Bendix™ VORAD® VS-400 Radar System Troubleshooting Guide Bendix™ VORAD® Collision Warning System Bendix™ SmartCruise® Adaptive Cruise Control Bendix™ BlindSpotter® Side Object Detection BW2771 (Formerly VOTS0100) June 2012
Table of Contents Warnings & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Safety Information Warnings and Cautions WARNING Improper use of this system could lead to a serious accident. Read this entire Driver Instructions document before operating the Bendix™ VORAD® VS-400 Forward Collision Warning System (CWS), Bendix™ SmartCruise® Adaptive Cruise Control System, or Bendix™ BlindSpotter Side Object Detection System. Pay particular attention to the safety messages below. This manual should be used in conjunction with proper training.
Product General Safety Information Information Recommended Tools PC to Vehicle J1939 Link Adapter • Nexiq P/N 125032 or Equivalent (J1939 compatible) Digital Volt/Ohm Meter • SPX/Kent-Moore P/N 5505027 or Equivalent Test Lead Adapter Kit • SPX/Kent-Moore P/N J-43318 Digital Level/Protractor • Eaton P/N VV-KIT-03 or Equivalent J1939 Data Link Tester • Eaton P/N MF-KIT-04 Straight Edge Rule • 4 to 6 Feet in Length Other Product Literature (available at www.bendix.
Product General Safety Information Information Before You Begin The VORAD® VS-400 system is comprised of a Forward Looking Radar (FLR) unit and Driver Interface Unit (DIU) that utilizes the vehicle’s J1939 data link to communicate with each other, as well as the vehicle’s engine and/or chassis (cab) controller.
Product Definitions Safety Information Definitions Forward Looking Radar (FLR) The VORAD® VS-400 Forward Looking Radar is a high frequency Doppler radar unit located on the front of the vehicle that transmits a focused beam of radio frequency (RF) energy ahead of the vehicle. Energy reflected off objects is reflected back to the FLR and processed by the unit’s internal headway controller to determine the speed, distance, direction, and lane position of all detected objects.
Product Pretest Safety Procedures Information VS-400 Pre-Test Procedures Power-Up Pretest Overview This section shows the start up and system status display of the VORAD® VS-400 system’s Driver Interface Unit. Note: Refer to the Side Object Detection section for information on the operation and testing of the Side Object Detection system. Power-up With the vehicle’s ignition turned to the ON position (Engine OFF), observe the power-up sequence of the VS-400 Driver Interface Unit (DIU).
Product Pretest Safety Procedures Information Retrieving Diagnostic Trouble Codes (DTCs) Overview This section determines if the Driver Interface Unit (DIU) and the Forward Looking Radar (FLR) are both communicating on the vehicle’s J1939 data link and if either component has set any Diagnostic Trouble Codes (DTCs). In order for the system to operate properly, the DIU and the FLR must be able to communicate with each other, as well as other ECU’s on the vehicle’s J1939 data link.
Product Pretest Safety Procedures Information Electrical Pretest Overview This test will verify that all electrical connections to the VORAD® VS-400 Forward Looking Radar (FLR) and the Driver Interface Unit (DIU) are correct for proper operation. This test should be performed before beginning any of the Diagnostic Trouble Code (DTC) isolation procedures. WARNING Note: Refer to the Side Object Detection section for information on testing the Side Object Detection electrical connections.
Product Pretest Safety Procedures Information Step Procedure A 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure and record the vehicle battery voltage at the battery terminals. a. If the battery voltage measures within 2 volts of the battery-rated voltage. (10-12 volts for a 12-volt battery) i. Proceed to Step B b. If the battery voltage measures less than 2 volts of the battery-rated voltage. (less than 10 volts for a 12-volt battery) i. Test Failed.
Product Pretest Safety Procedures Information Step Procedure B 1. Vehicle Ignition: Key-OFF, Engine-OFF. 2. Disconnect the 8-way connector from the back of the VS-400 Driver Interface Unit (DIU). 3. Measure for zero voltage on pins 4 and 5 on the harness connector. a. If the voltage is 0.5 volts or less. i. Proceed to Step C. b. If the voltage is greater than 0.5 volts, but less than battery voltage. i. Test Failed.
Product Safety Information Step Procedure C 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for ignition voltage on pins 4 and 5 on the harness connector. a. If the voltage is within 0.6 volts of the battery voltage measured in Step A. i. Proceed to Step D. b. If the voltage is less than 0.6 volts of the battery voltage measured in Step A or open. i. Test Failed. Check component fuse. Troubleshoot power supply to the DIU for open/corroded connections or shorts to ground and repeat Step.
Pretest Procedures Step D Procedure 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for J1939 data voltage on pins 7 and 5 of the DIU harness connector. (J1939 High to Ground) a. If the voltage is fluctuating between 2 to 5 volts. i. Proceed to Step E. b. If the voltage is a constant at 0 volts. i. Test Failed. Check for open/loose connections in the vehicle’s J1939 data link harness.
Pretest Procedures Step E Procedure 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for J1939 data voltage on pins 6 and 5 of the DIU harness connector. (J1939 Low to Ground) a. If the voltage is fluctuating between 0 to 3 volts. i. Proceed to Step F. b. If the voltage is a constant at 0 volts. i. Test Failed. Check for open/loose connections in the vehicle’s J1939 data link harness.
Pretest Procedures Step F Procedure 1. Vehicle Ignition: Key-OFF. 2. Measure for J1939 data link resistance across pins 7 and 6 of the DIU harness connector. (J1939 High to J1939 Low) a. If the resistance is between 57 and 63 ohms. i. Proceed to Step G. b. If the resistance is greater than 63 ohms or open (Infinite Resistance.) i. Test Failed. Check for missing J1939 data link terminating resistor(s) or open/loose connections in the vehicle’s J1939 data link harness. (See Note) c.
Pretest Procedures Step G Procedure 1. Vehicle Ignition: Key-OFF. 2. Measure the resistance across pins 7 and 5 (J1939 High to Ground.) 3. Measure the resistance across pins 6 and 5 (J1939 Low to Ground.) a. If both resistances are greater than 100K ohms or open (Infinite Resistance). i. Proceed to Step H. b. If either resistance is between 0 to 100K ohms. i. Test Failed. Check for shorted connections in the vehicle’s J1939 data link harness.
Pretest Procedures Step Procedure H 1. Vehicle Ignition: Key-OFF, Engine-OFF. 2. Disconnect the 10-way connector from the VS-400 Forward Looking Radar (FLR). 3. Measure for zero voltage on pins 10 and 9 on the harness connector. a. If the voltage is 0.5 volts or less. i. Proceed to Step I. b. If the vehicle is greater than 0.5 volts, but less than battery voltage. i. Test Failed. Check FLR power supply wiring for sources of stray voltage or shorts to voltage. c.
General Pretest Procedures Information Step Procedure I 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for ignition voltage on pins 10 and 9 of the harness connector. a. If the voltage is within 0.6 volts of the battery voltage measured in Step A. i. Proceed to Step J. b. If the voltage is less than 0.6 volts of the battery voltage measured in Step A or open. i. Test Failed. Check component fuse.
General Pretest Procedures Information Step J Procedure 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for J1939 data voltage on pins 4 and 9 of the FLR harness connector. (J1939 High to Ground) a. If the voltage is fluctuating between 2 to 5 volts. i. Proceed to Step K. b. If the voltage is a constant 0 volts. i. Test Failed. Check for open / loose connections in the vehicle’s J1939 data link harness.
General Pretest Procedures Information Step K Procedure 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for J1939 data voltage on pins 5 and 9 of the FLR harness connector. (J1939 Low to Ground) a. If the voltage is fluctuating between 0 to 3 volts. i. Proceed to Step L. b. If the voltage is a constant 0 volts. i. Test Failed. Check for open / loose connections in the vehicle’s J1939 data link harness.
General Pretest Procedures Information Step L Procedure 1. Vehicle Ignition: Key-OFF. 2. Measure the J1939 data link resistance across pins 4 and 5 of the FLR harness connector. (J1939 High to J1939 Low) a. If the resistance is between 57 and 63 ohms. i. Proceed to Step M. b. If the resistance is greater than 63 ohms or open (Infinite Resistance.) i. Test Failed. Check for missing J1939 data link terminating resistor(s) or open / loose connections in the vehicle’s J1939 data link harness.
General Pretest Procedures Information Step M Procedure 1. Vehicle Ignition: Key-OFF. 2. Measure the resistance across pins 4 and 9 (J1939 High to Ground). 3. Measure the resistance across pins 5 and 9 (J1939 Low to Ground). a. If the resistance is greater than 100K ohms or open (Infinite Resistance). i. Test Complete. b. If the resistance is between 0 to 100K ohms. i. Test Failed. Check for shorted connections in the vehicle's J1939 data link harness.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 13 (SA 140, SPN 893, FMI 12) DIU Component Diagnostic Trouble Code (DTC) Overview This code indicates that the Driver Interface Unit (DIU) has detected an internal failure. Diagnostic Trouble Code (DTC) Detection At power up and during operation, the DIU performs a self-test to verify the operation of its internal components. If the device detects an internal failure, this Diagnostic Trouble Code (DTC) is set.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 14 (SA 42, SPN 886, FMI 12) FLR Component Diagnostic Trouble Code (DTC) Overview This code indicates that the Forward Looking Radar (FLR) has detected an internal failure. Diagnostic Trouble Code (DTC) Detection At power up and during operation, the FLR performs a self-test to verify the operation of its internal components. If the device detects an internal failure, the Diagnostic Trouble Code (DTC) is set.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 25 (SA 42, SPN 898, FMI 13, 14) SmartCruise® Adaptive Cruise Control Configuration Error Overview This code indicates that the VS-400 Forward Looking Radar (FLR) has detected a SmartCruise configuration or compatibility issue with the engine.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 32 (SA 140, SPN 639, FMI 2) DIU J1939 Message Error Overview This code indicates that the Driver Interface Unit (DIU) has detected gaps or missing messages from the Forward Looking Radar (FLR) on the J1939 data link. Diagnostic Trouble Code (DTC) Detection At power up and during operation, the DIU and FLR continuously communicate with each other on the J1939 data link.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 33 (SA 42, SPN 639, FMI 2) FLR J1939 Message Error Overview This code indicates that the Forward Looking Radar (FLR) has detected gaps or missing messages from the Driver Interface Unit (DIU) or other devices on the J1939 data link. Diagnostic Trouble Code (DTC) Detection At power up and during operation, the FLR, DIU, and other devices continuously communicate with each other on the J1939 data link.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 35, 36 (SA 42, SPN 639, FMI 9) J1939 Data Link Diagnostic Trouble Code (DTC) Overview This code indicates that the VS-400 Forward Looking Radar (FLR) or the Driver Interface Unit (DIU) has detected that there is a J1939 data link Diagnostic Trouble Code (DTC) condition.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 39 (SA 42, SPN 158, FMI 3, 4) FLR Supply Voltage Out of Range Overview This code indicates that the Forward Looking Radar (FLR) has determined that the supply voltage is, or was, out of range. Diagnostic Trouble Code (DTC) Detection At power up and during operation, the FLR monitors supply voltage.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 41, 42 (SPN 1703, 1704, FMI 4, 5) Driver Interface Unit External Speaker Diagnostic Trouble Code (DTC) Overview Most vehicles use the DIU as a source of audio alerts, however, the chassis manufacturer has the option to install an external chassis speaker system.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Code 41, FMI 5 1. Check to see if Pin-1 of the DIU harness connector is populated. a. If no, test complete. The DIU does not utilize a RH external speaker. Disable the RH external speaker output using diagnostic software. b. If yes, continue to next step. 2. Check for an open circuit in the external speaker by measuring the resistance between Pin-1 and Pin-5 of the DIU harness connector. a.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 91 (SA 42, SPN 886, FMI 7) Forward Looking Radar Out of Alignment Overview This code indicates that the Forward Looking Radar (FLR) has determined that the radar is misaligned. Diagnostic Trouble Code (DTC) Detection When the vehicle is in motion, the FLR will calculate the vehicle’s center thrust axis and compare this to the radar’s physical horizontal alignment to determine if the radar is aligned properly.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 92 (SA 42, SPN 886, FMI 14) Forward Looking Radar Not Detecting Objects or Radar Blocked Overview This code indicates that the Forward Looking Radar (FLR) has not detected a target in an excessive amount of time or has become blocked. Diagnostic Trouble Code (DTC) Detection When the FLR has gone a period of time without receiving any reflected radar signals this Diagnostic Trouble Code (DTC) is set.
Diagnostic Trouble Code (DTC) General Information Isolation Procedures Component Code: 95 (SA 42, SPN 171, FMI 0, 1) Forward Looking Radar Ambient Temperature Out of Range Overview This code indicates that the Forward Looking Radar (FLR) has determined that the ambient temperature it is operating in is outside the component's operating range. Diagnostic Trouble Code (DTC) Detection At power up and throughout operation, the FLR monitors the outside air temperature.
Side General Object Information Detection Side Object Detection (SOD) System Operation Overview This section covers the operation of the Side Object Detection (SOD) system. The Side Object Detection system is a stand-alone system which can be installed as an all-on feature for the Bendix™ VORAD® VS-400 Forward Looking system. It is powered independently from the forward looking system and utilizes its own Driver Display Unit which is typically located on the windshield pillar.
Side General Object Information Detection Normal Operation When an object is detected within the sensor’s detection zone, the driver display illuminates the red detect lamp. During normal operation, the display will toggle between illuminating either the yellow or the red lamps, but never both at the same time (See SOD Failure Diagnostic Procedure). Alert Tone If the turn signal is active when an object is detected, the Driver Display Unit will sound an alert tone.
Side General Object Information Detection Diagnostic Trouble Code (DTC) Isolation Procedures System Diagnostic Trouble Code (DTC) (Both Red and Yellow Lamps ON) Overview The Side Object Detection (SOD) Driver Display Unit illuminates both the red and yellow lamps to indicate a system Diagnostic Trouble Code (DTC).
General Appendix Information 1. Forward Looking Radar Alignment Alignment WARNING The alignment of the Forward Looking Radar is critical to the correct operation of the Bendix™ VORAD® VS-400 system. Improper alignment can cause the system to improperly detect objects in the vehicle’s path. Every precaution should be taken to ensure the VS-400 system alignment (both horizontal and vertical), is correct.
General Appendix Information 3 3. Horizontal Alignment The Forward Looking Radar must be facing straight ahead (azimuth) of the vehicle in order to optimally detect objects in the vehicle path. 1. Select two truck reference points that are identical and symmetrical about the truck centerline. Ensure the reference points are equally aligned. Items such as fenders and headlights should not be damaged or distorted; otherwise the alignment will be inaccurate. 2.
Appendix General Information 3 continued Calibrating the FLR Horizontal Alignment After the physical horizontal alignment has been conducted on the chassis, there is a calibration procedure that should be implemented prior to delivery to the customer. This can also be performed as a service function at any point in time, if required. The calibration procedure requires the use of diagnostic software on a mobile computer that can be operated in the cab while the vehicle is in motion.
Appendix General Information 3 continued Fine-Tuning the Horizontal Alignment If the alignment function in the diagnostic software continuously shows an azimuth value greater than 0.5° or less than -0.5°, then the FLR needs to be physically adjusted in the horizontal direction beyond that already completed. Center FLR Azimuth Position (FLR aligned correctly) If the alignment function consistently shows an azimuth value of 0° +/- 0.
Appendix General Information 3 continued Negative Azimuth Adjustment (FLR too far to the left) If the alignment function shows a positive value, then the FLR is adjusted too far to the left, when looked at from the driver's seat. The radar needs to be adjusted to the driver's right. To accommodate this, adjust the horizontal alignment screw by turning it in a clockwise direction, when viewed from the front of the vehicle. Each full rotation of the alignment screw adjusts for approximately 0.
Appendix General Information 3 continued Positive Azimuth Adjustment (FLR too far to the Right) If the alignment function shows a negative value, then the FLR is adjusted too far to the right, when looked at from the driver's seat. The radar needs to be adjusted to the driver's left. To accommodate this, adjust the horizontal alignment screw, by turning it in a counterclockwise direction, when viewed from the front of the vehicle. Each full rotation of the alignment screw adjusts for approximately 0.
General Appendix Information 4A 4. Component Power Supply Test Overview The base Bendix™ VORAD® VS-400 system consists of two components, the FLR and DIU. Both should be powered by the main ignition power supply (12 Vdc). If one of these components is incorrectly connected to constant battery power or a secondary ignition source other than the main ignition power supply bus, there is the potential for J1939 communication Diagnostic Trouble Code (DTC) between the FLR and the DIU.
General Appendix Information 4B, 4C Step Procedure B 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for ignition voltage on pins 4 and 5 on the harness connector. a. If the voltage is within 0.6 volts of the battery voltage measured in Step A. i. Proceed to Step C. b. If voltage is less than 0.6 volts of the battery voltage measured in Step A or open. i. Test Failed. Check component fuse.
General Appendix Information 4D, 4E Step Procedure D 1. Vehicle Ignition: Key-ON, Engine-OFF. 2. Measure for ignition voltage on pins 10 and 9 on the harness connector. a. If the voltage is within 0.6 volts of the battery voltage measured in Step A. i. Proceed to Step E. b. If voltage is less than 0.6 volts of the battery voltage measured in Step A or open. i. Test Failed. Check component fuse.
General Appendix Information 5 5.
General Appendix Information 6 6. Connector Pin Descriptions A. Forward Looking Radar 10-pin TRW Connector PIN # 1 2 3 4 5 6 7 8 9 10 SIGNAL NAME NO_CONNECTION NO_CONNECTION J1939_SHIELD CAN_HI CAN_LO NO_CONNECTION NO_CONNECTION NO_CONNECTION GROUND IGNITION TYPE – – – – – – – POWER POWER INTERFACE LEVEL – – TRUCK J1939 LINK TRUCK J1939 LINK TRUCK J1939 LINK – – – CHASSIS GROUND +12V SWITCHED B.
General Appendix Information 6 C. Side Sensor Display Unit 4-pin Deutsch Connector PIN # 1 2 3 4 SIGNAL NAME POWER GROUND COMMUNICATION TURN_SIGNAL TYPE I POWER I I INTERFACE LEVEL +12V FROM SENSOR CHASSIS GROUND +12V D.
Appendix 7 7. Extracting Bendix™ VORAD® system Data A. Data Availability Data will not be stored by the system until the proper Bendix® ACom® Diagnostics license key is present and the "Clear Resettable Data Log" option is selected. See diagram (right). Contact Bendix (1-800-AIR-BRAKE) for the ACom Diagnostics license key and its set-up procedure. B. Data Overview At the fleet’s discretion, Bendix™ VORAD® makes a data log available.
Typical VORAD vehicle report Appendix 7 continued 50
General Appendix Information 8 Vendor Contact Information AMP/Tyco Harrisburg, PA Tel: 800.522.6752 http://www.tycoelectronics.com/ Littelfuse World Headquarters 800 E. Northwest Highway Des Plains, IL 60016 Tel: 847.824.1188 Fax: 847.391.0894 http://www.littelfuse.com Champlain Cable Corporation 175 Hercules Drive Colchester, Vermont 05446 Tel: 800.451.5162 http://www.champcable.com/ Deutsch LADD Industries 4849 Hempstead Station Dr. Kettering, OH 45429 Tel: 800.223.1236 http://www.laddinc.
901 Cleveland Street • Elyria, OH 44035 • 1-800-AIR-BRAKE • www.bendix.
