resolved (intermittent connection).

Paul,
If you have a level 2 Dongle, you should be able to clear the faults so you do not have to keep looking at the faults that happened a hundred hours ago.
Last edit: 2 months 2 days ago by Bill Hertzel.

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2 months 23 hours ago #20017 by porterjames
I pulled up my previous downloaded data from my engine. I have a level 3 dongle. Even though I have not had a lane warning light (since I zip tied the connectors), I have numerous fault codes in the records. The same as Paul discovered when looking at the fault codes from a different 912iS engine with no issues. Again, I think most of those are generated during start up and shut down (or lane tests during run up). In any case, I would be chasing non existent issues if I pursued them.
Instead of using the fault code page (unless the fault codes are time stamped) I suggest using the "Data" page and trying to connect a specific out of range engine function with the time period coincidental with the illumination of the lane warning light. On my computer those out of range functions are color coded.
If possible fly the airplane and use the dongle real time to see what is out of range when the lane light illuminates.
I certainly agree with Paul's concern about the lack of diagnostic information. There may be some Rotax document detailing the specifics of the engine computer but I am not aware of a list of possible failures that can trigger a solid or blinking warning light. That would at least narrow down the items to consider.

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1 month 3 weeks ago #20044 by PaulHamilton
Update. Yes I am going to reset/clear faults and try and correlate the hobbs time to the ECU time. My hobbs time is about 50 hours less than the ECU time (approx 10%). Not sure exactly what trigers what time. Perhaps the ECU time is registering any time the ECU is energized and the hobbs time is when the engine is running. Any one know what triggers the ECU time?

Yes I hooked up the live BUDS and recorded the flight and of course no Lane lights came on and everything was normal.

Lately NO LANE lightas have been coming on during flight now for the past 15 hours. Maybe it healed itself.

I fly these 912iS engines every day so I need to figure this out.

Again, I feel some basic guidance in the Rotax manuals for the downloaded error messages (like all the other Rotax systems) would be helpful and needed for the success of the engine.

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