WABCO ONGUARD Maintenance Manual
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WABCO ONGUARD Maintenance Manual

WABCO ONGUARD Maintenance Manual

Collision safety system
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ONGUARD™ COLLISION
SAFETY SYSTEM
MAINTENANCE MANUAL

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Summary of Contents for WABCO ONGUARD

  • Page 1 ONGUARD™ COLLISION SAFETY SYSTEM MAINTENANCE MANUAL...
  • Page 2 Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time.

  • Page 3: Table Of Contents

    Contents Asbestos and Non-Asbestos Fibers pg. i Section 1: Introduction Overview How OnGuard Works System Components Section 2: Diagnostics, Troubleshooting and Testing General Information Radar Sensor and Display Software Levels Fault Codes Troubleshooting Guide TOOLBOX Software Diagnostics Radar Software Version USO 1.XXXX Fault Code Table Radar Software Version USO 2.XXXX Fault Code Table...
  • Page 4 Employers and workers employed outside of the United States should consult the regulations that Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance. apply to them for further guidance. WABCO Maintenance Manual MM-0951 (Revised 08-18)

  • Page 5: Section 1: Introduction

    1 Introduction Overview How OnGuard Works 1 Introduction OnGuard is an Adaptive Cruise Control (ACC) and Collision Warning Adaptive Cruise Control System (CWS) and if equipped, a Collision Mitigation System (CMS). Adaptive Cruise Control (ACC) is an in-vehicle electronic system that...

  • Page 6: System Components

    OnGuard should not be relied on to track target vehicles when blocked by any foreign matter (dirt, snow, ice, stickers, etc.), otherwise a system fault will occur and the OnGuard system will not either or both vehicles (base and target) have entered and are operate.
  • Page 7 Several electrical harnesses are required for the OnGuard system. These include harnesses to connect the radar sensor to power and 4009028a ground, as well as the SAE J1939 systems and the OnGuard Figure 1.3 Display. The individual harnesses will be detailed throughout this maintenance manual.

  • Page 8: General Information

    Multiple fault codes may be present. If a fault code is shown on the reference during the procedures required in this manual and display, use the UP and DOWN keys on the OnGuard display to scroll for component replacement. through each fault code. Figure 2.3. Record each code for future reference.

  • Page 9: Troubleshooting Guide

    If the OnGuard display does not light up when the engine is on, The radar may not be aligned correctly. Refer to the Radar make sure that the display brightness is turned up sufficiently to Sensor Alignment procedure.

  • Page 10: Toolbox Software Diagnostics

    Consult with your dealer or engine supplier for engine software and parameter adjustments. 4008868a If the OnGuard display shows a red screen with a fault code, refer to Table A for Software Version USO 1.XXXX or Table B for Software Figure 2.7 Version USO 2.XXXX for a description.
  • Page 11 Displaying Radar Information: Retrieving Faults: To retrieve radar sensor information, select “Diagnostic Information” To display OnGuard radar sensor faults, select the “Display” from the OnGuard Radar Diagnostics home screen. Figure 2.9. option from the menu. From the pull-down menu, select “Diagnostic Trouble Codes”...
  • Page 12 Recording OnGuard J1939 Data: is not included in the “Diagnostic Trouble Codes” screen. Figure 2.14. To access OnGuard Radar J1939 Data, click on “J1939 Bus Data” from the OnGuard Radar Diagnostics home screen. Figure 2.9. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 13 Figure 2.17. Specific messages can also be viewed after saving the file by clicking on “Load Saved Data”, and then highlighting the desired message. Figure 2.18. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 14 The Application Parameters screen will then appear. Driveline Retarder, Transmission Type, Air Suspension Front Axle and Air Suspension Rear Axle can all be reset by clicking on “Reset Application Parameters.” Figure 2.20. 4008918a Figure 2.21 WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 15 Figure 2.22 Figure 2.23 4008920a Figure 2.23 If the radar software version is USO 2.0026 or higher, the parameters for “Air Suspension Front Axle” and “Air Suspension Rear Axle” are not available. Figure 2.24. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 16 USO 1.XXXX software only. Refer to the section Radar Sensor and Display Software Levels to determine the software level. If the display shows a fault code not listed in the table, contact WABCO North America Customer Care at 855-228-3203 for assistance.

  • Page 17: Radar Software Version Uso 1.Xxxx Fault Code Table

    Cycle the ignition to clear faults after engine servicing. 2A04/02 Cruise Control Invalid BRAKE_SWITCH Use the OnGuard “ACC FUNCTION” screen to Component Data Error signal CCVS message determine if brake switch is operational. Message Fault Verify engine ECU is functional and has correct...
  • Page 18 Verify correct fascia is installed correctly. 2A0A/02 Brake Control Data Invalid brake pedal position % Use OnGuard display “ACC FUNCTION” screen ABS System Error signal in EBC1 message to verify brake pedal position (BPP) sensor is Brake Pedal operational.
  • Page 19 Description Fault Description Repair Instructions Sub-Section 2A0C/02 Cruise Control Invalid clutch switch signal in Use OnGuard display “ACC FUNCTION” screen Component Data Error CCVS message to verify Clutch Switch is operational. Message Fault Verify correct radar sensor is installed in Message Data vehicle.
  • Page 20 16V. System Voltage If the voltage exceeds 16V, troubleshoot the Fault voltage regulator and alternator system. Also determine if a jump start or battery charging has occurred that could cause a vehicle overvoltage condition. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 21 Description Fault Description Repair Instructions Sub-Section 2A48/02 Brake Control Data Invalid EBS brake switch Use the OnGuard display “ACC FUNCTION” Component Error signal in EBC1 message screen to determine if the brake switch is Message Fault operating correctly. Message Data Verify ABS ECU is functional.
  • Page 22 Radar Multiple vehicle screen after several ignition cycles. Reset Fault Verify correct system operation. If the error occurs again after multiple ignition cycles, contact WABCO North America Customer Care at 855-228-3203 for further assistance. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 23 Verify ABS ECU is functional. Component Error signal in EBC2 message Message Fault Verify the correct ABS ECU part number is used on this vehicle. Message Data Error Cycle the ignition to clear faults after ABS servicing. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 24 ACC Control commands from ACC System Reprogram engine parameters if not correct. Programming Check for multiple faults using OnGuard Faults display. If multiple faults, this is a secondary fault caused by other faults. Correct other Component faults and cycle ignition to clear this fault.
  • Page 25 Fault Description Repair Instructions Sub-Section 2A8F/02 BPP Sensor Fault No BPP signal >0 for the last Use OnGuard display “ACC FUNCTION” screen ABS System 3 braking maneuvers to verify brake pedal position (BPP) sensor is Brake Pedal (< 1.5m/s2) without ACC operational.
  • Page 26 USO 2.XXXX software only. Refer to the section on Radar Sensor and Display Software Levels to determine the software level. If the display shows a fault code not listed in the table, contact WABCO North America Customer Care at 855-228-3203 for assistance.
  • Page 27 Cycle ignition and verify correct system Radar System between DSP and C Error operation. Radar Reset Fault If error occurs again, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86032/12 Radar Int Comm Internal communication error Cycle ignition and verify correct system Radar System between DSP and C...
  • Page 28 Radar Int DSP Error Internal DSP error Cycle ignition and verify correct system Radar System operation. Radar Reset Fault If error occurs again, WABCO North America Customer Care at 855-228-3203 for further assistance. 86039/12 Radar Int DSP Error Internal DSP error...
  • Page 29 Description Fault Description Repair Instructions Sub-Section 86046/12 Radar Amp Error PWM for base amplification If this error occurs, contact WABCO North Component control is at its maximum America Customer Care at 855-228-3203 for Replacement level for an excessive time. further assistance.
  • Page 30 Displayed SPN/FMI Description Fault Description Repair Instructions Sub-Section 86054/12 Radar Memory Corrupt EEPROM data is not If this error occurs, contact WABCO North Component Error backed up America Customer Care at 855-228-3203 for Replacement further assistance. Radar Sensor Replacement 86055/12...
  • Page 31 Displayed SPN/FMI Description Fault Description Repair Instructions Sub-Section 86062/12 Radar DSP Error DSP boot error If error occurs, contact WABCO North America Component Customer Care at 855-228-3203 for further Replacement assistance. Radar Sensor Replacement 86063/12 Radar DSP Error DSP boot error...
  • Page 32 Radar DSP Error Unknown DSP identification Cycle ignition and verify correct system Radar System operation. Radar Reset Fault If error occurs again, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86071/12 Radar Yaw Error Because of missing valid yaw...
  • Page 33 Displayed SPN/FMI Description Fault Description Repair Instructions Sub-Section 86081/12 Radar Int Comm Internal communication error If error occurs, contact WABCO North America Component Error Customer Care at 855-228-3203 for further Replacement assistance. Radar Sensor Replacement 86082/12 Radar OSEK Error OSEK shutdown routine was...
  • Page 34 Temperature Fault temperature > 80C air flow. Wait for the system to cool down. Verify correct system operation. If error is not cleared, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86088/12 Radar Missing FLASH memory CRC...
  • Page 35 Internal communication error Cycle ignition and verify correct system Radar System Comm Error operation. Radar Reset Fault If error occurs again, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86093/18 Under Temperature Vehicle speed > 6 mph...
  • Page 36 Section Displayed SPN/FMI Description Fault Description Repair Instructions Sub-Section 86101/12 Radar Application software error If error occurs, contact WABCO North America Component Programming Error Customer Care at 855-228-3203 for further Replacement assistance. Radar Sensor Replacement 86102/12 Radar Boot loader error...
  • Page 37 Drive the vehicle at speeds over 10 mph (15 kph) for longer than 30 seconds. If none of the above resolves the issue, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86111/10 Radar OSEK Error OSEK Task Failure...
  • Page 38 Harnesses 0.02s, 0.2s, 2.0s and 20s backbone. J1939 Network Verify all ECUs on the J1939 network are transmitting at 250 Kbits/sec. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 39 Verify engine ECU is functional and has correct Component Msg Timeout 5 messages parameters and software downloaded from Message Fault the engine database. Message Timeout Verify the J1939 network is operational. Cycle the ignition to clear faults after engine servicing. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 40 Verify that ABS ECU is connected to the J1939 Component Timeout 5 messages network. Message Fault Verify J1939 network is operational. Message Timeout Verify correct ABS part number is used. Possible fault during ABS diagnostics. Cycle ignition. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 41 Intermittent display power or intermittent J1939 data link. Verify harness is correct. Display Message Timeout 86330/9 Virtual Target VTRGT timeout > 5 If error occurs, contact WABCO North America Component Message Timeout messages Customer Care at 855-228-3203 for further Message Fault Error assistance.
  • Page 42 Control Data Error ASC1 message parameters and software. Message Fault Verify the ECAS part number is used on this Message Data vehicle. Error Troubleshoot ECAS front axle. Cycle the ignition to clear faults after ECAS servicing. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 43 Troubleshoot ECAS front axle. Cycle the ignition to clear faults after ECAS servicing. 86374/19 Cruise Control Invalid parking brake switch Use the OnGuard display “COMPONENT TEST” Component Data Error signal CCVS message screen to determine if the parking brake Message Fault switch is operational.
  • Page 44 SPN/FMI Description Fault Description Repair Instructions Sub-Section 86375/19 Cruise Control Invalid clutch switch signal in Use the OnGuard display “COMPONENT TEST” Component Data Error CCVS message screen to determine if the clutch switch is Message Fault operational. Message Data Verify engine ECU is functional and has correct...
  • Page 45 Cycle the ignition to clear faults after driveline retarder servicing. 86383/19 Brake Control Data Invalid EBS brake switch Use the OnGuard display “COMPONENT TEST” Component Error signal in EBC1 message screen to determine if the brake switch is Message Fault operating correctly.
  • Page 46 Message Fault message Verify the correct driveline retarder ECU part Message Data number is used on this vehicle. Error Cycle the ignition to clear faults after driveline retarder servicing. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 47 Error Cycle the ignition to clear faults after transmission servicing. 86402/19 Virtual Target Invalid distance signal in If error occurs, contact WABCO North America Component Distance Error VTRGT message Customer Care at 855-228-3203 for further Replacement assistance.
  • Page 48 Description Fault Description Repair Instructions Sub-Section 86405/19 Brake Control Data Invalid brake pedal position Use OnGuard display “COMPONENT TEST” ABS System Error % signal in EBC1 message screen to verify brake pedal position (BPP) Brake Pedal sensor is operational. Position Sensor Verify ABS ECU is functional.
  • Page 49 Alignment procedure. Check the display for the number of fault occurrences. If none of the above resolves the issue, contact WABCO North America Customer Care at 855-228-3203 for further assistance. 86417/13 Radar H Alignment Radar alignment error Realign radar using sensor alignment...
  • Page 50 ACC Control commands from ACC System Reprogram engine parameters if not correct. Programming Check for multiple faults using OnGuard Faults display. If multiple faults, this is a secondary fault caused by other faults. Correct other Component faults and cycle ignition to clear this fault.

  • Page 51: Radar Inspection And Preventive Maintenance Radar System Troubleshooting

    “OnGuard™” is on the bottom and is rightside incorrectly installed following service. When the connector is not up.
  • Page 52 Before starting the alignment procedure, visually verify that all three radar alignment screws are fully seated in the screw ball sockets, the ball sockets are not damaged or missing and the radar sensor is not loose. WABCO Maintenance Manual MM-0951 (Revised 08-18)
  • Page 53 For horizontal alignment, the vehicle must be driven and a RADAR ALIGNMENT target vehicle must be tracked. Start the engine and select Distance to Target the OnGuard Driver Display “Radar Alignment” screen by pressing the “MODE” button twice. Figure 2.29 and Figure 2.30. RSC Mass Est Drive on a smooth, level and straight road with traffic.
  • Page 54  1 mark of the If the fault re-occurs, replace the radar sensor per the Radar Sensor Replacement procedure. center arrows on the OnGuard Radar Alignment screen. After completing the alignment, attach the fascia and verify radar Radar Over Temperature Fault alignment tracking to 350-400 feet on a smooth, level and straight road.

  • Page 55: Electrical System And Harnesses Troubleshooting

    For the radar sensor, the maximum diameter is 0.015 inch (1/64 inch). For the OnGuard Display connector, the maximum diameter is 0.03 inch (1/32 inch).
  • Page 56 Key Off/Engine Off — Check across Pins 4 and 5 (SAE J1939) Figure 2.32 for resistance of 60 ohms. Remove the dash to access the back of the OnGuard Display and If the resistance between Pins 4 and 5 is greater than harness connector. Figure 2.33.

  • Page 57: Component Message Fault Troubleshooting

    Occasionally the vehicle battery, voltage regulator or alternator can wires and check all connections for corrosion or connector cause the OnGuard Collision Safety System to generate high or low damage. If damage is found, repair and replace as voltage faults. Refer to the Key ON section of the Radar Harness necessary.

  • Page 58: Cruise Control System Troubleshooting

    ON for one minute with the software that is incorrect, was not downloaded correctly or has the engine idling to clear the OnGuard fault. Verify that the fault incorrect parameter set. This information may reside in the vehicle has been cleared.

  • Page 59: Anti-Lock Braking System (Abs) Troubleshooting

    BPP sensor output is 0%. If not at 0% call WABCO North America Customer Care at Turn ON the ignition and wait for OnGuard to power up.
  • Page 60 Occasionally an ABS retarder relay fault may occur. The system uses this ABS function to turn ON and OFF the stop lamps when OnGuard is commanding the braking. If this ABS fault occurs, perform the following procedure: Use TOOLBOX™ to activate the stop lamp relay by using the retarder relay command.

  • Page 61: Section 3: Component Replacement

    This can the wording “OnGuard™” is on the bottom and is rightside up. cause any or all three of the sensor alignment screws to disengage If the fascia has a “chin”...
  • Page 62 Mount the radar sensor to the bracket. Walk the sensor “OnGuard™” is on the top and is rightside up. If the radar onto the bracket by rotating each screw about three...

  • Page 63: Display Replacement

    Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. There are two methods in which the OnGuard Display can be installed. Mounting screws through the instrument panel...

  • Page 64: Section 4: Appendix

    If the radar harness is worn or radar is not functioning, please use the following routing instructions for new radar harness The radar harness (P/N: 400 850 801 0). For additional OnGuard™ service end will plug into information, contact WABCO North America Customer Care at the “A”...
  • Page 65 Partnering with the transportation industry as it maps a route toward autonomous driving, WABCO also uniquely © 2018 WABCO North America – All rights reserved – MM-0951 / 08.2018...

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