WABCO

Operating Instructions
for the WABCO Diagnostic Controller
with Program Card ABS-Hydraulic
446 300 782 0
Operating Instructions
for the WABCO
Diagnostic Controller
with Program Card ABS-Hydr.
446 300 782 0

Edition: March 1998

© Copyright WABCO 1998

WABCO
Fahrzeugbremsen

A Division of
WABCO Standard GmbH

The right of amendment is reserved

TABLE OF CONTENTS
Page

1 Diagnostic Controller Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 What Systems Can Be Tested? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Connection of the Diagnostic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Program Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1.1 Error Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1.2 Component Actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1.3 Measured Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.4 Controller data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4.1 Online Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4.2 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4.3 ECUs for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Functional Fault in Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Pulse Program Sequence: Modulator Valves . . . . . . . . . . . . . . . . . . . . . 17
7 Plug Pin Assignment
ABS 446 044 07 . 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8 Connection Diagrams
ABS 446 044 07 . 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Test Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

LIST OF ABBREVIATIONS USED:

ABS Anti-Lock Braking System

ECU Electronic Control Unit
el. electrically
HA rear axle
hyd hydraulic
le left
ri right
VA front axle

2
1. DIAGNOSTIC CONTROLLER SET 446 300 331 0

3 6
5

Contents of Diagnostic Controller Set:

1. Diagnostic Controller 446 300 320 0

2. Carrying Case 446 300 022 2

Additional Test Equipment:

3. Program Card 446 300 782 0

4. Connector Cable ... ... ... .

5. Multimeter cable, black 894 604 301 2

Multimeter cable, red 894 604 302 2

6. Keyboard 446 300 328 0

3
The DIAGNOSTIC-CONTROLLER They form the memory which is similar to a
large cupboard with thousands of drawers.
1.1 General Every drawer contains some information,
and each one of these drawers has an
The Diagnostic Controller, referred to as the
“address“. At the gilt contacts the address
“Controller“ below, is a computer which is
lines begin; it is via these lines that the
capable of exchanging data with control
Controller accesses the contents of the
units (which are computers, too). In this
various “drawers“. For this reason the
context, data mean the following:
program card should be handled carefully
because any damage, even if it is only on
❑ error messages stored in the ECU
one contact or one line (scratch), can cause
❑ commands sent from the Controller to the whole of the card to fail.
the ECU where they trigger certain
processes.
Plug in Card:
In order to communicate with an ECU, a The contact side must face upwards
special program is required. This program is
stored on the respective program card.
Removing Card:
If an attempt is made to run an ECU with a Please do not pull
program card which is not intended for it, the hard. If a resistance
Controller will react by returning a message is felt, push its end
to this effect. upwards lightly with
your thumb whilst
pressing downwards
*** Unknown control unit *** lightly with your
Diagnosis not possible index and middle
with this program card ! fingers. This will
CONTINUE make it very easy to
remove.

Any attempt to manipulate the connected

ECU via the controller will be futile. 1.2 Operation

Operating Keys on the Unit

The Diagnostic Controller is operated by
pressing the three operating push-buttons
on its front, and by using an external
Program Card and ECU must match!
keyboard. The function of the push-buttons
The program card is an electronic storage depends on the instructions appearing in the
medium which contains both commands for display immediately above those push-
the Controller and the message appearing in buttons.
the display. Thousands of transistors have
been crammed into a very small space.

4
 Operating the External Keyboard
1 Diagnosis 4 Options 446 300 328 0
2 System check 5 Special functions
3 Multimeter
Select function! EXIT Ò START

display instruction
(function) push-buttons

Here are some examples for different push-

button functions:
The external keyboard is recommended
push-buttons function because it makes operating the Controller
very simple.
START Initiate program
Functions are only assigned to the marked
RETURN The display will return to the last keys.
main menu. E

Ò
N
T
E
0 .
Select an item from the main R
The keys can be used
menu. instead oft he three push-buttons on the
Scroll forward one item at a time diagnostic controller
by pressing the push-button.
The item selected will flash. Exception: if it is necessary to enter figures
during the program, this function does not
CONTINUE
apply.
The menu item selected is 0 1 to 9
Using the ten-key block
triggered, i. e. activated.
it is possible either to enter numerical data
ABORT You have the option to abort the (for example ISO addresses) or to select
function in the event of an error numbered items from the main menu.

END Ending the function you have E

N
been working on, i. e. setting T
E
R
parameters. Using the key, the menu item
indicated is executed. The key has the same
CHANGE Changing the parameters function as the controller key CONTINUE.
appearing in the display.
C
Using you can revert to the previous
COMPLETE
main menu displayed.
Confirms to the program that the *
Using , when there is a series of data
process demanded by the
displayed (eg., parameter, function test,
operator has been completed.
calibration data), you can revert to the
previous display.

5
2. WHAT SYSTEMS CAN BE
TESTED?
*) As per November ´97. Additional ECUs
This program card can be used to test may be suitable for testing.
certain ABS-hydraulic systems which are The program card won't realize any test
identified by the part number of the ABS if it cannot identify the ECU.
control unit.

system/plug 4-channel 6-channel

program card 446 300 782 0

ECUs which can be 446 044 071 0

tested *) 446 044 072 0

3. CONNECTING THE Now you push the program card into the slot
DIAGNOSTIC CONTROLLER provided. Make sure that the contacts on the
card face upwards. You will now see
The Diagnostic Controller is connected to something like this in the display:
the vehicle with a special cable (from
MERITOR WABCO):

Plug SUB DB9 Socket ABS-Hydraulic

Version 1.03 (English)
+12 V Pin ? + 12 V Pin 1 START
Ground Pin ? Ground Pin 2
A-Line Pin ? A-Line Pin 6
B-LIne Pin ? B-Line Pin 7

If this is not the case, please refer to Chapter

Connect the plug to the vehicle and the SUB 5 on Functional Defects “DIAGNOSIS“. The
DB9 socket to the Diagnostic Controller. first display shows the system tested and the
This not only establishes the diagnostic version (in this case 1.03).
connection but also provides the voltage
supply. Black bars will appear in the display.

6
4. PROGRAME STRUCTURE
Menu Selection ABS Hydraulics

1 Diagnosis
1 Error memory
2 Component actuate
1 Warning lamp
2 Pump
3 Modulator valves
1 Front-right
2 Front-left
3 Rear-right
4 Rear-left
4 Endurance brake *

3 Measured values
1 Voltages
2 Wheel speed

4 ECU parameters **
1 Reconfigure endurance brake relay

2 System check
3 Multimeter
1 Direct voltage (DC)
2 Alternating voltage (AC)
3 Resistance
4 Options
1 Online help
2 Version
3 Supported ECU’s

5 Special functions
* only if fitted on the vehicle
** only available after entering the PIN

7
4.1. DIAGNOSIS The following will appear on the display:

Let the cursor flash on “1“, and press the ❑ display of the error in plaintext
“START“ key. ❑ information on whether the error
currently exists or not. If not, the display
1 Diagnosis 4 Options shows how often it occurred.
2 System check 5 Special Functions
❑ To assist in repairs, repair information is
3 Multimeter
Select function! EXIT Ò START
displayed at the push of a button
If the repair button has been pushed for all
errors, the error memory is deleted

G automatically. Following this, the ignition has

to be switched off and then on again to allow
the ECU to perceive any errors now
When selecting the diagnostic function, encountered. The error memory is read
communication with the ABS control is again and any errors still stored at this point
established. are displayed.

A ECU type : ABS-Hydraulic 4.1.2 Component Actuate

WABCO Part No. : 446 044 071 0 “Actuate“ is used to make sure that certain
S Prod. date : 32 / 1997 components within the ABS system and
Software No.: V8551 CONTINUE their wiring are in good working order. For
this to work, those components of course
need to have been fitted
G Warning Lamp
The function of the warning lamp is tested.
When this has been achieved, the data of When entering the menu item, the warning
the ABS ECU are shown in the display. lamp is switched on. You will be asked
whether the warning lamp is on. If this is the
In the diagnostic mode, the following case, it is switched off and you are once
functions are now available for selection: again asked to confirm that it is in proper
working order. Finally the warning lamp is
again switched on.
1 Error memory 3 Measured values
2 Component actuate Pump

Select function! EXIT Ò START

The pump should only be activated after the
system has been pressurized. Then switch
on the hydraulic pump for no longer than 12
seconds. You should be able to hear the
pump working. At the same time, the voltage
4.1.1 Error memory at the return (Pin X2_8) is measured. If it is
If the ABS control unit has recognized a fault too low, the pump is switched off
in the system, this function helps to locate immediately (<10V after 30 milliseconds)
the fault and an error message will be returned.

8
Solenoid Valves having been fitted. If, at a later point in time,
A pulse programme can be used to make no relay is connected, the ECU will perceive
sure the solenoid valves and their wiring an error. This menu item can be used to
(hydraulic and electrical) are in proper once again achieve automatic recognition
working order, and that the allocation to all (reconfiguration). This item is available only
four ABS valves is correct. when a PIN has been entered.
For the pressure curve, please refer to the
diagram on Page 17. 4.2. SYSTEM CHECK

Retarder Relay System check permits a complete ABS test

The relay for switching off the retarder including print-out of a test log (e.g. after first
function in the event of ABS intervention installation or after extensive repairs).
during the braking process can be actuated.
It is switched on for the length of time the System check is divided into 2 sections:
push-button is depressed, i. e. the contacts
will open. The moment the retarder relay is ❑ functional test
actuated, the braking force must fall since
❑ print results
the retarder no longer affects the braking
process. This menu item is displayed only if
a retarder relay has been fitted. Important notes:
Once a test section has been initiated, this
4.1.3 Measuring Values has to be processed step by step. It is
In this part of the program, various neither possible to return to individual steps
measuring values provided by the ECU can nor to leave them out.
be displayed.
If the supply voltage to the Diagnostic
Voltages Controller is interrupted, all data measured
The ignition voltage (X2_2) and the valve and stored for the print log up to that point of
relay voltage (internal) are displaced. time are destroyed. Thus it is important that
the supply to the Diagnostic Controller is not
Wheel Speeds interrupted if a print log is required.
All four wheel speeds picked up by the
speed sensors (mph) are output in a
window. They will not be displayed until a Functional Test
speed of 1.1 mph has been reached. The functional test can be used only while
the vehicle is stationary (in current ignition-
on phase, its wheels may not simultaneously
4.1.4 Control Unit Data have exceeded a speed of 4.35 mph), and if
Reconfiguration of Retarder Relay no errors have been stored.
When it is first put into operation
(commissioning), the ECU will check
whether a retarder relay has been
connected at its terminals. If this is the case,
the relay is entered in the parameters as

9
Procedure: Functional Test - Commissioning

Start

read out modulator

Fehlerspeicher Modulator-
error memory valves
auslesen ventile front
VA
axle left
links

error
Fehler speed sensor
yes
Ja Drehzahl-
stored
gesp. ? ? rear axle
sensor HA
right
rechts
abort
Abbruch
no
Nein

voltages
Spannungen modulator
Modulator-
(U>10.78V) valves rear
ventile HA
axle right
rechts

warning lamp
Warnlampe speed sensor
Drehzahl-
rear axle
sensor HA
links
left

hydraulic
Hydraulik-
pump modulator
Modulator-
Pumpe
valves
ventile rear
HA
axle left
links

speed sensor
Drehzahl-
front axle wenn
sensor VA verbaut
right
rechts retarder
Retarder-
if fitted
relay
Relais

modulator
Modulator-
valves
ventile front
VA
axle right
rechts print
Bei findings
Bedarf
Ausdruck
on requestder
Ergebnisse

speed sensor
Drehzahl-
front
sensoraxle
VA
links
left
Ende
end

10
Print System Check The program works with EPSON FX-compa-
At the end of the test the results can be tible printers with a serial interface (RS 232).
printed. The transmission parameters of the printer
must be set to the configuration shown be-
As mentioned above, the Controller has to low:
be permanently connected to the voltage Speed: 1200 baud
supply. Any interruption will destroy all data Data bits: 8
stored. Stop bit: 1
Parity bit: X ON / X OFF
Connection with the printer is established via
the 25-pin socket on the rear and a serial
printer cable. The cable must have a DB 25-
plug (not socket !) at both ends.

11
4.3 MULTIMETER

1 DC voltage 3 Resistance Application:

2 AC voltage Direct voltage: supply voltage on vehicle
Alternating voltage:sensor voltage
Select function! EXIT Ò START Resistance: valves, relays, sensors,
wiring

The integrated multimeter function permits NOTE:

electric measurements on the vehicle. Only The measuring instrument is designed only
the desired measuring function (direct for measurings within the vehicle-specific-
voltage, alternating voltage or resistance) range (low voltage). It must not be used
needs to be selected. The measuring range beyond the above-mentioned measuring
is automatically set by the unit. range.

Range Display resolution Accuracy of measuring range. Final value 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 0.1volt ± 0.2 % ± 0.1 volt

AV-Voltage
2.0 volt 0.01 volt ± 0.6 % ± 0.02 volt
35.0 volt 0.1 volt ± 0.6 % ± 0.4 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
4.4 OPTIONS 4.4.3 ECUs for Testing
Indicates the WABCO numbers of the
4.4.1 Online Help control units supported by the program.

This function enables the user to obtain 4.5 SPECIAL FUNCTIONS

additional information on the program.
When the function is switched on, more de-
When a code (PIN) is entered in this menu,
tailed information will appear where suitable
the ECU’s specific parameters applying to
places. When the card is used for the first
that vehicle which normally cannot be
time the function will be switched on.
altered may be adjusted and transmitted
4.4.2 Version from one control unit to another.

This operation shows the version of the

components used (Controller and program
card). Authorization to modify these parameters
requires attending a WABCO training
course.

Hardware : V1 Multimeter: V1
Operating system : V3.1 (07.03.1991)
Program : V1.00 (19.06.1996)
Serial number : 22435 CONTINUE

13
5. 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 (Kontakte nach oben).

*** LOW VOLTAGE ***

CONT.

Cause Remedy

– Supply voltage too low (only during – check battery load capacity, and
diagnostic operation) ensure adequate supply.

14
 *** Initialization error ***
Switch ignition on!
Check diagnostic connection!
CONTINUE

Cause Remedy

– Insufficient supply voltage (< 8 volts) – Ensure supply

– No supply voltage (ignition off) – Switch on ignition

– Diagnostic lines switched or – Check lines and connections for

disconnected function and proper allocation

*** Wrong key word ***

Diagnosis impossible!

CONTINUE

Cause Remedy

– Wrong ECU connected – Check ECU part number

– Wrong „WABCO Data“ in ECU or – Change ECU and check ECU part
defective ECU number

*** Communication Breakdown (-xx) ***

Check diagnostic connection
and diagnostic lines.
Restart diagnostic procedure. CONT.

Cause Remedy

– Data transmission discontinued during – Check all connections

– Diagnostic Line or voltage disconnection
during diagnosis – switch on ignition
– critical error in diagnostic operation

15
 *** Unknown control unit ***
Diagnosis not possible
with this program card!
CONTINUE

Cause Remedy

– ECU cannot be tested with this – Use right 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

16
6 PULSE PROGRAM SEQUENCE: MODULATOR VALVES

How to test:
❑ Connect gauge to brake cylinders or use brake test
bench with individual wheel facility.
❑ Actuate brakes and keep actuated!
❑ Start pulse program and watch pressure reaction.

Sequence:
1. Pressure buildup to max. brake pressure and holding phase
2. Pressure reduction for 360 milliseconds
3. Holding phase 840 milliseconds
4. Pressure buildup to max. brake pressure and holding phase
5. Hold brake pressure 4.8 secs while
inlet valve (IV) is energized

possible errors possible causes

– pulse program has no effect – electrical

on actuated ABS valve Wrong connection of two ABS
valves. Wrong connection of cables
– deviations from pulse program
for inlet valve and outlet valve of an
ABS valve.
– hydraulic
Wrong connections
Defective ABS valve

17
7 PLUG PIN ASSIGNMENT

18
8 CONNECTION DIAGRAMS

Motor

Front axle Rear axle

19
9 TEST LOG

The printed commissioning log shows a

maximum version to be copied for operation
where there is no printer available. The
corresponding findings of the various steps
within the testing procedure are entered
from the commissioning run.

20
!-----------------------------------------------------------------------------------------------------------------------!
! *** SYSTEM CHECK PROTOCOL *** !
! Motor vehicle ABS-Hydraulic !
!-----------------------------------------------------------------------------------------------------------------------!
! !
! !
! ...................................... ................................. !
! Vehicle No. ECU No. !
! !
!====================================================================!
! Component rated value act. value judgement !
!-----------------------------------------------------------------------------------------------------------------------!
! ABS relay supply >10.78 Volt ______ ______ !
! UES >10.78 Volt ______ ______ !
! !
! !
! ABS warning light ______ !
! !
! !
! Pump and pump relay ______ !
! !
! Modulator wheel front right ______ !
! Modulator wheel front left ______ !
! Modulator wheel rear right ______ !
! Modulator wheel rear left ______ !
! !
! !
! Sensor wheel front right ______ !
! Sensor wheel front left ______ !
! Sensor wheel rear right ______ !
! Sensor wheel rear left ______ !
! !
! !
! Endurance brake relay ______ !
! !
! !
!====================================================================!
! !
! !
! ..................... ................ ........................... !
! Place Date Sign !
! !
!-----------------------------------------------------------------------------------------------------------------------!

21
 22
WABCO
WABCO

A Division of
Fahrzeugbremsen

WABCO Standard GmbH

30453 Hannover
Telefon (05 11) 9 22-0
Am Lindener Hafen 21

Telefax (05 11) 2 10 23 57

Copyright: WABCO ´98. Printed in Germany. No part of this publication may be reproduced without our prior permission. The right of amendment is reserved. Wabcodruck 815 000 267 3/03.98