WABCO TailGUARD TP19007 Installation Manual
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WABCO TailGUARD TP19007 Installation Manual

WABCO TailGUARD TP19007 Installation Manual

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TailGUARD
TM
INSTALLATION MANUAL
INSTALLATION GUIDE
TP19007

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Summary of Contents for WABCO TailGUARD TP19007

  • Page 1 TailGUARD INSTALLATION MANUAL INSTALLATION GUIDE TP19007...

  • Page 3: Table Of Contents

    Symbols Used in this Document ........................5 How to Obtain Additional Maintenance, Service and Product Information ............6 How to Obtain Parts and Kits ..........................6 WABCO TOOLBOX PLUS™ Software ......................6 WABCO Academy ..............................6 WABCO Online Product Catalog ........................6 Your Direct Contact to ZF CVS ..........................7 Safety Information.
  • Page 4 This publication is not subject to any update service. Information contained in this publication was in effect at the time the publication was approved for printing and is Edition 1 subject to change without notice or liability. ZF CV Systems North America LLC reserves Version 3 (03.2024) the right to revise the information presented or to discontinue the production of parts TP19007 (en) described at any time.

  • Page 5: General Information

    Description of a possible situation which may result in material damage if the warning is ignored. 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) Ö 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 find 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 Traffic Safety Administration (NHTSA) website to find 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 Pacific Drive Auburn Hills, MI 48326 Customer Care Center: (844) REACH-ZF https://www.zf.com/cv...

  • Page 8: Safety Information

    Safety Information Safety Information Provisions for a safer work environment Only trained and qualified auto technicians and automotive mechanics may carry out work on the „ vehicle. Read this publication carefully „ Follow all warnings, notices and instructions to help avoid personal injury and property damage. „ Always abide by the vehicle manufacturer’s specifications and instructions. „ Observe all accident regulations of the respective company as well as regional and national regulations. „...

  • Page 9: Important Information

    Important Information Important Information Use only genuine WABCO components. Other manufacturers’ parts are not designed for use with a WABCO ABS system and may not function correctly. WABCO recommends that a control line filter, part number 432 500 005 0, be installed on the air system’s control line, upstream of the ABS ECU/valve assembly.

  • Page 10: Tailguard™ Warnings, Cautions And Operating Guidelines

    TailGUARD™ Warnings, Cautions and Operating Guidelines TailGUARD™ Warnings, Cautions and Operating Guidelines Driver-Related Information WARNING The TailGUARD System is a driver aid only. It is designed to assist the vehicle operator in maintaining a safe rear end distance of obstacles during parking maneuvers and, if needed, provide braking to reduce the severity of a possible collision. The TailGUARD is no substitute for the most important factor in vehicle safety, which is a safe, conscientious driver. Use of TailGUARD cannot compensate for a driver that is distracted, inattentive or impaired by fatigue, drugs or alcohol.

  • Page 11: Environment-Related Information

    The driver, however, remains fully responsible for vehicle movement and any damage that results „ from operating the vehicle. WABCO cannot be held liable for an accident that is caused despite of using this system; this is a „ support system only.

  • Page 12: System Malfunction Information

    TailGUARD™ Warnings, Cautions and Operating Guidelines System Malfunction Information WARNING If the TailGUARD is not correctly identifying obstacles that are in its path, this may be due to ultrasonic sensors operational issues. Typically, these are ultrasonic sensors operational issues that can result from the following problems: Debris (dirt, snow, ice) on the sensor fascia. This must be removed. „ A loose sensor or one that is not tightly secured on the mounting bracket. „...

  • Page 13: Introduction

    Introduction Introduction TailGUARD reduces risk when reversing by detecting stationary and moving objects in the blind spot behind the trailer and actively braking the trailer at a safe distance from the object. The system reduces stress for the driver while reversing and helps to avoid collisions with pedestrians, loading ramps, barriers, trees, forklifts, cars and other objects behind the vehicle. TailGUARD is activated automatically when it senses the trailer is moving backwards The system brakes the trailer automatically if it approaches an object within a parameterized distance between 1.6 and 6.5 ft (50 and 200 cm). Distance configuration shall be set during the installation process. The TailGUARD default...

  • Page 14: General System Overview

    Introduction 5.1.1 General System Overview 4016247a Item Designation RSSplus Electronic extension module Ultrasonic sensors Reverse signal box + reverse sensor Junction box External marker lights...

  • Page 15: System Configurations

    Introduction 5.1.2 System Configurations Features TailGUARD™ TailGUARDroof™ TailGUARDMAX™ Loading ramps and large objects, such as Areas with restricted Areas with small and/ palettes, vehicles and heights: e.g. or moving objects: e.g. Typical logistical posts of metal or wood warehouses, loading forklift loading, street environment that vary in shape or size gates, trees and roof signs, shops, residential and are unknown to the constructions.
  • Page 16 TailGUARDMAX With the reverse monitoring system, the entire area behind the trailer is monitored with ultrasonic sensors (functional details). WABCO recommends a minimum system of three sensors on the main level (TailGUARD). TailGUARD supports the driver when the vehicle is moving in reverse (ie “reversing”). Here, in interaction with Trailer RSSplus, the trailer applies brakes automatically before reaching the load ramp or a wall, as example.
  • Page 17 Introduction 5.1.4.2 Deactivation The function is deactivated (switched off) by: Speed > 7.5 mph (12 km/h) and/or supply pressure lower than 65 psi (4.5 bar); or „ A failure in the RSSplus system (RSSplus cannot brake automatically in this case); or „ A failure in the TailGUARD system components. „ If the system is deactivated, external marker lights are not actuated; however, the buzzer will be normally activated. Deactivating TailGUARD is stored as an event in the operating data recorder (ODR).

  • Page 18: Components

    Components Components The following table provides a general list of TailGUARD system components. For specific kit part numbers, refer to Appendix II. Item Component Part Number RSSplus 480 107 001 0 4016254a RSSplus power cable 449 351 047 0 – 4.7 m 4016255a RSSplus wheel speed sensor cable 449 723 030 0 – 3 m 4016256a Electronic Extension Module 446 122 071 0...
  • Page 19 Components Item Component Part Number ELEX to junction box cable 449 908 060 0 4017267a Junction box 446 122 633 0 4016266a Buzzer (optional) 894 450 000 0 Green external light (optional) 446 105 523 2 4017319a External light cable (optional) 449 900 100 0 – 10 m 4017320a ELEX cover (optional) 895 310 005 2...

  • Page 20: Installation

    Installation Installation Required Components In addition to RSSplus, the electronic extension module (ELEX), ultrasonic sensors, reverse sensor with reverse signal box and respective cables are required. The external marker lights must be connected through a junction box to the electronic extension module. The buzzer (optional) is connected to the reverse signal box. 7.1.1 Electronic Extension Module Mount the electronic extension module vertically only, with the cable openings facing the bottom or the side.
  • Page 21 Installation 4016270a Legend GIO12 ELEX to junction box cable 449 908 060 0 GIO14 Reverse signal box 446 122 200 0 GIO17 Cable for ultrasonic sensors 449 806 060 0 Power supply cable for electronic extension module 449 303 020 0 connected to POWER sub-system port at RSSplus Diagnostic cable 449 609 060 0 must be connected to subsystem port for system...
  • Page 22 NOTICE Observe the following safety instructions for handling the lights: Plan the installation position so that lights are visible to the driver through the mirrors. „ WABCO recommends installing lights at the sides of trailers close to the rear of the trailer. „ The external lights are only indicators that the TailGUARD system is functioning properly. „ If the lights do not start to blink when the vehicle is in reverse, the TailGUARD system needs to „...
  • Page 23 Installation EXTERNAL MARKER LIGHT CABLE 449 900 100 0 4017321a Light Cable Wire Colors Power White Wire Ground Black Wire ELEX EXTERNAL MARKER LIGHT CABLE 449 908 060 0 4017322a ELEX Light Cable Wire Colors Permanent Power Pink Wire Right Side Light Yellow/Brown Wire Left Side Light Yellow/Black Wire...
  • Page 24 Installation To install external marker lights, the wires from ELEX cable 449 908 060 0 and the external lights cables 449 900 100 0 need to be connected through the junction box 446 122 633 0, following the steps. Permanent power (blue wire) from the trailer needs to be connected to ELEX cable via pink wire. „...

  • Page 25: Ultrasonic Sensors

    (this is required to protect the drainage holes in the rear against direct high-pressure cleaning). Ultrasonic sensors must not be mounted in a U-profile because this could negatively interfere „ in the performance of the system. WABCO recommends mounting the ultrasonic sensors mechanically protected to avoid damages. The ability to detect objects largely depends on the ultrasonic sensors position on the trailer. „...
  • Page 26 Installation The figure below shows only one of many possible ultrasonic sensor positions. The yellow areas represent an example of the area monitored by the ultrasonic sensors. 4016271a When planning the routing of cables, note the maximum length of 131 ft (40 m) between the Electronic Extension Module and the last ultrasonic sensor. 7.1.4.1 TailGUARD Mount the outside two ultrasonic sensors, 446 122 450 0, inclined horizontally inwards.
  • Page 27 Installation 7.1.4.2 TailGUARDroof Mount the five ultrasonic sensors horizontally in two levels. „ Mount the outside ultrasonic sensors 446 122 450 0 inclined horizontally inwards. „ If the middle sensor, 446 122 450 0, is not exactly centered, mount it so that it is inclined in the direction „ of the farther away outer sensor. The designation has to be entered in TOOLBOX PLUS™ software. „...
  • Page 28 Installation 7.1.4.3 TailGUARDMAX Mount 6 ultrasonic sensors horizontally in two levels. „ • Only if the 6 ultrasonic sensors are mounted on the vehicle in the arrangement shown in the following will the system meet all requirements of ISO 12155 (obstacle detection device during reversing). Both levels follow the same install guidelines: Mount the outside ultrasonic sensors 446 122 450 0 (10°) inclined inwards.
  • Page 29 Installation 7.1.5 Reverse Signal Box WARNING Risk of accidents: TailGUARD function not available due to incorrect installation of reverse signal box and reverse sensor. The reverse signal box and the reverse sensor must be installed correctly according to the procedures and diagrams provided in this manual. If sensor is not installed correctly, the TailGUARD system may not detect trailer moving backwards not triggering the monitoring system, resulting in risk of accidents.
  • Page 30 Installation The reverse sensor is responsible for detecting when the trailer starts to move backwards and activates „ the TailGUARD system. A sensor holder need to be installed at trailer axle, current wheel speed sensor holder is not compatible „ with the reverse sensor. Sensor holder must follow the design of current speed sensor and protect as much as possible the „...

  • Page 31: System Configuration Tailguard

    Installation System Configuration TailGUARD EXTERNAL LIGHTS GIO12 POWER REVERSE OPTIONAL SIGNAL BOX BUZZER CONNECTION REVERSE SENSOR GIO14 GIO17 4016279c Legend GIO12 External marker lights via cable 449 908 060 0 GIO14 Reverse signal box 446 122 200 0 GIO17 Cable for ultrasonic sensors 449 806 060 0 Power supply cable for electronic extension module 449 303 020 0 connected to sub- POWER system port at RSS...

  • Page 32: Full System Installation Overview

    Installation Full System Installation Overview JUNCTION REVERSE SIGNAL 4016280a...

  • Page 33: Start-Up

    Installation Start-up Start-up requires assembly of the components on the trailer, connection of the diagnostic computer, supplying the system with power, and starting the TOOLBOX PLUS™ Software. 7.4.1 Diagnosis Hardware 7.4.1.1 Diagnosis Direct at ELEX Component/Part Number Figure Noregon DLA 2.0 or DLA+PLC Adapter 4016292a 4016281a Noregon 9-pin Heavy-Duty Cable...
  • Page 34 Installation 7.4.2 Configuration Setup Schematic DIAGNOSTIC CABLE 449 609 060 0 INTERFACE/VEHICLE POWER CABLE SUBSYSTEM PORT DLA DIAGNOSTIC INTERFACE ELEX 446 122 071 0 INTERFACE USB CABLE 4017390a For TailGUARD start-up, connect the configuration cable to the Subsystem port on the ELEX. Then, use the 9-pin Heavy-Duty Cable with NOREGON DLA 2.0 or DLA+PLC Adapter to connect to the notebook with TOOLBOX™ Software installed. 7.4.3 Start-up TOOLBOX PLUS™ 1. Open the TOOLBOX PLUS™ software. 4017158a...
  • Page 35 Installation 2. Select adapter from the list according to your adapter availability. 4016982a 7.4.3.1 Start Parameter Setting 1. To start parameter setting, select the icon with the green arrow as shown. 4016983a...
  • Page 36 Installation 2. Select “Test of the signal outputs” box, and then click on Start. Select Next. 4017159a 3. Input operator name and trailer VIN number as shown at figure below and click on “Next”. 4017160a...
  • Page 37 Installation 4. Select Next. 4017161a 7.4.3.2 Parametrization of TailGUARD (Reverse Monitoring System) (RMS) If a system of 3 sensors is installed on the trailer, only the left box highlighted below should be completed. If a system of 5 or 6 sensors is installed on the trailer, the box “Reverse monitoring system expanded” should be selected, and both boxes left and right highlighted should be completed.
  • Page 38 Installation General: A maximum of six sensors can be connected in parallel to GIO 17 and 18. Vehicle width The maximum trailer width shall be entered. 3 Ultrasonic sensors A system with three ultrasonic sensors can be chosen. The middle sensor is only to be installed with an offset upward or downward by a maximum of 4 in (10 cm). Distance sensor 1 (left) - sensor 2 (right) The distance between the two outer ultrasonic sensors (measured center to center) is entered.
  • Page 39 Installation If “Expanded reverse system” is selected 2 Ultrasonic sensors A system with extra two ultrasonic sensors can be chosen. It will be TailGUARDRoof configuration with a total of five sensors. 3 Ultrasonic sensors A system with extra three ultrasonic sensors can be chosen. The middle sensor is only to be installed with an offset upward or downward by a maximum of 4 in (10 cm). It will be TailGUARDMAX configuration with a total of 6 sensors installed in two levels of maximum 1.3 ft (40 cm) between each other. Distance sensor 1 (left) - sensor 2 (right) The distance between the two outer ultrasonic sensors (measured center to center) is entered.
  • Page 40 Installation Next, the “Options” box needs to be completed as shown following the instructions below: 4017164a Reverse signal lights Select “No light installed” from drop box menu Buzzer The option “No buzzer” must be selected from drop box. If the optional buzzer is installed with the reverse signal box, it will be functional without any parametrization at the software. Reverse signal Input „ Select the option “Reverse signal on GIO 14-3” „ This is an input for the reverse signal. Here, the reverse signal will be read in via the GIO 14 analog input from the reverse signal box.
  • Page 41 Installation Marker lights control If external markers lights are installed, this box need to be checked. After you input all the settings, select Next. 4017165a 1. Check if the reverse signal is defined at GIO14, and no error messages appear. 2. Select “Write to ECU”, and then select “OK”. 7.4.3.3 Start-up of the Ultrasonic Sensors Requirements: For start-up of the ultrasonic sensors and TailGUARD system, the “monitoring area” must be identified using the following tests.
  • Page 42 Installation 1. Teaching the ultrasonic sensors The ultrasonic sensors must “learn” to detect the position on the trailer after installing. Click on button Start initial start-up as shown. „ Cover the ultrasonic sensors completely and without touching them for 1-2 seconds. To accomplish the „...
  • Page 43 Installation If objects are still detected, ultrasonic sensors or attachment parts must be positioned differently. „ • Another measurement is then made to determine whether reflections of other objects have to be masked. • If objects are still detected, LIN ultrasonic sensors or attachment parts must be positioned differently. 4017166a 4017167a...
  • Page 44 Installation 3. Test body detection If the system is fault-free, an object test is performed. This requires a test specimen, e.g. a plastic pipe, which is higher than the installation height of the „ ultrasonic sensors, at 2 ft left (0.6 ± 0.1 m) and 5.2 ft right (1.6 m ± 0.2 m) in the area behind the trailer. •...
  • Page 45 Installation 4016996a 7.4.3.5 Check the external marker lights Next window will show to check the function of external marker lights (position lights). 4017168a 1. Click on the position lights icon, and look in the trailer, if the lights are activated.
  • Page 46 Installation 2. If the lights are working, click on ‘Yes’ at the box “Correct function control?”, as shown. 4017169a Next screen will show up showing all tests were concluded and the system is ready for use. 4017170a...

  • Page 47: Workshop Notes

    After faults have been eliminated, the diagnostic memory should always be cleared. Repair and Replacement Defective cables and devices must be replaced with original WABCO products of identical part number. If ultrasonic sensors or the control unit are replaced, a start-up procedure via system diagnosis must be carried out again.

  • Page 48: Pin Assignment "Electronic Extension Module

    Appendix I Appendix I Pin Assignment “Electronic Extension Module” Connections Electronic Extension Module POWER, 8-pin Power in CAN High 5V CAN Low 5V Ground 4016288a SUBSYSTEM, 8-pin Power out CAN High 5V CAN Low 5V Ground 4016289a GIO12, 8-pin Power in from trailer External marker light left out External marker light right out 4016290a...
  • Page 49 Appendix I Connections Electronic Extension Module GIO14, 4-pin Voltage out to reverse signal box Ground Analog input from reverse signal box 4016291a GIO17, 4-pin LIN ground LIN ultrasonic sensor LIN supply voltage 4016291a...
  • Page 50 Appendix II Appendix II The following tables provide kit part numbers for all TailGUARD configurations. TailGUARD - 400 612 036 0 Part Number Quantity ELEX 446 122 071 0 ELEX – power cable 449 303 020 0 Ultrasonic sensors 446 122 450 0 ELEX – sensor cable 449 806 060 0 Sensor distribution cable 894 600 024 0 Reverse signal box...
  • Page 51 Appendix III Appendix III LEFT EXTERNAL RIGHT EXTERNAL MARKER LIGHT MARKER LIGHT 446 105 523 2 446 105 523 2 EXTERNAL MARKER EXTERNAL MARKER LIGHTS CABLE LIGHTS CABLE ULTRASONIC SENSORS 449 900 100 0 449 900 100 0 446 122 450 0 RSSplus 480 107 001 0 JUNCTION BOX...
  • Page 52 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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