Kal-Equip OBD II System Tester 9615 User manual

1
OBD II System
Tester '$#
Vehicle Service Information . . 2
Safety Precautions . . . . . . . . . . 3
Section 1: Welcome to the OBD II
System Tester . . . . . .
1-1 Overview . . . . . . . . . . . . . . . . . . . . . 4
1-2 The OBD II System Tester . . . . . . . . 4
1-3 Diagnostic Connector and Location . 4
1-4 O erating the OBD II System Tester . 5
Powering-Up . . . . . . . . . . . . . . . 5
Keypad . . . . . . . . . . . . . . . . . . . 5
Display . . . . . . . . . . . . . . . . . . . . 6
Lists, Menus and Questions . . . . . 6
Other Fun tions & Keys . . . . . . . . 7
1-5 OBD II System Tester Setu . . . . . . 7
Section 2: Diagnosing with the
Tester . . . . . . . . . . . . . 8
2-1 Preliminary Checks . . . . . . . . . . . . . 8
2-2 OBD II Functions . . . . . . . . . . . . . . . 8
Read Codes . . . . . . . . . . . . . . . 9
Pending Codes (or Continuous
Test Codes) . . . . . . . . . . . . . 10
Erase Codes . . . . . . . . . . . . . . 11
View Data . . . . . . . . . . . . . . . . . 12
View Freeze Data . . . . . . . . . . . 12
Re ord Data . . . . . . . . . . . . . . . 13
Playba k Data . . . . . . . . . . . . . 14
O2 Monitor Test . . . . . . . . . . . . . 16
Non-Continuous Tests . . . . . . . 17
On-Board Systems . . . . . . . . . . 18
I/M Readiness . . . . . . . . . . . . . 18
Table of Contents
Section 3: Diagnostic Trouble Code
Lookup . . . . . . . . . . . 20
Section : On-Line Help and
Troubleshooting Tips 22
4-1 How to Use On-Line Hel . . . . . . . 22
4-2 Tool Problems . . . . . . . . . . . . . . . 22
4-3 Vehicle Problems . . . . . . . . . . . . . 23
4-4 OBD II System Tester Self-Tests . . 23
Display Test . . . . . . . . . . . . . . . 24
Keyboard Test . . . . . . . . . . . . . 24
Appendix A: Vehicle Computer
Basics . . . . . . . . . 25
Appendix B: Data Parameter List
& Definitions . . . . 31
Appendix C: Glossary of Terms 36

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Vehicle Service Information
The following is a list of ublishers who have manuals containing
electronic engine control diagnostic information. Some manuals may
be available at auto arts stores or your local ublic library. For others,
you need to write for availability and ricing, s ecifying the make,
model and year of your vehicle.
Vehicle Service Manuals
Chilton Book Company
Chilton Way
Radnor, PA 19089
Haynes Publications
861 Lawrence Drive
Newbury Park, CA 91320
Cordura Publications
Mitchell Manuals, Inc.
Post Office Box 26260
San Diego, CA 92126
Motors Auto Repair Manual
Hearst Com any
250 W. 55th Street
New York, NY 10019
Suitable manuals have titles
such as:
Electronic Engine Controls
Fuel Injection and Feedback
Carburetors
Fuel Injection and Electronic
Engine Controls
Emissions Control Manual
. . . or similar titles
Vehi le Servi e Manuals from General
Motors Corporation:
Buick, Cadillac, Chevrolet, GEO, GMC,
Oldsmobile, & Pontiac
Helm Incor orated
Post Office Box 07130
Detroit, MI 48207
Saturn
Adistra Cor oration
c/o Saturn Publications
101 Union St.
Post Office Box 1000
Plymouth, MI 48170
Vehi le Servi e Manuals from Ford
Motor Company:
Ford, Lincoln, & Mercury
Ford Publication Department
Helm Incor orated
Post Office Box 07150
Detroit, MI 48207
Vehi le Servi e Manuals from Chrysler
Corporation:
Chrysler, Plymouth, & Dodge
Chrysler Motors Service Training
26001 Lawrence Avenue
Center Line, MI 48015

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Safety Precautions
General Safety Guidelines to Follow When Working on Vehicles
To prevent accidents that could result in serious injury and/or damage
to your vehicle or test equipment, carefully follow these safety rules
and test procedures at all times when working on vehicles:
 Always wear a roved eye rotection.
 Always o erate the vehicle in a well-ventilated area. Do not inhale exhaust gases
 they are very oisonous!
 Always kee yourself, tools and test equi ment away from all moving or hot engine
arts.
 Always make sure the vehicle is in Park (Automatic transmission) or Neutral
(manual transmission) and that the parking brake is firmly set. Block the drive
wheels.
 Never lay tools on vehicle battery. You may short the terminals together causing
harm to yourself, the tools or the battery.
 Never use OBD II System Tester if its internal circuitry has been ex osed to any
liquids.
 Never smoke or have o en flames near vehicle. Va ors from gasoline and
charging battery are highly flammable and ex losive.
 Never leave vehicle unattended while running tests.
 Always kee a fire extinguisher suitable for gasoline/electrical/chemical fires handy.
 Always use extreme caution when working around the ignition coil, distributor ca ,
ignition wires, and s ark lugs. These com onents contain High Voltage when the
engine is running.
 When erforming a road test, Never o erate the OBD II System Tester alone while
driving the vehicle. Always have one erson drive the vehicle while an assistant
o erates the tester.
 Always turn ignition key OFF when connecting or disconnecting electrical com o-
nents, unless otherwise instructed.
 Always follow vehicle manufacturers warnings, cautions and service rocedures.
WARNING!
Some vehicles are equi ed with safety air bags. You must follow
vehicle service manual cautions when working around the air bag
com onents or wiring. If the cautions are not followed, the air bag
may o en u unex ectedly, resulting in ersonal injury. Note that the
air bag can still o en u several minutes after the ignition key is off
(or even if the vehicle battery is disconnected) because of a s ecial
energy reserve module.

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Section 1: Welcome to the OBD II System Tester
1-1 Overview
OBD II (On-Board Diagnostic, second generation) systems are designed to meet or
exceed a set of standards and regulations designed to im rove air quality. The
Environmental Protection Agency (EPA), in conjunction with California Air Research
Board (CARB), issued these standards and regulations through the Clean Air Act
of1990. OBD II systems are required to monitor the erformance of emission related
systems and their com onents. The ability to detect hard and intermittent faults are
further requirements of an OBD II com liant system. The Society of Automotive
Engineers (SAE) defined several standards for OBD II systems. These standards
include criteria for the diagnostic link connector, communication, Diagnostics trouble
codes (DTCs), descri tor names, and other re air information.
This OBD II System Tester will work on OBD II com liant cars and light trucks. If you
use a vehicle service manual along with the tester, you will be able to diagnose and
re air many automotive-related roblems. Before roceeding, make sure you have
read and fully understand the material in this Manual.
1-2 The OBD II System Tester
KAL Equi s OBD II System Tester was develo ed by ex erts in the automotive
service industry to hel diagnose todays vehicles and assist in troubleshooting
rocedures. When a roblem occurs in the vehicle, its com uter will store a record of
the event and take corrective action to adjust the circuit at fault. The OBD II System
Tester will allow you to monitor these vehicle events and read DTCs from the
com uters memory to in oint roblem areas. The OBD II System Tester will
inter ret the com uter signals and rovide you with a real time readout of vehicle
data. In addition, the Code Looku feature allows you to reference code descri tions
without having to age through an instruction manual. A detailed descri tion of the
functions are rovided in Section 2: Diagnosing with the Tester.
1-3 Diagnostic Connector and Location
The OBD II System Tester communicates with
the vehicle via a diagnostic link connector (DLC).
OBD II S ecification J1962 defines the DLCs
hysical and electrical ro erties. The DLC is
known as the J1962 connector. The S ecification
J1962 was introduced by the SAE (Society of
Automotive Engineers) to make all com liant
vehicles use the same DLC with the generic link
information available on the same ins, no
matter what make of vehicle. In addition to the
connector s ecification, there is a guideline on
where to locate the DLC or J1962 connector, which
states it should be located under the dashboard on the
drivers side of the vehicle. Even with this guideline, not
all OBD II DLCs are located under the dash on the
drivers side. If the DLC is not located in the s ecified area, then a note will be laced
where the DLC should be informing the user of the location. If you cannot find the
DLC, see the vehicle service documentation for its location.

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1- Operating the OBD II System Tester
POWERING-UP
Connect the OBD II System Tester to the DLC. This
connection will rovide ower for the OBD II System
Tester. The DLC contains ower even when the ignition
is turned off. Connection to the battery is not necessary.
When the OBD II System Tester owers u , a series of screens are dis layed. The
screens start with a Welcome screen and end with a Hel for Instructions screen.
Before the Hel for Instructions screen, the tool erforms a self-test and then dis lays
the software version SW ID: xxxx. Refer to this software version if you need to contact
Actrons technical su ort line with a roblem.
The Hel for Instructions screen allows the
user to review the key ad definitions. Press the
? key for instructions or the ENTER key to
continue and dis lay the MAIN MENU.
NOTE: Your OBD II System Tester requires a minimum of 8 volts to ower u . If the
ower-u ersists, review Section -2: Tool Problems to find the cause.
KEYPAD
The OBD II System Tester software was designed for ease in o eration and naviga-
tion through the menus. Sim ly follow the instructions that match the key ad symbols
and you will be using your OBD II System Tester like an ex ert in no time.
CAUTION! DO NOT use solvents like ALCOHOL! This could remove the key ad aint! Use
a mild detergent or water to clean. Let dry thoroughly before o erating tool.
Keyboard Functions
The OBD II System Tester uses 6 keys to navigate through the user-friendly software:
ENTER - Used to select functions and res ond
to requests.
? - Used to request hel when the (|) symbol is
dis layed on the lower right hand corner of
the dis lay.
BACK - Used to move one screen back in OBD II
System Tester flow.
ARROWS
UP & DOWN - are always used to move the solid
cursor (`) in the direction of the arrow or
scroll the data list in the direction you want to
move the list.
LEFT/RIGHT - The left/right arrow key is used to answer Yes or No questions.
Tester Keypad
MAIN MENU
`1)OBDII Functions
2)Tool Setup [
3)Tool Self Test |
Welco e To The
OBDII SYSTEM TESTER
by
KAL Equip
Press *|*For
Instructions
Press ENTER To Cont

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DISPLAY
The OBD II System Tester has a 4 line x 20 character liquid crystal dis lay (LCD) for
easy viewing. This hel s make the OBD II System Tester more user friendly by
offering a large viewing area to dis lay most Hel and Instructional messages. This
uts more information on the dis lay to reduce reference to rinted materials. The
dis lay will su ort a number of hel ful symbols that will rom t you through test
routines. These symbols are shown and defined below:
|Question Mark in lower right corner means there is help available for this screen
or current selectable item.
`Pointer (cursor) is used to indicate current selectable choice.
[Down Arrow indicates there is additional
information on the next screen.
]U Arrow indicates there is additional
information on previous screen.
LISTS, MENUS AND QUESTIONS
The OBD II System Tester is designed to be as intuitive as ossible. That is, its
functions and controls should be easy to understand and use the first time you try it.
All menu and screen lists o erate the same way. By using the UP and DOWN arrow
keys, you can move the cursor to a selection of your choice. The ENTER key selects
that function or item. The screen exam le above illustrates a few selections available
on the OBD II Function Menu.
Notice, in the screen below on the left, how the cursor (`) is ointing at 1)Read
Codes. If you wish to read the vehicles DTCs, ress the ENTER key to select that
function. To make a different choice, such as View Data, use the DOWN arrow key to
move the cursor down to ) View Data and ress the ENTER key to select the View
Data function.
Sometimes, a list will be longer than three or four items, and will not fit on a single
screen. In these cases, the down arrow symbol ([) is visible in the last column of the
dis lay, indicating that there are more choices on the next screen, as shown below
on the left. To go to the next choice, use the DOWN arrow key to move the cursor
down the list. Kee going even after you have reached the bottom of the screen. The
dis lay will scroll to the list, shown above on the right:
You should see that there are now arrows in the last column ointing u and ointing
down. This indicates that you can use the UP arrow key to move the cursor to the
revious screen or the DOWN arrow key to move the cursor to the next screen.
Once the bottom of the list is reached, you will notice that there is now only an UP
arrow (]) in the last column. This indicates that you have reached the end of this list,
and that all other choices are on revious screens. You can return to those screens
by ressing the UP arrow key. These u and down arrow characters on the screen
are used throughout the OBD II System Tester. The UP and Down arrow keys work
exactly the same way, even if you are just scrolling through text such as the On-Line
Hel screen.
2)Pending Codes
`3)Erase Codes ]
4)View Data [
5)View Freeze Data |
OBD II FUNCTION MENU
`1)Read Codes
2)Pending Codes [
3)Erase Codes |
1)Read Codes
2)Pending Codes ]
3)Erase Codes [
`4)View Data |

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Occasionally, you may be asked a question by
the OBD II System Tester. These will always be
YES or NO questions, and are answered in
almost the same way you make choices in a
Function Menu. In these screens, brackets <>
will automatically a ear next to the default res onse. If you wish to acce t the default
choice, sim ly ress the ENTER key. If you wish to change the answer, use the LEFT/
RIGHT arrow key to move the brackets to the other res onse and ress the ENTER key.
OTHER FUNCTIONS & KEYS
As you have reviewed moving through lists and functions in earlier sections, you
robably noticed another symbol on the screen. In the lower right-hand corner of some
screens, there is a |. This question mark indicates that On-Line Help is available for
that articular screen or item. To enter On-Line
Help, ress the ? key. The O erating Error
hel screen is shown at the right.
The text in On-Line Help screens are in
CAPITAL letters to remind you that you are
viewing On-Line Help screens and not screens associated with a function. Some On-
Line Hel messages are longer than one screen. If this is the case, the arrow
symbols (][) will a ear in the last column of the dis lay. A [ means more
information available on the next screen and a ] means more information available
on the revious screen. Use the UP and DOWN arrow keys to age u or down
through a series of On-Line Hel screens.
The On-Line Hel screen shown above has a [in the last column. To view the next
On-Line Hel screen, ress the DOWN arrow key.
Notice now that both arrow symbols (][) are
visible in the last column of the dis lay. This
indicates that you can either age u to a
revious On-Line Hel screen, or age down to
the next On-Line Hel screen by using the UP
and DOWN arrow keys. The revious On-Line Hel screen is always the one you just
viewed, just as with Function Menu.
1-5 OBD II System Tester Setup
Tool Setup is used to change the OBD II
System Testers default measurement units.
Select the Tool Setu o tion from the MAIN
MENU and ress the ENTER key.
The TOOL SETUP MENU a ears. Use the UP
and DOWN arrows to select English or Metric
measurement units and then ress the
ENTER key. Press ENTER again to acce t or
the BACK key to change.
NOTE: If you change the Measurement Units to a setting other than the default, then
it will revert back to the default settings the next time the OBD II System Tester
is used.
Operating Error
Check Connections!
Try Again?
<YES> NO |
THE TESTER CAN NOT
COMMUNICATE WITH
VEHICLE. CHECK THE [
FOLLOWING:
1.IGNITION KEY ON?
2.HOOKUP TO VEHICLE ]
TEST CONNECTOR OK? [
3.EMISSION LABEL
MAIN MENU
1)OBDII Functions
`2)Tool Setup [
3)Tool Self Test |
TOOL SETUP MENU
`1)Metric Units
2)English Units

8
Section 2: Diagnosing with the Tester
2-1 Preliminary Checks
Before using the OBD II System Tester on your vehicle, it is a good idea to erform a
com lete visual ins ection. You can find the cause of many driveability roblems by
just looking, thereby saving yourself a lot of time. Check the following items before
roceeding with OBD II System Tester testing:
oHas the vehicle been serviced recently? Sometimes things get reconnected in
the wrong lace, or not at all.
oDont take shortcuts. Ins ect hoses and wiring which may be difficult to see
because of location beneath air cleaner housings, alternators and similar
com onents.
oIns ect the air cleaner and ductwork for defects.
oCheck sensors and actuators for damage.
oIns ect all vacuum hoses for:
 Correct routing. Refer to vehicle service manual, or Vehicle Emission Control
Information (VECI) decal located in the engine com artment.
 Pinches and kinks.
 S lits, cuts or breaks.
oIns ect wiring for:
 Contact with shar edges (this ha ens frequently).
 Contact with hot surfaces, such as exhaust manifolds.
 Pinched, burned or chafed insulation.
 Pro er routing and connections.
oCheck electrical connectors for:
 Corrosion on ins.
 Bent or damaged ins.
 Contacts not ro erly seated in housing.
 Bad wire crim s to terminals.
NOTE: Problems with connectors are common in the engine control system. Ins ect
them carefully for corrosion, bent ins, ushed out ins, or over ex anded
ins. Some connectors use a s ecial grease on the contacts to revent
corrosion. Do not wi e off! Obtain extra grease, if needed, from your vehicle
dealer. It is a s ecial ty e for this ur ose.
2-2 OBD II Functions
During the functions described below, a communication link is established, allowing
the OBD II System Tester and the vehicles PCM to exchange information. The way in
which this information is exchanged is referred to as a data stream or data links. The
OBD II Function Menu shows all OBD II Generic functions. Not every vehicle will have
every function that is listed. If the function or art of function selected is not su orted
by the vehicle, a message screen informing you of this will be dis layed.

9
After you select OBDII Functions from the MAIN MENU the OBD II System Tester will
automatically link to the PCM and check the OBD II Readiness Monitors. OBD II
Readiness Monitors are strategies designed to test the o eration of emission related
systems or com onents. The PCM may erform s ecial tests on a system or
com onent to com lete its monitor. The vehicle may have to be o erated under
certain conditions to initiate a monitor. If the PCM loses ower or the codes are
erased the monitors will be cleared. The OBD II System Tester will dis lay the
condition of vehicles OBD II Monitors.
Below is an exam le of the screen when the OBD II readiness monitors are com-
leted. If any of the monitors are not com leted, the following screen on the right will
be dis layed.
Press the down arrow key to view a list of the monitors. The monitor list consists of
the OBD II monitor name followed by the monitors condition. A monitor that is not
su orted by the test vehicle will be followed
by n/a, (not a licable). A monitor that has
been com leted will be followed by OK. If a
monitor has not been com leted, it will be
follower by inc for incom lete.
Press the BACK key and the OBD II Function Menu will dis lay. Use the UP and
DOWN arrow keys to scroll through the choices.
IMPORTANT: If you choose a test that your vehicle does not su ort, you will get a
message telling you that the test is not a licable.
Read Codes
The Read Codes function is used to retrieve Diagnostic Trouble Codes (DTCs) from
the vehicles on-board com uter. Diagnostic Trouble Codes are set when the PCM
recognizes a condition outside reset ranges. A Malfunction Indicator Lam (MIL) that
is on indicates that a DTC has been recorded. Because DTCs indicate a circuit or
system failure not com onent failures they are very useful in diagnosing vehicle
concerns.
NOTE: Changing arts without diagnosing the circuit or system may result in good
com onents being unnecessarily re laced.
Select Read Codes from the OBD II Function
Menu and ress the ENTER key. The PCM will
check its memory and re ort trouble condi-
tions that were stored.
NOTE: If you get an O erating Error message, make sure the DLC ada ter cable is
ro erly attached to the vehicle connector. If the roblem remains, refer to
Section : On-Line Help and Trouble-Shooting Tips.
On-Board Readiness
Tests are Co plete
Press A Key to Cont
Not All Supported
On-Board Readiness
Tests Are Co plete.
Use [ To View Tests
Misfire Monitor OK
Fuel Syste Mon inc
Co p Co ponent n/a[
Catalyst Mon OK
OBDII Function Menu
`1)Read Codes
2)Pending Codes [
3)Erase Codes |

10
When the tester has finished reading the DTCs, one of two ossible screens is
dis layed. If there are no DTCs stored in the vehicles on-board com uter, a
System Pass screen is dis layed. If there are DTCs stored in the vehicles on-
board com uter, then the OBD II System Tester dis lays the number of codes found.
If codes are retrieved, ress the DOWN arrow to view the DTC(s). Definitions for
Generic DTCs (SAE J2012) will be dis layed. Manufacturer s ecific DTCs will just
dis lay the code, no definition. Use an a ro riate service manual to obtain code
definitions. When more than one DTC is received, the DOWN arrow will be dis layed
on the right of the screen. The arrow indicates additional code information is avail-
able. Use the DOWN arrow key to view the codes stored in memory. The last code
screen will just have a ]symbol in the last column of the dis lay. This indicates that
this is the last screen and additional code information is found on revious screens.
Use the BACK key to return to the OBD II Function Menu.
Pending Codes (or Continuous Test Codes)
The ur ose of this function is to obtain test results for continuously monitored
emission-related owertrain com onents and systems. Certain tests are run
continuously as the vehicle is driven within ro er o erating conditions. Unlike some
trouble codes this function re orts the test results after a single drive cycle. The
Pending Codes function is identical to the Continuous Test function and is useful
after a vehicle re air or after clearing the PCMs diagnostic information. Test results
re orted by this function do not necessarily indicate a faulty com onent or system.
To view the test results, select Pending Codes or Continuous Test from the OBDII
Function Menu and ress the ENTER key.
If no Pending Codes exist, the OBD II System
Tester will dis lay a single message screen
indicating this condition.
P0101
MAF Or VAF
CKT Range/Perf [
P0102
MAF Or VAF ]
Circuit Low Input
Syste Pass:
No Faults Detected.
Press Any Key For
Function Menu
Codes Found: 2
Use [ To View Codes
Write Down Codes [
For Reference.
Syste Pass:
No Faults Detected.
Press Any Key For
Function Menu
OBDII FUNCTION MENU
1)Read Codes
`2)Pending Codes [
3)Erase Codes |
6)Record Data
7)Playback Data ]
8)O2 Monitor Test [
`9)Continuous Test |