Operating Instructionsfor the WABCO Diagnostic Controller with Program Card ABS/ASR (ATC) D446 300 732 0

WABCO

Operating Instructions

for WABCO Diagnostic Controller 446 300 320 0withProgram Card ABS/ASR (ATC) D446 300 732 0

Edition: August 1997

© Copyright WABCO 1997

WABCOFahrzeugbremsen

A Division ofWABCO Standard GmbH

The right of amendment is reserved

2

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

1. Diagnostic Controller Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. What Systems Can Be Tested? . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Connection of the Diagnostic Controller . . . . . . . . . . . . . . . . . . . . 6

4. Operation of the Diagnostic Controller. . . . . . . . . . . . . . . . . . . . . . 7

5. Programe Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6. Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1 Error Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1.1 Component Actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.1.2 Measured Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.1.3 Controller data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.2. System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.3. Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.4. Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.5. Special functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7. Testing of Ancillary ABS equipment . . . . . . . . . . . . . . . . . . . . . . . 14(Info Module, Trailer Socket)

8. Functional Fault in Diagnostic System . . . . . . . . . . . . . . . . . . . . . 16

9. Test Cycle of Modulator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10. Test Cycle of Differential Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 20

Circuit Diagram 4-Channel ABS Basic . . . . . . . . . . . . . . . . . . . 21

4-Channel ABS . . . . . . . . . . . . . . . . . . . . . . . . 22

6-Channel ABS . . . . . . . . . . . . . . . . . . . . . . . . 23

Print-out of Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3

LIST OF ABBREVIATIONS USED:

ABS Anti-Lock Braking System

ASR Anti-Spin Regulation (Drive-Slip Control)

ECU Electronic Control Unit

L1/L2 Wheels on steered axle (diagonals 1/2)

A1/A2 Wheels on driven axle (diagonals 1/2)

Z1/Z2 Wheels on third axle (diagonals 1/2)

MRV Modulator valve (ASR)

Diff. valves Differential brake valve (ASR)

IV Inlet valve which when energized prevents further pressure increase at thewheel brake

OV Outlet valve which when energized allows pressure at the wheel brake to bereleased

PIN Individual connector in the ECU plug

MOT-valve Engine valve with on/off control for ASR (also known as black / white valve)

PROP-valve Engine valve with proportional control for ASR operation

> greater than

< less than

Ω ohm

kΩ kilo ohm

The following abbreviations are protected trade names of engine control systems fromcertain manufacturers:

EMR Electronic motor regulation (ASR engine control)

ESW Electronic set-point emitter (ASR engine control)

PRIO Priority signal emitter (ASR engine control)

PWMR Pulse-width modulated acknowledgement signal (ASR engine control)

PWMV Pulse-width modulated adjustment signal (ASR engine control)

EMS Electronic engine control (ASR engine control)

EDC Electronic Diesel Control

4

1. DIAGNOSTIC CONTROLLER SET 446 300 331 0

Contents of Diagnostic Controller Set:

1. Diagnostic Controller 446 300 320 0

2. Carrying Case 446 300 022 2

Additional Test Equipment

3. Connector Cable (ISO 9141) 894 604 303 2

4. Program Card 446 300 732 0

5. Inter-Adapter 446 300 404 0

1

2

3

4

5

5

2. WHAT SYSTEMS CAN BE TESTED?

This program card can be used to test certain ABS/ASR systems which are identified by thepart number of the ABS/ASR control unit.

ABS/ASR D (ISO)

* no support for settingsAs per June ´97. Additional ECUs may be suitable for testing. The program card won't realize any test if it cannot identify the ECU.

system/plug 4-channel 6-channel

program card 446 300 732 0 446 300 732 0

inter-adapter

application:if no diagnosticplug (to ISO 9141)on vehicle

446 300 404 0 446 300 404 0

ECUs which can be tested*

446 004 404 0446 004 406 0

to446 004 414 0

446 003 403 0446 003 404 0446 003 407 0446 003 408 0

6

3. CONNECTION OF THE DIAGNOSTIC CONTROLLER

3.1a. Diagnostic socket to ISO 9141available on vehicle

The allocation of PINs in the diagnosticsocket must correspond to the ISO 9141standard as shown below. ConnectDiagnosstic Cable to diagnostic socket onvehicle.

Allocation of diagnostic socket: 1 battery positive (terminal 30 ) 2 battery negative (terminal 31) 8 diagnostic K-linie10 diagnostic L-linie

3.1b No diagnostic socket to ISO 9141available

If there is no ISO diagnostic socket on thevehicle, an inter-adapter (accessories) canbe fitted between the ECU and the vehicleharness connector.

4-Channel

6-Channel

3.2. Connect the 9-pin plug of the connectorcable (or the inter-adapter) to the DiagnosticController, thus establishing both thediagnostic connection and the voltagesupply. Switch on ignition. The display willshow black bars until a program card isinserted.

3.3. Insert program card, pushing it fullyhome (contact side first, black surface facingupwards). The display will now show whichcard has been inserted

1

8

2

10

7

4. OPERATION OF THE DIAGNOSTIC CONTROLLER

The Controller is operated by means of threepush-buttons on its front panel. Theirallocation is shown via the instructionsappearing on the display directly above therespective push-button.

1 Diagnosis 4 Options2 System check 5 Special Function3 MultimeterSelect function! EXIT Ò START

display instruction (function) push buttons

Push-button Function

START Initiate programe.

RETURN The display will return to the lastmain menu.

(ARROW) Select an item from the main menu.

Ò Scroll forward one item at the time

by pressing the push-button. Theitem selected will blink.

REPAIR This command will activate thetrouble shooting with regard tothe the displayed error. Howe-ver, by pressing CONTINUE youmay display all errors first.

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5. PROGRAME STRUCTUREABS/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 : Automatic perephery detection

Remark 2 : 1. Reset of components

2. Engine control adaptation ( only if a Prop-valve and a Diff-valve are detcted)

3. Speed ( without PIN input onlydisplay )

9

6. DIAGNOSIS

1 Diagnosis 4 Options2 System check 5 Special Functions3 MultimeterSelect function! EXIT Ò START

When selecting the diagnostic function,communication with the ABS control isestablished.

A ECU type : ABS/ASR-DWABCO Part No. : 446 004 0. . 0

S Prod. date : week / yearSoftware No. : 83 CONTINUE

The WABCO data of the ABS ECU aredisplayed.

After that the following displays will beeshown :

1. The serial-number of the connectedECU

2. The connected system e.g. 4S/4M andadditional components

3. Additional displays will show theinstalled switches e.g. :

PIN 6/18: ASR-traction-switchPIN 5/18: ABS-off-road-push-buttonPIN 4/18: ASR-off switch

1 Error memory 3 Measured values2 Component actuate 4 ECU parameters

Select function! EXIT Ò START

In the diagnostic mode, the followingfunctions are available for selection:

1.1 Error memory1.2 Component actuate1.3 Measured values1.4 ECU parameters

6.1 Error memory

If the ABS control unit has recognized a faultin the system (safety lamp on), this functionhelps to locate the fault (example see Page15). Depending on the type of ABS-systemused and the type of error encountered, thefollowing advice will appear on the display.

– 1. SID : A detected fault does identifywhich component of the system failed,e.g. wheel speed sensor front left.

– 2. FID : Fault description :e.g. - short circuit

- air gap- wheel-end runout- frequencey of the fault occurred.

Note: The failure could only beacknowledged by the ECU only onceafter ignition on.

– display „actual“ means that when thediagnostic mode was selected the errorexisted. This is followed by a detailedfault location routine with specificinstructions on how to proceed inlocating the error. If there is noinformation about a present error on thedisplay, this means that the fault did notexist when the diagnostic mode wasselected, i.e. it cannot be located bymeans of electrical measurement.

– Integrated multimeter function. The tester isinstructed to carry out electrical measure-ments (e.g. resistance measure- ments) by

10

means of the inter-adapter. Both prescribedand actual values appear on the display andcan be compared.

– When correction of the fault is confirmed,this fault is deleted from the ECU.

– The fault location routine can be left only whenall faults have been corrected.

6.1.1 Component Actuate

With „Component Actuate“ certaincomponents of the ABS system can beactuated and tested. For this the respectivecomponents must, of course, be fitted.

6.1.1.1 ASR lamp

The ASR lamp can be switched on or off bypush-button.

6.1.1.2 Warning lamp

The ABS warning lamp can be switched onor off by push-button.

6.1.1.3 Endurance brake

The relay of the third brake (e.g. retarder)can be actuated by push-button ( on someinstallations the click sound of the relay canbe possibly heard ).

6.1.1.4 Differential valve

The differential brake valve of the ASRsystem can be individually actuated by push-button. By pressing the respective button,the valve is briefly actuated. If the buttonremains pushed, the valve is continuouslyactuated for short cycles.

6.1.1.5 ASR engine control

Depending on the equipment of the vehicle

this function will give the possibility toactuate either the electronic engine control,the CAN or the pneumatic ASR enginecontrol.

6.1.1.5.1 Electronic engine interfaces:

The connected interface will beautomatically detected.

Test: Start engine, increase enginespeed and hold constant. Reducespeed via push-button „ON“. Afterreleasing the button, engine speed isreturned to its original level.

6.1.1.6 ABS modulator valves

6.1.1.6.1 Pulse programe

Both function and allocation of the ABSmodulator valves can be individuallychecked by means of a pulse programe. Forpressures see diagram on page 19.

6.1.1.6.2 Time settings

The times T1 and T5 for pressure build-upand pressure reduction are adjustable(compare diagram on page 19). For vehicleswith large brake chambers, it may be ofadvantage to increase pulse times to ensurethat (visible) pressurization and venting issufficient. The value is preset at 51milliseconds.

6.1.2 Measured values

This part of the programe is used to displayvalues and switch positions.

6.1.2.1 Voltages

The actual voltages measured by the ECUare displayed. The valve relay voltages arejust below the supply voltage. Figures for 12volt systems are in brackets.

11

6.1.2.2 Wheel speeds

The speeds of the ABS-controlled wheelsare displayed. As soon as the wheel speedis more than 1.3 km/h, it will appear on thedisplay.

Further displays :

- Umin and Umax of the sensor amplitude

- Umin/Umax as proportion value

For example this value can detect a wheel-end runout.

When the wheel is stationary, the display willshow < 1.3 km/h.

Note:

The ASR-controlled wheels must not turn atspeeds higher than approx. 3.5 km/h sincethis would cause the ASR function to initiate.

6.1.2.3 Switch positions

The positions of the ABS- and ASR switchesand the status of the ASR lamp aredisplayed.

6.1.3 ECU parameters

The following system-specific ECU data aredisplayed:

1. display system2. change parameters3. dump parameters (print)

Regarding item 2, parameter change, thereare the possibilities as follows :

1. Reset components2. Adaption of Engine.-control

(if detected )3. Speed thresholds

6.2. SYSTEM CHECK

System check permits a complete ABS testincluding print-out of a test log (e.g. after firstinstallation or after extensive repairs).

System check is divided into 3 sections:

– component test

– functional test

– print results

Important notes:Once a test section has been initiated, thishas to be processed step by step. It isneither possible to return to individual stepsnor to leave them out.

If the supply voltage to the DiagnosticController is interrupted, all data measuredand stored for the print log up to that pointioftime are destroyed. Thus it is importantthat the supply to the Diagnostic Controller isnot interrupted if a print log is required.

Functional Test

This test is carried out with the ECUconnected. The Controller instructs the ECUto follow certain control instructions. Thetester is confronted with individual yes/noinquiries.

Procedure:

– actuate warning lampASR lampthird brakeABS/ASR switch

– pulse programemodulators: see 1.2.6.2 fortime setting, for pulse programmesee page 19.

12

– actuatediff. valves of ASR-controlleddriving wheels for pulseprogramme see page 20

– actuate

pneumatic engine control(PROP- or MOT-valve) or alternatively electronic inter-face

– For testing optional ABS features, seePage 14.

Print System Check

At the end of the test the results can beprinted.

As mentioned above, the Controller has tobe permanently connected to the voltagesupply. Any interruption will destroy all datastored.

Connection with the printer is established viathe 25-pin socket on the rear and a serialprinter cable. The cable must have a DB 25-plug (not socket !) at both ends.

The programe works with EPSON FX-compatible printers with a serial interface(RS 232). The transmission parameters ofthe printer must be set to the configurationshown below:

Printer Controller

Speed: 1200 baudData bits: 8Stop bit: 1Parity bit: noProtocol: X ON / X OFF

13

6.3. MULTIMETER

The integrated multimeter function permitselectric measurements on the vehicle. Onlythe desired measuring function (directvoltage, alternating voltage or resistance)needs to be selected. The measuring rangeis automatically set by the unit.

Application:

Direct voltage: supply voltage on vehicleAlternating voltage: sensor voltageResistance: valves, relays, sensors, wiring

NOTE:

The measuring instrument is designed onlyfor measurings within the vehicle-specific-range (low voltage). It must not be usedbeyond the above-mentioned measuringrange..

6.4. OPTIONS

6.4.1 ISO Adress

The ISO Address is an international code forvehicle electronics suitable for diagnosis.The valve which can be modified is the„selection number“ from the Controller to theECU (see also 1.4).Preset addresses

Motor vehicle ABS : 8Trailer ABS : 10Motor vehicle ECAS : 16Trailer ECAS : 18

6.4.2 Online Help

This function enables the user to obtainadditional information on the programe.When the function is switched on, more de-tailed information will appear where suitableplaces. When the card is used for the firsttime the function will be switched on.

6.4.3 Versions

This function will show the initial values ofthe test facilities:

Range Display resolution Accuracy of measuring range. Final value at 20°C

DC-voltage 2.0 volt20.0 volt50.0 volt

0.1 volt0.1 volt0.1volt

± 0.2 %± 0.2 %± 0.2 %

± 0.0 volt± 0.1 volt± 0.1 volt

AV-Voltage 2.0 volt35.0 volt

0.01 volt0.1 volt

± 0.6 %± 0.6 %

± 0.02 volt± 0.4 volt

Resistance 20.0 Ω200.0 Ω

2.0 kΩ 20.0 kΩ 95.0 kΩ

0.1 Ω 0.1 Ω 1.0 Ω 10.0 Ω 100.0 Ω

± 0.3 %± 0.2 %± 0.2 %± 0.1 %± 0.2 %

± 0.1 Ω± 0.1 Ω± 1.0 Ω± 10.0 Ω± 100.0 Ω

14

– Controller hardware

– Controller operating system with date ofmanufacturing

– Multimeter

– Program card with softwaremanufacturing date and check total

6.5. SPECIAL FUNCTIONS

In this menu it is possible to change the pa-rameters of the ECU after an input of a PIN-code.The authoriziation to change any of theparameters of the ECU requires a specialWABCO-training.

Testing Procedure without Info module:

Testing Procedure with Info module:

7. TEST OF OPTIONAL ABS FEATURES(24 volts)(only for vehicles with trailer hitch)

The following optional ABS features are notincluded in the 35-pole or 54-pole ABS-ECUwiring. Therefore, thay can not be tested bymeans of the Diagnostic Controller:

– ABS trailer socket to ISO 7638

– Info module

– Info lamp

– ABS trailer warning lamp

Necessery Equipment :

– Test plug for 24N socket 446 007 310 0

– Test plug for ABS trailer socket 446 007 316 0

One additional person is required for part ofthe test process.

Teststep Ignition Brake

actuate

Test plugin

ABS socket

Trailerwarning

lamp

1. on no yes on

2. off no yes off

Teststep

IgnitionBrake

actuated

Test plugin

24N socket

Test plugin

ABS socket

Infolamp

Trailerwarning lamp

1. on no no no off off

2. on noyes

lamp offno on off

3. on Jayes

lamp onno on off

4. on noyes

lamp offyes

lamp onoff on

5. off noyes

lamp offyes

lamp onoff off

15

Faults:

Test step Fault Cause

1. 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

2. Info lampe stays off – Info module or info lamp defective

– Line and/or contact fault

– ABS trailer plug-in connection/test plug not released

3. 24N test plug lamp off – Stop-light relay defective

– Lamp of 24N test plug defective

4. ABS trailer testplug lamp off

– Line and/or contact fault between contacts 1or 4 of ABS socket

– Lamp of ABS trailer test plug defective

5. ABS trailer test pluglamp is not on anylonger

– Lines between 1 and 2 and ABS socket mixed up

30 15

24V

25AMax.5A 15

54

30

87 87a

85

86

54

31

123451,5mm2

6,0mm21,5mm21,5mm26,0mm2

UA UES ZS OV IL RK AK

+

-

INFO MODUL446 016 00. 0

BLS

BATTERY

IGNITION

TRACTORWARNING LAMPWARNING LAMP RELAY3rd. BRAKE RELAY

BRAKE-LIGHT RELAY

TRACTORBRAKE-LIGHT

TRAILER-ABS WARNING LAMP

MAX. 10 W(RED)

TEST PLUGABS-TRAILERSOCKET446 007 316 0

TEST PLUG24N SOCKET446 007 310 0

ISO 7638SOCKET

ISO 1185SOCKET

INFO-LAMPMAX. 10W(YELLOW)

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8. FUNCTIONAL FAULT IN DIAGNOSTIC SYSTEM

no display

black „bars“

*** LOW VOLTAGE ***

CONTINUE

Cause Remedy

– no voltage supply– undervoltage (less than about 7 volts)

ISO diagnostic plug:

– Check plug allocation

– Voltage between PIN1 and PIN2 = supply voltage on vehicle

Cause Remedy

– program card not inserted – Insert program card, push it fully home

Cause Remedy

– insufficient supply voltage (only during diagnosis)

– Check condition of battery and ensure sufficient supply

17

*** Initialization error ***Switch ignition on!

Check diagnostic connection!CONTINUE

*** Wrong key word ***Diagnosis impossible!

CONTINUE

Defective Program Card !

CONTINUE

Cause Remedy

– Insufficient supply voltage (< 18 volts)

– No supply voltage (ignition off) – ISO address set incorrectly

– no ECU or wrong ECU connected– Diagnostic lines switched or disconnected

– 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

Cause Remedy

– Wrong ECU connected– Wrong „WABCO Data“ in ECU or defective ECU

– Check ECU part number– Change ECU and check ECU part number

Cause Remedy

– Defective program card– Wrong program card

– Change program card

18

*** COMMUNICATIONBREAKDOWN ***

Restart diagnostic procedure!CONTINUE

*** Unknown control unit ***Diagnosis not possiblewith this program card!

CONTINUE

*** Error during self-test ***EEPROM of Dignostic Controller faulty

CONTINUE

Cause Remedy

– Data transmission discontinued during diagnostic Line or voltage disconnection during diagnosis

– Check all connections– ISO socket on vehicle – switch on ignition

Cause Remedy

– ECU cannot be tested with this program card

– Use right program card

Cause Remedy

– EEPROM (Diagnostic Controller's) non-volatile memory of DC defective

– Repair Diagnostic Controller

19

9. PULSE PROGRAMMESEQUENCE:MODULATOR VALVES

Test procedure:

– Connect pressure gauge to brake chambersor

– Use brake test bench with independent wheelfacility

– Actuate and hold brake !

– Start pulse programe and observe pressurereadings !

Gauge (according to above-menttionedpulse programe sequence):

1. maximum brake pressure *)Pressure holding phase

2. Pressure reductionPressure holding phase

3. Pressure reduction to 0 barPressure holding phase

4. Pressure increasePressure holding phase

5. Pressure increase to brake pressure *)

*) Can vary from axle to axle ( e.g. due toload sensing ). The initial brake pressurewill fall during the test (air consumption).

T 6

T 1

T 2 T 3 T 4

T 5

12

34

5

Brake pressure

Foot brake

Outlet valve

Inlet valve

20

10. PULSE PROGRAME SEQUENCE: DIFFERENTIAL VALVES

Test procedure:

– Connect pressure gauge to brakechambers

– Start pulse programe and observe pressurereadings !

no brake pressure

maximum brake pressure

*) Time depends on the Specification of the Controller

Brake pressure

Diff. Valve

Inlet valves Outlet valves

driven axle IV on IV + OV on

on off

off

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!-----------------------------------------------------------------------------------------------------------------------!! *** SYSTEM CHECK PROTOCOL *** !! Motor vehicle ABS/ASR-D !!-----------------------------------------------------------------------------------------------------------------------!! !! ........................................ ........................................ !! Vehicle No. ECU No. !! !!====================================================================!! Function test !!-----------------------------------------------------------------------------------------------------------------------!! !! ABS warning light ______ !! ASR light ______ !! 3. 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 ______ !! !!====================================================================!! !! ................ .............. ............... !! Place Date Sign !! !!-----------------------------------------------------------------------------------------------------------------------!

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WABCOFahrzeugbremsenA Divison ofWABCO Standard GmbH

Am Lindener Hafen 2130453 HannoverTelefon (05 11) 9 22-0Telefax (05 11) 2 10 23 57

WABCO