Operating Instructions: For WABCO Diagnostic Controller 446 300 320 0 With Program Card ABS/ASR C1/C2 446 300 516 0
Operating Instructions: For WABCO Diagnostic Controller 446 300 320 0 With Program Card ABS/ASR C1/C2 446 300 516 0
WABCO
Fahrzeugbremsen
Ein Unternehmensbereich
der WABCO Standard GmbH
1
TABLE OF CONTENTS
Page
Diagnostic Controller Set 4
Which Systems Can Be Tested? 5
Connecting the Diagnostic Controller 6
Operating the Diagnostic Controller 6
Programme Structure 7
1. Diagnosis 8
1.1 Error Memory 8
1.2 Component Actuate 8
1.3 Measured Values 9
1.4 Controller data 10
2. System Check 10
3. Multimeter 12
4. Options 12
Testing of Ancillary ABS Features
(Info Module, Trailer Socket) 13
Example of Fault Search 15
Functional Fault in
Diagnostic System 17
Test Cycle of Modulator Valves 20
Circuit Diagram
4-Channel ABS (Full Air) 21
Circuit Diagram
6-Channel ABS 22
Print-out of Test Results 23
2
LIST OF ABBREVIATIONS USED:
The following abbreviations are protected trade names of engine control systems from
certain 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
3
DIAGNOSTIC CONTROLLER SET 446 300 331 0
4
WHICH 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.
ABS/ASR C1/C2 (ISO)
system/plug 4-channel/35 poles 6-channel/54 poles
program card 446 300 516 0 446 300 516 0
ECUs which can be 446 004 031 0 to 037 0 446 003 034 0
tested 041 0 038 0
043 0 039 0
044 0 044 0
046 0 051 0
051 0 to 054 0 054 0
064 0* 058 0*
066 0* 064 0*
068 0* 066 0*
073 0* 068 0*
* no support for settings
As per June ´95. Additional ECUs may be suitable for testing.
The program card will refuse to perform any test if it cannot identify the ECU.
5
CONNECTING THE DIAGNOSTIC 6-Channel
CONTROLLER
1a. 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. Connect Diag-
nostic Cable to diagnostic socket on vehicle.
1b. No diagnostic socket to ISO 9141 3. Insert program card, pushing it fully home
available (contact side first, black surface facing up-
wards). The display will now show which
If there is no ISO diagnostic socket on the
card has been inserted.
vehicle, an inter-adapter (accessories) can
be fitted between the ECU and the vehicle
harness connector (see diagram). OPERATING THE DIAGNOSTIC
4-Channel CONTROLLER
1 Diagnosis 4 Multimeter
2 System check 5 Options
6
Push-button Function PROGRAMME STRUCTURE
ABS/ASR C1/C2
START : Initiate programme.
RETURN : The display will return to the
last main menu. 1 Diagnosis
(ARROW): Select an item from the main 1 error memory
menu. 2 component actuate
Scroll forward one item at the
ê time by pressing the push- 1 ABS warning lamp
button. The item selected will 2 ASR lamp
blink. 3 third brake
CONTINUE: The item selected is activated 4 differential valves
or released. 5 ASR engine control
REPAIR This command will activate the
1 electronic engine interface
failure search for the displayed
2 PROP-/MOT-Valve
error. However, by pressing
CONTINUE you may display 6 modulator valves
all errors first.
1 modulator test cycle
2 set pulse time
3 measured values
1 voltages
2 wheel speeds
3 switch positions
4 ECU parameters
2 System check
3 Multimeter
4 Options
1 ISO address
2 online help
3 versions
7
1. DIAGNOSIS – cause and location in plain writing, e.g.
sensor error wheel A (steering axle S2),
short circuit or broken wire.
1 Diagnosis 3 Multimeter – frequency at which the fault occurred.
2 System check 4 Options Note: The ECU can recognize the error
only once each time the ignition is
Select function! EXIT ê START switched on.
– „error exists at present” means that when
the diagnosis mode was selected the
When selecting the Diagnosis function, error existed. This is followed by a
communication with the ABS control is detailed fault location routine with
established. specific instructions on how to proceed in
locating the error. If „error does not exist
A ECU type : ABS/ASR-C2 at present” appears on the display, this
WABCO Part No. : 446 004 054 0 means that the fault did not exist at the
S Prod. date : week / year time the diagnostic mode was selected,
Software No. : 83 CONTINUE i.e. it cannot be located by way of
electrical measurement.
– Integrated multimeter function. The
The WABCO data of the ABS ECU is tester is instructed to carry out electrical
displayed. measurements (e.g. resistance measure-
ments) with the aid of the inter-adapter.
1 Error memory 3 Measured values Both prescribed and actual values
2 Component actuate 4 ECU parameters appear on the display and can be
compared.
Select function EXIT ê START – When correction of the fault is confirmed,
that fault is deleted from the ECU.
– The fault location routine can be left only
In the Diagnosis mode, the following functions when all faults have been corrected.
are available for selection:
1.1 Error memory 1.2 Component Actuate
1.2 Component actuate
1.3 Measured values With „Component Actuate”, certain compo-
1.4 ECU parameters nents within the ABS system can be
actuated and tested. For this the respective
components must, of course, have been
1.1 Error memory
fitted.
If the ABS control unit has recognized a fault
in the system (safety lamp on), this function
helps locate the fault (example see Page 1.2.1 Warning lamp
15). Depending on the type of ABS system The ABS warning lamp can be switched on
used and the type of error encountered, the or off at the push of a button.
following advice will appear on the display.
8
1.2.2 ASR lamp Test: start engine, increase engine
The ASR lamp can be switched on or off at speed and hold constant. Reduce speed
the push of a button. via push-button „ON”. After releasing the
button, engine speed is returned to its
1.2.3 Third brake original level.
The relay of the third brake (e.g. retarder)
can be actuated at the push of a button 1.2.6 ABS modulator valves
(possible to hear the click sound of the relay
on some installations). 1.2.6.1 Pulse programme
Both function and allocation of the ABS
1.2.4 Different valves
modulator valves can be individually
The differential brake valves of the ASR checked by means of a pulse programme.
system can be individually actuated at the For pressures, see diagram on Page 20.
push of a button. By pressing the respective
button, the valve is actuated briefly. If the
button remains pushed, the valve is conti- 1.2.6.2 Time settings
nuously actuated with short cycles. The times T1 and T5 for pressure build-up
and pressure reduction are adjustable
1.2.5 ASR engine control (compare diagram on Page 20). For vehicles
With this function, the electronic or pneu- with large brake chambers, it may be of
matic ASR engine control fitted in the vehicle assistance to increase pulse times to ensure
can be actuated. Select the system fitted. that sufficient (visible) pressurization and
venting takes place. The value is preset at 51
1.2.5.1 Electronic engine interfaces: milliseconds.
– VDO ESW/PRIO (is recognized
automatically) 1.3 Measured values
– VDO PWMR/PWMV
This part of the programme is used to display
– Bosch EMS values and switch positions.
– Bosch EDC
Test: start engine, increase engine 1.3.1 Voltages
speed and hold constant. Using the
push-button, reduce engine speed, then The actual voltages measured by the ECU
increase to original level. When test is are displayed. The valve relay voltages are
active an increase of engine torque slightly below the supply voltage. Figures for
should not be possible. 12 volt systems are in brackets.
9
When the wheel is stationary, the display will System check is divided into 3 sections:
show < 1.8 km/h. – component test
Note: The diagnosis will be interrupted if – functional test
all wheels are driven.
The ASR-controlled wheels must not – print results
turn at speeds in excess of approx. 3.5 Important notes:
km/h since this would cause the ASR Once a test section has been initiated, this
function to initiate. has to be processed step by step. It is not
possible to return to, or skip, individual steps.
If the supply voltage to the Diagnostic
Controller is interrupted, all data measured
1.3.3 Switch positions and stored for the print log up to that point in
The positions of the ABS and ASR switches time are destroyed. Thus it is important that
and the status of the ASR lamp are the supply to the Diagnostic Controller is not
displayed. interrupted if a print log is required.
Components Test
1.4 Controller data
The ABS components fitted are checked for
The following system-specific ECU para- their electrical specifications. This test is
meters are displayed: carried out without the ECU. Instead, the
inter-adapter is plugged into the cable
– WABCO ECU data
socket permitting the required measure-
– ABS configuration ments to be taken using the multimeter
– ECU parameters cable.
limiting speed: preset top speed Procedure:
MIR definition: ABS bias factor on – replace ECU by inter-adapter
steering axle – inquiry 24 volt-/12 volt-system
ISO address:
– measure the supply voltage
„Telephone number” defined for
– inquiry: number of sensors and
vehicle electronics. The address of
modulators (MRV), e.g. full-
ECU and Controller (see 4.1) must
air 4-channel, generally
correspond.
4S/ 4M
Fixed address for motor vehicle
– measure:
ABS = 8.
resistance of relays
resistance of MRVs
10
– inquiry sensor type: Print System Check
cone-type sensor At the end of the test, the results can be
imprint „K” (from approx. '89) printed.
step-type sensor As mentioned above, the Controller has to
imprint „S” (from approx. '93) be connected to the voltage supply at all
cylinder-type sensor times. Any interruption will destroy all data
no imprint (before '89) stored.
– measurement sensors resistance Connection with the printer is established via
sensors voltage inquiry the 25-pin socket on the rear and a serial
printer cable. The cable must have a DB 25-
– replace inter-adapter by ECU
plug (not socket !) at both ends.
The programme works with EPSON FX-
compatible printers with a serial interface
Functional Testing (RS 232). The transmission parameters of
the printer must be set to the configuration
This test is carried out with the ECU
shown below:
connected. The Controller instructs the ECU
to follow certain control instructions. The Printer Controller
tester is confronted with individual yes/no
inquiries.
Procedure:
– actuate warning lamp
ASR lamp
third brake
ABS/ASR switch
– pulse programme
modulators: for time setting,
see 1.2.6.2; for pulse pro-
gramme, see Page 20.
– actuate
diff. valves of ASR-controlled
driving wheels
– actuate
pneumatic engine control Speed: 1200 baud
(PROP- or MOT-valve) or
Data bits: 8
alternatively electronical
interface Stop bit: 1
Parity bit: X ON/X OFF
– For testing optional ABS features, see
Page 13.
11
3. MULTIMETER
AC-voltage
2.0 volts 0.01 volt ± 0.6 % ± 0.02 volt
35.0 volts 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
2.0K Ω 1.0 Ω ± 0.2 % ± 1.0 Ω
20.0K Ω 10.0 Ω ± 0.1 % ± 10.0 Ω
95.0K Ω 100.0 Ω ± 0.2 % ± 100.0 Ω
Application:
direct voltage: supply voltage on vehicle
alternating voltage: sensor voltage 4. OPTIONS
resistance: valves, relays, sensors, wiring
12
Preset addresses – Program card with software creation date
motor vehicle ABS: 8 and check total
trailer ABS: 10
motor vehicle ECAS: 16
Testing Optional ABS Features (24 volts)
trailer ECAS: 18
(only for vehicles with trailer facility)
4.2 Online Help The following optional ABS features are not
included in the 35-pole or 54-pole ABS-ECU
This function enables the user to obtain wiring and can, therefore, not be tested by
additional information on the programme. means of the Diagnostic Controller:
When the function is switched on, more de- – ABS trailer socket to ISO 7638
tailed information will appear in suitable
places. When the card is used for the first – Info module
time, the function will be switched on. – Info lamp
– ABS trailer warning lamp
4.3 Versions
Testing Procedure:
13
Faults:
6,0mm2 1
TEST PLUG
1,5mm2 2
ABS-TRAILER
1,5mm2 3
SOCKET
6,0mm2 4 446 007 316 0
1,5mm2 5
ISO 7638
INFO MODUL SOCKET
446 016 00. 0
UA UES ZS OV IL RK AK 54
85 TEST PLUG
87 87 BRAKE-LIGHT
a 24N SOCKET
RELAY 446 007 310 0
31
30 86
TRACTOR ISO 1185
BRAKE-LIGHT SOCKET
54
TRAILER-ABS
Max. BLS WARNING LAMP
25A 5A 15 MAX. 10 W
INFO- (RED)
TRACTOR LAMP
WARNING LAMP MAX. 10W
WARNING LAMP RELAY (YELLOW)
3rd. BRAKE RELAY
30 15
IGNITION
+
24V BATTERY
-
14
Example for Locating the Fault NOTE:
„Sensor Cable Break” When using the inter-adapter, switch off
ignition only using read toggle switch.
The ABS control unit has 4-channel: inter-adapter 35 pins
stored 1 error(s) in the error memory. 6-channel: inter-adapter 54 pins
CONTINUE
Check resistance: PIN 15 / 32
SHOULD BE: 0.7–3.0 kΩ ACTUAL: 0.02 kΩ
Check acutal value!
Displays number of errors found. LOW CORRECT HIGH
15
No FURTHER errors stored in the Switch ignition off and on again!
ABS control unit.
CONTINUE CONTINUE
No FURTHER errors have been stored. After switching the ignition off and then on,
the ECU will check the wiring once again.
Switch ignition off! When using the inter-adapter the ignition
THEN disconnect measuring pin adapter, must be switched off using the red toggle
connect ABS control unit and switch switch.
ignition on again. CONTINUE
NO errors stored in the
ABS control unit.
Proceed as described in Step No. 4 but in
reverse sequence. CONTINUE
16
FUNCTIONAL FAULT IN DIAGNOSTIC SYSTEM
no display
Cause Remedy
– no voltage supply a) ISO diagnostic plug:
– undervoltage (less than about 7 volts) – Check plug allocation
– Voltage between PIN1 and PIN2 =
supply voltage on vehicle
b) Inter-adapter:
– Switch on ignition at adapter
– Check all plug-in connections
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII black „bars”
Cause Remedy
– program card not inserted – Insert program card, pushing it fully
home
CONTINUE
Cause Remedy
– insufficient supply voltage (only during – Check condition of battery and ensure
diagnosis) sufficient supply
17
*** Initialisation error ***
Switch ignition on!
Check diagnostic connection!
CONTINUE
Cause Remedy
– insufficient supply voltage (< 18 volts) – Ensure supply
– no supply voltage (ignition off) – Switch on ignition
– ISO address set incorrectly – Reset ISO address. Preset ABS/ASR
address 8 (see 4.1 „ISO Adress”)
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
CONTINUE
Cause Remedy
– defective program card – Change program card
– wrong program card
18
*** COMMUNICATION
BREAKDOWN ***
Restart diagnosis procedure!
CONTINUE
Cause Remedy
– Data transmission aborted during – Check all connections
diagnosis Line or voltage disconnection a) ISO socket on vehicle:
during diagnosis – switch on ignition
b) inter-adapter:
– move red toggle
– switch to „1” position
Cause Remedy
– ECU cannot be tested with this – Use right program card
program card
Cause Remedy
– EEPROM (Diagnostic Controller's) – Repair Diagnostic Controller
nonvolatile memory defective
19
PULSE PROGRAMME SEQUENCE: MODULATOR VALVES
1 5
2 4
3
Brake pressure
Foot brake
T1
Outlet valve
T2 T3 T4
Inlet valve
T5 T6
Testing procedure:
– Connect pressure gauge to brake
chambers, or
– Use brake test bench with independent
wheel facility
– Actuate and hold brake !
– Start pulse programme and observe
pressure readings !
20
21
22
!--------------------------------------------------------------------------------------------------------------------!
! SYSTEM CHECK PROTOCOL !
! Motor vehicle ABS/ASR-C !
!--------------------------------------------------------------------------------------------------------------------!
! !
! ...................... ......................... !
! Vehicle No. ECU No. !
!===================================================================!
! Component test !
!--------------------------------------------------------------------------------------------------------------------!
!Component Should be Actual Unit Value !
!--------------------------------------------------------------------------------------------------------------------!
!ECU power-supply voltage 21.6 - 32.0 ______ volts ______ !
!ABS-relay 1 and SILA-relay 105 - 215 ______ ohms ______ !
!ABS-relay 2 210 - 430 ______ ohms ______ !
!3.Brake-relay 210 - 430 ______ ohms ______ !
! INLET valve Steer-axle 11.7 - 16.5 ______ ohms ______ !
!OUTLET valve Steer-axle 11.7 - 16.5 ______ ohms ______ !
! INLET valve Wheel C (D1) 11.7 - 16.5 ______ ohms ______ !
!OUTLET valve Wheel C (D1) 11.7 - 16.5 ______ ohms ______ !
! INLET valve Wheel D (D2) 11.7 - 16.5 ______ ohms ______ !
!OUTLET valve Wheel D (D2) 11.7 - 16.5 ______ ohms ______ !
!Sensor resistance Wheel A (S2) 1.4 - 2.0 ______ kohms ______ !
!Sensor to ground Wheel A (S2) > 45 ______ kohms ______ !
!Sensor voltage Wheel A (S2) > 0.10 ______ volts ______ !
!Sensor resistance Wheel B (S1) 1.4 - 2.0 ______ kohms ______ !
!Sensor to ground Wheel B (S1) > 45 ______ kohms ______ !
!Sensor voltage Wheel B (S1) > 0.10 ______ volts ______ !
!Sensor resistance Wheel C (D1) 1.4 - 2.0 ______ kohms ______ !
!Sensor to ground Wheel C (D1) > 45 ______ kohms ______ !
!Sensor voltage Wheel C (D1) > 0.10 ______ volts ______ !
!Sensor resistance Wheel D (D2) 1.4 - 2.0 ______ kohms ______ !
!Sensor to ground Wheel D (D2) > 45 ______ kohms ______ !
!Sensor voltage Wheel D (D2) > 0.10 ______ volts ______ !
!DIFF valve Wheel C (D1) 29.5 - 42.0 ______ ohms ______ !
!DIFF valve Wheel D (D2) 29.5 - 42.0 ______ ohms ______ !
!PROP/MOT valve 15.2 - 22.6 ______ ohms ______ !
!===================================================================!
! Function test !
!--------------------------------------------------------------------------------------------------------------------!
!No errors stored in the electronic control unit (ECU) !
!ABS warning light ______ !
!ASR light ______ !
!3. Brake ______ !
!ABS offroad switch ______ !
!ASR function switch ______ !
!Modulator Wheel A (S2) ______ !
!Modulator Wheel B (S1) ______ !
!Modulator Wheel C (D1) ______ !
!Modulator Wheel D (D2) ______ !
!DIFF valve Wheel C (D1) ______ !
!DIFF valve Wheel D (D2) ______ !
!PROP/MOT Engine control ______ !
!Electronic Engine control ______ !
!===================================================================!
! !
! ............... ............... ............... !
! Place Date Sign !
!--------------------------------------------------------------------------------------------------------------------!
23
NOTIZEN
24
WABCO Am Lindener Hafen 21
Fahrzeugbremsen 30453 Hannover
Telefon (0511) 922-0
Ein Unternehmensbereich Teletex 511 886 WABCO
der WABCO Standard GmbH Telefax (0511) 2102357
25
Operating Instructions
for WABCO Diagnostic Controller
with Program Card ABS/ASR C1/C2
446 300 516 0
26