WABCO

Operating Instructions
for the WABCO Diagnostic Controller with Program Card ABS/ASR (ATC) D 446 300 732 0

Operating Instructions
for WABCO Diagnostic Controller 446 300 320 0 with Program Card ABS/ASR (ATC) D 446 300 732 0

Edition: August 1997

© Copyright WABCO 1997 WABCO Fahrzeugbremsen A Division of WABCO Standard GmbH The right of amendment is reserved

. . . . . . . . . . . 7 Programe Structure . . . . . . 6. . . . . . . . . 9. . . . . . . . . . 5. . . . . . . . . . . . . . 2.3.2. . . . . . . . . 9 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . 10 6. 14 Testing of Ancillary ABS equipment . . . . . . . . . 6. . . . . 6. . . . . . . . . . . . . . . . . . . 23 Print-out of Test Results . . . . . . . . . . . Trailer Socket) Functional Fault in Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Measured Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 8. . . System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . 20 Circuit Diagram 4-Channel ABS Basic . . . . . . . 10. . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Test Cycle of Differential Valves. . . . . . . . . . . . . . . . . . . . . . 14 (Info Module. . . . . . . . . 5 Connection of the Diagnostic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1. . 8 Diagnosis . . . . . . . . . . . . . . . .1 Component Actuate . 4 What Systems Can Be Tested? . 7. . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Multimeter . . . 10 6. . . . . . . . . . . 22 6-Channel ABS . . . . . . . . . . . . . . . . . . . . 9 Error Memory . . . 6. . . . . . . . . . . . .TABLE OF CONTENTS . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . 11 6. . . . . . . . . . 21 4-Channel ABS . 6 Operation of the Diagnostic Controller. . . 13 Options . . . . . . 13 Special functions. . . . . . 16 Test Cycle of Modulator Valves . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Controller data . . . .1. . . . . . . . .4. . . .1 Diagnostic Controller Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . .

LIST OF ABBREVIATIONS USED: ABS ASR ECU L1/L2 A1/A2 Z1/Z2 MRV Diff. valves IV OV PIN MOT-valve > < Ω kΩ Anti-Lock Braking System Anti-Spin Regulation (Drive-Slip Control) Electronic Control Unit Wheels on steered axle Wheels on driven axle Wheels on third axle Modulator valve (ASR) Differential brake valve (ASR) Inlet valve which when energized prevents further pressure increase at the wheel brake Outlet valve which when energized allows pressure at the wheel brake to be released Individual connector in the ECU plug Engine valve with on/off control for ASR (also known as black / white valve) greater than less than ohm kilo ohm (diagonals 1/2) (diagonals 1/2) (diagonals 1/2) PROP-valve Engine valve with proportional control for ASR operation The following abbreviations are protected trade names of engine control systems from certain manufacturers: EMR ESW PRIO PWMR PWMV EMS EDC Electronic motor regulation (ASR engine control) Electronic set-point emitter (ASR engine control) Priority signal emitter (ASR engine control) Pulse-width modulated acknowledgement signal (ASR engine control) Pulse-width modulated adjustment signal (ASR engine control) Electronic engine control (ASR engine control) Electronic Diesel Control 3 .

4. DIAGNOSTIC CONTROLLER SET 446 300 331 0 2 1 4 3 5 Contents of Diagnostic Controller Set: 1. 5. Connector Cable (ISO 9141) Program Card Inter-Adapter 894 604 303 2 446 300 732 0 446 300 404 0 4 . 2. Diagnostic Controller Carrying Case 446 300 320 0 446 300 022 2 Additional Test Equipment 3.1.

2. ABS/ASR D (ISO) system/plug program card 4-channel 446 300 732 0 6-channel 446 300 732 0 inter-adapter application: if no diagnostic plug (to ISO 9141) on vehicle 446 300 404 0 446 300 404 0 ECUs which can be tested* 446 004 404 0 446 004 406 0 to 446 004 414 0 446 003 446 003 446 003 446 003 403 404 407 408 0 0 0 0 * no support for settings As per June ´97. Additional ECUs may be suitable for testing. 5 . WHAT SYSTEMS CAN BE TESTED? This program card can be used to test certain ABS/ASR systems which are identified by the part number of the ABS/ASR control unit. The program card won't realize any test if it cannot identify the ECU.

The display will show black bars until a program card is inserted. Insert program card.2. Connect Diagnosstic Cable to diagnostic socket on vehicle. Allocation of diagnostic socket: 1 battery positive (terminal 30 ) 2 battery negative (terminal 31) 8 diagnostic K-linie 1 10 diagnostic L-linie 2 8 10 3. Switch on ignition. Diagnostic socket to ISO 9141 available on vehicle The allocation of PINs in the diagnostic socket must correspond to the ISO 9141 standard as shown below. black surface facing upwards). an inter-adapter (accessories) can be fitted between the ECU and the vehicle harness connector. CONNECTION OF THE DIAGNOSTIC CONTROLLER 6-Channel 3. pushing it fully home (contact side first. 4-Channel 3. Connect the 9-pin plug of the connector cable (or the inter-adapter) to the Diagnostic Controller. thus establishing both the diagnostic connection and the voltage supply. 3.1a.3.1b No diagnostic socket to ISO 9141 available If there is no ISO diagnostic socket on the vehicle. The display will now show which card has been inserted 6 .3.

by pressing CONTINUE you may display all errors first. Their allocation is shown via the instructions appearing on the display directly above the respective push-button. However.4. RETURN The display will return to the last main menu. 7 . (ARROW) Select an item from the main menu. Ò REPAIR Scroll forward one item at the time by pressing the push-button. This command will activate the trouble shooting with regard to the the displayed error. OPERATION OF THE DIAGNOSTIC CONTROLLER The Controller is operated by means of three push-buttons on its front panel. 1 Diagnosis 2 System check 3 Multimeter Select function! 4 Options 5 Special Function EXIT Ò START display instruction (function) push buttons Push-button START Function Initiate programe. The item selected will blink.

PROGRAME STRUCTURE ABS/ASR D — 1 Diagnosis — 1 Error memory — 2 Component actuate — 1 ABS warning lamp — 2 ASR lamp ( except Basic-Version ) — 3 Endurance brake — 4 Differential valve ( except Basic-Version ) — 5 ASR engine control ( except Basic-Version ) see remark 1 — 6 Modulator valves — 1 Modulator test cycle — 2 Set pulse time — 3 measured values — 1 Voltages — 2 Wheel speeds — 3 Switch positions — 4 ECU parameters — 1 System display — 2 Parameter change (PIN) see remark 2 — 3 Parameter dump — 2 System check — 3 Multimeter — 1 Direct voltage (DC) — 2 Alternating voltage (AC) — 3 Resistance — 4 Options — 1 ISO address — 2 Online help — 3 Versions — 5 Special function ( PIN input ) Remark 1 : Remark 2 : Automatic perephery detection 1. Engine control adaptation ( only if a Prop-valve and a Diff-valve are detcted) 3. Reset of components 2. Speed ( without PIN input only display ) 8 .5.

After that the following displays will bee shown : 1. Integrated multimeter function.g. DIAGNOSIS 4 Options 5 Special Functions EXIT In the diagnostic mode. – display „actual“ means that when the diagnostic mode was selected the error existed. date Software No. The serial-number of the connected ECU The connected system e. . 3.e.ments) by 9 The WABCO data of the ABS ECU are displayed. A ECU type WABCO Part No.air gap .g.2 1. i.1 Error memory Component actuate Measured values ECU parameters Error memory 1 Diagnosis 2 System check 3 Multimeter Select function! Ò START When selecting the diagnostic function. Note: The failure could only be acknowledged by the ECU only once after ignition on. .g. 2. this function helps to locate the fault (example see Page 15).g. the following functions are available for selection: 1. This is followed by a detailed fault location routine with specific instructions on how to proceed in locating the error. wheel speed sensor front left. : ABS/ASR-D : 446 004 0. S Prod.frequencey of the fault occurred. the following advice will appear on the display.1 1.short circuit .g. SID : A detected fault does identify which component of the system failed.wheel-end runout . e. 2. this means that the fault did not exist when the diagnostic mode was selected. – 1. communication with the ABS control is established. FID : Fault description : e. resistance measure. : show the – PIN 6/18: ASR-traction-switch PIN 5/18: ABS-off-road-push-button PIN 4/18: ASR-off switch 1 Error memory 3 Measured values 2 Component actuate 4 ECU parameters Select function! EXIT Ò START – .6.3 1. Depending on the type of ABS-system used and the type of error encountered. 0 : week / year : 83 CONTINUE If the ABS control unit has recognized a fault in the system (safety lamp on). 4S/4M and additional components Additional displays will installed switches e. it cannot be located by means of electrical measurement. The tester is instructed to carry out electrical measurements (e. If there is no information about a present error on the display.4 6.

1.1.4 Differential valve The times T1 and T5 for pressure build-up and pressure reduction are adjustable (compare diagram on page 19).1.g.1 With „Component Actuate“ certain components of the ABS system can be actuated and tested. If the button remains pushed. 6. Component Actuate this function will give the possibility to actuate either the electronic engine control. By pressing the respective button. 6.6 ABS modulator valves The ASR lamp can be switched on or off by push-button.6.1.1. increase engine speed and hold constant.1 Pulse programe Both function and allocation of the ABS modulator valves can be individually checked by means of a pulse programe. of course. will be 6.3 Endurance brake The relay of the third brake (e.1.1. The valve relay voltages are just below the supply voltage. be fitted. The fault location routine can be left only when all faults have been corrected. For this the respective components must.5.1.1.1 ASR lamp 6. Reduce speed via push-button „ON“. 6. The value is preset at 51 milliseconds. the valve is briefly actuated.– means of the inter-adapter.1.1.1 Electronic engine interfaces: – The connected interface automatically detected.1.1. 6. 10 . it may be of advantage to increase pulse times to ensure that (visible) pressurization and venting is sufficient.1.2.5 ASR engine control This part of the programe is used to display values and switch positions. engine speed is returned to its original level.1 Voltages Depending on the equipment of the vehicle The actual voltages measured by the ECU are displayed. retarder) can be actuated by push-button ( on some installations the click sound of the relay can be possibly heard ). 6. After releasing the button.1.2 Time settings 6. Figures for 12 volt systems are in brackets.1. 6. the CAN or the pneumatic ASR engine control. Test: Start engine. For pressures see diagram on page 19. Both prescribed and actual values appear on the display and can be compared. For vehicles with large brake chambers.1.2 Measured values The differential brake valve of the ASR system can be individually actuated by push -button. 6.2 Warning lamp The ABS warning lamp can be switched on or off by push-button.6.1.1. 6. the valve is continuously actuated for short cycles.1. When correction of the fault is confirmed. this fault is deleted from the ECU. 6.1.

Umin and Umax of the sensor amplitude . The tester is confronted with individual yes/no inquiries. Note: The ASR-controlled wheels must not turn at speeds higher than approx. Further displays : . parameter change. it will appear on the display. this has to be processed step by step.1. the display will show < 1. When the wheel is stationary.5 km/h since this would cause the ASR function to initiate.1. 2. 2.2. all data measured and stored for the print log up to that point ioftime are destroyed.3 km/h. It is neither possible to return to individual steps nor to leave them out. after first installation or after extensive repairs). Thus it is important that the supply to the Diagnostic Controller is not interrupted if a print log is required.-control (if detected ) Speed thresholds .2. Procedure: – actuate warning lamp ASR lamp third brake ABS/ASR switch – pulse programe modulators: see 1.g.3 Switch positions The positions of the ABS. for pulse programme see page 19. SYSTEM CHECK System check permits a complete ABS test including print-out of a test log (e. As soon as the wheel speed is more than 1.1. display system change parameters dump parameters (print) Regarding item 2.and ASR switches and the status of the ASR lamp are displayed. 6. If the supply voltage to the Diagnostic Controller is interrupted.3 km/h.2 for time setting.2. 3. there are the possibilities as follows : 1.6. Reset components Adaption of Engine.2 Wheel speeds 6. Functional Test This test is carried out with the ECU connected.3 ECU parameters The following system-specific ECU data are displayed: 1.2.6. 11 The speeds of the ABS-controlled wheels are displayed. The Controller instructs the ECU to follow certain control instructions. System check is divided into 3 sections: – component test – functional test – print results Important notes: Once a test section has been initiated. 6. 3.Umin/Umax as proportion value For example this value can detect a wheelend runout. 3.

The cable must have a DB 25plug (not socket !) at both ends. As mentioned above. The programe works with EPSON FXcompatible printers with a serial interface (RS 232). Connection with the printer is established via the 25-pin socket on the rear and a serial printer cable.– actuate diff. The transmission parameters of the printer must be set to the configuration shown below: Printer Controller Print System Check At the end of the test the results can be printed. Any interruption will destroy all data stored. the Controller has to be permanently connected to the voltage supply. Speed: Data bits: Stop bit: Parity bit: Protocol: 1200 baud 8 1 no X ON / X OFF 12 . valves of ASR-controlled driving wheels for pulse programme see page 20 – actuate pneumatic engine control (PROP.or MOT-valve) or alternatively electronic inter-face – For testing optional ABS features. see Page 14.

relays.0 kΩ 20.1 Ω ± 1. It must not be used beyond the above-mentioned measuring range.0 Ω ± 0.1volt ± 0.1 Ω 1. OPTIONS 6.0 volt 35. Preset addresses Motor vehicle ABS : 8 Trailer ABS : 10 Motor vehicle ECAS : 16 Trailer ECAS : 18 This function enables the user to obtain additional information on the programe.1 Ω 0.4 volt 0. 6.3.0 Ω ± 10.0 volt ± 0. When the function is switched on. Application: Direct voltage: supply voltage on vehicle Alternating voltage: sensor voltage Resistance: valves.1 ± 0.1 volt 0.2 % % % % % Online Help ± 0. alternating voltage or resistance) needs to be selected.1 volt ± 0.3 Versions This function will show the initial values of the test facilities: 13 .6 % ± 0. Range DC-voltage 2.4..0 volt 20. more detailed information will appear where suitable places. Final value at 20°C 0.4.1 Ω ± 0.2 % ± 0.4).02 volt ± 0.0 Ω 100.2 ± 0. Only the desired measuring function (direct voltage.01 volt 0.0 volt 50. wiring NOTE: The measuring instrument is designed only for measurings within the vehicle-specificrange (low voltage).4.0 Ω ± 100.0 Ω 2.0 Ω 6.3 ± 0.2 6. When the card is used for the first time the function will be switched on.1 volt 0.0 volt Resistance 20.1 volt 0.6 % ± 0.4.2 % ± 0. MULTIMETER The integrated multimeter function permits electric measurements on the vehicle. The measuring range is automatically set by the unit.1 ISO Adress The ISO Address is an international code for vehicle electronics suitable for diagnosis.2 ± 0.1 volt ± 0.0 volt AV-Voltage 2.2 % ± 0.6. The valve which can be modified is the „selection number“ from the Controller to the ECU (see also 1.0 Ω 10.0 Ω 200.0 kΩ 95.0 kΩ Display resolution Accuracy of measuring range. sensors.

on on on on off no no Ja no no no yes lamp off yes lamp on yes lamp off yes lamp off no no no yes lamp on yes lamp on off on on off off off off off on off 14 . Testing Procedure without Info module: Test step Ignition Brake actuate Test plug in ABS socket Trailer warning lamp – – Necessery Equipment : – – Test plug for 24N socket 446 007 310 0 Test plug for ABS trailer socket 446 007 316 0 1. Testing Procedure with Info module: Test step Ignition Brake actuated Test plug in 24N socket Test plug in ABS socket Info lamp Trailer warning lamp 1. 2. TEST OF OPTIONAL ABS FEATURES (24 volts) (only for vehicles with trailer hitch) The following optional ABS features are not included in the 35-pole or 54-pole ABS-ECU wiring.– – Controller hardware Controller operating system with date of manufacturing Multimeter Program card with software manufacturing date and check total 7. on off no no yes yes on off One additional person is required for part of the test process. SPECIAL FUNCTIONS In this menu it is possible to change the parameters of the ECU after an input of a PINcode. 3. thay can not be tested by means of the Diagnostic Controller: – – ABS trailer socket to ISO 7638 Info module Info lamp ABS trailer warning lamp – – 6. The authoriziation to change any of the parameters of the ECU requires a special WABCO-training. 4.5. 2. 5. Therefore.

0 UA UES ZS OV IL RK AK 87 a 87 85 BRAKE-LIGHT RELAY 86 TRACTOR BRAKE-LIGHT 54 TEST PLUG 24N SOCKET 446 007 310 0 31 ISO 1185 SOCKET 30 54 25A Max. 10 W (RED) 15 . Info lampe on – Consumer at contact AK of info module or at terminal 54 of 24N socket – Info module defective – Line and/or contact fault – Info module or info lamp defective – Line and/or contact fault – ABS trailer plug-in connection/test plug not released – Stop-light relay defective – Lamp of 24N test plug defective – Line and/or contact fault between contacts 1or 4 of ABS socket – Lamp of ABS trailer test plug defective 2. ABS trailer test plug – Lines between 1 and 2 and ABS socket mixed up lamp is not on any longer 6.0mm2 1.5mm2 1 2 3 4 5 ISO 7638 SOCKET TEST PLUG ABS-TRAILER SOCKET 446 007 316 0 INFO MODUL 446 016 00. 24N test plug lamp off ABS trailer test plug lamp off 5.0mm2 1. 4. BRAKE RELAY 15 30 IGNITION + 24V BATTERY INFOLAMP MAX.5mm2 1. Info lampe stays off 3.Faults: Test step Fault Cause 1. 5A TRACTOR WARNING LAMP WARNING LAMP RELAY 3rd.5mm2 6. 10W (YELLOW) BLS 15 TRAILER-ABS WARNING LAMP MAX.

FUNCTIONAL FAULT IN DIAGNOSTIC SYSTEM no display Cause – no voltage supply – undervoltage (less than about 7 volts) Remedy ISO diagnostic plug: – Check plug allocation – Voltage between PIN1 and PIN2 = supply voltage on vehicle black „bars“ Cause – program card not inserted Remedy – Insert program card. push it fully home *** LOW VOLTAGE *** CONTINUE Cause – insufficient supply voltage (only during diagnosis) Remedy – Check condition of battery and ensure sufficient supply 16 .8.

*** Initialization error *** Switch ignition on! Check diagnostic connection! CONTINUE Cause – Insufficient supply voltage (< 18 volts) – No supply voltage (ignition off) – ISO address set incorrectly Remedy – Ensure supply – Switch on ignition – Reset ISO address. Preset ABS/ASR address 8 (see 4.1 „ISO Adress“) – Check ECU and connection – Check lines and connections for function and proper allocation – no ECU or wrong ECU connected – Diagnostic lines switched or disconnected *** Wrong key word *** Diagnosis impossible! CONTINUE Cause – Wrong ECU connected – Wrong „WABCO Data“ in ECU or defective ECU Remedy – Check ECU part number – Change ECU and check ECU part number Defective Program Card ! CONTINUE Cause – Defective program card – Wrong program card Remedy – Change program card 17 .

*** COMMUNICATION BREAKDOWN *** Restart diagnostic procedure! CONTINUE Cause – Data transmission discontinued during diagnostic Line or voltage disconnection during diagnosis Remedy – Check all connections – ISO socket on vehicle – switch on ignition *** Unknown control unit *** Diagnosis not possible with this program card! CONTINUE Cause – ECU cannot be tested with this program card *** Error during self-test *** EEPROM of Dignostic Controller faulty CONTINUE Remedy – Use right program card Cause – EEPROM (Diagnostic Controller's) non-volatile memory of DC defective Remedy – Repair Diagnostic Controller 18 .

– – – 19 . Pressure increase Pressure holding phase 5. Pressure reduction Pressure holding phase 3.9. maximum brake pressure *) Pressure holding phase 2. due to load sensing ). PULSE PROGRAMME SEQUENCE: MODULATOR VALVES 1 2 4 3 5 Brake pressure Foot brake T1 Outlet valve Inlet valve T2 T3 T4 T5 T6 Test procedure: – Connect pressure gauge to brake chambers or Use brake test bench with independent wheel facility Actuate and hold brake ! Start pulse programe and observe pressure readings ! Gauge (according to above-menttioned pulse programe sequence): 1.g. Pressure increase to brake pressure *) *) Can vary from axle to axle ( e. The initial brake pressure will fall during the test (air consumption). Pressure reduction to 0 bar Pressure holding phase 4.

PULSE PROGRAME SEQUENCE: DIFFERENTIAL VALVES Brake pressure Diff. Valve IV + OV on driven axle IV on on off Inlet valves Outlet valves off no brake pressure *) Time depends on the Specification of the Controller maximum brake pressure Test procedure: – Connect pressure gauge to brake chambers Start pulse programe and observe pressure readings ! – 20 .10.

WABCO 21 841 801 277 0 .

22 WABCO 841 801 151 0 .

WABCO 841 801 278 0 23 .

... ! ! Vehicle No.... ECU No............. ...................... Brake ______ ! ! ABS offroad switch ______ ! ! ASR function switch ______ ! ! Modulator Wheel A (L2) ______ ! ! Modulator Wheel B (L1) ______ ! ! Modulator Wheel C (A1) ______ ! ! Modulator Wheel D (A2) ______ ! ! Modulator Wheel E (Z2) ______ ! ! Modulator Wheel F (Z1) ______ ! ! DIFF valve Wheel C (A1) ______ ! ! DIFF valve Wheel D (A2) ______ ! ! PROP/MOT Engine control ______ ! ! Electronic Engine control ______ ! ! ! !====================================================================! ! ! ! ..................................!-----------------------------------------------------------------------------------------------------------------------! ! *** SYSTEM CHECK PROTOCOL *** ! ! Motor vehicle ABS/ASR-D ! !-----------------------------------------------------------------------------------------------------------------------! ! ! ! ........ ! ! Place Date Sign ! ! ! !-----------------------------------------------------------------------------------------------------------------------! 24 . ... ! ! ! !====================================================================! ! Function test ! !-----------------------------------------------------------------------------------------------------------------------! ! ! ! ABS warning light ______ ! ! ASR light ______ ! ! 3...... ...................................

. The right of amendment is reserved. Printed in Germany.97 26 WABCO Fahrzeugbremsen A Divison of WABCO Standard GmbH Am Lindener Hafen 21 30453 Hannover Telefon (05 11) 9 22-0 Telefax (05 11) 2 10 23 57 . Wabcodruck 815 000 260 3/08.WABCO Copyright: WABCO ´97. No part of this publication may be reproduced without our prior permission.