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WABCO

Operating Instructions
for the WABCO Diagnostic Controller
with Program Card ABS-D KWP
446 300 739 0
Operating Instructions
for the WABCO
Diagnostic Controller
446 300 320 0
with Program Card ABS-D KWP
446 300 739 0

Edition: December 2000

© Copyright WABCO 2000

WABCO
Vehicle Control Systems
An American Standard Company

The right of amendment is reserved


TABLE OF CONTENTS
Page
1. DIAGNOSTIC CONTROLLER SET 3
1.1 General 4
1.2 Operation of the Diagnostic Controller 4
2. CONNECTING THE DIAGNOSTIC CONTROLLER 5
3. PROGRAM STRUCTURE 6
3.1 Menu Selection 6
3.2 Functional Scope of Menu Items 7
3.2.1 Diagnosis 7
3.2.1.1 Error Memory 7
3.2.1.2 Component Actuate 8
3.2.1.3 Testing and Measuring Values 10
3.2.1.4 Control Unit Data 10
3.2.2 Commissioning 11
3.2.2.1 Functional Testing 11
3.2.2.2 Order in Which Components Are Tested 11
3.2.2.3 Printing the Test Log 11
3.2.3 Multimeter 12
3.2.4 Options 13
3.2.4.1 Help Texts 13
3.2.4.2 Version 13
3.2.4.3 ECUs Which Can Be Tested 13
3.2.4.4 Change Address 13
3.2.5 Special Functions 13
4. Functional Defects 14
5. Log Examples 18
5.1 Commissioning 18
5.2 Parameter Settings 19
5.3 Error Memory 20

List of abbreviations used:


ABS Anti-Lock Braking System
ASR Anti-Spin Regulation (Drive-Slip Contol)
ECU Electronic Control Unit
HA rear axle
li left
re right
VA front axle
VR front right

2
1. DIAGNOSTIC CONTROLLER SET 446 300 331 0

6
3
5

Contents of Diagnostic Controller Set:


1. Diagnostic Controller 446 300 320 0
2. Carrying Case 446 300 022 2

Accessories:
3. Program Card 446 300 739 0
4. Connector Cable 446 300 404 0
5. Multimeter Cable, black 894 604 301 2
Multimeter Cable, red 894 604 302 2
6. Keyboard 446 300 328 0

3
1.1 General ing on the display directly above the
respective push-buttons.
The Diagnostic Controller, referred to as the
“Controller“ below, has been developed for
the purpose of testing Electronic Control
Units (ECUs). It can be used to read out data 1 Diagnosis 4 Options
from the ECU, and to write into them. In ad- 2 System check 5 Special functions
dition, commands can be sent to the ECU 3 Multimeter
which are used to actuate individual compo- Select function! EXIT ê START
nents on the vehicle.

In order to be able to communicate with an


ECU, a special Diagnostic Program is re- display instruction
quired. This is stored on a Program Card. If (function) push-buttons
an attempt is made to connect and operate
an ECU with a Diagnostic Program which is
not intended for that ECU, the Controller will
react by showing the following message:
Here are some examples for different push-
button functions:

push-button function
*** Unknown control unit *** START The menu item selected is
Diagnosis not possible initiated.
with this program card !
EXIT The display will return to the previ-
CONTINUE
ous menu or program item.
ê Selecting a menu item from the
main menu. Every time the button is
The Program Card is an electronic storage pressed, the next menu item is
medium whose address lines start at the addressed. The selected menu item
gold-plated contact points. Any damage to will flash.
any of these points or to a lead (scratch) can
CONTINUE
cause the card to fail altogether.
The menu item selected is trig-
gered, i. e. activated.
Insert card:
Make sure the contact side faces upwards. ABORT You have the option to abort the
function in the event of an error.
END Ending the function you have
been working on, i. e. setting
1.2 Operation of the Diagnostic parameters.
Controller
CHANGE Changing the parameters
appearing in the display.
The Controller is operated by means of three
push-buttons on the front panel. Their allo-
cation is shown via the instructions appear-

4
1.2.2 Operating the External Key- 2. CONNECTING THE
board 446 300 328 0 DIAGNOSTIC CONTROLLER

The Diagnostic Controller is connected to


the vehicle with a special cable:

SUB DB9 Socket

The use of an external keyboard is recom-


mended as it makes it very easy to operate
the Controller. Pin 1 +24 volts (red)
Only the push-buttons marked are reserved Pin 2 ground (brown)
for special functions. Pin 8 K-line (yellow)
E
N
T
E Connect the plug to the vehicle and the SUB
0 . R
The keys can be used DB9 socket to the Diagnostic Controller.
instead oft he three push-buttons on the Di- This not only establishes the diagnostic
agnostic Controller. connection but also provides the voltage
supply. Black bars will appear in the display.
Exception: if it is necessary to enter figures
during the program, this function does not Now you push the program card into the slot
apply. provided. Make sure that the contacts on the
0 1 9
card face upwards.
to
Using the ten-key block
it is possible either to enter numerical data You will now see something like this in the
(for example ISO addresses) or to select display:
numbered items from a menu.

E
N
T
E DIAGNOSTIC PROGRAM ABS-D KWP
R
Using the key, the menu item Version 1.00 (English)
indicated is executed. The key has the same
function as the controller key CONTINUE. START
C
Using you can revert to the previous
main menu displayed.
If this is not the case, please refer to Chapter
*
Using , when there is a series of data 4 on Functional Defects “DIAGNOSIS“. The
displayed (eg., parameter, function test, first display shows the system tested and the
calibration data), you can revert to the version (in this case 1.00).
previous display.

5
3. PROGRAME STRUCTURE

3.1 Menu Selection ABS-D KWP


1 Diagnosis
1 Error memory
2 Component actuate
1 Lamps
1 Pulse programmes
1 Front axle left (A1l)
2 Front axle right (A1r)
3 Rear axle left (A2l)
4 Rear axle right (A2r)
2 Time setting
2 Differential valve
3 Sustained-action brake
4 Engine control
5 Lamps
3 Measured values
1 Voltages
2 Speed sensor
1 Sensor front axle left
2 Sensor front axle right
3 Sensor rear axle left
4 Sensor Rear axle right
3 Switch positions
4 Pressure sensor
4 ECU data
1 System Information
2 Component reset
3 Change parameters
4 Print
1 Parameters
2 Error memory
5 WABCO data
2 System check
3 Multimeter
1 DC voltage
2 AC voltage
3 Resistance
4 Options
1 Help texts
2 Version
3 ECUs which can be tested
4 Change address
5 Special functions

6
3.2 Functional Scope of number of errors stored:
Menu Items

3.2.1 Diagnosis The ABS ECU has


Let the cursor flash on “1“, and press the stored 2 errors
“START“ key.
CONTINUE
1 Diagnosis 4 Options
2 System check 5 Special Functions
3 Multimeter
Select function! EXIT ê START
/

When you push “CONTINUE“; the first error

/
 stored will be displayed in cleartext. The first
line will show the exact location of the er-
ror/defect (in this case “speed sensor VR“).
The second line shows the type of error/de-
When selecting the diagnostic function, fect (in this case “signal interrupt“). In addi-
communication with the ABS control is esta- tion, the third line shows whether the error
blished. currently exists or not, i.e. whether the error
When this has been achieved, the data of was detected as the diagnostic connection
the ABS ECU are shown in the display. was being established:

ECU type : ABS-D KWP Speed sensor VR


Part No. : 446 004 320 0 Signal interrupt
Prod. date : 14 December 1999 SID: 2 FMI: 5 current: no
Serial No. : 42 CONTINUE counter: 3h REPAIR CONTINUE

/
In the diagnostic mode, the following
functions are now available for selection:

In addition, the third line will show the error


1 Error memory 3 Measured values code consisting of SID and FMI. The last line
2 Component actuate 4 ECU parameter shows the error counter. This error counter
provides a rough idea on how long the error
Select function! EXIT ê START prevailed, or when it was first detected.

3.2.1.1 Error memory When pushing the “REPAIR“ button, more


Here the ECU's error memory is read out information will appear to provide an indica-
first. This is followed by a display of the tion where the cause is likely to be.

7
This is followed by the error memory being
Check the wiring, read again, and the findings displayed. If
replace sensor as required. other errors are stored, the procedure is
again as described above.
CONTINUE

3.2.1.2 Components Actuate


/
“Actuate“ can be used to actuate specific
components of ABS to verify that they are
fully operational. If a component is selected
When pushing the “CONTINUE“ button, the which, according to the parameters, has not
next error will be displayed. been installed on the vehicle, a correspond-
ing message will be displayed.
When all errors have been displayed, the er-
ror memory of the ECU can be deleted.
1 Modulators 4 Engine control
2 Differential valve 5 Lamps
3 sustained-action brake
Delete error memory Select function! BACK ê CONTINUE
of the ABS ECU ?

YES NO
3.2.1.2.1 Modulators
For testing the modulators, a pulse program
If the answer to this question is “NO“, the er- is available which can be executed both on
ror search is aborted. If it is “YES“, the error a roller dynamometer or by using pressure
memory of the ECU is erased and you will gauges.
briefly leave the diagnostic mode (to allow
the electronics to again detect any errors Sequence of the pulse program for the mod-
and to store them in the error memory). ulators:

max
Max
control pressure
Bremsdruck min
Min

max
Max
Pedalbetätigung
pedal actuation min
Min

Heben
raise
modulator actuate
Modulatoransteuerung
Halten
hold
T1: 3 ... 500 ms
T2: 4s Senken
lower
T3: 2s
T1 T2 T3 T3 T1 T2 T3

8
Time T1 determines the level of control pres- 3.2.1.2.3 Sustained-Action Brake
sure for the time T2. Time T1 can be set This menu item can be used to check the de-
within a range of 3 to 500 ms. For this pur- activation of the sustained-action brake.
pose, menu item 1.2.1.2 Time Setting is This test can be done on the roller dy-
used. A value of 50 ms has been preset. namometer. However, the vehicle MUST be
secured to make sure it cannot roll away.
The sustained-action brake can be switched
off while the button is being pushed. This de-
activation acts on the deactivation relay for
3.2.1.2.2 Differential Valve the sustained-action brake and on the sus-
A pulse program is also available for the dif- tained-action brake capable of CAN.
ferential valve. This program may NOT be
executed on the roller dynamometer as the 3.2.1.2.4 Engine Control
vehicle would ’jump’ from the roller when its If the vehicle has an engine interface, the
rear axle is braked. engine speed can be reduced to its idling
level for approx. 5 sec. If the parameter for a
The course of the control pressure on the towing torque has been set, the engine
rear wheels must be measured using pres- speed is then increased for approx. 5 sec. to
sure gauges. 10% of full power.

max Max

control pressure
Bremsdruck
min Min

on An

Differential
Diff.-Ventil valve off Aus
raise Heben

modulator actuate
Modulatoransteuerung
hold Halten

lowerSenken
T1: 3 ... 500 ms T1 T2 T2 T2 T3
T2: 2s
T3: 150 ms

Again the control pressure for time T2 is de-


pendent on time T1. This time can be set as
described for Menu Item 1.2.1.2 Time Set-
ting. A value of 50 ms has been preset.

9
3.2.1.2.5 Lamps 3.2.1.3.4 Pressure Sensors
All lamps which have been installed can be If the parameter has been set for a pressure
switched on and off manually, one by one. sensor, the sensor’s output voltage in [mV]
and the brake light status (activated/deacti-
3.2.1.3 Testing and Measuring Values vated) will be displayed.
This part of the program can be used to dis-
play switch positions and measuring values.
In the event of a component supplying an 3.2.1.4 Control Unit Data
invalid signal, the program will show three This menu item has been provided for show-
dashes ‘---‘ instead of the (wrong) measur- ing and adjusting manufacturing data and
ing value. If a component is selected which, the system configuration.
according to the ECU’s parameters, has not
been installed on the vehicle, a correspond-
ing message will appear. No measuring val- 1 System Info 4 Print
ue will then be displayed. 2 Components reset 5 Display WABCO data
3 Change parameter
3.2.1.3.1 Voltages Select function! EXIT ê START
The supply voltages Uvent and Ues are dis-
played. In addition to the current voltages,
the reference values will also be shown.

3.2.1.3.2 Speed Sensors 3.2.1.4.1 System Information


The minimum and maximum output voltage Two consecutive illustrations show which
amplitudes of the speed sensors, the ratio of components have been installed on the ve-
maximum/minimum amplitude and the hicle.
wheel speed are shown. The wheel speed is
shown from speeds in excess of 1.3 k.p.h. 3.2.1.4.2 Components Reset
To allow the ECU to automatically recognize
3.2.1.3.3 Switch Positions the components installed on the vehicle, this
The positions of the following switches are function can be used to trigger the automatic
displayed: learning process. Afterwards, the ignition
must be switched off and then on again.
ABS function (normal/off-road)
3.2.1.4.3 Change Parameters
ASR function (normal/off-road or
deactivated) The parameters for the vehicle are dis-
played. After entering the PIN, these param-
Brake signal (activated/deactiva-
eters can be changed. If you press ‘ * ’ on the
ted)
external keyboard, you will return to the pre-
vious parameter.
The display of the switch status of the ASR
switch/button depends on the parameters When the last parameter has been reached,
set. If no ASR function has been implement- or by pushing the ’END’ button, the new val-
ed, three dashes are shown instead of a sta- ues can be stored in the ABS control unit.
tus message.

10
3.2.1.4.4 Printing 3.2.2.1 Functional Testing
This menu item can be used to either print The functional test can only be performed if
the parameters which have been set, or the no errors have been stored. The vehicle may
contents of the error memory. be moved only if the program expressly asks
the operator to do so.
3.2.1.4.5 WABCO Data
The ECU’s manufacturing data are dis-
played.
3.2.2.2 Order in Which Components
Are Tested
error memory
3.2.2 Commissioning operating voltages
’Commissioning’ is used to perform a full lamps
system test of ABS (e.g. after its initial instal- switches
lation or after major repairs).
pressure sensor
Commissioning is divided into three sec- modulators and speed sensors by
tions: wheels
differential valve
l Function testing sustained-action brakes
l Error output engine interface
l Print log

Please note: 3.2.2.3 Print System Check


If the voltage supply for the Controller is bro- At the end of the test the results can be
ken, all data previously stored are deleted. printed.
For this reason the diagnostic connection
should never be severed if a printed log is re- As mentioned above, the Controller has to
quired. be permanently connected to the voltage
supply. Any interruption will destroy all data
All steps within the test procedure can be re- stored.
peated until they have been successfully
completed. Connection with the printer is established
via the 25-pin socket on the rear and a
In some cases, the Controller may decide serial printer cable. The cable must have a
automatically whether a step within the test DB 25-plug (not socket !) at both ends.
procedure has been performed properly
(e.g. actuation of a button). Otherwise the
operator will be asked to assess the proce-
dure (e.g. after pulse programs).

11
3.2.3 Multimeter

1 DC voltage 3 Resistance
2 AC voltage

Select function! EXIT ê START

The integrated multimeter function permits


electric measurements on the vehicle. Only
the desired measuring function (direct volta-
ge, alternating voltage or resistance) needs
to be selected. The measuring range is au-
tomatically set by the unit.

The program works with EPSON FX-compa- Application:


tible printers with a serial interface (RS 232). Direct voltage: supply voltage on the
The transmission parameters of the printer vehicle
must be set to the configuration shown be- Alternating voltage: sensor voltage
low: Resistance: valves, relays,
Speed: 1200 baud sensors, wiring
Data bits: 8
Stop bit: 1 PLEASE NOTE: The measuring instru-
Parity bit: X ON / X OFF ment is designed only for measurings within
the vehicle-specific-range (low voltage). It
must not be used beyond the above-men-
tioned measuring range.

Range Display resolution Accuracy of measuring range at 20°C


DC voltage
2.0 volt 0.1 volt ± 0.2 % ± 0.0 volt
20.0 volt 0.1 volt ± 0.2 % ± 0.1 volt
50.0 volt 0.1 volt ± 0.2 % ± 0.1 volt

AC voltage
2.0 volt 0.01 volt ± 0.6 % ± 0.02 volt
35.0 volt 0.10 volt ± 0.6 % ± 0.40 volt

Resistance
20.0 Ω 0.1 Ω ± 0.3 % ± 0.1 Ω
200.0 Ω 0.1 Ω ± 0.2 % ± 0.1 Ω
2.0 kΩ 1.0 Ω ± 0.2 % ± 1.0 Ω
20.0 kΩ 10.0 Ω ± 0.1 % ± 10.0 Ω
95.0 kΩ 100.0 Ω ± 0.2 % ± 100.0 Ω

12
3.2.4 Options 3.2.4.3 ECUs for Testing
Indicates the WABCO numbers of the con-
trol units supported by the program
1 Help texts 3 ECUs for testing
2 Version 4 Change address
3.2.4.4 Change Address
Select function! BACK ê CONTINUE The address of the ABS ECUs is stored in
the Controller. If this address has not been
stored in your Controller, it will attempt un-
successfully to establish a connection with
3.2.4.1 Online Help the ECU. Enter the proper address under
This function enables the user to obtain ad- this menu item. The new address is then
ditional information on the program. When stored in the Controller.
the function is switched on, more de-tailed The standard value is 40. In the event of any
information will appear where suitable pla- deviations, please ask your vehicle manu-
ces. When the card is used for the first time facturer for the right address.
the function will be switched on.

3.2.5 SPECIAL FUNCTIONS


3.2.4.2 Version When a code (PIN) is entered in this menu,
This operation shows the version of the the ECU’s specific parameters applying to
components used (Controller and program that vehicle which normally cannot be
card). altered may be adjusted and transmitted
from one control unit to another.

Hardware : V1 Multimeter: V1 Authorization to modify these parameters


Operating system: V3.1 (07.03.1991) requires attending a WABCO training
Program : V1.00 (21.02.2000) course.
Serial number : 15735 CONTINUE

13
4. FUNCTIONAL FAULT IN DIAGNOSTIC SYSTEM

no display

Cause Remedy

– no voltage supply – check all plugged connections

– undervoltage (less than about 7 volts) – check supply voltage

black “bars“

Cause Remedy

– program card not inserted – push program card in as far as the


stop (Contacts overhead).

*** Initialization error ***


switch on ignition, check diagnostic
connection and ECU address!
CONTINUE

Cause Remedy

– Insufficient supply voltage – Ensure supply


(< 18 volts)
– No supply voltage (ignition off) – Switch on ignition

– Diagnostic lines switched or – Check lines and connections for


disconnected function and proper allocation
– wrong ECU address – Set ECU address (under Options)
default is 40.

14
*** Wrong key word ***

Diagnosis impossible!

Cause Remedy

– Wrong ECU connected – Check ECU part number


– Wrong “WABCO Data“ in ECU or – Change ECU
defective ECU

Defective program card


(serial number missing!)

Cause Remedy

– Program card defective – Change program card


– wrong program card

*** communication abort ***


Check diagnostic connection and
restart diagnosis.
CONTINUE

Cause Remedy

– Data transmission aborted during – Check all connections


diagnosis. Line interrupt or voltage-
interrupt during diagnosis – Switch on ignition

– Severe error in diagnostic mode

15
*** Unkown control unit ***
Diagnosis not possible
with this program card

Cause Remedy

– ECU cannot be tested with this – Use proper program card


program card

*** Error during self-test ***


EEPROM of Diagnostic Controller
faulty
CONTINUE

Cause Remedy

– EEPROM (Diagnostic Controller's) – Repair Diagnostic Controller


non-volatile memory of DC defective

*** Diagnostic code cannot be ***


read !
No diagnosis possible !

Cause Remedy

– Wrong ECU connected – Check ECU Part No.


– ECU defective – If right ECU installed,
replace

16
*** Error during start of routine ***
Command cannot be executed.
Vehicle not stationary !

Cause Remedy

– When a component of the system was – Stop vehicle, restart diagnosis


actuated, vehicle was not stationary
– If vehicle is stationary,
(at least on one axle v=0).
check speed sensors

17
5 Log Examples

5.1 Commissioning
!====================================================================!
! !
! *** COMMISSIONING LOG *** !
! !
! ***** ABS-D KWP ***** !
!====================================================================!
! !
! Equipment Type : ABS-D KWP !
! WABCO Product-No. : 446 004 320 0 !
! Production Date : 14. October 1999 !
! Software Vers.(ECU) : 42 !
! Prg. Card No. : 00033 !
! !
!====================================================================!
! !
! Component Findings !
! !
! ---------------------------------------------------------------------------------------------------------------------!
! !
! Operating voltages OK !
! ABS telltale OK !
! ASR flash code lamp OK !
! ASR button / switch OK !
! Brake light switch OK !
! Pressure sensor OK !
! Differential valve Not installed !
! Engine interface SAE J 1939 Not installed !
! Speed sensor VA left (A1l) ** WRONG SIDE ** !
! Speed sensor VA right (A1r) ** WRONG SIDE ** !
! Speed sensor HA left (A2l) OK !
! Speed sensor HA right (A2r) OK !
! Modulator VA left (A1l) OK !
! Modulator VA right (A1r) OK !
! Modulator HA left (A2l) * testing error * !
! Modulator HA right (A2r) OK !
! Deactivate sustained-action brake 1 OK !
! Deactivate sustained-action brake 2 OK !
! Deactivate sustained-action brake 3 Not installed !
! Deactivate sustained-action brake 4 Not installed !
! !
!====================================================================!
! !
! ................................ ............................... !
! Vehicle No. Vehicle Type !
! !
! ................................ ............................... !
! Manufacturer Testing Equipment !
! !
! .............. .......... ................. !
! Place Date Signature !
! !
!====================================================================!

18
5.2 Parameter Settings
!====================================================================!
! !
! *** PARAMETER LOG *** !
! !
! ***** ABS-D KWP ***** !
!====================================================================!
! !
! Equipment Type : ABS-D KWP !
! WABCO Product-No. : 446 004 320 0 !
! Productions-Date : 14. October 1999 !
! Software Vers.(ECU) : 42 !
! Prg. Card No. : 00033 !
! !
!====================================================================!
! !
! Meaning Value !
! !
! --------------------------------------------------------------------------------------------------------------------- !
! !
! Tyres’ nominal rolling circumference VA : 2550 mm !
! !
! Tyres’ nominal rolling circumference HA : 3200 mm !
! !
! EBL function : Activated !
! !
! EBL special function : Activated !
! !
! EBL Start offset : 0.10 g !
! !
! EBL nominal offset for a pressure sensor signal of !
! !
! 2 volt : 0.325 g !
! 1 volt : 0.075 g !
! !
! Overbrake factor : 0.0 % !
! !
! Brake signal via : pressure sensor !
! !
! Switch-over of ASR function via : switch !
! !
! Function of ASR switch / button : ASR deactivate !
! !
! Cut-in value towing torque control : 0% !
! !
!====================================================================!
! !
! ................................ ............................... !
! Vehicle No. Vehicle Type !
! !
! ................................ ............................... !
! Manufacturer Testing Equipment !
! !
! .............. .......... ................. !
! Place Date Signature !
!====================================================================!

19
5.3 Error Memory
!====================================================================!
! !
! *** ERROR LOG *** !
! !
! ***** ABS-D KWP ***** !
!====================================================================!
! !
! Equipment Type : ABS-D KWP !
! WABCO Product No. : 446 004 320 0 !
! Production Date : 14. October 1999 !
! Software Vers.(ECU) : 42 !
! Prg. Card No. : 00033 !
! !
!====================================================================!
! !
! Number of errors in memory : 4 !
! !
!====================================================================!
! !
! Error Active Error type / Error code !
! !
! counter Yes/No Error path SID/FMI !
! !
! -------------------------------------------------------------------------------------------------------------------- !
! !
! 3 ASR Configuration 253/ 1 !
! !
! Yes Engine interface SAE-J1939 missing !
! !
! 1 Brake light switch 16/ 5 !
! !
! No Short to mass !
! !
! 2 Pressure modulator front axle left, A1L 7/ 5 !
! !
! No Interrupt !
! !
! 1 DBR sustained-action brake 13/ 5 !
! !
! No Interrupt !
! !
!
! !
!====================================================================!
! !
! ................................ ............................... !
! Vehicle No. Vehicle Type !
! !
! ................................ ............................... !
! Manufacturer Testing Equipment !
! !
! .............. .......... ................. !
! Place Date Signature !
! !
!====================================================================!

20
22
WABCO
An American Standard Company
Vehicle Control Systems

30453 Hannover

www.wabco-auto.com
Telefon (05 11) 9 22-0
Am Lindener Hafen 21

Telefax (05 11) 2 10 23 57


WABCO Fahrzeugbremsen
© Copyright: WABCO ´2000. Printed in Germany. No part of this publication may be reproduced without our prior permission. The right of amendment is reserved. Wabcodruck 815 000 343 3/12.2000

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