WABCO ONGUARD MAINTENANCE MANUAL Pdf Download (2024)

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  • Contents
  • Table of Contents
  • Troubleshooting
  • Bookmarks

Table of Contents

  • Table of Contents

  • General Information

  • Symbols Used in this Document

  • How to Obtain Additional Maintenance, Service and Product Information

  • How to Obtain Parts and Kits

  • WABCO TOOLBOX PLUS™ Software

  • WABCO Academy

  • WABCO Online Product Catalog

  • Your Direct Contact to ZF CVS

  • Safety Information

  • Provisions for a Safe Work Environment

  • The Onguard Family*: Warnings, Cautions and Operating Guidelines

  • Driver-Related Information

  • Environment-Related Information

  • System-Function Information

  • System Functions and Miscellaneous Information

  • System Malfunction Information

  • Introduction

  • Overview

  • How the Onguard Family Works

  • Operating Modes

  • System Limitations

  • System Components

  • Diagnostics, Troubleshooting and Testing

  • General Information

  • Troubleshooting Guide

  • TOOLBOX PLUS™ Software

  • Onguard and Onguardactive Radar Diagnostic Trouble Code Table

  • Radar Inspection and Preventive Maintenance

  • Radar System Troubleshooting

  • Electrical System Troubleshooting

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OnGuard

, OnGuardALERT

®

TM

AND OnGuardACTIVE

®

MAINTENANCE MANUAL

MM1306

Table ofContents

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WABCO ONGUARD MAINTENANCE MANUAL Pdf Download (1)

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Summary of Contents for WABCO OnGuard

  • Page 1 OnGuard , OnGuardALERT ® AND OnGuardACTIVE ® MAINTENANCE MANUAL MM1306...

  • Page 3: Table Of Contents

    Your Direct Contact to ZF CVS .......................... 7 Safety Information............................... 8 Provisions for a safe work environment ......................8 The OnGuard Family*: Warnings, Cautions and Operating Guidelines..............9 Driver-Related Information ..........................9 Environment-Related Information ........................10 System-Function Information ........................... 11 System Functions and Miscellaneous Information ...................12...
  • Page 4 Table of Contents Component Replacement Procedures........................50 Hazard Alert Messages ............................50 Radar Sensor Replacement ..........................50 Display Replacement ............................52 This publication is not subject to any update service. Information contained in this publication was in eff ect at the time the publication was approved for printing and is Edition 1 subject to change without notice or liability.

  • Page 5: General Information

    Important information, notices and/or tips Reference to information on the Internet Descriptive text – Action step Action step 1 (in ascending order) Action step 2 (in ascending order)  Result of an action • Listing Indicating the use of a tool / WABCO tool...

  • Page 6: How To Obtain Additional Maintenance, Service And Product Information

    Refer to the Society of Automotive Engineers (SAE) website to fi nd all current SAE documents and standards applicable to WABCO products (such as SAE J447 and SAE J908 at www.sae.org). Refer to the National Highway Traffi c Safety Administration (NHTSA) website to fi nd all current documents referenced in the manual at www.nhtsa.gov.

  • Page 7: Your Direct Contact To Zf Cvs

    General Information Your Direct Contact to ZF CVS ZF CV Systems North America LLC 1220 Pacifi c Drive Auburn Hills, MI 48326 Customer Care Center: (855) 228-3203 www.zf.com/cv wabconacustomercare@zf.com...

  • Page 8: Safety Information

    Safety Information Safety Information Provisions for a safe work environment  Only experienced, trained and qualifi ed automotive technicians may carry out work on the vehicle.  Read this publication carefully.  Follow all warnings, notices and instructions to avoid personal injury and property damage. ...

  • Page 9: The Onguard Family*: Warnings, Cautions And Operating Guidelines

    Never wait for an OnGuard CMS or FCW warning before applying the brakes. Failure to do so can result in serious personal injury or death, and/or severe property damage.

  • Page 10: Environment-Related Information

    Curvy roads can make it diffi cult for the OnGuard CMS or FCW radar to track vehicles in its  path. While in a sharp turn or if the preceding vehicle is in a sharp turn, OnGuard may no longer track a vehicle in front of you. Your vehicle could then unexpectedly accelerate to the previously selected speed.

  • Page 11: System-Function Information

    Do not allow the installation of bumpers, cattle guards or other such items in front of the radar area. If the radar is blocked, the OnGuard CMS or FCW will have limited or no functionality, which can lead to an accident. Serious personal injury or death, and/or severe property damage can result.

  • Page 12: System Functions And Miscellaneous Information

    Do not allow the installation of bumpers, shields, defl ectors, guards or other such items in front of the radar area. Do not allow items to block the radar or the OnGuard CMS or FCW will have limited or no functionality, which can lead to an accident. Serious personal injury or...

  • Page 13: System Malfunction Information

    WARNING If the OnGuard CMS or FCW is not correctly tracking vehicles that are in your lane or is tracking vehicles that are not in your lane, this may be due to radar operational issues. Typically, these are radar operational issues that can result from the following problems: ...
  • Page 14 The OnGuard Family*: Warnings, Cautions and Operating Guidelines WARNING If the OnGuard CMS or FCW are not correctly tracking vehicles that are in your lane or is tracking vehicles that are not in your lane, the radar may not be aligned correctly. If this occurs, immediately have the OnGuard CMS or FCW radar inspected and corrected as needed.

  • Page 15: Introduction

    Family ® OnGuard and OnGuardACTIVE are Collision Mitigation Systems (jointly referred herein as “CMS”) that off er Following Distance Alert (FDA) and Adaptive Cruise Control (ACC) with active braking, if equipped. These systems are currently available for pneumatically braked vehicles.
  • Page 16 The active braking application is intended to assist the driver to avoid or reduce the severity of a collision. The driver must take the appropriate corrective action in response to the collision warning. OnGuard Family warnings will not be issued below a vehicle speed of 15 mph or 9 mph depending on software version.

  • Page 17: Operating Modes

    If equipped, the vehicle operates as usual when the ACC speed is not set. The system will still emit audible and visual warnings when it detects a possible rear-end collision. The OnGuard CMS is active above 9 or 15 mph, depending on software version, and will request brake application if deemed necessary. The OnGuardACTIVE or OnGuardALERT are active from 9 or 15mph and up to-77 mph, depending on software version, and will request brake application if deemed necessary.
  • Page 18 ACC and approaches a vehicle too closely. The OnGuard Following-Distance Alert will not provide warnings when the vehicle speed is below 15 mph. The OnGuardACTIVE Following-Distance Alert will not provide warnings when the vehicle speed is below 15 mph or over 77 mph.

  • Page 19: System Limitations

    The OnGuard Family will not be active when the vehicle’s speed is below 15 mph or 9 mph or over 77 mph, depending on software version. If the OnGuard Family detects a stationary object (such as a disabled car) it will provide an audible alert, followed by a haptic warning and then a brake application to reduce the vehicle’s speed.

  • Page 20: System Components

    Radar Sensor The radar sensor is used to detect vehicles and obstacles for the OnGuard Family. It is mounted in the front of the vehicle near the center of the bumper and recessed in the bumper in most applications. The sensor has an electrical connector that provides power, ground and communication to the SAE J1939 network which is required for correct operation.
  • Page 21 Introduction 4010554a 4.5.4 SAE J1939 Network The SAE J1939 Serial Control and Communications Heavy-Duty Vehicle Network allows various electronic controllers on the vehicle to interact effi ciently and in coordination with each other. The interactions between controllers include sharing sensor data, calculated information, subsystem operating state and confi...

  • Page 22: Diagnostics, Troubleshooting And Testing

    Diagnostics, Troubleshooting and Testing Diagnostics, Troubleshooting and Testing General Information 5.1.1 Radar Sensor and Display Software Levels Many diagnostic and troubleshooting procedures will require knowledge of the software version of the radar sensor and display. The radar sensor software version is determined using TOOLBOX PLUS™ Software 12.2 or higher.
  • Page 23 Diagnostics, Troubleshooting and Testing Multiple DTCs may be active simultaneously. If a DTC is shown on the display, use the UP and DOWN keys on the display to scroll through each code. Record each DTC for future reference. DISPLAY UP/DOWN KEYS 4010554b DTCs may become active during service procedures on other electrical system components (e.g., engine, transmission, ABS, etc.).

  • Page 24: Troubleshooting Guide

    The system is sensitive to faults in other vehicle systems and will set a DTC as a reaction. As such, it is recommended that all faults in any other vehicle ECUs are diagnosed and repaired prior to diagnosing OnGuard and OnGuardACTIVE DTCs.
  • Page 25 Diagnostics, Troubleshooting and Testing Table A: System Error Screen Repair Action Display Message Repair Action Troubleshooting Section System Error OnGuard DISABLED SERVICE VEHICLE Count 517503 4010632a Remove snow, mud, etc. from fascia or Blocked between radar and fascia System Error...
  • Page 26 OFF for at least two minutes, turn the ignition back ON, start the engine and run at idle speed for one minute. OnGuard and OnGuardACTIVE DTCs caused by other systems that have been repaired should be cleared. If active DTCs remain, continue troubleshooting.

  • Page 27: Toolbox Plus™ Software

    Diagnostics, Troubleshooting and Testing If the vehicle’s standard cruise control is working and the OnGuard or OnGuardACTIVE ACC is not working, consult your dealer or engine supplier. This can occur if the engine controller has been re-programmed or the engine parameter that activates ACC has been turned off . Consult with your dealer or engine supplier for engine software and parameter adjustments.
  • Page 28 Diagnostics, Troubleshooting and Testing This will display the radar sensor part number and radar software version, as well as other important information. “ 4012507a Retrieving DTCs: To display radar sensor DTCs, select the “Display” option from the menu. From the pull-down menu, select “Diagnostic Trouble Codes”. A description of the DTC, the number of times the DTC occurred, the suspect parameter number (SPN) and the failure mode identifi...
  • Page 29 Diagnostics, Troubleshooting and Testing When you click on one of the DTCs in the window, the “Extended DTC Information” will populate below. The following data is shown for the First and Last Occurrence of the DTC:  Vehicle speed  Odometer reading ...
  • Page 30 Diagnostics, Troubleshooting and Testing Displaying Parameter Decoder Information: To display Parameter Decoder information, select the “Display” option from the menu. From the pull-down menu, select “Parameter Decoder”. “ 4012510a Critical event information from the radar will be displayed on screen. 4012511a...

  • Page 31: Onguard And Onguardactive Radar Diagnostic Trouble Code Table

    The following table provides repair instructions and the corresponding Troubleshooting Sections in this manual for SPN/FMI DTCs that are readable using TOOLBOX PLUS™ Software. If the display shows a code not listed in the table, contact the WABCO Customer Care Center at 855-228-3203 for assistance. Table B: Diagnostic Trouble Code Table...
  • Page 32 ERC1 message from and parameters. engine retarder Incorrect J1939 Brake Pedal  Use WABCO TOOLBOX PLUS™ Software PC Diagnostics to Position data received in EBC1 test the ABS Brake Pedal Pressure Sensor. message from ABS  Verify the correct radar part number is installed on the vehicle.
  • Page 33 Diagnostics, Troubleshooting and Testing Cause/Description Action/Repair Instructions Incorrect J1939 Transmission  Verify the correct radar part number is installed on the vehicle. Driveline Engaged data Cycle the ignition to clear DTCs after transmission servicing. received in ETC1 message from  Verify transmission ECU is functional and has correct software transmission and parameters.
  • Page 34 Cycle ignition to clear DTCs after ABS servicing. 1121 Incorrect J1939 EBS Brake  Use WABCO TOOLBOX PLUS™ Software PC Diagnostics to Switch data received in EBC1 test the ABS Brake Pedal Pressure Sensor. message from ABS Verify the correct radar part number is installed on the vehicle.
  • Page 35 Diagnostics, Troubleshooting and Testing Cause/Description Action/Repair Instructions 1590 Incorrect J1939 ACC Mode data  Check for multiple active DTCs in the radar. in ACC1 message received from  If there is more than one active code, repair all other codes, engine.
  • Page 36 Bootloader error usually caused  Run the software update again. when there is an issue during a  Is usually seen in WABCO TOOLBOX PLUS™ Software PC radar software update. Diagnostics with SPN 197120 FMI 31 on the display. 516096 J1939 Cruise Control/Vehicle Verify the correct radar part number is installed on the vehicle.
  • Page 37  parameter enabled. 516499 Malfunction in the Anti-Lock  Use WABCO TOOLBOX PLUS™ PC Diagnostics to test the Braking System caused the Anti-Lock Braking System. system to be temporarily  Verify the correct radar part number is installed on the vehicle.
  • Page 38  Road conditions, icy spots or loose gravel.  Check vehicle speed signal source, possible tone ring or sensor issues. 516998 WABCO Production Data could  Cycle the ignition to clear DTCs. not be read from EEPROM during startup 517503 Radar Sensor blocked by ice, ...
  • Page 39 Diagnostics, Troubleshooting and Testing Cause/Description Action/Repair Instructions 517525 Unknown error during alignment.  Perform Service Alignment. Software did not respond on time 517527 Alignment monitoring failed in  Check for damage to radar sensor, bracket and fascia. azimuth  Perform Service Alignment. - Radar sensor is looking too far to the right.
  • Page 40 Diagnostics, Troubleshooting and Testing Cause/Description Action/Repair Instructions 517558 Electrical supply voltage too low  Verify that the voltage at the radar sensor connector is greater than 6 VDC with a 1 amp load (e.g. tail light or marker light bulb). ...

  • Page 41: Radar Inspection And Preventive Maintenance

    Diagnostics, Troubleshooting and Testing Cause/Description Action/Repair Instructions 517657 Motor Azimuth: bemf speed is  Verify no visible/physical damage to radar. out of range for more than 5  Check power ground and load test at the radar harness minutes connector. ...

  • Page 42: Radar System Troubleshooting

    DTCs. Ensure all service alignments as prescribed in the Required Maintenance section have been completed. If driveability concerns persist with no DTCs or assignable cause, contact WABCO Customer Care Center at 855-228-3203 for further assistance. Before calling the WABCO Customer Care Center, please download the system DTC report and the parameter (par) fi...
  • Page 43 The radar sensor can become blocked by snow, ice, dirt or other foreign matter. If this occurs, the radar sensor will have limited or no functionality. If a “Blocked Radar” error occurs, the next two screens will be presented on the display: System Error OnGuard DISABLED SERVICE VEHICLE Count 517503...
  • Page 44 Diagnostics, Troubleshooting and Testing If the radar sensor needs to be aligned, the radar sensor mounting system has become damaged or has loosened, or new radar sensor software has been installed, a Radar Sensor Service Alignment will need to be performed. If a Radar Sensor Service Alignment is required, the Radar Not Aligned Screen may be displayed as shown below.

  • Page 45: Electrical System Troubleshooting

    (or in some way serviced) and then repeat the Radar Sensor Service Alignment procedure. Contact the WABCO Customer Care Center at 855-228-3203 if the radar service alignment fault cannot be resolved. Before calling the WABCO Customer Care Center, please download the system DTC report and the parameter (par) fi...
  • Page 46 Diagnostics, Troubleshooting and Testing 5.7.1 Harness Routing and Associated Wire Fatigue or Abrasion Wire fatigue will occur at any harness location where suffi cient harness motion allows bending of the wiring. When this occurs, individual harness wires become weakened and can break. The harness can have intermittent or permanent open circuit failures causing the system to malfunction.
  • Page 47 Diagnostics, Troubleshooting and Testing 5.7.1.2 Display Connector Pinouts The display harness is connected to the display mounted in the dashboard. Remove the dash to access the back of the display and harness connector. 4011862a Table D: Display Harness Connector Pins Circuit No Connection No Connection...
  • Page 48 Diagnostics, Troubleshooting and Testing Measurements should read as follows: Location Measurement Across J1939 High and Low Approximately 60 ohms J1939 Low Voltage 0.1V-2.4V J1939 High Voltage 2.5-5.0V J1939 High or J1939 Low to No continuity Ground or Power 5.7.2 Component Message Fault Troubleshooting Refer to the Diagnostic Trouble Code Table for further information.
  • Page 49 Diagnostics, Troubleshooting and Testing After ECU servicing has been completed, cycle the ignition OFF for one minute and then back ON for one minute with the engine idling to clear the system DTC. Verify that the DTC has been cleared. 5.7.3 Cruise Control System Troubleshooting Refer to the Diagnostic Trouble Code Table for further information.
  • Page 50 Component Replacement Procedures Component Replacement Procedures Hazard Alert Messages Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. WARNING To prevent serious eye injury, always wear safety eye protection when you perform vehicle maintenance or service.
  • Page 51 Component Replacement Procedures a. The center point of the bracket must be mounted within 18″ (450 mm) of the tractor center point. b. The face of the bracket must be mounted perpendicular (90 degrees ±3 degrees) to the level road surface.
  • Page 52 Component Replacement Procedures Reconnect the sensor connector by pushing on the connector until it snaps into the radar sensor. Slide the rubber boot over the connector until the connector is completely covered by the boot. 10. Replace the fascia using the fasteners and washers that were removed or recommended hardware per OEM requirements.
  • Page 54 fl eets operate more safely and sustainably. CVS unites ZF’s former Commercial Vehicle Technology and Commercial Vehicle Control Systems divisions, the latter being formed following ZF’s acquisition of WABCO in Spring 2020. For more information, visit: www.zf.com/cv...

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WABCO ONGUARD MAINTENANCE MANUAL Pdf Download (2024)
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