Home

tire pressure control system

1. Step Setting Metric Speed Terrain Arrows Loaded OCP Channel Indicator English Indicator Arrow Indicator HWY OFF HWY EMER Front Rear Trailer 1 Metric English On 2 Highway Over Speed On On 3 Highway Loaded Front Pressure On On On 4 Highway Loaded Rear Pressure On On On 5 Highway Loaded Trailer Pressure On On On 6 Highway Unloaded Front Pressure On On 7 Highway Unloaded Rear Pressure On On 8 Highway Unloaded Trailer On On Pressure 9 Off Highway Over Speed On On On On 10 Off Highway Loaded Front On On On Pressure 11 Off Highway Loaded Rear On On On 9 Pressure a 12 Off Highway Loaded Trailer On On e Pressure 5 13 Off Highway Unloaded Front On On Pressure 2 14 Off Highway Unloaded Rear On On S Pressure 15 Off Highway Unloaded Trailer On Pressure 16 Emergency Over Speed On On 17 Emergency Loaded Front Pressure On On On 18 Emergency Loaded Rear Pressure On On On 19 Emergency Loaded Trailer On On On Pressure 20 Emergency Unloaded Front On On Pressure 21 Emergency Unloaded Rear On On Pressure 22 Emergency Unloaded Trailer On On Pressure 3 Channel Only Diagnostics Diagnostics This section covers the equipment and procedures used to find and correct Tire Pressure Control System problems Test Equipment Tire Pressure Control System troubleshooting can be performed at three levels 1 PC diagno
2. gt Service Codes Group 11P Codes 44 45 46 Type Tire Leak Imbalance System Mode Condition Possible Causes Listed in Likely Order of Occurrence pressure tire than others on same channel Channel only checks Tire pressure lower on one Minor tire leakage at start up leaked down overnight Severe tire damage or leaks Leaking lines Contaminated wheel valve filters Restricted tire valve stem Leaking seals Leaking wheel valve Crimped or restricted control lines Air Pressure Check The Tire Pressure Control System is not continuously pressurized pressure checks occur on a periodic basis During tire pressure checks the system delivers compressed air to each channel for approximately two seconds while monitoring the pressure in that channel Code Description Group 11P indicates that pressure imbalance may exist Using a tire pressure gauge to manually compare tire pres sures on the indicated channel will allow you to identify the specific tire involved Very slow leaks may require that you allow the vehicle sit overnight for sufficient air loss to occur To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 11P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostic
3. Check adjustment on threaded pencil speed sensor or drive tang on mechanical speed sensor Sensor problem No Use industry standard tools to verify data link signal is OK gt a EN o 5 Repair as necessary Switch off ignition Disconnect speed input from signal source and ECU from harness Check for shorts on ECU connector Y F1 to K2 e Switch off ignition Disconnect speed sensor and ECU from harness e Check for shorts on ECU connector F2toF3 Check continuity of ECU F2 to K2 connector F1 to speed input F3 to K2 Repair and verify speed signal source j Move vehicle at greater than 5 mph Repair harness as necessary No Y Check for opens Short speed sensor harness connector A and B together Measure continuity between F2 and F3 on ECU connector Did active code clear Yes Complete Repair harness No as necessary Y Replace ECU No Y Replace speed sensor Note ECUs are not a typical cause of problems If an ECU is replace the system should be carefully rechecked to make sure the problem has been fixed and does not reoccur 22 Service Codes Group 4C Code 15 Type Display Control Communications
4. Plug in pressure switch and retest system Refer to Service Manual 15 the pressure switch plugged in EN 9 gt 1 N eo N Repair harness and retest Yes Y Using the diagnostic tool verify pressure switch operation Verify wiring e Switch off ignition Disconnect ECU harness connector and Nop supply tank pressure switch connector e Verify continuity between ECU harness connector pin G3 and pressure switch harness connector PRESS SW wire e Verify other press switch wire is grounded Replace pressure switch and retest pressure switch close above 110 Yes Verify air system capacity by checking supply tank pressure buildup time Are Repair connections Nope harness and OK retest Repair vehicle air supply Does the system and retest N Refer to Service Manual supply tank build up pressure Yes Replace pressure switch Y and retest system Yes Refer to Service Manual Service code is not active Reverify flowchart steps and wait for fault to reoccur 40 Service Codes Group 8P Code 35 Type Atmospheric System Mode Condition Possible Causes Listed in Likely Order of Occurrence Pneumatic Control Unit pressure out of range Pressure check only Fault
5. displays logo only DDM displays dash dash nothing else on display System Mode Condition Possible Causes Listed in Likely Order of Occurrence Inflate Only Blank Display No power to Driver Interface No ground connection to Driver Interface System voltage out of range 9 19 volts DC Inflate Only Operator Control Panel No power or ground to ECU Driver Interface to Electronic Control Unit lines open Driver Interface to Electronic Control Unit lines shorted to ground Driver Interface to Electronic Control Unit lines shorted to power Driver Interface to Electronic Control Unit lines shorted together Faulty Driver Display Module Operator Control Panel Faulty Electronic Control Unit Code Description Group 4C indicates a communication problem between the DDM Display Harness Connector Electronic Control Unit ECU and the driver interface either the Driver Display Module or Operator Control Panel Code 4C will only be observable on a diagnostic tool as code 15 It will not show on the Operator Control Panel Instead the Operator Control Panel may be blank indicating a power problem All of the troubleshooting steps for code 4C involve checking the condition of Electronic Control Unit and driver interface circuits If no circuit problems are found Code 4C indicates either a faulty driver interface or a fault
6. 26 Service Codes Group 12C Codes 51 52 53 54 55 56 Type PCU Solenoids e Front 51 e Rear 52 e Trailer 53 e Supply 54 e Deflate 55 e Control 56 System Mode Condition Possible Causes Listed in Likely Order of Occurrence No operation Pneumatic Control Unit solenoid failed electrical diagnostic test Connector unplugged or faulty wiring Solenoid wire open Solenoid wire shorted to ground Solenoid wire shorted to power Faulty solenoid Faulty Electronic Control Unit Code Description Group 12C indicates an electrical fault in the Pneumatic Control Unit PCU Codes 51 through 56 specifically designate which solenoid in the PCU is faulty System operation is disabled when this fault is detected The system shuts down in a fail safe mode and turns off power to the solenoids The troubleshooting tree first tests internal solenoid circuitry Resistance outside the specified range of 7 to 25 ohms indicates a defective solenoid Successive steps check continuity of the wire harness circuits between the Pneumatic Control Unit and the Electronic Control Unit ECU If the problem can be traced to a faulty circuit or connector make PCU Connector PCU Harness Connector OWE the necessary repairs If the troubleshooting routine leads to a TE problem with the solen
7. Code 17 Type Power System Mode Condition Possible Causes Listed in Likely Order of Occurrence No Operation Power out of range Low battery voltage Poor ground connection to Electronic Control Unit Poor switched ignition connection to Electronic Control Unit High vehicle electrical system voltage Faulty Electronic Control Unit Code Description Group 1C 17 indicates a power fault and sets when the sys tem power is outside the acceptable range of 9 to 32 volts The fault could be caused by low battery power or some other problem with the basic vehicle electrical system If the vehicle power system checks out satisfactorily other possible causes include bad Electronic Control Unit ECU connections or a faulty Electronic Control Unit In inspecting circuits and connections for a Code 1C fault pay particular attention to a bad ground connection that could be causing the fault See Troubleshooting Tips for general guidelines on system diagnostics ECU Harness Connector TH ORES N IE 1 19 Service Codes Power Code 17 With ignition switched on and engine running measure battery voltage across battery terminals ls voltage reading gt 32 volts No Y With ignition switched on but engine not running measure battery voltage across battery terminals ls voltage reading 9 volt
8. HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 GROUND CONFIG 1 POWER CONFIG 2 70 Configuration Connections CONFIG 5 HARNESS CONNECTOR GROUND CONFIG B POWER CONFIG2 D C WITH OPTIONAL TRAILER CONFIG 6 A Reserved L NFIG 7 HARNESS NIS BOTH STEERS NON DRIVEN CONNECTOR GROUND A CONFIG B POWER CONFIG2 D HARNESS CONNECTOR GROUND CONFIGI B POWER CONFIG2 D OR HARNESS CONNECTOR GROUND CONFIG B POWER CONFIG2 D 71 This page intentionally left blank For spec ing or service assistance call 1 877 777 5360 or visit our website at www dana com Dana Commercial Vehicle Products Group 3939 Technology Drive d Maumee Ohio USA 43537 DANA SPICER Drivetrain Products www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to change without notice or obligation Printed in USA AXTS 0020 04 07
9. Spicer TPCS SPICER Tire Pressure Control System Troubleshooting Guide AXTS0020 April 2007 General Information Warnings and Cautions The descriptions and specifications contained in this service publication are current at the time of printing Dana reserves the right to discontinue or modify its models Any refere nce to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equiva lents may and or procedures and to change specifications at any time without notice be used IMPORTANT NOTICE This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator WARNING Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician CAUTION Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the
10. Torque screws 40 to 45 in Ibs Verify presence of O rings in bases of solenoid operator assemblies and reinstall operators onto Pneumatic Control Unitbody Verify 2 way operator solid metal top is in Deflate location Specific location of other operators 3 way is not important Install solenoids on operators verifying proper location per labels on solenoids and Pneumatic Control Unit body Carefully tuck solenoid wires in area between transducer and solenoids while reinstalling the solenoid covers Service Procedures Note It is necessary to position both covers on the body at the same time 18 Carefully tighten cover screws ensuring that wires are not pinched between cover and body Torque screws 40 to 45 in Ibs 19 Reinstall Pneumatic Control Unit in vehicle 20 Conduct TPC system checkout to verify integrity of cleaning assembly C LI co 58 Service Procedures Solenoid Assembly and Cartridge Typical Pneumatic Control Unit Assembly Optional Trailer Channel 59 Service Procedures Typical Solenoid Assembly PCU Cleaning amp Inspection p DPHHLJ 142 2 5 2 A e D 3 Typical Cartridge PISTON 0 RING 114 CARTRIDGE 020 60 Service Procedures Service Guidelines The Tire Pressure Control System requires normal mainte nance much the same as other
11. Code System Status Description 10P 41 Inflate Only Tire Leak Front not passing tire pressure confirm check multiple attempts 42 Inflate Only Tire Leak Rear not passing tire pressure confirm check multiple attempts 43 Inflate Only Tire Leak Trailer not passing tire pressure confirm check multiple attempts 44 Pressure Check Only Tire Leak Front tire pressure imbalance or line leak 45 Pressure Check Only Tire Leak Rear tire pressure imbalance or line leak 46 Pressure Check Only Tire Leak Trailer tire pressure imbalance or line leak 12P 61 Normal Operation Sluggish Shut Off Front lost minor pressure during wheel valve shut off 62 Normal Operation Sluggish Shut Off Rear lost minor pressure during wheel valve shut off 63 Normal Operation Sluggish Shut Off Trailer lost minor pressure during wheel valve shut off 64 Normal Operation Shut Off Failure Front cannot close wheel valve s and vent lines 65 Normal Operation Shut Off Failure Rear cannot close wheel valve s and vent lines 66 Normal Operation Shut Off Failure Trailer cannot close wheel valve s and vent lines 2 47 48 Reserved 47 48 57 Spare 1 connector unplugged faulty wiring or component 58 Spare 2 connector unplugged faulty wiring or component 67 68 Reserved 67 68 71 75 Reserved 71 75 78 Reserved 78 rJ 11 C 7 3 3 lt Service Codes Group 1C
12. ID Only Dual Trailers 4 to 5 Axles 2800 in3 60 to 85 1 2 OD 7 to 9 per axle 5 16 ID Only 12 gal 75 to 100 5 16 ID 7 to 9 per axle 5 16 ID Only Notes Air line sizes shown with an outer diameter measurement are for DOT approved nylon air brake tubing meeting SAE J844 Air line sizes shown with an inner diameter measurement are for DOT approved reinforced rubber hose meeting SAE J1402 For Pneumatic Control Unit to Glad Hand plumbing when using a coiled hose include the coiled hose length in the overall measurement Example A 22 coil air hose with a 15 working length is actually 22 in length Wire braid hose diameter is inside diameter I D Nylon hose diameter is outside diameter O D 66 c an w I ze i 4 Iz Connector Illustrations All views shown looking into connector 67 Harness Connectors OCP J1939 Can Link Diagnostics DDM Terrain Switch DDM Display m oc Bw Harness and Component Connectors Pressure Switch Harness Component Speed Sensor PCU Sensor Configuration PCU Sensor PCU Sensor Conn
13. PCU Sensor signal wire open PCU Sensor signal wire shorted to ground PCU Sensor XDCR VREF wire open PCU Sensor XDCR VREF wire shorted to ground PCU Sensor XDCR COMMON wire open Faulty PCU Sensor Faulty Electronic Control Unit No operation High pressure transducer reading PCU Sensor signal wire shorted to VBATT or XDCR VREF Faulty PCU Sensor Faulty Electronic Control Unit Code Description Group 5C displays when the Electronic Control Unit ECU receives an unusually high or low reading from the PCU Sensor A diagnostic tool will specify 33 for a high reading and 34 for a low reading Initial troubleshooting steps involve checking for a shorted to ground or an open PCU Sensor circuit If the circuits check out OK secondary causes could involve a faulty transducer or a faulty Electronic Control Unit See Troubleshooting Tips for general guidelines on system diagnostics 25 PCU Sensor Harness Connector ECU Harness Connector Service Codes PCU Sensor Codes 33 34 With ignition off inspect socket connections at ECU connector and at PCU sensor 3 way T gt 75 7 oe A Replace ECU ls voltage Note ECUs are not a typical cause of Are between 4 9 and NoJ9 problems If an ECU is replaced the Repair c
14. Type Tire Leak Confirm failure System Mode Condition Possible Causes Listed in Likely Order of Occurrence Inflate only Channel confirmation Damaged or leaking tire Leaking line between wheel valve and tire Air passage restriction Wheel Valve shut off failure Air Pressure Check The Tire Pressure Control System is not continuously pressurized pressure checks occur on a periodic basis During tire pressure checks the system delivers compressed air to each channel for approximately two seconds while monitoring the pressure in that channel Code Description Group 10P code indicates that the system is unable to confirm that tires on a given channel are able to sustain the target pressure when the channel is depressurized After any change of pressure on a given channel the Tire Pressure Control System will return to that channel to confirm or double check the new pressure before returning to the periodic check interval If the pressure is not the same or more than the last reading the system will inflate again and then reconfirm that channel After 7 10 confirmation attempts the system will log a 10P code and complete Operations on any remaining channel It will then illuminate the check tires warning or code 10P on the OCP and the appropriate channel indicator and continuously pressurize the subject channel to inflate the tire s and sustain the tire pressure In this manner th
15. power ECU harness connector pin K1 and ground ECU harness connector pin K2 Inspect fuses Is voltage within range No repair harness to power ECU Yes Y Check continuity between ECU and DDM Display or OCP Harness Pin Harness Pin Harness Pin K3 6 9 J3 T 10 Is there continuity Inspect and repair communications circuit in harness faulty Yes y Check for communication circuits shorted to ground power or shorted to each other Check between Replace ECU Note ECUs are not a typical cause of problems If an ECU is replaced the system should be carefully rechecked to make sure the problem has been fixed and does not reoccur No DDM Display Harness Pins or OCP Harness Pins 6 and 4 9 and 6 7 and 4 10 and 6 7 and 5 9 and 5 6 and 5 10 and 5 6 and 7 9 and 10 Inspect and MT s repair faulty Is any circuit shorted Yes Wire or connection No Replace driver interface e Switch on ignition 4 34 Is driver interface functioning correctly Ye Complete 24 gt gt 75 17 Service Codes Group 5C Codes 33 34 Type PCU Sensor System Mode Condition Possible Causes Listed in Likely Order of Occurrence No operation No PCU sensor reading PCU Sensor electrically disconnected
16. Code Summary Diagnostics Group Code System Status Description 1C 17 No Operation Power battery voltage out of range at the ECU 3C 18 Normal Operation Speed Signal no speed detected during multiple ignition cycles 76 Normal Operation J1587 Speed Message not receiving expected messages on J1708 data link 77 Normal Operation J1939 Speed Message not receiving expected messages on data link 4C 15 Inflate Only Display Control Communications ECU not receiving communications from user interface 5C 33 No Operation PCU Sensor signal voltage too high 34 No Operation PCU Sensor connector unplugged signal voltage too low 12C 51 No Operation PCU Solenoid Front connector unplugged faulty wiring or solenoid 52 No Operation PCU Solenoid Rear connector unplugged faulty wiring or solenoid 53 No Operation PCU Solenoid Trailer connector unplugged faulty wiring or solenoid 54 No Operation PCU Supply Solenoid connector unplugged faulty wiring or solenoid 55 No Operation PCU Deflate Solenoid connector unplugged faulty wiring or solenoid 56 No Operation PCU Control Solenoid connector unplugged faulty wiring or solenoid 1P 11 No Deflation Deflate Signal Front could not generate a vacuum in control lines 12 No Deflation Deflate Signal Rear could not generate a vacuum in control lines 13 No Deflation Deflate Sign
17. Gi 71939 A gt 31939 J1939 11939 SHIELD 5 COMMUNICATIONS GROUND A gt conet P CONFIGURATION Pow C SELECTION conrig2 p PNEUMATIC CONTROLLER e Jumper plug may tie each config line to POWER or GROUND to select config See configuration connectors for details 68 m rj p m iv D co rj 3 o rj Driver Interface Options 69 Driver Display Module DDM COMM GROUND POWER COMM COMM COMM GROUND DIMMER DIMMER DIMMER POWER GROUND POWER LAMP DIMMER GROUND GROUND GROUND GROUND GROUND POWER DIMMER DIMMER N Operator Control Panel OCP COMM 9 COMM 10 GROUND 6 POWER 5 LAMP DIMMER 8 NO CONNECTION 7 NV VV Or Display Load Switch Terrain Switch Configuration Connections CONFIG 0 HARNESS CONNECTOR GROUND CONFIG 2 CONFIG 1 A B D CONFIG 2 A B C CONFIG 3 HARNESS L3 CONNECTOR OR GROUND CONFIG 1 C WITH OPTIONAL TRAILER D POWER CONFIG 2 CONFIG 4 HARNESS LJ CONNECTOR A WITH OPTIONAL TRAILER D E OR n 7
18. at least 125 psi Repair air system and retest system Refer to Service Manual Yes Y Using the diagnostic tool check faults to identify the faulty channel Front 23 24 Trailer 25 Initiate deflate mode on the identified channel Are the wheel valves deflating slowly gt On the tire or axles that deflate slowly check for Restricted wheel valve exhaust port e Clogged wheel valve filters Plugged tire valve stem Refer to Service Manual No Y Initiate inflate mode on the identified channel and check for crimped or restricted lines 36 gt a 3 4 N N N gt Service Codes Group 5P Codes 26 27 28 Type Low Pressure Reading System Mode Condition Possible Causes Listed in Likely Order of Occurrence Pressure Check Only Extreme pressure loss Leaking axle seals Open line between Pneumatic Control Unit to channel Crimped or plugged line between supply tank and Pneumatic Control Unit Pressure switch failure shorted closed Pneumatic Control Unit failure supply or control off Faulty pressure transducer Air Pressure Check The Tire Pressure Control System is not continuously pres surized pressure checks occur on a periodic basis During tire pressure checks the system delivers comp
19. conditions only and should not be used for normal driving System Operation wx CTIS S FRT RR TLR OVERSPEED CHECKTIRE e Display The DDM uses a multi function display to indicate the current selections The display will show HY for highway pressures OH for off highway pres sures and E for emergency pressures e Terrain Selection The terrain selection is changed by depressing the terrain rocker switch up to increase pressures and down to decrease pressures Any switch operation which does not change pres sures will command the system to do a pressure check e Load Selection Vehicle load selection is repre sented by a horizontal bar graph under the mode dis play Depress the load rocker switch to change the selection up for increasing load and down for decreasing load A CAUTION Operating a loaded vehicle at unloaded tire pressures may result in tire overheating and reduced tire life or blowout e Pressure Display If the terrain switch is held in the up position for 5 seconds numerical tire pressures in PSI for each channel will alternate in the display with the selected mode Note The system is designed to allow tire pressure increase due to heat buildup during vehicle use This system will not automatically deflate these pressure buildups lower pressure mode selection by the operator must be selected to initiate a deflate e Channel
20. for audible air leak in PCU E T v 17 42 Service Codes Group 9P Codes 36 37 38 Type Inflate Trend System Mode Condition Possible Causes Listed in Likely Order of Occurrence Channel inoperative Loss of channel pressure in inflate mode Damaged or leaking tire Leaking lines Leaking seals Leaking wheel valve Faulty Pneumatic Control Unit Faulty Electronic Control Unit Code Description Components located after the wheel valve that may cause a code 9P include Group 9P displays when system pressure is dropping while e Tire damage in inflate mode This can occur when air is leaking from the tire s or the system more quickly than the compressor can e leaks replace it The air leak that is causing code 9P is often audi e Valve stem leaks ble Codes 36 37 and 38 designate the condition on the front rear or trailer channel respectively e Leaking air lines from the wheel valve e Faulty wheel valve The air leak can be located either before or after the wheel valve location The components located before the wheel To identify the root cause of the problem connect the valve that may cause a group 9P include e Leaking control lines between the PCU and the wheel ends e Leaking axle air seals e Leaking wheel valve inlet lines or exhaust por
21. on a periodic basis During tire pressure checks the system delivers compressed air to each channel for approximately two seconds while monitoring the pressure in that channel 49 Code Description Group 12P code indicates that the system is unable to confirm that tires on a given channel are able to sustain the target pressure when the channel is depressurized After any change of pressure on a given channel the Tire Pressure Control System will return to that channel to confirm or double check the new pressure before returning to the periodic check interval If the pressure is not the same or more than the last reading the system will inflate again and then reconfirm that channel After 7 10 confirmation attempts the system will log a 12P code and complete Operations on any remaining channel The system will classify the loss of air due to wheel valve closure as minor codes 61 62 and 63 on front rear and trailer respectively or major codes 64 65 and 66 on front rear and trailer respectively Note Leaks from the tire s may be noted after the truck has been idle overnight as the tire s lose s air when the truck is off and the system inoperative By observing the time required to achieve normal tire pressures after starting the vehicle many tire punctures can be identified well before the tire incurs non repairable damage A confirmation failure can be caused by e Damaged or leaking tire s e Leaking air
22. service of this unit Always use genuine Spicer replacement parts Every effort has been made to ensure the accuracy of all infor mation in this guide However Dana Commercial Vehicle Systems Division makes no expressed or implied warranty or representation based on the enclosed information Any errors or omissions may be reported to Marketing Services Dana Commercial Vehicle Systems Division Box 4097 Kalamazoo MI 49003 Table of Contents General Information Service Procedures m Tire Pressure Control System 1 Final System Checkout 99 Key Feature obe ve Rb ERI USt 1 Pneumatic Control Unit Cleaning and Inspection 57 Component Description 2 Solenoid Assembly and Cartridge 59 Simplified System Schematic 4 Service Guidelines 61 s Joint Compounds and 06 61 Operator Instructions Air Filter Change dietus bald a Be reta 62 a Troubleshooting Wheel End Seals 63 Driver Display Module DDM 5 Hose and Supply Tank Selection Chart 65 Operator Control Panel OCP 8 OCP Programming 12 Wire Harness Diagnostics Connector Illustrations Fd Sa tur Dra E S C Nd 67 Electrical 68 Diagnosti68 i oe 13 Configuration Connecti
23. trigger a service code Possible Causes Since a service code was not set these conditions may be universal and not call for a troubleshooting routine Service Where fault codes appear refer to the troubleshooting procedures listed under that code DRIVER INTERFACE DDM or OCP Intermittent Driver Interface operation Intermittent ground or power connection to Driver Interface or Electronic Control Unit Follow troubleshooting for 4C group No operation blank display Fuses Faulty ground or power connection Check fuses Repair power ground Blank Driver Interface No power to Driver Interface Bad ground to Driver Interface Bad switched ignition line to Driver Interface Faulty Driver Interface Voltage out of range 9 18 volts Follow troubleshooting for 4C group Operator Control Panel display is always dim and no backlighting on Operator Control Panel buttons Lamp 2 wire is disconnected It should be grounded for bright and tied to 12V for dim and backlight See wiring schematic or Installation Guide System loses programmed tire pressure settings Intermittent connection at config connector Improperly followed programming procedure Faulty Electronic Control Unit See wiring schematic Reference programming procedure Replace Electronic Control Unit No display of pressures on Operator Control Panel Operat
24. wheel valve filter Make repairs to faulty components and 4 recheck the system Refer to Service Manual Are any wheel readings high No Y Place the channel into the inflate mode and check for audible leaks Place channel in normal mode 28 2 gt Make repairs to faulty components and recheck system Refer to Service Manual an audible leak Also check axle Check the system for kinked lines Repair faulty components and recheck the system Refer to Service Manual Does wheel valve close No Y Place the channel into the hold mode and check for leaks using a soap solution if necessary to locate the source of the leak No Is leak found N Replace the wheel valve and recheck system Refer to Service Manual Yes Y Make repairs to faulty components and recheck system Refer to Service Manual 48 Service Codes Group 12P Codes 61 62 63 64 65 66 Type Wheel Valve Shut Off System Mode Condition Possible Causes Listed in Likely Order of Occurrence Normal Operation Loss of pressure during shut off Wheel Valve shut off failure Air passage restriction Air Pressure Check The Tire Pressure Control System is not continuously pressurized pressure checks occur
25. will enable disassembly Inspect condition of poppets 14 15 inside operator Note Deflate plunger 15 is specific to the deflate operator and is identified by its solid metal top If poppets appear in good condition thoroughly clean poppet and operator assembly Verify the absence of any sticky residue from oil contamination 10 11 12 13 Reassemble each operator with the base Do not install assemblies on PCU body until it is completely cleaned Spray cleaning solvent on cartridge bores within PCU body to remove debris and oil residue Thor oughly dry cartridge bores prior to further assembly Replacing cartridges is not typically required however it may be desirable to replace the 3 outer O rings on each or any individual cartridge These are standard nitrile O rings and the sizes are provided on the following page Replacement cartridges are available if required See Illustrated Parts List AXIP 0010 Lightly lube cartridge O rings with silicone grease and install cartridges in body verifying that the one normally closed cartridge 9 is installed in the Supply IN port Note Excess lube on piston O rings can block hole from sole noid to top of piston Be careful only to wipe lube on O rings Do not pack grooves 14 15 16 17 Install base gasket 10b base cover plate 10a and screws 10 If 3 channel Pneumatic Control Unit install gasket 10d plate 10c and screws 106
26. 50 ECU resets with no active faults 13 Service Codes The Service Codes are described in the Troubleshooting section Some service codes also identify the component that is associated with the problem A list of possible causes is shown in order of most likely occurrence Test Modes Diagnostic tools allow the system to be placed in several diagnostic modes Info Display ECU information and configuration Codes Active and historic codes are listed as reported by the ECU Monitor Normal TPCS operates normally while status of system components is observed Test The following operations can be performed on each channel axle group e Check amp Hold System checks and displays the pressures then holds pressure in air lines quick test of control line and seal integrity e Deflate System manually deflates test the deflation signal e Inflate System manually inflates test for large leaks e Hold Pressure is held in control lines test for small leaks Setup Allows the technician to modify parameters such as target tire pressures etc Diagnostics PC Diagnostics To use this program an RP1210A compatible interface box and cables are needed to connect the PC to the vehicle A CAUTION For these types of interface boxes to work with the Dana Diagnostic Tool program you must install RP1210 driver A battery charger is not an adequate source of power 1 4 program provide
27. CU 22 inHg Individual channels 1 inHg of Isolated PCU 55 Service Procedures Use Diagnostic tool to MONITOR SYSTEM e Deflate the system by selecting Highway Unloaded Upon successfully achieving Highway Unloaded use pressure gauge to verify tire pressures are within 3 psig of desired pressure e Select Highway Loaded Upon successfully achieving Highway Loaded use pressure gauge to verify tire pressures are within x3 psig of desired pressure e Drive vehicle and verify diagnostic tool display coincides with vehicle speedometer If not recalibrate the pulse mile count in the Modify System Data section of the diagnostic tool Is the vehicle speed calibrated Yes No Use Diagnostic tool to DISPLAY SERVICE CODES e Verify no codes have been set during checkout process clear if necessary Exit diagnostics Note If any suspected issues arise inflation and deflation to other mode settings is appropriate to aid diagnosis a c lt an c 11 rJ A e 56 Service Procedures Pneumatic Control Unit Cleaning and Inspection The following describes the procedure for disassembly cleaning and inspection of the Spicer Tire Pressure Control System Pneumatic Control Unit P N 673336 and 673316 Components requiring replacement can be found in the Illustrated Parts List AXIP 0010 A CAUTION Do not use cleaning solvents which are not compatible with elastomer or rubber comp
28. Deflate Restricted flow at wheel valve air filters or tire valve stems Plugged or restricted Pneumatic Control Unit vent port Leaking lines Plugged or restricted wheel valve exhaust port Code Description Group 4P displays if any channel inflates or deflates too slowly as shown below e 23 Front Channel e 24 Rear Channel e 25 Trailer Channel The maximum allotted time for each channel is 40 minutes for an inflate or 20 minutes for a deflate The most likely cause is a faulty compressor or similar problem resulting in inadequate air supply to the Tire Pressure Control System 35 If the system air supply is functioning properly code group 4P may indicate that a leak or restriction exists in an air passage The components that may contain a restricted or leaking air passage include e Wheel valve air filters e Pneumatic Control Unit PCU vent port restriction e Air supply lines e Wheel valve exhaust port deflate mode only To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 4P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Channel Between Modes Codes 23 24 25 Verify Tire Pressure Control System air system capacity by checking air system pressure buildup Does the air system build up to
29. Fault System Mode Condition Possible Causes Listed in Likely Order of Occurrence Inflate Only Inappropriate vacuum Faulty or contaminated Pneumatic Control Unit generation Code Description Group 3P displays when the system is generating a vacuum at a time when the Electronic Control Unit ECU is not requesting a vacuum Creation of an unexpected vacuum is highly unlikely The most likely cause of an unexpected vacuum is a contaminated or faulty Pneumatic Control Unit PCU Verify the problem before replacing the Pneumatic Control Unit See the procedure in the 3P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics 33 Vacuum Fault Code 21 Service Codes Verify the problem Replace or clean PCU Caution Verify clean no oil dry air system on vehicle This condition can be caused by contamination in PCU Reference PCU Cleaning and Inspection for cleaning procedure Verify the repair 34 9 iar N Service Codes Group 4P Codes 23 24 25 Type Channel Between Modes System Mode Condition Possible Causes Listed in Likely Order of Occurrence Pressure Check Only Slow Inflate Faulty compressor Restricted flow at wheel valve air filters or tire valve stems Crimped or plugged lines Slow
30. IRE A IMPORTANT Tires can still go flat Although the Tire Pressure Control System is designed to identify under inflated tires and fill these tires to the desired operating pressure you can still expect that tires will occasionally be punctured or other wise damaged during normal use and no longer retain air reliably A daily walk around inspection of the vehicle at the start of the day including a manual check of the tires is still an important responsibility of the vehicle operator Tire damage is more apparent after the vehicle has been idle overnight and will be more difficult to detect visually once the TPCS equipped vehicle is in operation Although obser vation of excessive inflation periods through the driver interface can help identify a tire problem you should have damaged tires replaced prior to placing the vehicle in oper ation Operator Instructions Terrain and Load Pressure Selection TPCS displays both the selected terrain and load and may be configured to display numerical tire pressures in PSI if desired Tire pressures for the following terrain modes can be programmed and may be selected by the operator e Highway For travel on paved surfaces at higher speeds e Off Highway OH For reduced speed operation on secondary roads and unpaved surfaces e Emergency E For selection of extremely low tire pressures to help free a stuck vehicle A CAUTION The Emergency selection is for extreme
31. Indicators The DDM indicates FRT RR or TLR respectively for front rear or trailer axle groups If a channel indicator is on continuously that chan nel has achieved the target pressure FRT RR TLR mE i N E 5 lt 7 5 Operator Instructions Service Code Indication The DDM will not display service codes directly but will exhibit two dashes if service is required Accessing the service codes will require a diagnostic tool Note See the Service Codes Section to diagnose and repair RUN FLAT Indicator If the TPC System determines that a tire or tires may not be holding air it may reduce the pressure check interval to minimize the possibility of air loss from the tire by switching to RUN FLAT operation See RUN FLAT in the Key Fea tures section If RUN FLAT is activated the DDM will alternate the display of the terrain setting and RF and the CHECK TIRE indicator will be illuminated 7 CHECKTIRE Tire Pressure Control System Programming Spicer s Tire Pressure Control System is fully programmable allowing the technician to program tire pressures for each channel axle group and maximum speeds for each terrain mode If equipped with the Driver Display Module DDM programming must be done with a diagnostic tool Programmable settings include Individual pressure settings for the front rear and trailer axle groups Loaded and unloaded axle group programming fo
32. N FLAT RUN FLAT reduces the pressure check interval to 15 seconds helping to assure that the tire will remain inflated despite minor tire damage General Information Component Description Tire Pressure Control System Components Driver Display Module DDM Operator Control Panel OCP Speed Sensor or Alternate Speed Inputs Pressure Switch Trailer Connector Pneumatic Control Unit shown with optional 3rd channel Electronic Control Unit c 3 3 3 57 a General Information Wheel Valve All axles use a Wheel Valve WV at each end Dual wheels are typically connected through one WV to provide tire pressure balance although individual wheel valves for each tire may be installed When the system is idle the wheel valve isolates the tire s ensuring fail safe operation A standard valve stem is included on the WV for manual inflation deflation pressure checking Electronic Control Unit ECU The Electronic Control Unit ECU is the control center for the entire Tire Pressure Control System The ECU receives com mands from the driver through the Driver Display Module DDM or Operator Control Panel OCP and transmits and monitors appropriate signals throughout the system Driver Interface Options are available for the TPCS driver interface The Driver Display Module DDM includes two rocker switches and a mu
33. Unit Faulty Pneumatic Control Unit Inflate Only No sustained vacuum in Line leaks control lines Air seals oil lip seals Code Description Group 1P indicates inadequate vacuum in the Pneumatic Control Unit PCU prior to channel selection or failure to sustain a vacuum in the control lines following channel selection These codes will be set when the nominal vacuum of 26 Hg drops to 17 Hg Codes can be generated by one channel multiple channels or a combination of channels When a deflate is requested the system first shuts off all the channel control lines and generates a vacuum in the Pneu matic Control Unit alone A failure to generate this vacuum will result in Diagnostic Code 22 Once the vacuum has been established in the Pneumatic Control Unit the individual channel control line s are opened and a vacuum is routed to them If a vacuum is not sustained in the control lines a 1P fault is logged as follows 11 Front Channel 12 Rear Channel 13 Trailer Channel 16 Individual channels OK but a combination of channels results in low vacuum Note If a vacuum loss occurs during an attempt to deflate two or more channels at the same time the system will halt the deflate and re attempt it one channel at a time This will result in a Code 16 being stored in the ECU 29 Group1P can be caused by e Line leak e Air seal or oil lip seal leaks e Plugged or restricted Pneumatic Control Unit ven
34. al 18 to 21 5 8 OD 6 to 8 per axle 5 16 ID Only 21 to 25 13 32 ID 6 to 8 per axle 5 16 ID Only 25 to 29 1 2 OD 6 to 8 per axle 5 16 ID Only Dual Front 2 Axle 1 Driven 1 Non Driven 2800 in3 12 gal 18 to 21 5 8 OD 6 to 8 per axle 5 16 ID Only 21 to 25 13 32 ID 6 to 8 per axle 5 16 ID Only 25 to 29 1 2 OD 6 to 8 per axle 5 16 ID Only Rear Channel Plumbing Requirements Min Tank Size Main Run Jounce Single Rear 1 Axle 1400 in3 15 to 17 5 8 OD 7 to 9 per axle 5 16 ID Only 6 gal 18 to 20 13 32 ID 7109 per axle 5 16 ID Only 21 to 24 1 2 OD 7 to 9 per axle 5 16 ID Only Tandem Rear 2 Axle 1400 in3 14 to 17 5 8 OD 7 to 9 per axle 5 16 ID Only 6 gal 16 20 13 32 ID 7 to 9 per axle 5 16 ID Only 18 to 24 1 2 OD 7 to 9 per axle 5 16 ID Only Tridem Rear 3 Axle 2800 in3 16 to 20 13 32 ID 5107 per axle 5 16 ID Only 12 gal 18 to 24 1 2 OD 5 to 7 per axle 5 16 ID Only 65 Service Procedures Trailer Channel Plumbing Requirements Min Tank Size Main Run Jounce Tractor PCU to Glad Hand N A 16 to 22 5 8 OD 19 to 25 13 32 I D 22 to 30 1 2 OD Single Trailer 2 to 3 Axles 1400 in3 35 to 40 1 2 OD 7 to 9 per axle 5 16 ID Only 6 gal 40 to 50 5 16 ID 7 to 9 per axle 5 16
35. al Trailer could not generate a vacuum in control lines 16 Normal Operation Deflate Signal could not generate a vacuum in one or more channel s control lines 22 Inflate Only Deflate Signal PCU could not generate a vacuum in pneumatic control unit 2P 14 Inflate Only Deflate Trend tire pressure did not decrease properly during deflate 3P 21 Inflate Only Vacuum unintentional vacuum in PCU 4P 23 Pressure Check Only Between Modes Front inflated or deflated too slowly 24 Pressure Check Only Between Modes Rear inflated or deflated too slowly 25 Pressure Check Only Between Modes Trailer inflated or deflated too slowly 5P 26 Pressure Check Only Low Pressure Front open line or large seal leak 27 Pressure Check Only Low Pressure Rear open line or large seal leak 28 Pressure Check Only Low Pressure Trailer open line or large seal leak 7P 31 Pressure Check Only Pressure Switch failed closed or wiring shorted 32 Pressure Check Only Low Air Supply pressure switch did not close 8P 35 Pressure Check Only Atmospheric PCU sensor reading out of range 9P 36 Channel Inoperative Inflate Trend Front tire pressure decreased during an inflate 37 Channel Inoperative Inflate Trend Rear tire pressure decreased during an inflate 38 Channel Inoperative Inflate Trend Trailer tire pressure decreased during an inflate 17 Diagnostics Group
36. and recheck system Complete 38 v gt i 1 7 N N Service Codes Group 7P Codes 31 32 Type Low Air Supply System Mode Condition Possible Causes Listed in Likely Order of Occurrence Pressure switch won t close 32 Pressure check only Compressor governor cut out set too low Air dryer needs service Pressure switch unplugged Open or broken line from supply tank to Pneumatic Control Unit Crimped or plugged line from supply tank to Pneumatic Control Unit Faulty pressure switch Faulty compressor Supply Tank pressure too low 32 Governor cut in too low Faulty compressor Leaking lines Pressure switch failed closed 31 Wiring to pressure switch shorted together Faulty pressure switch Air Pressure Check The Tire Pressure Control System is not continuously pressurized pressure checks occur on a periodic basis During tire pressure checks the system delivers compressed air to each channel for approximately two seconds while monitoring the pressure in that channel Code Description Group 7P displays if the system air pressure supply is too low to perform a valid tire pressure check This may occur because the pressure switch will not close inadequate air supply code 32 or because the pressure switch or its wiring is shorted allowing the actual s
37. and should not be used for normal driving E J gt a D Operator Instructions System Operation Gin ES a Oo QOO o0 UV M HWY 00 Ea 4 Display The OCP uses graphic display to indicate the selection for both terrain mode and vehicle load Above the selector keys labeled HWY highway OFF HWY off highway and EMER emergency an illu minated arrow designates the current selection Terrain Selection The terrain selection is changed by depressing the desired mode on the keypad When the system is actively changing tire pressure the arrow above the target mode will flash Pressing the key for a current mode will command a pressure check Load Selection Vehicle load selection is represented by an arrow above the rear wheels in the graphic display Depress the keypad button labeled L U to change from loaded to unloaded A CAUTION Operating a loaded vehicle at unloaded tire pressures may result in tire overheating and reduced tire life or blowout Pressure Display If the keypad button labeled Select is pressed after vehicle start numerical pres sures will be displayed sequentially for each active channel Subsequent actuation of the Select key will lock the display on individual channels or turn it off again Note The system is designed to allow tire pressure increase Channel Indicators The OCP display
38. before and after each deflate If the pressure readings indicate that the pressure either increased or failed to drop properly the system shuts down the deflate sequence Group 2P can be caused by e Plugged or restricted control lines e Plugged or restricted Pneumatic Control Unit vent line e Contaminated or faulty Pneumatic Control Unit To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 2P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics 31 Service Codes Deflate Trend Code 14 Use diagnostic tool to manually deflate the tires on each channel N p 75 17 gt Check for conditions preventing vacuum reaching tires Restrictions in valve stems valve cores filters rubber etc Restricted PCU vent line Loss of vacuum on channel see 1P flowchart e Inoperative or restricted wheel valve All tires on each channel deflate Yes y Replace or clean PCU Caution Verify clean no oil dry air system on vehicle This condition can be caused by contamination in PCU Reference PCU Cleaning and Inspection for cleaning procedure Verify repair by monitoring System deflate 32 Service Codes Group 3P Code 21 Type Vacuum
39. d by the manufacturer of the interface box If you do not have this program it can normally be obtained from the manufacturer s web site Please contact the manufacturer of your interface box if you have any questions regarding this process Visit www dana com for free download of Dana Diagnostic Tool DDT PC diagnostics are easy to use and provide the quickest diagnostic capabilities e Retrieve historical data faults and tire pressures e Pressurize system to detect leaks e Access troubleshooting flowcharts and service procedures Connect to diagnostic connector Attach computer to RP1210A communications box Download free Dana Diagnostic Tool from dana com Note Program requires Windows 98 or AW KLAUS Caution Test Mode wil allow tire pressures to go past preset imis Follow on screen instructions i J e y an Diagnostics Handheld Tester A Prolink handheld tester may be used to read and clear service codes and to obtain a short description of failures The tester can initiate test sequences for controller outputs and can also read system parameters when equipped with the Dana program card 15 Multimeter Based upon system schematics and aided by component specific service codes a multimeter can be used to check sensor and solenoid resistances and to find wiring harness faults The multimeter can be used to chec
40. e system will determine whether the failure to confirm was due to tire or air line leakages codes 41 42 and 43 on front rear and trailer respectively or failure of the wheel valve to properly close Note Leaks from the tire s may be noted after the truck has been idle overnight as the tire s lose s air when the truck is off and the system inoperative By observing the time required to achieve normal tire pressures after starting the vehicle many tire punctures can be identi fied well before the tire incurs non repairable damage 45 A confirmation failure can be caused by e Damaged or leaking tire s e Leaking air line between the wheel valve and tire e Air passage restriction between the PCU the wheel valve e Wheel valve contamination or failure To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 10P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Tire Leak Confirm Codes 41 42 43 Service Codes Stop vehicle and connect the diagnostic tool to the system Identify affected channels Front 41 Rear 42 e Trailer 43 Tire or air line leak Spray soap solution on tires bead area wheel valve and wheel valve hose Repair all leaks and perform checkout test 46 i
41. ector tea PCU c A Connector PCU 10 way R ala mok Pneumatic Control Unit Electrical Schematic Note Schematic is shown for point to point troubleshoot ing only Actual OEM implementations may vary with bulkhead connectors etc ECU Connector COND SPEED DIMMER PRESS SW GROUND J1708A J1708B J1939 4 J1939 J1939 SHIELD C3 CONFIG 1 CONFIG 2 SUPPLY SOL DEFLATE SOL CONTROL SOL STEER SOL DRIVE SOL TRAILER SOL XDCR SIGNAL XDCR VREF XDCR COMMON CONDITIONED SPEED INPUT DIMMER INPUT 0V Dim 12V Bright SPEED A SPEED B SPEED SENSOR INPUT or COND SPEED DIMMER Note Not used with DDM BUZZER LAMP BUZZER OUTPUT 5V 25mA MAX PRESS SW PRESSURE GROUND Ls SWITCH INPUT COMM XX COMM DRIVER END INTERFACE POWER Note Actual connector may not be present LAMP See next page for options OCP or DDM VEHICLE POWER PANEL GROUND A VBATT DASH LAMPS IGNITION 15 A FUSE SWITCH SUPPLY x00 DEFLATE 00 CONTROL gt 00 STEER gt 00 DRIVE gt REL K TRAILER 1 gt 1 00 T 3CHANNEL SYSTEMS gt gt PCU SENSOR A SWACC 9 PIN 6 PIN POWER B C SCR Alore X X 117088
42. engths for each channel Incorrect air line replacement can affect both performance and operation of the system Refer to the Tire Pressure Con trol System service manual for length and diameter infor mation 61 Joint Compounds and Fittings Here are some important DO s and DON Ts regarding the use of thread sealant Do apply a thin coating of PTFE based compound on male threads of pipe joints tubing connections and other system fittings Don t use any compound on O ring compression or flare fitting connections Instead apply a thin coat of silicone grease to O rings and flares Don t use Teflon thread tape anywhere in the air system Teflon tape shreds can become lodged in valves and cause malfunctions Do follow manufacturer recommended guidelines when tightening fittings Service Procedures Air Filter Change prevent air loss SAE 37 degree flare plug 3 8 tube size 9 16 18 thread The Air Filter Change illustration shows the location of the air 2 Remove the adapter fitting from the tire port filter in each wheel valve This filter must be replaced when ever the tire or wheel valve is serviced Use the illustration as a reference in completing the air filter replacement as follows Use a flat blade screwdriver to remove unscrew counterclockwise the air filter from the wheel valve Discard the used air filter A WARNING 4 Install a new air filter by pressing it straight into wheel valve
43. es Y Initiate deflate mode on the trailer channel Record the reading Initiate inflate pressure hold on channel with the lowest vacuum reading e Check for leaks Make repairs to faulty components Initiate pressure check and hold on trailer channel Check all air lines and fittings for leaks as well as exhaust port of wheel valves Make repairs to faulty components Is the vacuum gt 20 Hg Verify by initiating deflate mode on repaired channels Note Line leakages occasionally occur which are unidirectional i e they might occur under vacuum and not pressure or vice versa Inability to determine the cause of vacuum loss on an individual channel may dictate replacement of air lines and or fittings on that channel Be sure all replaced air lines and fittings are identical in all respects including length to the parts replaced 30 Service Codes Group 2P Code 14 Type Deflate Trend System Mode Condition Possible Causes Listed in Likely Order of Occurrence Inflate Only Pressure increased or failed Plugged or restricted control lines to drop appropriately Plugged or restricted Pneumatic Unit vent line Plugged or restricted wheel valve exhaust port Faulty Pneumatic Control Unit Code Description Group 2P is the result of a deflate that did not occur properly The system measures tire pressure
44. fy the extent of tire damage 2 IMPORTANT Tires can still go flat Although the Tire Pressure Control System is designed to identify under inflated tires and fill these tires to the desired operating pressure you can still expect that tires will occasionally be punctured or other wise damaged during normal use and no longer retain air reliably A daily walk around inspection of the vehicle at the start of the day including a manual check of the tires is still an important responsibility of the vehicle operator Tire damage is more apparent after the vehicle has been idle overnight and will be more difficult to detect visually once the TPCS equipped vehicle is in operation Although obser vation of excessive inflation periods through the driver interface can help identify a tire problem you should have damaged tires replaced prior to placing the vehicle in oper ation Terrain and Load Pressure Selection TPCS displays both the selected terrain and load and may be configured to display numerical tire pressures in PSI if desired Tire pressures for the following terrain modes can be programmed and may be selected by the operator e HWY For travel on paved surfaces at higher speeds e OFF HWY For reduced speed operation on secondary roads and unpaved surfaces e For selection of extremely low tire pressures to help free a stuck vehicle A CAUTION The EMER key is for extreme conditions only
45. g tire pressures or during pressure checks Wheel valves isolate the tires from the rest of the system Electronic Braking Priority A pressure switch installed in the supply tank controls the TPCS s use of air This optimizes and protects the brake sys tem s primary tank pressures during system operation Self Diagnostic and Auto Shut Down The Spicer TPCS provides self diagnosis during operation If the system detects a problem it will display a service code on the driver interface to alert the driver If necessary it will close the wheel valves and shut down Diagnostic Capability The Spicer TPCS provides for easy troubleshooting using PC based or industry standard tools PC supported diagnostics improve troubleshooting reduce maintenance time provide manual control of TPCS test sequences and give historical and active service code data Speed Pressure Control and Warning If truck speed exceeds the maximum allowable speed for a given setting a warning is activated by TPCS to alert the driver If speed is not reduced the system automatically inflates the tires to the appropriate pressure Manual Tire Inflation Deflation A valve stem has been included on each wheel valve and may be used for manual inflation deflation or measurement of tire pressures Run Flat Operation The TPCS normally checks tire pressures at intervals of 15 minutes If possible tire damage is detected the system will activate Auto RU
46. gnostic tool to pressurize and hold the faulty channel Locate leak check axle vents for air leakage also repair and recheck system Does pressure drop quickly Yes No Y Verify that the pressure switch opens when the supply tank is below 80 psi Note Primary and secondary air brake gauges do not reflect actual pressure in the supply tank Does the pressure switch open Replace pressure switch and recheck system Refer to Service Manual Is there a restricted line between the wet tank and Yes Identify cause of air loss repair and recheck system Refer to Service Manual PCU After a pressure check is the pressure reading 5 psi No Y Check harness and PCU for open supply or control solenoids See Group 12C PCU Solenoids Codes 54 or 56 for procedure E Replace PCU and recheck system Note While replacing the PCU pay particular attention to possible air line contamination e g oil water particles which may suggest further air system maintenance needs Refer to Service Manual Does fault reoccur Yes Replace ECU and recheck system Note ECUs are not a typical cause of problems If an ECU is replaced the system should be carefully rechecked to make sure the problem has been fixed and does not reoccur Replace PCU sensor
47. icer TPCS and an accurate tire pressure gauge Select Highway Loaded Upon successfully achieving Highway Loaded verify tire pressures are within psig of desired pressure If significant tire imbalance exists balance should be achieved by using the system to generate a short deflate followed by re inflating the tires or by manually adjusting Verify governor cut out pressure Acceptance criteria 120 125 psig Verify the Pressure Switch cycles open amp closed during inflation Yes No Use Diagnostic tool to verify proper configuration If downloadable configuration is used verify proper pressure settings speeds etc have been set Use Diagnostic tool to DISPLAY SERVICE CODES e Clear any existing historical codes Use Diagnostic tool to PERFORM DIAGNOSTIC TESTS e Select channel and Pressure Check Tires and Hold option to pressurize each individual channel Check for air leaks record the initial pressure and then the stabilized pressure 10 seconds later System Pressure Front Rear Trailer Initial Pressure Pressure after 10 sec Acceptance criteria Pressure should not drop e Select item Pneumatic Control Unit then Read Isolated PCU Vacuum and record PCU vacuum Next individually select each channel and record System Pressure while deflating Isolated PCU Vacuum Front Rear Trailer PSIA inHg inHg inHg inHg Acceptance criteria Isolated P
48. includes rings inside the tires of the truck graphic The pressure shown in the display reflects the channel with the lighted rings Service Code Indication The OCP will display ser vice codes using a number and letter combination followed by an exclamation point Note See the Service Codes Section to diagnose and repair Metric English Indicator The OCP may be pro grammed to display pressure in metric BAR or English PSI units see Programming section RUN FLAT Indicator If the TPC System determines that a tire or tires may not be holding air it may reduce the pressure check interval to minimize the possibility of air loss from the tire by switching to RUN FLAT operation See RUN FLAT in the Key Fea tures section If RUN FLAT is activated an asterisk will be illu minated in the display of the OCP This asterisk matches the symbol on the RUN FLAT key and it indicates that the RUN FLAT feature is selected The OCP also allows the driver to select RUN FLAT by depressing that key to manually reduce the pressure check interval This may be desirable when operating under conditions i e sharp rocks or construction debris where tire punctures may be anticipated The RUN FLAT feature will automatically de select after 10 minutes but may be re selected due to heat buildup during vehicle use This system will not automatically deflate these pressure buildups lower pressure mode selection by the opera
49. k the Tire Pressure Control System wiring and components for e Continuity e Ground e Broken wires e Open circuits e Shorted circuits e Incorrect battery voltage Diagnostics Troubleshooting Tips This checklist outlines some general hints and guidelines that will be helpful in tracking down and correcting operating problems Operator Control Panel only displays one active code Only the most recent service code displays on the Operator Control Panel In troubleshooting be alert for related codes Use of a diagnostic tool offers the advantages of spotting mul tiple active codes as well as retrieving historical codes Acleared code alone does not indicate a corrected problem A code is set by a specific fault condition and may be cleared by switching the ignition off It s possible to clear a code i e remove it from the driver interface only to have it display again when the fault condition reoccurs To ensure that a problem is fixed you must run the system through the same operating modes that caused the problem and verify that the service code does not appear Disconnect the Electronic Control Unit connector with igni tion off To avoid setting electrical service codes make sure that the ignition is off before unplugging the wire harness connection at the Electronic Control Unit module Reconnect the connector before switching on the ignition C Service Codes are often connection problems The m
50. l Wheel Valve Assembly Assembly Valve Tire Tire System Key Pneumatic mammam Flectrical Operator Instructions Operator Instructions Driver Display Module DDM TPCS may be equipped with one of two driver interface devices a Driver Display Module DDM or an Operator Con trol Panel OCP The Driver Display Module DDM is illus trated below and the following section explains the features and use RR TLR OVERSPEED CHECKTIRE Warning Icons TPCS includes two distinct warnings to report possible tire problems and inappropriate vehicle operation You must take immediate action to either reduce vehicle speed or check tire condition whenever these warnings are displayed Reduce Vehicle Speed A CAUTION Failure to respond may result in overheated tires and possible tire failure This signal reports that the vehicle speed is too fast for the pressure selected You must either reduce speed or select a higher pressure by pressing the appropriate key Continued operation in this mode will result in the system automatically selecting a more appropriate pressure setting OVERSPEED Check Tire Condition This signal reports that one or more tires may be at a signifi cantly lower pressure than the others and could indicate that a tire is not holding pressure Stop the vehicle immediately in a safe place and identify the extent of tire damage CHECKT
51. l falsely identify the 7 25 ohm coils as shorted Are any pins shorted to ground Repair or replace connections coils or PCU No Y Disconnect ECU harness connectors e Check continuity of harness pins shown in chart for given fault code PCU harness connector to ECU harness connector Are circuits continuous Repair or replace harness Yes Y Measure at PCU harness connector e Verify continuity between AandF Aand H e Verify no continuity between any combination of pins B C D E G K on PCU harness connector and K2 on ECU harness connector Do not use multi meter s continuity beep mode as most meters will falsely identify the 7 25 ohm coils as shorted Are connections OK Repair or replace harness Yes y Replace ECU ECU is replaced the system should be carefully rechecked to make sure the problem has been fixed and does not reoccur Note ECUs are not a typical cause of problems If an 28 E N gt 7 ol Service Codes Group 1P Codes 11 12 13 16 22 Type No Deflate Signal System Mode Condition Possible Causes Listed in Likely Order of Occurrence Inflate Only Inadequate vacuum the Plugged or restricted Pneumatic Control Unit vent line Pneumatic Control
52. line between the wheel valve and tire Air passage restriction between the PCU and the wheel valve e Wheel valve contamination or failure To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 10P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Wheel Valve Shut Off Codes 61 62 63 64 65 66 Stop vehicle and connect the diagnostic tool to the system N v Codes Front 64 Codes 64 65 66 Rear 65 e Trailer 66 Wheel valve closure major Which codes are identified Codes 61 62 63 Codes Front 61 62 e Trailer 63 Wheel valve closure minor Check airflow and look for restrictions between the wheel valve and PCU Were restrictions found Replace wheel valve and N Yes Repair restrictions and perform checkout test perform checkout test 50 Code No Code Type Miscellaneous Service Codes Although the Tire Pressure Control System is self diagnosing there are some problems that may not trigger a Service code The following chart lists these conditions along with possible causes and solutions Condition Operating problems that do not
53. lti function display The Operator Control Panel OCP uses a six button keypad and graphic display Pneumatic Control Unit PCU The Pneumatic Control Unit PCU is a solenoid controlled manifold that controls the air system It also contains the Pressure Sensor transducer which reads tire pressures Vehicle Speed Speed is read from the vehicle data link or a separate speed sensor Pressure Switch The Pressure Switch PS acts as an electronic brake priority switch It prevents the Tire Pressure Control System from using air from the supply tank until the brake system is fully charged The PS also ensures that enough pressure exists for the system to operate properly Air Lines The Tire Pressure Control System uses a dedicated pneumatic system plumbed from the vehicle s existing supply tank Wiring wiring harness Dana or OEM supplied provides for electri cal signals between appropriate components General Information Simplified System Schematic Tire Tire Wheel Rotary FSI Rotary Wheel Valve Joint Joint Valve Interface Speed Sensor Y To Primary Electronic Pressure dmm and Secondary Supply Tank Switch Unit Tanks Air Dryer guuummmmmmumEHH Y Pneumatic Control Unit Trailer Connector Wheel Seal Seal Wheel Valve Assembly Assembly Valve PCU Sensor JAUEN E 11 N lt N d 3 Tire Wheel Seal mE Sea
54. of inflate or deflate display shows completion before reaching targeted pressures Intermittent Pneumatic Control Unit sensor short or open Follow troubleshooting for 5C group Wheel end oil leak Faulty air or oil seal Refer to Service Manual Trailer present not detected Disconnected trailer air line connector Clogged trailer air lines Crimped control line on trailer channel Refer to Service Manual Trailer detected not present Trailer connector on tractor side doesn t seal when disconnected Leaking line between Pneumatic Control Unit and trailer air line connector Refer to Service Manual High reading gt 100 psi on trailer channel with no trailer connected Leaking trailer connector Refer to Service Manual No communications by the PC diagnostic or handheld tool No power to the communication interface box comm box No communications to comm box Faulty comm box Verify power to the communication interface box comm box Verify ECU connection to data link see wiring diagram Try different comm box Possible causes are listed in order of likely occurrence 53 Service Codes This page intentionally left blank 54 Service Procedures Final System Checkout Test Requirements This test requires use of a diagnostic tool PC or handheld to control and monitor the functions of the Sp
55. oid itself the Pneumatic Control Unit ca must be repaired or replaced If both the solenoid and the circuitry check out the Electronic Control Unit is faulty ECU See Troubleshooting Tips for general guidelines on system diagnostics 27 Harness Connector B c o ppp 3 Service Codes PCU Solenoids Codes 51 52 53 54 55 56 Code 12C Indicates one or more solenoid faults Use service tool to determine the specific solenoid When the troubleshooting instructions refer to connector test points use chart select the pin test point for use with the particular fault code you are diagnosing Solenoid Any Any Front Rear Trailer Supply Deflate Control Code Code Code 51 52 53 54 55 56 PCU Harness H F G E K A C B D Connector ECU Harness K2 D1 D2 E1 K2 B1 B2 B3 Connector e Switch off ignition Disconnect harness at PCU 10 way connector Measure solenoid coil resistance on PCU 10 way connector Front 51 F G Supply 54 H C Rear 52 Deflate 55 H B Trailer 53 A K Control 56 F D Are all resistance measurements 7 25 ohms N Repair or replace connections coils or PCU Yes Check for shorts between PCU connector pins B C D G E K and vehicle ground Do not use multi meter s continuity beep mode as most meters wil
56. on Speed Sensor Group 3C indicates a faulty speed sensor signal In general Harness Connector the system is configured to accept speed signals from any one of several sources analog or digital J1708 J1587 J1939 In this standard configuration loss of speed signal fault is indicated by code 18 In some specific instances a vehicle may be configured to only accept speed from a spe cific data link In these cases codes 76 SAE J1708 J1587 and code 77 SAE J1939 may be used to indicate a speed signal fault e A wiring or sensor connection ECU Harness Connector e A misadjusted or faulty sensor e A missing data link speed signal J1939 or J1708 J1587 Note These codes will occur if ECU power has been cycled 50 times and no speed signal is received Fifty power cycles can occur after 25 engine starts without moving the vehicle however the code will clear as soon as a speed signal is received See Troubleshooting Tips for general guidelines on system diagnostics 21 Service Codes Speed Signal Codes 18 76 77 This fault is set when ECU power has been cycled 50 times without sensing any speed input Move vehicle at greater than 5 mph Did fault clear No C Determine type of speed sensor input Digital TTL signal from engine ECU or speedometer e X Analog pole sensor or VR type e Data Link SAE J1708 1587 or SAE J1939
57. onents Use of Brake Cleaners or solvents containing Xylene or Methyl Ketone is not recommended 1 Remove unit from the vehicle refer to Service Manual AXSM 0010 Remove bottom cover plate screws 10 cover plate 10a and gasket 10b If the unit has a trailer module remove screws 106 plate 10c and gasket 10d All cartridges 8 are normally open units with the exception of the supply channel 9 which is nor mally closed Ensure the normally closed cartridge 9 is reinstalled in the supply port following clean ing The cartridges can be removed by pulling them from the bottom of the PCU If the unit is a 3 channel system remove 6 solenoid cover screws 3c and 4 trailer module cover screws 7 Lift solenoid cover trailer module cover together to clear solenoids Remove solenoids from operators by removing 9 16 hex nuts on top of solenoids Remove solenoid operators from PCU body using a 1 wrench on the brass base 13 Note All operators with the exception of the deflate operator 8 9 97 are 3 way indicated by threaded port in top of part Do not mix deflate operator or its internal plunger 15 with other operators or plungers 14 Ensure that both O rings 11 12 in operator bases are not lost Remove operator stem from base 13 on all opera tors using spanner wrench 16 If spanner wrench is not available double nutting the operator stem with the 9 16 hex nuts
58. onnections 5 1V system should be carefully rechecked conditions as N mechanically and to make sure the problem has been necessary electrically fixed and does not reoccur sound Yes Y Check harness inside PCU Yes cover for continuity Y AtoA Disconnect the ECU connector e 4 and the PCU sensor connector 0 Check continuity between the ls there No Repair mini harness inside cover following points continuity PCU Sensor ECU Harness Harness Pin Connector Pin Yes c gt gt H2 gt Y Check harness inside PCU cover for shorts e Ato B BtoC e CtoA Inspect and repair faulty 4 harness 15 there continuity Yeo Repair mini harness inside cover Yes y Check for short circuits between each pair of PCU sensor harness pins No e AandB Y pus A Replace PCU sensor Replace ECU Inspect and repair faulty 4 harness Note ECUs are not a typical cause of No B gt problems If an ECU is replaced the system should be carefully rechecked to make sure the problem has been fixed and does not reoccur Is the active fault cleared Yes Yes Complete Reconnect ECU connector Check voltage between PCU sensor harness pin B and ground with ignition switch on
59. ons 70 Troubleshooting 5 16 Service Code Summary 17 Service Codes Group 1C Code 17 19 Group 3C Codes 18 76 77 21 Group 46 Code 15 23 Group 5C Codes 33 34 25 Group 12C Codes 51 52 53 54 55 56 27 Group 1P Codes 11 12 13 16 22 29 Group 2P Code 14 31 Group Code 21 33 Group 4P Codes 23 24 25 35 Group 5P Codes 26 27 28 37 Group 7P Codes 31 32 39 Group 8P Code 35 41 Group 9P Codes 36 37 38 43 Group 10P Codes 41 42 43 45 Group 11P Codes 44 45 46 47 Group 12 Codes 61 62 63 64 65 66 49 Code No Code 51 General Information Tire Pressure Control System Spicer Tire Pressure Control System features driver control of tire air pressure through e Simple push button operation e independent Front Rear and Trailer operation e Electronic braking priority for air system e Vehicle speed sensing and response capability Self diagnostics Key Features Depressurized Control Lines The only time the system is pressurized is when changin
60. or Control Panel is in Quiet Mode Refer to Select Key in section 3 of Operator Instructions No display of pressures and no apparent inflate or deflate Pressure switch not closed Follow troubleshooting for 7P group ECU left in DIAGNOSTIC mode Move vehicle 5mph Possible causes are listed in order of likely occurrence 51 Service Codes Condition Operating problems that do not trigger a service code Possible Causes Since a service code was not set these conditions may be universal and not call for a troubleshooting routine Service Where fault codes appear refer to the troubleshooting procedures listed under that code TIRE PRESSURE Display shows tires at higher pressure than target yet system does not attempt to deflate No apparent inflate or deflate Tire pressure rises due to temperature are not bled off by the Tire Pressure Control System This is normal opera tion System will only initiate a deflate if a mode with a lower target pressure than current target is selected Pressure imbalance tires on same channel at different pressures Defective hose Clogged filters Follow troubleshooting for 11P group No inflate or deflate of particular tire Valve stem core not removed on tire Remove hose from tire valve stem and remove core Replace hose Inaccurate tire pressures Leaking control lines Fault
61. ost likely cause of component faults will be damaged wires or connections As a first step in troubleshooting all C service codes switch off vehicle ignition then disconnect applicable connectors and inspect for damage Switching off the ignition is required before disconnecting the harness at the Electronic Control Unit but is also a recommended prac tice before all other electrical system disconnections Clean or repair all suspicious connections before proceeding System is not continually pressurized When troubleshooting P service code faults keep in mind that the air system is only pressurized as needed for exam ple in the inflate mode This means that such procedures as checking for leaks require the system to be in an active pressurized state This can be accomplished most easily by using a diagnostic tool Basic vehicle air and power systems are not covered in this guide The Tire Pressure Control System requires air pressure and electrical power supply from the base vehicle systems Diagnosis and service of these systems is outside the scope of this manual Some faults will halt inflate or deflate sequences Upon sensing some service codes the Tire Pressure Control System will immediately go to the maintain mode This may cause mode arrows to stop flashing before the system has actually attained the pressures for the indicated mode 1 a Lam 7 Service
62. r highway off highway and emergency conditions Over speed warning threshold for highway off highway and emergency conditions Operator Instructions Operator Instructions Operator Control Panel OCP TPCS may be equipped with one of two driver interface devices a Driver Display Module DDM or an Operator Con trol Panel OCP The Operator Control Panel OCP is illus trated below and the following section explains the features and use mi J J L U HWY OFF HWY RUN FLAT aad VOY Cee eee Warning Icons TPCS includes two distinct warnings to report possible tire problems and inappropriate vehicle operation You must take immediate action to either reduce vehicle speed or check tire condition whenever these warnings are displayed Reduce Vehicle Speed A CAUTION Failure to respond may result in overheated tires and possi ble tire failure This signal reports that the vehicle speed is too fast for the pressure selected You must either reduce speed or select a higher pressure by pressing the appropriate key Continued operation in this mode will result in the system automatically selecting a more appropriate pressure setting gt mph kph Check Tire Condition This signal reports that one or more tires may be at a signifi cantly lower pressure than the others and could indicate that a tire is not holding pressure Stop the vehicle immediately in a safe place and identi
63. ressed air to each channel for approximately two seconds while monitoring the pressure in that channel 37 Code Description Group 5P indicates an extreme pressure loss on the front 26 rear 27 or trailer 28 channels Possible causes are leaking axle air seals or an open line which would be clearly audible during pressure measurements Note In extremely cold conditions air seals will sometimes leak resulting in a code 5P This code may clear by simply driving the vehicle for a few minutes to warm up the seals allowing proper system operation Other possible causes of a group 5P are e Open line from Pneumatic Control Unit PCU to channel e Restricted line between the supply tank and Pneu matic Control Unit e Faulty PCU Sensor e Faulty PCU To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 5P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Low Pressure Reading Codes 26 27 28 Using the diagnostic tool check faults to identify the faulty channel Front 26 Rear 27 e Trailer 28 Initiate inflate mode for the faulty channel Identify cause of air loss repair and recheck system Refer to Service Manual Is there extreme pressure loss Yes gt No Y Use the dia
64. s No y Switch off ignition Disconnect ECU connector Switch on ignition Check SWACC circuit by measuring voltage between ECU harness connector pins K1 and K2 Does Yes M Base vehicle power is out of range Refer to Service Manual Base vehicle power is out of range Refer to Service Manual measured voltage match battery voltage reading obtained in previous No Inspect for failure in SWACC circuit including vehicle power panel and or ground connections Repair or replace as indicated Step Yes Is code 1C fault cleared Yes Complete N Inspect wire sockets ECU pins If okay replace ECU gt mr Service Codes Group 3C Codes 18 76 77 Type Speed Signal System Mode Condition Possible Causes Listed in Likely Order of Occurrence Normal Operation No speed signal ECU power cycled 50 times without vehicle being moved Sensor disconnected or loose plug Either speed sensor wire is open broken wire Either speed sensor wire is shorted to ground bare wire is touching the frame Faulty speed sensor Sensor actuation failure Tang drive broken disconnected on mechanical sensor Gap not adjusted correctly on pole sensor Sensor wires shorted together Code Descripti
65. s between the tires on the front 44 rear 45 or trailer 46 channel after the system has achieved the target pressure This code can be caused by e Damaged tire s tires will continue to lose air after the vehicle is shut off e Leaking air lines between the wheel valve and tire tires will continue to lose air after the vehicle is shut off e Plugged or contaminated wheel valve filter s one tire of an axle group will deflate slower than others and 11P will be set after completion of the deflate sequence due to one tire being higher in pressure e Leaking air lines between the PCU and wheel valve tires may not exhibit actual imbalance air line leaks between PCU and wheel valve resulted in pneumatic signature which imitated the fault 47 Service Codes Tire Leak Imbalance Codes 44 45 46 Use diagnostic tool to verify proper vehicle configuration selection Using the diagnostic tool identify the faulty channel Front 44 45 e Trailer 46 Manually check the tire pressures at the wheel valves on the faulty channel Check the following e Tire Damage Wheel valve filter Air line leaks Ld Are any wheel readings low Wheel seal air leaks Wheel valve leaks Repair faulty components and recheck the system No Refer to Service Manual Check for a blocked wheel valve exhaust or plugged
66. stics 2 Handheld tester 3 Operator Control Panel service codes if vehicle is equipped with an OCP Regardless of the testing equipment used the troubleshoot ing procedures will be based upon the diagnostic service codes Diagnostic tools offer the advantages of computer aided testing without interpreting service codes Tire Pressure Control System Diagnostics The onboard system diagnostics are an important feature of Spicer s Tire Pressure Control System This section describes the use of service codes to identify Tire Pressure Control System operating problems The Tire Pressure Control System uses a code to identify ser vice issues The codes can be extracted from the ECU mem ory using a diagnostic service tool equipped with the appropriate software In addition systems equipped with an Operator Control Panel OCP will report codes directly on the display Refer to the service code chart for more detailed information on service codes Historical Service Codes Any time a fault occurs the system will log a fault in memory of the ECU If the system becomes inoperative the Driver Dis play Module DDM will report two dashes or an actual service code will be displayed on the Operator Control Panel Only the most recent code is displayed by the Operator Control Panel Historical codes are stored in memory Historical codes can only be accessed by a diagnostic tool Historical codes are automatically cleared after
67. systems on the vehicle Fol lowing are some general rules that apply to Tire Pressure Control System service Clean and Dry Air Supply The Spicer Tire Pressure Control System requires a constant supply of clean dry air An adequately sized and properly maintained air dryer is critical for continued proper operation of the Tire Pressure Control System Even though the air dryer may be working properly moisture can accumulate in the supply tank during normal operation due to the increase in air consumption It is important to drain the supply tank daily Draining the supply tank completely when the truck is not in use will also help keep moisture under control Line Replacement and Routing When replacing air lines do not allow kinks sharp bends or stretching in order to tighten joints If any tube or hose seg ment does not appear to fit easily it could mean you are not using the proper part or that you are not following service procedures properly Ensure that replacement lines are the correct length and size Be cautious of any contaminants rub ber flash plastic particles etc getting into the lines when replacing them Each segment of the pneumatic system must be secured to the vehicle frame or other installed line After completing assembly of each segment use cable ties to anchor the seg ment at approximately 18 intervals A CAUTION Proper Tire Pressure Control System operation requires correct air line diameters and l
68. t 43 diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 9P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Inflate Trend Codes 36 37 38 Using the diagnostic tool check faults to identify the faulty channel Front 36 37 e Trailer 38 9 gt 1 7 e N Is there a damaged tire on the identified channel Repair tire and retest system No Initiate inflate mode on the faulty channel Are there any leaks in the channel s control lines or seals Repair leak and retest Is there a leaking hose between a tire and wheel valve Replace the hose and retest the system No Replace PCU and retest Is air leaking out the PCU vent port Note While replacing the PCU pay Yes particular attention to possible air line contamination e g oil water particles which may suggest further air system maintenance needs Is a wheel valve leaking through the valve exhaust Replace the wheel valve and retest the system No Service code is not active Reverify flowchart steps and wait for fault to reoccur 44 Service Codes Group 10P Codes 41 42 43
69. t line e Faulty Pneumatic Control Unit To identify the root cause of the problem connect the diagnostic tool see Diagnostic Section for test equipment and descriptions and follow the procedure in the 1P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes No Deflate Signal Codes 11 12 13 16 22 Using the diagnostic tool test vacuum in isolated PCU Is the PCU vent line plugged or restricted Replace PCU and recheck Is the vacuum lt 6 Hg System Refer to Service Manual Yes Yes y Initiate deflate mode on the steer channel Record the reading Repair PCU restriction and recheck system Refer to Service Manual Initiate pressure check and hold on steer channel e Check all air lines and fittings for leaks as well as exhaust port of wheel valves Make repairs to faulty components Is the vacuum gt 20 Hg Yes Y Initiate deflate mode on the drive channel Record the reading Initiate pressure check and hold on drive channel e Check all air lines and fittings for leaks as well as exhaust port of wheel valves Make repairs to faulty components Is the vacuum gt 20 Hg T 9 N Problem is a cumulative effect of individual channel leaks Y
70. tire port Be sure to use appropriate eye and ear protection m 5 Clean the adapter replace and lubricate the O ring if necessary and reinstall the adapter in the wheel valve A CAUTION tire port Tighten to 16 19 Ibs ft Do not crush the air filter when installing adjustable 6 Remove the plug and reinstall the tire hose assembly straight thread O ring adapters to the adapter on the wheel valve tire port Torque to Note Air filters should not be cleaned or reused Always 16 19 Ibs ft replace with a new air filter Note For installation of adjustable straight thread O ring 1 Working quickly to prevent air loss remove the tire adapters d the service manual to hose assembly from the fitting on the tire port near prevent crushing the filter est the tire fill valve of the wheel valve Plug hose to Control Port E ene gt T 5 n Air D 62 Service Procedures Troubleshooting Wheel End Seals Perform an air seal pressure check as follows refer to Wheel End Seals illustration 1 Connect a hose from a pressure reservoir 2 ID x 12 long with 2 long 3 8 hose or equivalent volume to the inlet tube 2 Plug hub air port with a 3 8 pipe plug or 9 16 18 straight thread O ring plug as appropriate 3 Open the valve from the air supply line and stabilize the pressure in the reservoir to 100 PSI minimum Close air supply valve Rotate the hub assembl
71. tor must be selected to initiate a deflate bar psi amp RUN FLAT Operator Instructions Tire Pressure Control System To program the system follow these steps Programming 1 Enter the Tire Pressure Control System program ming sequence by pressing the SELECT and L U but tons at the same time A flashing bar or PSI verifies that you are in the programming mode and also indi cates that the first selection English or metric val ues is ready for programming Refer to Operator Control Panel Programming Sequence for sample Spicer s Tire Pressure Control System is fully programmable allowing the technician to program tire pressures for each channel axle group and maximum speeds for each terrain mode The system allows programming directly through the Operator Control Panel or with a diagnostic tool trol System pressure and speed programming steps procedure Programmable settings include 2 Press the up down arrows on the L U and EMER e Individual pressure settings for the front rear and keys to select options or change settings pressure trailer axle groups or speed and press the SELECT button to record a selection in memory and move to the next step e e Loaded and unloaded axle group programming for highway off highway and emergency conditions Press the SELECT button repeatedly to move through the program steps one step for each time e Over speed warning threshold for high
72. upply pressure to be lower than anticipated by the system Note To assure a nominal compressor output code 32 will not be set unless the pressure switch does not close for a preset period while the vehicle is being driven at a speed of over 20 mph 39 The components that can cause the pressure switch to remain open include e Air dryer needs service e Pressure switch unplugged or damaged wire harness e Faulty pressure switch e Faulty compressor e Open or broken line from supply tank to Pneumatic Control Unit e Crimped or plugged line from supply tank to Pneu matic Control Unit e Faulty Electronic Control Unit To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 7P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Low Air Supply Codes 31 32 Use diagnostic tool to determine type of fault Pressure switch failed Open or closed Is the governor cutout pressure set at 120 125 psig Reset governor cutout No gt pressure and retest system Refer to Service Manual Closed Verify wiring e Switch off ignition Disconnect ECU harness connector and supply tank pressure switch connector Check for shorts between ECU harness connector pins G3 and K2 Yes
73. way the SELECT button is pressed Refer to the program off highway and emergency conditions ming reference chart for specific Tire Pressure Con AY E 4 To complete the programming sequence or exit the programming mode continue to press the SELECT button to step through to the end of the procedure or press the SELECT and L U buttons at the same time Note If no buttons are pressed for more than one minute the Operator Control Panel will end the programming sequence saving any changes made during programming Operator Instructions Operator Control Panel Programming Sequence Example for Step 1 Programming see OCP Programming Chart gt L U Y SELECT Press at the same time to enter Flashing bar or psi programming indicates you have entered programming down up arrow arrow gt or gt SELECT sz EMER A Press to record a selection to Toggle in memory and move between metric the next step and English Make selection L U 7 SELECT Press at the same time to exit programming Example for Step 7 Programming see OCP Programming Chart down gt or SELECT SELECT SELECT SELECT SELECT SELECT SELECT L U 7 EMER A S Press to set highway 5222 programming Press SELECT six times to go to step 7 unloaded drive pressure L U 7 SELECT Exit programming 11 Operator Instructions OCP Programming Chart
74. y Electronic Control Unit See Troubleshooting Tips for general guidelines on system OCP Harness Connector diagnostics ECU Harness Connector 5 6 8 9110 e e oye 3 A Bc Die 4 23 Service Codes Display Control Communications Code 15 With vehicle running measure battery voltage across battery terminals Turn on ignition 5 driver interface completely blank 15 voltage reading gt 19 volts Base vehicle power is out of range Refer to Service Manual No Y With ignition switched on but engine not running measure battery voltage across battery terminals 15 voltage reading 9 volts Base vehicle power is out of range Refer to Service Manual No Y Disconnect driver interface e With ignition on measure voltage between DDM Display or OCP Harness Pins Harness Pins 4 and 5 5 and 6 Does measured voltage match battery voltage reading obtained Repair harness power or ground connections to driver interface in previous Step Yes Y Replace driver interface Switch ignition off Disconnect ECU connector Disconnect driver interface connector Switch ignition on Verify adequate voltage 9 32 Vdc between
75. y PCU Sensor Faulty Pneumatic Control Unit Faulty Electronic Control Unit Air Pressure Check The Tire Pressure Control System is not continuously pressurized pressure checks occur on a periodic basis During tire pressure checks the system delivers compressed air to each channel for approximately two seconds while monitoring the pressure in that channel 41 Code Description When the system measures tire pressures it also uses the pressure sensor in the PCU to read atmospheric pressure Group 8P displays if the atmospheric pressure reading is out of range The components that can cause a group 8P to be set include e Faulty PCU Sensor or wiring e Faulty Pneumatic Control Unit e Faulty Electronic Control Unit ECU To identify the root cause of the problem connect the diagnostic tool see Diagnostics Section for test equipment and descriptions and follow the procedure in the 8P Troubleshooting Tree See Troubleshooting Tips for general guidelines on system diagnostics Service Codes Atmospheric Code 35 Using the diagnostic tool read the atmospheric pressure 15 the reading between 8 and 20 psia Is any audible air flowing through the PCU See service code 5C PCU sensor and follow troubleshooting chart Yes Yes Y Service code is not active Reverify flowchart steps and wait for fault to reoccur See service code No Code
76. y pressure transducer Follow troubleshooting for 8P and 11P group Incorrect config connector or bad connection Faulty Electronic Control Unit See wiring schematic AIR LEAKS Air bleeding from rear axle vents Air Seal degradation Refer to Service Manual Tires fail to deflate when lower pressures are requested Pneumatic system problem Follow troubleshooting for 3P group Leaking tires Damaged tire Loose connection between wheel valve and tire Loose leaking tire valve stem Faulty wheel valve Refer to Service Manual Air bleeding audible through Pneumatic Control Unit when ignition is turned off Wheel valve is leaking back through control lines Identify tire with low pressure and determine obstruction or replace wheel valve Possible causes are listed in order of likely occurrence 92 Service Codes Condition Operating problems that do not trigger a service code Possible Causes Since a service code was not set these conditions may be universal and not call for a troubleshooting routine Service Where fault codes appear refer to the troubleshooting procedures listed under that code OTHER Apparent continuous operation or slow inflates or deflates Tire s leakage Between mode Trend fault Follow troubleshooting for 4P 9P and 10P group System stopped in middle
77. y while monitoring the pressure gauge The pressure reading should not drop more than 15 PSI in 20 seconds Vote If the air leakage exceeds 15 PSI in 20 seconds the hub may need to be rotated several times to ensure a complete pressure seal If air leakage rate remains outside of accepted limit locate source of leak e Loose Fittings e Spindle Sleeve Outer O ring e Air Seals Refer to the Service Manual for replacement procedure 63 Service Procedures Wheel End Seals Shop Air 5 Reservoir Supply ADS 2 D Pipe 12 Long mA B Air Port Plugged for Test Oil Fill Plug b 2 Long 3 8 1 0 Hose Air Seals O Ring Backup Ring and O Ring O Rings Required on Hubs with Grooves 64 11 rn N 1 N Service Procedures Hose and Supply Tank Selection Chart The following hose lengths and sizes are necessary for correct TPCS operation Any deviations may cause the system to function incorrectly and may reduce the ability to detect low tires Front Channel Plumbing Requirements Min Tank Size Main Run Jounce Standard Front 1 Axle 1400 in3 6 gal 18 to 20 5 8 OD 6 to 8 per axle 5 16 ID Only 21 to 23 13 32 ID 6 to 8 per axle 5 16 ID Only 25 to 27 1 2 OD 6 to 8 per axle 5 16 ID Only Dual Front 2 Axle Both Non Driven 1400 in3 6 g

tire pressure control system

Contents

Download Pdf Manuals

Related Search

Related Contents