Compact Tester II 446 300 430 0 User Manual
Contents
1. 15t digit 2d digit 3 digit Path of error Type of error Occurrences On the front panel of the Compact Tester the errors are decoded with the help of pic tograms Groups of errors which are relat ed are marked with a horizontal line sensor modulator or system Different combinations of path and type of error may occur Examples Display Meaning 411 Sensor wheel D air gap too large has detected once 872 Hydraulic pneumatic modula tor wheel B short to Ugay has detected twice H59 Retarder ISS cable break has detected 9 or more times 001 Recirculation pump pump sticks has detected once LE1 ECU overvoltage has detect ed once Number or character Path of error 1 Wheel A L2 2 Wheel B L1 3 Wheel C A1 Sensor 4 Wheel D A2 5 Wheel E Z2 6 Wheel F Z1 7 Wheel A 8 Wheel B 9 Wheel C Modulator A 10 Wheel D C 11 Wheel E E 12 Wheel F F 13 DIFF valve H 14 Retarder ISS P 15 Engine con trol Interface J 16 Generic I O O 17 Recirculation pump d 18 Valve relay U 19 Shuttle valve switch L 20 ECU 10 WABCO Buttons Compact Tester Il Right side of the front panel Number or character Type of error 1 Air gap too large 2 Pole wheel defe2. 0 446 004 3xx 0 446 004 6xx 0 446 003 7xx 0 KWP 2000 446 004 6xx 0 446 003 7xx 0 ABS E version Hydraulic ABS ECUs 446 044 070 0 446 044 074 0 446 044 0750 446 044 076 0 446 044 0770 446 044 078 0 400 500 070 0 to 400 500 089 0 446 044 079 0 KWP 2000 446 044 080 0 446 044 088 0 446 044 089 0 446 044 092 0 446 044 093 0 Trailer ECUs 446 105 001 0 to 446 105 052 0 JED 677 Vario C 446 108 030 0 to 446 108 050 0 400 500 030 0 to 400 500 067 0 I ee 472 500 001 0 to 472 500 021 0 TCS 1 400 500 101 0 to 400 500 106 0 SAE met TCS Il 446 108 070 0 to 446 108 089 0 PET En 8 WABCO Functions Startup Compact Tester Il 4 Functions e Error display e Deletion of stored errors Display of system configuration e Functional testing of components e Re setting system and system initialisa tion e Odometer VCS I VCS Il and TCS 5 Startup Push the nine pole socket of the WABCO diagnostic cable e g 446 300 401 0 for truck into the con nector on the Compact Tester Push plug on the vehicle side of the diagnostic cable into the diagnostic socket on the vehicle Switch on ignition The tester s display will be illuminated im mediately display 888 After approx 1 second the tester tries to establish the diagnostic connection with the ECU which is indicated by runni
3. h PB se Run recirculation 60 Pump Pump Relay ON L_ APPLY turned wheel Inlet vave V f E l RELEASE 100 RELEASE All valves ko msec turned wheel Outlet valve OV Pulse program of HABS valve actuation WABCO Compact Tester Il System reconfiguration initialisation 8 System reconfiguration initialisation Do not activate the reconfiguration in e itialisation if you have present errors because the could be changed system Activating the reconfiguration initalisation Press SYSTEM button The actual system is displayed Press SYSTEM button for more than 2 seconds 8 1 Truck ABS The ABS system can be made to once again recognize the components connect ed to it ASR engine control The new sta tus is stored in the parameters of the ECU This function is available only for ABS D E systems In Truck ABS when the system reconfigu ration initialisation is activated the display will be cleared and after a short period the type of ECU identified shall appear in the display Switch the ignition OFF and ON again If the display shows after activat e ing the system reconfiguration initiali sation it indicates that the system cannot be reconfigured 8 2 Trailer ABS In Trailer ABS when the system reconfigu ration initialisation is activated the display starts to flash with the acknowledged sys tem It is a
4. D 1 4S3M A A 2 1M rear B B 1 C C 2 D C 1 4S4M A A 2 B B 1 C Cc 2 D D 1 6S3M A A 2 B A 1 C C 2 D D 1 E D 1 F Cc 2 6S4M A A 2 B B 1 C Cc 2 D D 1 E D 1 F Cc 2 6S5M A A 2 B B 1 Cc C 2 D D 1 E F 1 F F 2 6S6M A A 2 B B 1 C Cc 2 D D 1 E E 1 F F 2 After successful functional testing the system is operable 16 WABCO Functional testing Compact Tester Il 7 2 Trailer ABS not available After 2 seconds SYS appears on the dis in Vario C without brake Play pressure 7 2 1 System check Activating the functional testing The system check should only be done Press SYSTEM button when there are no errors present When a single wheel is rotated and stopped the ap System configuration is displayed propriate modulator valve is triggered Press CLEAR button for more than 2 This cycle can be repeated if required by seconds rotating the wheel Wheel speed 4kp hL Pressure decrease Modulator Actuation Pressure hold Pulse Pulse program 1 Startup cycle for wheels Z1 Z2 and L2 without brake pressure Wheel speed 4k p h LON Modulator Actuation Pressure decrease AR Pulse Pulse program 2 Startup cycle for wheels H1 H2 and L1 d c without brake pressure WABCO 77 Compact Tester Il Functional testing 7 2 2 Assignment of pulse program System Rotated Actuated Pulse configu wheel mod
5. SYS If a button other than CLEAR is e pressed the functional testing is abort ed and the display shows AbS 7 1 2 Testing retarder control When the CLEAR button is pushed again for longer than 0 5 second the retarder is inactive for 5 seconds display 005 000 Depending on the type of re tarder used the effect of this will vary For more information please refer to the test in structions for the appropriate retarder If no retarder is identified the first digit of the display shows a dash in place of a zero 7 1 3 Allocation testing During allocation testing ASR is disabled to enable ASR function the ignition must be switch off and on again After testing retarder control any wheel can be turned without pressing the CLEAR button again The display then shows the actual speed of the wheel being turned in km h This is done in full figures Example If the speed of wheel A is 5 6 km h the display shows A 0 5 14 WABCO Functional testing Compact Tester Il If the ECU detects a speed on more e than one wheel the display shows 1 In this case the functional test cannot be initiated as the Compact Tester does not know which modulator valve to address A speed of more than 4 km h must have been measured to allow the modulator valves to be actuated When the wheel which had previously been turned is once again stationary the appropriate modulator is actuated The sensor m
6. ary protective clothing Attach a clearly marked note on the steer ing wheel that repair work diagnosis is being performed on the vehicle Do not touch any vehicle components that are hot Make sure that nobody stays in danger ar eas Keep your hands and hair away from moving parts Do not wear a tie wide clothing open hair bracelets or watches etc when working on the vehicle CAUTION A Never use the Compact Tester in the area of Please do the following to ensure trouble free oper ation of your Compact Tester e Sources of heat such as ovens e Exhaust gases e Magnetic fields e Sources of electricity Otherwise trouble free functioning could be impaired Do not expose the Compact Tester to im pact shock or moisture water or other liquids Never repair or service the internal com ponents yourself but take it to your WABCO dealer WABCO 5 Compact Tester Il Meaning of pictograms 2 Meaning of pictograms Front panel Sensor gt gt Modulator gt gt Modulator gt DIFF valve J Retarder ISS gt Engine control era gt Generic VO gt Recirculation pump OD Valve relay gt Y d Shuttle valve switch gt ECU gt Abbreviations ECU Electronic Control Unit ISS Integrated Speed Switch I O Input Output Air gap Pole wheel defect Defective signal Wrong tyre size Cable
7. break Internal short circuit Short to Ugatt Short to ground Short circuit Time error Slip error Overvoltage Undervoltage Defect relay or switch position Defective component ECU Pump sticks Pressure sensor Wrong configuration ECU ABS warning lamp 6 WABCO Meaning of pictograms Compact Tester Il Displayed when ignition is ON No error System variant Back panel 888 0 Bro lt 4 3 ecu as 3m lt UC 1 VARIOC1 2 VARIOC2 5 VCS1 UI ves2 lt a E cABSC2IC3 dABS D E ABS E Hd 5 HYDRAuLICABS lt f ECU type 1RD B 2RD Q A 1YE Q D 2YE 8 F 1BU c 2BU E lt Wheel assignment for Vario C lt Wheel assignment WABCO 7 Compact Tester Il WABCO ECUs supported by Compact Tester 3 WABCO ECUs supported by the Compact Tester Compact Tester 446 300 430 0 is an easy to use diagnostic tool which can be used to diagnose all WABCO ECUs for Truck Trailer and Hydraulic ABS systems The ECUs supported by the Compact Tester are listed below Part Number Data Link Layer Version Type Truck ECUs 446 004 Oxx 0 JED 677 446 003 Oxx 0 ABS C version 446 004 3xx 0 446 004 4xx 0 JED 677 446 003 4xx 0 446 004 3xx 0 KWP 2000 446 004 3xx 0 446 004 4xx 0 SAE J 1587 446 003 4xx 0 ABS D version 446 004 3xx 0 446 004 6xx 0 JED 677 446 003 7xx
8. ct 3 Defective signal 4 Wrong tyre size 5 Cable break 6 Internal short circuit 7 Short to Ugatt 8 Short to ground 9 Short outside energy source shorted coil A 10 Time error C 11 Slip error E 12 Overvoltage F 13 Undervoltage H 14 Defective relay switch position P 15 Defective component ECU O 17 Pump sticks d 18 Pressure sensor U 19 Wrong configuration of ECU L 20 ABS warning lamp While the ECU s error memory is being searched and sorted by the tester a run ning display is shown Activating error search Presently existing errors are displayed old is displayed NOT presently existing errors are displayed End of error search Type of ECU is displayed By continuing to push the ERROR button each sub sequent error will be displayed First any existing errors RAM are displayed When all existing errors have been displayed old will appear This is followed by all non current his torical errors EEPROM being displayed When the last error has been dis played the type of ECU identified by the tester will be shown once again e g AbS 1 When a button other than ERROR is pressed the error search is aborted and the type of ECU identified by the system is displayed WABCO Compact Tester Il Buttons 6 1 1 Error search Hydraulic ABS Hydraulic ABS has two options for error dis play Aft
9. display the first 3 places Press again any button to display the next 3 places Example 149 322 149 322 total km travelled If all figures one after another have been asked for ECU type is displayed 9 2 Display speed threshold only for VCS I Display the speed threshold value in k p h Simultaneously press ERROR and CLEAR button If no speed threshold is present the display shows OFF 9 3 An additional feature in future VCS elec tronic units is a service interval counter in km When this service interval is exceeded the driver is informed by the rapid blinking 8 flashes of the dash warning lamp after the ignition is switched on Reset Service Interval To reset the service signal Press simultaneously ERROR and SYSTEM button Acceptance of command is indicated by rapid blinking of WABCO 2 Compact Tester Il Summary for trailer 10 Summary for trailer Key Display example Function Comments ERROR 471 Fault display 4 Path of error 7 Type of error 1 Occurrences CLEAR Clr Clear memory Requirement no actual fault present SYSTEM 4 2 System display e g 4S 2M 4r2 e g 4S 2M with retarder 4U2 e g 4S 2M with ISS Special functions see sequence 1 SYSTEM 2 2 Press and release key 2 SYSTEM 2 2 flash System configuration Hold key 2 seconds See detected sys tem 1 SYSTEM 2 2 Press and relea
10. el ABS 446 004 0XX 0 4 channel ABS Display of the system for ABS C 15t digit 2 digit 3 digit 4 chan 4 nel ABS 6 chan 6 nel ABS 12 WABCO Buttons Compact Tester Il 6 3 2 ABS D amp E Display of system for ABS D amp E 6 3 4 Trailer Display of the systems only for VCS1 st digit pnd digit 3rd digit 4st digit 2nd digit ard digit number of number of number of number of r for number of sensors modulators modulators Sensors retarder modulators if 1 modula if 1 modula POEs tor at front tor at rear if nS 3M System Display 2S1M 2 1 System Display 2S1M retarder 2r1 4S2M 4 2 2S1M ISS 2U1 4S3M V 43 2S2M 2 2 6S3M 63 2S2M retarder 2r2 4S3M H 4 3 2S2M ISS 2U2 4S3 1M 431 4S2M 4 2 4S4M 4 4 4S2M retarder 4r2 4S4Mx4 44 4S2M ISS 4U2 6S3 1M 631 4S3M 4 3 6S4Mx4 64 4S3M retarder 4r3 6S4 1M 641 4S3M ISS 4U3 SEM coat Display of the systems for Vario C VCS Il 6S6Mx4 66 TCS and TCS II st digi nd gigi rd ini 6 3 3 Hydraulic ABS li Ei E A Fe SEE qe numberof number of 1 digit 2 digit 3 digit sensors modulators number of number of sensors modulators System Display 2S1M 2 1 System Display 2S2M 2 2 4S4M 4 4 4S2M 4 2 4S3M 4 3 WABCO Compact Tester Il Functional testi
11. er initialization of the Hydraulic ABS ECU the display option will be 1 digit 2d digit 3 digit Path of error Type of error Simultaneously press SYSTEM and ERROR button for changing the display option Change of display option will be indicated by flashing of for 2 seconds Now the error display will be Failure Number corre sponds to individual failure memory e g 011 for error code 1 1 070 for error code 7 0 104 for error code 10 4 Simultaneously press SYSTEM and CLEAR button for changing the display option again to the previous one 6 2 Clearing error memory CLEAR button Switch the ignition off and then on again Push the CLEAR button for more than 0 5 seconds to clear the whole error memory of the ECU RAM EEPROM The deletion of error memory will be indi cated by Clr on the display Push ERROR button again to make sure that no error is in the memory However this is only done if there are e no existing errors After this the display once again shows the type of ECU identified e g AbS 6 3 System information SYSTEM button Push the SYSTEM button The configuration of the system identified by the ECU will be displayed The indica tions for various ECU types are given be low 6 3 1 ABS C C2 C3 For ABS C the system is displayed as 4 channel or 6 channel WABCO Part Number 446 003 0XX 0 6 chann
12. ing retarder control 14 adaptors 23 7 1 3 Allocation testing 14 Additional instructions information or tips that you should always observe Explanation of symbols b WARNING Potentially hazardous situation which if not avoided could re List A sult in death or serious injury Step CAUTION Potentially hazardous situation which if not avoided may result A in minor or moderate injury j WABCO Safety instructions Compact Tester Il 1 Safety Instructions WABCO will only guarantee the safety e reliability and performance of the Com pact Tester if you follow all of the safety instructions from this manual Carefully read through all the safety in structions before starting diagnosis or repair work Never start a diagnosis or repair work until you have read and understood all the information required for the diagno sis Before you start diagno sis or repair work please follow the instructions to avoid situations that could result in injury or death While diagnosing always adhere to the contents of this user manual WARNING A Only trained and qualified personnel may use the Compact Tester or do repair work Always follow the specifications and in structions of the vehicle manufacturer Comply with the company and national accident prevention health amp safety regu lations Please make sure that the vehicle cannot move away Wear any necess
13. m User Manual Compact Tester II 446 300 430 0 W 1st Edition This publication is not subject to any update service You will find the new version in INFORM under www wabco auto com Copyright WABCO 2006 WABCO Vehicle Control Systems An American Standard Company The right of amendment is reserved Version 001 09 06 en 815 010 107 3 Compact Tester Il Table of contents Table of contents 1 Safety Instructions 5 7 1 4 Assignment of pulse i programm 16 2 Meaning of pictograms 6 7 2 Trailer ABS not 3 WABCO ECUs supported by available in Vario C the Compact Tester 8 without brake pressure 17 7 2 1 System check 17 4 Functions 9 7 2 2 Assignment of Er Sa 9 pulse program 18 Arup 7 3 Hydraulic ABS 18 6 Buttons 10 7 3 1 Allocation testing 18 6 1 Readout error memory 8 System reconfiguration moe he on ER 10 initialisation 20 a rror search Hydraulic ABS 42 8 1 Zu ABS 20 5 8 2 Trailer ABS 20 6 2 Clearing error memory CLEAR button 12 8 3 Hydraulic ABS 20 6 3 System information 9 Special functions SYSTEM button 12 only for trailer ABS 21 6 3 1 ABS C C2 C3 12 9 1 Odometer reading 21 6 3 2 ABS D amp E 13 633 Trailer 13 9 2 Display speed 6 3 4 Hydraulic ABS 13 threshold only for VCS I 21 9 3 Reset Service Interval 21 7 Functional Testing 14 7 1 Truck system without 10 Summary tor trailer 22 brake pressure 14 11 Appendix 23 7 1 1 Testing engine control 14 List of WABCO Diagnostic cables 7 1 2 Test
14. ng 7 Functional testing This menu item should be addressed e only if no error is present After the initial installation of the ABS sys tem or any modifications done to that sys tem the proper pneumatic hydraulic and electrical allocations of the components must be checked 7 1 Truck system without brake pressure The functional test is activated by pushing the following buttons Push SYSTEM button and release System used e g 4 2 is displayed Push CLEAR button for more than 2 seconds After 2 seconds SYS appears on the dis play If the warning lamp was on it will be go off before the CLEAR button is released The ASR lamp if present will then come on for 1 second Pushing the CLEAR button for longer than 0 5 second causes the next test step to be addressed If any other button is pushed for longer than 0 5 second the functional test is aborted and the type of ECU identified appears on the display ABS 7 1 1 Testing engine control For 10 seconds the Compact Tester trans mits the request for idle operation This is done to test engine control for ASR and any speed limiter During that time push the accelerator pedal down The engine speed will not increase within the 10 seconds The display will show the remaining actuation time in seconds If no ASR is identified the first digit of the display shows a dash in place of zero After this test the display shows
15. ng dashes on the display e Upper three dashes Searching inside Truck ECUs e Middle three dashes Searching inside Trailer ECUs e Lower three dashes Searching inside Hydraulic ABS ECUs When the connection has been successful ly established the type of system identified will be displayed Speed threshold display ISS VCS Reset service interval VCS 1 Display of Compact Tester Il software version PIN compatible to Diagnostic Controller and Diagnostic Interface You can use existing diagnostic cables Display Comment Truck Systems If Compact Tester establishes a as connection with the ECU Only if D E version or above is ASR being used and ASR has been identified C C2 C3 Version c u C version with v limiter d D Version d u D version with v limiter E E Version Trailer Systems UC1 Vario C1 UC2 Vario C2 UCS VCS UII VCS II tCS TCS tll TCS Il Hydraulic ABS HdS Due to repeated searching of ECUs the display shows the running dashes when a system which cannot be tested by the Compact Tester is connected WABCO 3 Compact Tester Il Buttons 6 Buttons 6 1 Readout error memory ERROR button Push ERROR button to read out the ac tual RAM and the historical EEPROM error memory The error is shown as follows Error allocation on housing sticker Left side of the front panel
16. odulator allocation is checked by determining that the correct sensor modulator has been paired by way of listening or feeling The functional test is aborted by press e ing any button If wheels C or E are being turned any DIFF valve which may have been installed is actuated during the pulse program If any of the wheels B D or F are rotated the pulse program 1 shall be followed If any of the wheels A C or E are rotated the pulse program 2 shall be followed This cycle can be repeated if required by rotat ing the wheel Pictorial representation of the pulse programs is shown in following di agrams Wheel speed 4 km h 7 Pressure decrease Modulator actuation Pressure hold Pulse Pulse program 1 Commissioning cycle of wheels B D amp F if 6S6M with control pressure Wheel speed decrease 4 km h a Modulator actuation Pressure Pressure hold l Pulse Pulse program 2 Commissioning cycle of wheels A C amp E if 6S6M with control pressure WABCO 5 Compact Tester Il Functional testing 7 1 4 Assignment of pulse program System Actuated configuration Rotated wheel modulator valve Pulse program no 4S2M A A 2 5x briefly 1M front B A 1 once prolonged 1M rear C C 2 D C 1 4S3M A A 2 1M front B A 1 C Cc 2 D
17. rChrys e Diagnostic cable EBS Euro Diagnostic cable trailer Diagnostic connection for Trailer ABS VCS e Diagnostic connection for Trailer EBS WABCO za Compact Tester Il Notes 2a WABCO Notes Compact Tester Il WABCO Compact Tester Il Notes 26 WABCO
18. se key 2 CLEAR SyS System check Hold key 2 seconds to start system check 1 CLEAR total km display SYSTEM 2 Any key 149 Read as 3 Any key 322 149 322 km ERROR CLEAR OFF or 060 k p h Speed threshold Display of speed threshold in k p h only VCS I ERROR SYSTEM rapid blinking Reset Service Inter vall 22 WABCO Appendix Compact Tester Il 11 Appendix List of WABCO Diagnostic cables adaptors ECU Type Part number Part number WABCO Adaptor WABCO Diagnostic cable ABS C 446 300 327 0 35 pole 446 300 319 0 54 pole ABS D E 446 300 404 0 ISO 9141 446 300 405 0 SAE J1587 446 300 408 0 Basic ISO 9141 446 300 407 0 Basic SAE J1587 Hydraulic ABS 446 300 327 0 35 pole 894 604 303 2 ISO 9141 Vario C 446 300 318 0 446 300 329 2 Trailer VCS 449 612 020 0 with connecting box length 1 m 446 300 401 0 directly to the test device length 6 m 446 300 329 2 Trailer VCS Il 449 615 010 0 with connecting box length 1 m 446 300 455 0 directly to the test device length 6 m WABCO recommends to you the diag e e nostic accessory case Part number 446 301 020 0 In this case all important adaptors for diag nosis on WABCO s electronical systems are clearly arranged e Diagnostic Interface Set e 35 pin adaptor for ABS EPS und ECAS ler Adaptor ABS D e Central diagnostic plug Daimle
19. ula pro ration tor valve gram No 2S1M Z1 H1 1 H1 H1 2 2S2M H2 H2 2 H1 H1 2 4S2M H2 H2 2 H1 H1 2 Z2 H2 1 Z1 H1 1 4S3M H2 H2 2 H1 H1 2 Z2 1 Z1 2 7 3 Hydraulic ABS Activating the functional testing Press SYSTEM button Press CLEAR button for more than 2 seconds After 2 seconds SYS appears on the dis play 7 3 1 Allocation testing If the tester is directly fed from the bat e tery whenever the ECU is switched off and then on again the tester also needs to be switched off and on again When the system enters allocation test mode all inlet valves will be continuously closed Depress the brake pedal constantly If one wheel is turned by hand faster than 4 km h the system responds with a short pressure increase phase at the related wheel Therefore the turned wheel stops and can be turned freely again after the pressure phase has finished This test can be per formed at all four wheels It is especially important with driven axles that only one wheel spins If nec essary other wheels must be blocked The display always shows the wheel indica tor A D and the actual speed of the turned wheel in km h If the ECU detects a speed on more than one wheel the display shows and the allocation test cannot be continued be cause the compact tester does not know which modulator valve to address 18 WABCO Functional testing Compact Tester Il 4k p
20. utomatically recognised the er ror memory is cleared and then the recognised system is displayed 8 3 Hydraulic ABS The Hydraulic ABS system can be made to once again recognise the retarderconnec ted to it The new status is stored in the pa rameters of the ECU In Hydraulic ABS when the system recon figuration initialisation is activated the dis play will be cleared and after a short period the type of ECU identified shall appear in the display Now the ignition should be switched OFF and ON again If the display shows after the but ton is pressed it indicates that the sys tem cannot be reconfigured o gt During functional testing if any other button is pressed for more than 0 5 sec the tester displays the type of ECU de tected 20 WABCO Special functions only for trailer ABS Compact Tester Il 9 Special functions only for trailer ABS 9 1 Odometer reading With the Compact Tester the total number of km can be read out The necessary tyre parameters tyre diameter polewheel tooth no are already set in the memory of the ECU The number of km can be displayed with the following button combination Simultaneously press CLEAR and SYSTEM button The starting signal for the km display is 3 horizontal lines The km covered is displayed to 6 places The digits are dis played 3 at a time starting with the 3 high est figures Press any button to
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