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SERVICE MANUAL - Tire Pressure Control International

1. port of the compressor D2 governor 1 3 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS rire Pressure Control SERVICE MANUAL TIREBOSS NOTE The standard Pressure Protection AIR and ELECTRICAL Valve as installed in the TIREBOSS SCHEMATIC WITH Installation Guide is not required with this drying system as the B EN DIX AD IS DRYER AD IS dryer incorporates internal pressure protection valves OPERATOR CONTROL UNIT The switching out of OCUs between trucks is not recommended as settings and speed functions have to be adjusted per truck specifications Truck Battery 12 24 V sl optional LL Compression Hose Fitting Remote Alarm Cable NOTE Position Fittings as required TIREBOSS Valve Box At truck frame Air Supply to Tires 000000000000 0 TIREBOSS Main Air Supply 6 e AD IS pre factory _ ressure Helle Air Drying Valve System 4 UNL 4 Truck Compressor Air Governor P gt gt e 5 f LI Pressure ES Protection amp pneumatic control lines Switch Air A Main air supply lines Line
2. Ooo 3 Drain secondary air tanks comment on moisture content O 4 Clean in line Y strainers s at valve box 4 3 Close wheel valves and drain air pressure prior to cap removal Inspection done by Date Repairs completed by Date f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Service Inspection Explanations MONTHLY MAIN LINES PLUMING amp ATTACHMENTS Test with tires higher pressure i e 100 psi Manual valves condition operation Check valves for cracks corrosion and smooth operation Hoses and hardware condition Check for rub through and cracks Ensure hose protectors are on rub points Ensure all lines are securely fastened Air flow check from each tire amp control valve Refer to Section 4 3 in the Service Manual Tire pressure loss warning operation Refer to Section 4 4 in the Service Manual leaks Soap water test all hoses hardware and pneumatic connections with system at 100 psi AIR SUPPLY SYSTEM Check dryers unloading OK check with TIREBOSS system off Refer to CR Dryer Service Manual Drain wet tank and secondary air tanks comment on moisture content Purge Wet Tank and note water quantities and if oil contamination is present Clean in line Y strainers s at valve box Close wheel valves and drain air pressure prior to cap removal Take note of excessive
3. 1 BOC 143 204 Nuw Lota Wwe vesuraearrm EOM Page one gives a quick Page two and three outlines the operation features to outline ofthe be used by the driver during a haul cycle as well as Operator Control Unit the three most important safety features push button functions for the operator COMPANY NAME NOTE always keep current Application Pres sure Setting Cab Card in front of sleeve for easy operator reference Armmr Troller MAX UESGKIFTION PSI PSI Kph TIME Highway Unlasdad 100 50 45 none LIMIT Highway Unloaded 90 27 80 Loaded Siow Speed 60 40 35 28 NO LIMIT Loaded Medium Spana 70 45 48 45 fno uur Haut rasdtondes 95 65 60 80 Highway Loaded _ 100 100 95 none wo uwr APPLICATION NUMBER APPLICATION NAME Page four has a clear plastic sleeve which contains the Pressure Setting Cab Cards for that particular unit They show the specific pressure speed settings and maximum allowable times for each application setting A system may have as many as eight Application Cards 1 14 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS rire Pressure Control SERVICE MANUAL SECTION 2 ADJUSTMENTS AND SETTINGS TIREBOSS rire Pressure Control SERVICE MANUAL Truck Air Compressor Governor Adjustment Trucks with a single D2 air compressor governor a 0 200psi
4. electronic signal lines 64695 6568 9 5 4656 46 5 6 9 f tec manuals Service SERVICEv4 p65 1 4 V4 0807 TIREBOSS Tire Pressure Control TIREBOSS WIRING DIAGRAM VALVE PACK BOX White Wire Positive SERVICE MANUAL Use 24 volt only if circuit board heaters and controller have been set for 24 volt use o Truck Battery 12 volt Fuse holder with 15 amp fuse Batter y Nair Ports 2 Os 12 voli to tires gt Black Wire 4 Ground NOTE Black Wire to SA V gt neg battery post unless aN truck has a Power Discon GA lt a nect Switch Then Black SA To Wire must be connected to truck frame lt gt A DATA LOGGER IN TERFACE PORT PROGRAM PORT FUSED RED 12 24V IGNITION SWITCHED ON Not Accessory 12 24V IGNITION SOURCE e BLACK _ 7 DATA STREAM BUS Data Link input DATA STREAM BUS Data Link input SPEED SIGNAL From Data Link Impulse Sender Frequency Gen erator or Frequency Convertor f tec manuals Service SERVICEv4 p65 4 0807 OPERATOR CON Remote Alarm optional The switching out of OCUS between trucks is not recommended as settings and speed func tions have to be adjusted per truck specifications TROL UNIT Cab Mounted TIREBOSS rire Pressure Control SERVICE MANUAL OPERATOR CONTROL C
5. rrt e 4 8 Service Inspection Check Lists ene e oie ee VALVE REBUILD PROCEDURES SECTION 5 This Service Manual has been developed for typical North American designed vehicles Electrical and air supply systems for European vehicles may require different settings and procedures to work properly with those vehicles The TIREBOSS operational procedures are similar for all vehicle types For further information contact TPC International or a local TIREBOSS technical representative f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL SYSTEM DESCRIPTION The TIREBOSS Tire Pressure Control system consists of a computerized Operator Control Unit OCU mounted in the cab which monitors system activity and displays clear text messages to the operator of the vehicle The OCU is linked to a computerized Valve Control Module VCM and pneumatic control valves located outside of the cab The operator makes simple selections at the OCU based on load and speed which in turn sends messages to the VCM allowing the control valves to inflate or deflate the tire pressures within strict parameters set by the OCU The control valves are connected to the tire groups and individual tire valve stems through air lines and various types of rotary couplings mounted at the wheel ends The air is transferred into or out of the tires through this hardware while the vehic
6. 1 11 Operator Control Unit Button and Screen Descriptions 1 12 Operator Control Unit Selection Sequences 1 13 Operator Guide and Pressure Setting Cab Cards 1 14 ADJUSTMENTS AND SETTINGS SECTION 2 Truck Air Compressor Governor Adjustment 2 1 Pressure Protection Valve Adjustment 2 3 Viewer Program Installation tier ene er Ue tee o ies 2 4 Pressure Setting File Loading ss 2 4 TROUBLE SHOOTING SECTION 3 Warning RNC RTT 3 1 i qz e eM UNCTIO MC M EE 3 2 Heater Current Error eiie ter e bue ena eed ep reete Pcr px 3 4 HEATER ANEQ br Pese urat rect tre acuti rc 3 8 Valve No PoWer Alert tb t e tai 3 9 Slight Air Leak Through Exhaust Port 3 13 TRANS RANGE ERROR AIBFL o tra tnm 3 15 MAINTENANCE PROCEDURES SECTION 4 System Maintenance Overview sisi 4 1 Rotary Union Maintenance iii 4 2 Air Flow Check Procedures e e p re EU 4 3 TIRE PRESSURE LOSS WARNING Check Procedures 4 4 Testing Overspeed Function scott meet Cet be ee eco bte Rt senes 4 5 Drive Axle Hanger Bracket and Hose 4 6 Tre Changing Procedures
7. view from top of VCM LI Tl __ Li 3 16 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL TRANSDUCER INPUT OUTPUT VOLTAGE CHART INPUT OUTPUT VOLTAGE VOLTAGE 7 5 027 0 02 0276 027 0 27 0 27 0 274 0274 027 9 vi 5 0 268 02 0 26 0 26 0 2 0 2 0 26 0 260 0 260 0 258 0 258 0 25 ojojo ojo olololo olololo jo o gt 912181518191 IBA AS 69 9 9 oL Im m oi o ei et grigio ala 0 25 f tec manuals Service SERVICEv4 p65 V4 0807 INPUT OUTPUT VOLTAGE VOLTAGE __025 025 02 0248 0 0 0 2 gt gt B o om DIN I 023 0 23 olololelolololololololololo olololololole BISISIS SISISISISIS SISISISISISISISISISISIGISISISISISISIS S 5S o3 o9 65 eS 5 99 S IS 4 LS LS IS d Sd 69 2 29 3 8 103 Q AJN 0 234 0 25 0 23 0 229 0 227 45 022 INPUT OUTPUT VOLTAGE VOLTAGE N 0 222 0 221 028 025 021 02 olole o 5 o 020 gt In mmn TIREBOSS rire Pres
8. DOWN ENTER Wwe MENU ENTER MENU ENTER DOWN MENU DOWN ENTER MENU DOWN DOWN ENTER Ev MENU DOWN DOWN DOWN ENTER v v MENU DOWN ENTER 4 times MENU DOWN ENTER v five times MENU DOWN ENTER v six times MENU DOWN ENTER v seven times MENU DOWN ENTER eight times ENTER 86 DETAILS change Setting number within an application Will display Application Name and Number currently in use Will change application number pushing up or down will scroll through applications Stop on desired application and push and hold ENTER Will display number of hertz being sensed by system Will display customer system se rial number ie M tboss00000 ca Will display cab firmware program version number ie CabV301 Will display valve firmware pro gram version number ie ValV202 display TPC Serial Number of Valve Box ie MigBCA00J0000 Will display software version num ber ie 2 0 8 1 405 used to display heater Volts and Watts used for testing heaters used to program Operator Control Unit SERVICE MANUAL NOTE pushing up or down once will indi cate current setting and pushing up or down more than once will scroll set ting Stop on desired setting System will change automatically in 5 seconds or push ENTER for immedi ate activation
9. SUSPENSION PRESSURE CIF USED RED 11 30 VDC IGN SIGNAL CAB CONTROLLER SPEED IGN CABLE IGNITION SPEED CABLE K BLACK SPEED SIG SPEED DATA INPUT CONNECTOR SPEED 515 SPEED DATA INPUT FRONT VIEW f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Cont rol SERVICE MANUAL 9 White Wire Positive Black Wire Ground J7 PHeteheHekere Steer NOTE Black Wire to neg battery post unless truck has a Power Disconnect Switch Then Black Wire must be con nected to truck frame 20 6 MALTS DO NOT INSTALL MOUNT SCREWS INTO THESE TWO HOLES AS THEY WILL SHORT CIRCUIT BOARD VALVE CONTROL MODULE CIRCUIT Truck BOARD Battery Trailer 12 volt Battery INF INF AXLE GROUP 1 AXLE GROU Use 24 volt only if circuit board heaters and controller 25 2 5 have been set for 24 volt use Ww U e lt AXLE 1 INFLATE Le SOLENOID AXLE 1 DEFLATE CX SOLENOID AXLE 2 INFLATE SOLENOID AXLE 2 DEFLATE SOLENOID RED POWER DATA CABLE f tec manuals Service SERVICEv4 p65 V4 0807 WHITE RED GREEN BLACK WHITE AXLE 3 BROWN INFLATE SOLENOID OCU AXLE 3 POWERDATA DEFLATE Can CABLE SOLENOID 4 CONNE
10. Rubber O ring 16000 116 Spring Spring Washer 1 Rubber O ring Cartridge Body VA Rubber O ring CART RI DG E Rubber O ring Part 16750 Style 16000 026 BREAKDOWN DRAWING 3 Exploded view for reference only parts not sold separately Valve Seat Poppet prep Brass End Cap Lock Washer Allen Screw FATecManuals Service TBValverebuild08 p65 5 7
11. Ohms f 3 8 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL VALVE NO POWER ALERT Valve Circuit Board 1393 01 This alert appears on the Cab Controller display to indicate an existing problem related to the system Valve Controller circuit board power Notes i In the following descriptions RLY is Relay and VPS is Valve Power Supply ii In the following description and trouble shooting sequence when the word voltage is used the meaning is a nominal 11 15 volts DC as measured against ground iii When checking for voltages at RLY or VPS it is important to monitor the voltage at the respective terminal for at least 5 10 seconds because when the Valve No Power fault occurs the Cab Controller automatically cycles the voltage to RLY On and Off Therefore checking for voltage just momentarily may provide inaccurate information iv An intermittent voltage condition such as that caused by a loose wire connection on the VPS circuit will cause the Cab Controller to display a Valve No Power alert An intermittent voltage condition on the RLY circuit will cause the Cab Controller to first display Valve No Power alert followed by a Com Error alert vi Refer to drawing on page 1 5 for location of Cab Controller components vii Refer to drawing on page 1 7 for location of Valve Controller circuit board components Short description of the v
12. is Valve Power Supply ii In the following description and trouble shooting sequence when the word voltage is used the meaning is nominal 11 15 volts DC as measured against ground 24 volt systems only use 24V for the heater circuit The voltage is then switched to 12 volt for the rest of the operating system iii When checking for voltages at RLY or VPS it is important to monitor the voltage at the respective terminal for at least 5 10 seconds because when the Valve No Power fault occurs the Cab Controller automatically cycles the voltage to RLY On and Off Therefore checking for voltage just momentarily may provide inaccu rate information iv An intermittent voltage condition such as that caused by a loose wire connection on the VPS circuit will cause the Cab Controller to display a Valve No Power alert An intermittent voltage condition on the RLY circuit will cause the Cab Controller to first display Valve Power alert followed by a Com Error alert vi Refer to drawing on page 1 5 for location of Cab Controller components vii Refer to drawing on page 1 8 for location of Valve Controller circuit board components Short description of the valve power circuit operation When the Cab Controller is On voltage is supplied from the Cab Controller to the Valve Controller through the Orange RLY wire in the Power Data cable The RLY circuit begins at the Cab Controller circuit board connector J1 Pin 4
13. Open On the Open screen select the file you want to load amp click Open The file will appear on the Viewer screen 4 Ensure the power switch on back of controller is OFF Plug in the 9 serial cable from your computer 9 pin serial port to the 9 pin programming port on back of controller bottom port 5 Plug in the 2 power cables to the appropriate input plugs on back of controller 6 pin to power data and 4 pin to speed ignition Plug the 120VAC 12VDC adapter end of power cable into a 120VAC outlet 6 While pressing the Stop button on front of controller turn on the power switch Continue holding stop button until Begin Transfer appears Release Stop button 7 On the Viewer program select Communication and then select Write To Module Transfer In Process will appear on controller File is being transferred 8 When the upload is completed Process Complete Press Cancel to Exit will appear on controller amp Completed writing data to module will appear in Viewer program Select OK Press Cancel controller and it will begin operation Shut off power switch amp remove all cables 10 Close all windows in the Viewer program f tec manuals Service SERVICEv4 p65 V4 0807 2 4 TIREBOSS Tire Pressure Control SERVICE MANUAL SECTION 3 TROUBLE SHOOTING WARNING TIREBOSS Tire Pressure Control SERVICE MANUAL TIREBOSS WARNINGS The system has seven
14. always keep current Application Pressure Setting Cab Card in front in sleeve for easy operator reference Should read 0 Hz when vehicle is stationary Screen will return to normal view after 30 seconds Screen will return to normal view after 30 seconds Screen will return to normal view after 30 seconds Screen will return to normal view after 30 seconds this number MUST match the serial number inside the valve box on bracket Screen will return to normal view after 30 seconds Screen will return to normal view after 30 seconds efer to OCU Heater Info Screen in this manual for more details done by factory authorized personal only PROGRAM MODE versions with out heater info screen MENU DOWN ENTER v seven times f tec manuals Service SERVICEv4 p65 V4 0807 used to program Operator Control Unit 1 13 done by factory authorized personal only TIREBOSS Tire Pressure Control SERVICE MANUAL OPERATOR GUIDE AND PRESSURE SETTING CAB CARDS Supplied with each system at time of install is an Operator Guide and a set of Pressure Setting Cab cards Pressure Setting Cab Cards are specific to each truck and application Operator Guide and Pressure Setting Cab cards must remain with the T RE BOSS equipped vehicle at all times TIREBOSS tre Pass Get o o START UP CHANGING SETTING Tire Pressure Control e OPERATOR GUIDE
15. be present VALVE UNIT Voltage is too low at the valve con check fuse and connections at main power NO POWER trol module There may be a fault supply battery see page 3 9 or 3 11 with the relay on the valve board or the connections wiring from the valve board to Operator Control Unit check ground connections at frame or battery check wiring at valve control for breaks or poor connections check all plug in connectors and ground con nections replace cab control or valve board TRANS RANGE ERROR see page 3 15 the system detects a tire pres sure signal from a transducer that is either too low i e less than zero PSI or too high i e greater than 150 PSI check wiring at valve control or at transducer for breaks or poor connections replace transducer recalibrate transducer f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL ALERT CAUSE POSSIBLE SOLUTIONS TRANSDUCER the Operator Control Unit can check transducer wiring or connections within ERROR not locate valve transducer and or valve control unit transducers check operator control cable for worn or bro ken wires change transducer CURRENT valve control detects sole remove the solenoid harness and ensure ERROR noid current when the valve is not there is a good connection on the pins and inflating or deflating or detects no receptacle solenoid curr
16. terminal touch the red probe to the terminal marked OUT on the transducer which is connected to the green transducer wire 8 Record the output voltage reading Now compare the readings you have recorded to the chart on the following pages Find your recorded input voltage on the chart If the output voltage on the chart differs from what your readings are you will have to calibrate the transducer To calibrate the transducer locate the adjusting screw and turn until the multi meter reads the correct output voltage as on the chart NOTE you may have to remove hot glue from the end of the adjusting screw once you have completed the calibration replace a small amount of hot glue or silicone on adjusting screw to ensure it stays at desired position 3 15 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL TRANS RANGE ERROR ALERT con t i Transducer Adjusting Screw ET Transducer Transducer Wires Red Green and Black JU l Transducer Manifold SIDE VIEW Attach Black probe here Connection to CPU circuit board Transducer Adjusting Screw E Air line to Transducer 1 pe Attach Red probe here for output reading Attach Red probe here for input reading Transducer Manifold
17. After road test ensure proper adjustment of Pressure Protection Valve following this procedure with truck at lower pressure setting on Operator Control Unit ie 6016 on drives allow tire pressures to stabilize immediately after dryers unload with truck at idle change setting on Operator Control Unit to higher setting ie 100lbs on drives LOW AIR SUPPLY warning should NOT appear on Operator Control Unit If LOW AIR SUPPLY warning does appear readjust Pressure Protection Valve Repeat test until LOW SUPPLY warning does not appear 10 Shut off truck and remove test gauge and replace plug Install security cap and security wire Build system to maximum pressure and soap leak test all valves and fittings Pressure Protection Valve To Truck Primary and Secondary Tanks Attach 1 4 line to back of Th Pressure Protection Valve opposite Pressure Switch z Um 3 8 Air Line to Brake Pressure Protection Switch Compressor Governor Sensing Line Air Supply to TIREBOSS Valve Box Supply Line from Compressor 3 8 Compression Fitting installed in upright position tec manuals Service SERVICEv4 p65 4 0807 2 3 TIREBOSS rire Pressure Control SERVICE MANUAL Viewer Program Installation Insert TIREBOSS Viewer disk into 7 Drive On Windows desktop click on Start button Click on Run and enter A Setup exe Click on OK
18. COM Note Activating the TEMP SENSOR can be accomplished by either performing the test in an environment where the ambient temperature is below 3 degrees 38 degrees or by spraying the TEMP SENSOR using an aerosol spray freeze solution 4 Check and ensure that the correct numbers of heaters are installed 1 for each valve 5 Check for the correct heater circuit resistance Note that this must be performed with the controller shut off to ensure that there is no power present at the heaters Remove the heater wires from Terminal Strip J2 at locations HT COM and 28V OR 14V and using a multi meter set to measure resistance connect one of the multi meter leads to each heater wire The resistance in Ohms for the corresponding number of heaters should be within 2 Ohm of the values listed in the following table Note that all heaters are connected together to acommon pair of wires going to the valve board HT COM and 28V OR 14V If only 1 heater is in the circuit and the measured resistance is outside of the acceptable range replace the heater If more than 1 heater is in the circuit then separate the heaters and check each individual heater to determine which one is faulty 12V 30W HEATERS Ideal Acceptable Range 1 heater 4 8 Ohms 5 0 Ohms 4 6 Ohms 2 heaters 2 4 Ohms 2 6 Ohms 2 2 Ohms 3 heaters 1 6 Ohms 1 8 Ohms 1 4 Ohms 24V 40W HEATERS 12V 40W HEATERS Ideal Acceptable Ideal Acceptable
19. VPS proceed to step 5 3 If L2 is Off determine if voltage is present at terminal VPS If voltage is not present at terminal VPS determine if voltage is present at terminal RLY If voltage is not present at terminal RLY then proceed to step 6 4 If voltage is present at RLY but not at VPS check to determine if voltage is present at both terminals of fuse F9 Note Fuse F9 is located between Terminal strips J2 and J7 Fuse F9 is the fuse closest to the lower edge of the circuit board If voltage is not present at one of the fuse terminals using your finger lightly touch the fuse body to deter mine if itis hot If the fuse body is hot then a short to ground exists somewhere along the VPS wire between the Valve Controller and the Cab Controller If voltage is not present at either terminal of fuse F9 then either replace relay 1CR on the Valve Controller circuit board or replace the Valve Controller circuit board 5 Remove the rear cover of the Cab Controller leaving the unit turned On with all electrical connectors in place Using a multi meter set to DC volts connect the negative lead at J1 terminal 2 black wire Using the positive multi meter lead determine if there is voltage present at the Power Data circular 6 pin connector on inside of rear cover where the VPS Green wire terminates If voltage is not present first check for continuity on the Green wire through the connector on the rear cover If no continuity t
20. a new selection is made to hone in on the new setting Following the initial trimming time the tire pressures are allowed to increase above the trim tolerance to allow for normal heat build up If the tire pressure exceeds a maximum limit the TIRE OVER PRESSURE ALERT will be displayed indicating an overheat condition in the tire which may be caused from improper pressure settings or a failure of other vehicle compo nents such as the brakes overheating 6 LOAD SENSING FEATURE Applicable to air suspension vehicles only Vehicles equipped with air suspension on the drive axles can be fitted with a load sensing option A load sensing pressure switch indicates to the control system when the vehicle is loaded and will not allow any of the unloaded set tings to be selected This feature limits the selections to the driver and ensures only the appropriate tire pressures are being used for current vehicle load In addition to the system safety features outlined above it should be noted that the TIREBOSS systems use only quality components such as DOT approved drive axle air hosing The TPCS computer continu ously monitors tire pressure and controls the inflating deflating or maintaining of a pre selected target tire pressure The systems carry operational decaling which is further explained in an operator s manual carried in each vehicle f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS rire Pressure Control SERVICE MANUAL SECTIO
21. and ends at the Valve Controller circuit board connector strip J2 at terminal 14 marked RLY Voltage present at RLY will energize relay 1CR on the Valve Controller circuit board When 1CR is energized a voltage signal is supplied back to the Cab Controller through the Green VPS wire in the Power Data cable Voltage on the VPS wire indicates to the Cab Controller that the Valve Controller has power The VPS circuit begins on the Valve Controller circuit board at connector strip J2 at terminal 12 marked VPS and ends at connector J1 Pin 3 on the Cab Controller circuit board With the Cab Controller On voltage should be present in the RLY circuit as well as the VPS circuit The absence of voltage in EITHER the RLY or VPS circuit will trigger the Valve No Power alert Trouble shooting a Valve No Power fault Perform the following trouble shooting steps in the order listed to isolate the cause of the fault 1 With the Cab Controller turned On remove the Valve Controller cover and determine that wires at terminals RLY Orange and VPS Green are tight and secure 3 11 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL 2 On the Valve Controller board check if LED light L2 is On or Off Using a multi meter set to DC volts connect the negative lead at the terminal If L2 is On determine if voltage is present at terminal VPS If voltage is present at terminal
22. fittings Soap water test all hoses and fittings for leaks Check for rub throughs Ensure line is securely fastened and protected Check wet tank drain operation Ensure drain is not plugged and seals after closing Drain wet tank and secondary air tanks comment on moisture content Purge Wet Tank and note water quantities and if oil contamination is present Check Air Dryer s and Alcohol Injector s if applicable Refer to CR Dryer Service Manual Adjust Pressure Protection Valve to 100 psi truck idling with drive hose open to atmosphere Refer to Section 2 3 of Service Manual Check Compressor Governor Operation Refer to Section 2 1 of Service Manual CONTROL SYSTEM SERVICE Check Valve Pack Box and Brackets Check and tighten mount bolts on valve box Inspect for cracks and valve box lid seal leakage Check Drive Hose hangers brackets and springs Check and tighten mount bolts on hanger brackets Inspect for cracks hanger positioning and spring tension Retorque drive axle manifolds on rear wheels Torque to 100 ft Ibs Retorque Rotary Unions Using a crowfoot and extension retorque to 55 ft Ibs Check Valve Heater s operation if applicable Freeze thermistor with an aerosol spray freeze solution and ensure heaters activate Rebuild Valve Pack customer to authorize Refer to Section 5 1 in Service Manual Clean in line Y strainers at Valve Box Refer to Section 4 3 in Service Manual ROAD TEST
23. gauge must be installed into the available 4 NPT port on the Pressure Protection Valve opposite of the electric pressure switch Refer to Pressure Protection Valve Adjustment section in this guide with the 55 Operator Control Unit turned off ensure truck air compressor is set to min 115psi cut in pressure to a maximum 140 psi cut out pressure the pressure at which the dryer unloads If wet tank cut in pressure is below 115psi follow the procedures listed below this adjustment must be done with the TIREBOSS Operator Control Unit turned off if truck air compressor cut in is below 115psi locate the D2 air compressor governor Remove the governor end cap Loosen the 7 16 jam nut and with a flat blade screw driver turn the set screw counter clockwise to increase the air compressor cut in pressure turn only 1 8 turn at a time Tighten jam nut and check the air compressor cut in pressure by bleeding down the air system until the air compressor engages pressure rebuilds and the dryer unloads Continue this procedure min of 115psi cut in pressure is maintained reinstall the governor end cap NOTE some governors are non adjustable and will have to be changed out with an adjustable governor Jam Nut a 2 Set Screw turn counter clockwise to D 2 Governor Governor End Cap increase cut in pressure Adjustment f tec manuals Service SERVICEv4 p65 V4 0807 2 1 TIREBOSS Pressure Contro
24. it automatically changes to the next higher setting and ensure the system starts to inflate in the new setting If the system does not operate as described above you may have one of the following problems poor connection or inconsistent speed signal Operator Control Unit not pulse speed calibrated properly speed board in Operator Control Unit in wrong position fitec manuals Service SERVICEv4 p65 V4 0807 4 5 TIREBOSS Tire Pressure Control SERVICE MANUAL Drive Axle Hanger Brackets and Hose Maintenance Typical Wheel Hanger Position amp Hose Length for units NOT using tire chains Note position of hanger brackets Units not using tire chains should have the hanger brackets adjusted to the lowest possible position without going below the centre line of Rotary Unions Ideal height and hose length Top of hoses should drop just below bottom line of Rotary Union Hoses too long May wrap around Rotary Union or kink Hoses too short May create excessive wear on Rotary Unions as axles travels up and down Typical Wheel Hanger Position and Hose Length for units using tire chains Note position of hanger brackets Units using tire chains should have the hanger brackets adjusted to the highest possible position Ideal height and hose length Top of hoses should drop just below bottom line of Rotary Union Hoses too long May wrap around Rotary Union or kink Hoses too short May create exc
25. valve cores MUST be removed for the TIREBOSS system to operate prop the TIREBOSS system will be unable to maintain proper tire pressures Typical DRIVE Tire Removal Procedures See following Diagram B Ensure all Drive axle TIREBOSS wheel valves are closed 2 Shut the power switch OFF on the TIREBOSS Operator Control Unit switch on back left side 3 Relieve air pressure from the TIREBOSS tire mainline by the Schrader valve bottom Schrader marked with a D located on the right side of the TIREBOSS valve box usually located on the truck frame 4 At the drive wheel end undo the orange drive hose from the rotary union compression fitting and tuck end out of the way 5 MARK with a grease pencil one wheel stud and rim location to ensure the proper alignment of wheel hoses during reinstallation of the wheel 6 Undo TIREBOSS wheel hoses from the wheel end manifold swivel fittings 7 Undo wheel nuts and remove outer wheel In most cases the rim will fit over the TIREBOSS wheel end manifold 8 Before removing the inner wheel MARK rim at the same location as the previously MARKED stud 9 Remove inner wheel 10 Remove TIREBOSS wheel hose from valve stem and repair or replace tire as required If rim is changed MARK new rim in same location as old rim as orientated from valve stem Typical DRIVE Tire Re installation Procedures See following Diagram B 1 Ensure al
26. valve stem Repair or replace tire as required If rim is changed MARK new rim in same location as old rim as orientated from the valve stem Typical TRAILER Tire Re installation Procedures See following Diagram 1 Ensure all valve cores are removed Reinstall the wheel hose onto valve stem Do not overtighten the nut it should be just snug Soapwater test for leaks Inner wheel uses the straight wheel hose fitting and when installed the rubber hose protector should be slid to the base of the valve stem Outer wheel uses the curved wheel hose Outer wheel valve stem should be turned into the rim to avoid damage to wheel hose or valve stem 2 Reinstall inner wheel matching up previously MARKED stud and rim 3 Reinstall outer wheel by inserting inner wheel hose into appropriate rim hole and matching up the previously MARKED stud and rim 4 Tighten and torque wheel nuts as per manufacturers specifications 5 If hub cap tee fitting was removed apply thread sealing compound and re install using a wrench to hold the hub cap fitting WARNING When removing or replacing hubcap tee fitting from hub cap always use V a wrench to hold hub cap fitting Failure to do so will twist air lines inside hub cap and cause breakage and air loss of trailer tires 6 Using a small amount of anti seize compound reattach the wheel hose to the hub cap tee ensuring the hub cap fitting does not turn and valve handles are parallel with the sidewal
27. warning conditions The following chart indicates the cause of the warnings and some possible solutions If the problem persists contact TPC International or one of their authorized installers and speak to a service technician CAUSE POSSIBLE SOLUTIONS TIRE PRESSURE a continuous pressure drop in one identify air loss problem search for broken OVER PRESSURE 20 psi above set point and continues to rise LOSS or more axle groups even though air line broken fitting etc Repair as required STOP VEHICLE System is trying to inflate 22 for small leak on static tank and at NOW transducer LOW AIR air brake tank pressure is lower adjust pressure protection valve to 100 PSI as SUPPLY than safety pressure switch setting per page 2 3 of this manual Switch is sensing wet tank check pressure switch wiring for breaks so a drop may not be indicated on poor connections Continuous warning indi truck brake pressure gauges cates an open circuit The switch is normally open and closes on pressure rise Normally open conditions activates Low Air Supply A cycling of warnings off and on indicates im properly adjusted pressure protection valve replace pressure switch mounted on side of pressure protection valve TIRE system senses tire pressure check for external heat sources i e dragging brakes bearing failure causing hub and wheel to build heat and increase tir
28. wiring Any problem related to the TEMP SENSOR or its circuit will cause a Temp Sensor Error alert to appear on the operator control screen Trouble shooting a Heater Current Error fault Perform the following trouble shooting steps in the order listed to isolate the cause of the fault 1 Check to ensure that the main Power and Ground wire connections to the heaters at terminals HT 1 and HT 2 are tight Using a multi meter connect the negative lead at the VBAT terminal and check to ensure there is 11 15 VDC present on both sides of Fuse F2 With the Cab Controller on and the TEMP SENSOR activated again using a multi meter with the negative lead connected at the VBAT terminal check to ensure there is 11 15V present at terminal HT 1 Note Activating the TEMP SENSOR can be accomplished by either performing the test in an environment where the ambient temperature is below 3 degrees C 38 degrees F or by spraying the TEMP SENSOR using an aerosol spray freeze solution Check and ensure that the correct numbers of heaters are installed 1 for each valve Check for the correct heater circuit resistance Note that this must be performed with the controller shut off to ensure that there is no power present at the heaters Remove the heater wires from Terminal Strip J2 at locations HT 1 and HT 2 and using multi meter set to measure resistance connect one of the multi meter leads to each heater wire The resistance in Ohms for
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30. BOSS Tire Pressure Control System will immediately warn the operator with an audible alert and a warning flashing on the Operator Control Unit screen TIRE PRESSURE LOSS STOP VEHICLE NOW It is important to regularly check this function 1 With the TIREBOSS Tire Pressure Control System at a maximum setting and tires inflated to maximum and stabilized keep truck at a low idle 2 Test each zone separately For testing Drives zone Disconnect one of the orange hoses at the drive axle hose hanger For testing Steer zone Disconnect one of the supply hoses at the steer shut off valves For testing the trailer zone Disconnect the whip line or trailer supply line and open trailer supply valve CAUTION These lines are under high pressure Wear safety glasses during this procedure 3 Once the hose is disconnected the audible alarm should sound and the warning should appear on the Operator Control Unit screen NOTE If the truck is equipped with an optional Remote Alarm it should also sound at this time 4 Reinstall the air lines as removed in 2 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Testing Overspeed Function The TIREBOSS system is equipped with an Overspeed function which will NZ automatically increase the selected pressure speed setting to the next pressure speed setting in the event of an continuous Overspeed situation The testing of this function sh
31. CTOR ORANGE BRAKE PRESSURE PROTECTION SWITCH BLUE NORMALLY OPEN GREEN SUSPENSION BLACK PRESSURE SWITCH e WHITE NORMALLY CLOSED 1 8 BLUE 12 24 VDC REMOTE ALARM POSITIVE SUPPLY VALVE CIRCUIT BOARD 1393 02 12 24v Jumper blue gt wow 50 gt 92 aa 55 nn ce E E lt lt ui ui T Ir gt gt gt gt a gt oma awa Deuk gt 40 lt il VALVE BODY HEATER CONTROL THERMISTOR I4 IF EQUIPPED EXTERNAL REMOTE ALARM IF EQUIPPED TIREBOSS Tire Pressure Control SERVICE MANUAL VALVE CIRCUIT BOARD 1393 02 INDICATOR LIGHT DESCRIPTIONS The LED indicator lights on the valve circuit board may assist in trouble shooting and or diagnosing of the electronic circuits When the TIREBOSS system is operating and communicating correctly the LED indicator lights will illuminate as follows OFF LED 12 and LED L4 illuminated solid green with main power available at V Bat Key ON All LED s illuminated solid green and LED L3 flashing RED equipped POWER DISCONNECT SWITCH must ON If an LED light illuminates dim flickers or does not come on as described above lt a fault with that electronic circuit be present a S The diagram below indicates
32. Green Harness with White Black Harness MANUAL LEVER MANUAL LEVER Fittings to receive air pressure from Air Suspension if equipped Exhaust Port m Supply Inlet Brake Pressure Air Supply Line from Protection Switch Truck Wet Tank Air Line amp Fitting 3 8 Air Brake Tube THERMISTOR only mounted on the top valve m only on systems with valve heaters Truck Frame front view of valve f tec manuals Service SERVICEv4 p65 V4 0807 1 1 1 TIREBOSS Tire Pressure Control MANUAL OPERATOR CONTROL UNIT OCU BUTTONS AND SCREEN DESCRIPTIONS Displays each axle group status INF Inflation cycle active Shows axle group being DEF Deflation cycle active controlled If steer or trailer O K within programmed pressure tolerances is not 55 equipped trailer axles only disabled Displays actual axle group that axle group status and BLANK A warning has appeared and pressure s can be pressure will not appear function has been suspended displayed in PSI or KPA TM L TIREBOSS Pressure Control AXLE Steer Will allow Drive Operator to Trailer scroll up through se Eu lections MENU CANCEL SELECT Will a Op Coo erator to scroll down Allows Operator to enter MENU options Will allow Operator to through selec push menu once and Application screen _ cancel an alert tions wi
33. IRCUIT BOARD ELTEK 1483 00 Datalogger Speed Board Mount Header Stand Off Posts Programming Header Sonalert Header Power ON OFF Header Speed Ignition Power Data Header Header OPERATOR CONTROL CIRCUIT BOARD SPEED BOARD SPEED BOARD POSITION LABEL J or P 1 6 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS rire Pressure Control SERVICE MANUAL VALVE CIRCUIT BOARD 1393 01 6555555559 FSF EQ om R 7o oce eag S A l m cio oon I1 RO RD Oce Rid RAD RD RASE RIGO me no 0 aso T oo RUE E caen 239 D DIRES Ore a 00934 9226 oc ha 5 E ORIG 11 15 VDC amp GND SUPPLY gt J FRUM VEHICLE a B VALVE BODY HEATER FUSE b0 6 Y31173 37 CAB CONTROLLER POWER DATA CABLE CONNECTOR FRONT VIEW RED BROWN POWER DATA CABLE NOTE WHITE WIRE NOT USED AXLE 1 INFLATE SOLENOID AXLE 1 VALVE BODY HEATER USED AXLE 1 DEFLATE AXLE 2 SOLENOID VALVE BODY HEATER USED AXLE 2 INFLATE AXLE 3 SOLENOID VALVE BODY HEATER USED AXLE 2 DEFLATE SOLENOID VALVE BODY HEATER CONTROL THERMISTOR CONLY IF HEATER IS USED AXLE 3 INFLATE SOLENOID 11 30 VDC REMOTE ALARM AXLE 3 POSITIVE SUPPLY DEFLATE SOLENOID REMOTE lt EXTERNAL gt Ct ALARM USED BRAKE PRESSURE PROTECTION SWITCH
34. MANUAL 2 On the Valve Controller board check if LED light L1 is On or Off Using a multi meter set to DC volts connect the negative lead at the terminal If L1 is On determine if voltage is present at terminal VPS If voltage is present at terminal VPS proceed to step 5 3 If L1 is Off determine if voltage is present at terminal VPS If voltage is not present at terminal VPS determine if voltage is present at terminal RLY If voltage is not present at terminal RLY then proceed to step 6 4 If voltage is present at RLY but not at VPS check to determine if voltage is present at both terminals of fuse F9 Note Fuse F9 is located between Terminal strips J2 and J7 Fuse F9 is the fuse closest to the lower edge of the circuit board If voltage is not present at one of the fuse terminals using your finger lightly touch the fuse body to determine if it is hot If the fuse body is hot then short to ground exists somewhere along the VPS wire between the Valve Controller and the Cab Controller If voltage is not present at either terminal of fuse F9 then either replace relay 1CR on the Valve Controller circuit board or replace the Valve Controller circuit board 5 Remove the rear cover of the Cab Controller leaving the unit turned On with all electrical connectors in place Using a multi meter set to DC volts connect the negative lead at J1 terminal 2 black wire Using the positive multi meter lead determin
35. N 1 SYSTEM SCHEMATICS AND DIAGRAMS TIREBOSS Pressure Control SERVICE MANUAL SYSTEM OVERVIEW Steer Shut off Valves located on frame Speed Ignition Operator Cable Control Unit Operator Control Cable Steer Axle Main Line optional TPGS Air Supply Line Valve Box Truck Wet Tank Pressure Protection Valve Brake Pressure Protection Switch Air Line Drive Axle Main Line Y Fitting Drive Axle Hose Hangers Wheel End Manifold Assembly Drive Axle Hoses NQ f tec manuals Service SERVICEv4 p65 V4 0807 1 1 TIREBOSS rire Pressure Control SERVICE MANUAL OPERATOR CONTROL UNIT TI REBOSS AIR and ELECTRICAL SCHEMATIC Truck Battery TOPPED The switching out of OCUs 12 V 24 V 1 between trucks is not recom mended as settings and 1 speed functions have to L specifications i lt lt p po 5 A 6 Air Drying Truck po pi System Compressor Es 0 2 I sr ompressor Governor Sensing Line Governor c Brake Pressure 4 protection Switch Protection Air Line po e 5 TIREBOSS e e Valve Box At truck frame Air Supply to Tires Pr
36. On Y filter cap 6 RUBBER O RINGS on valve cartridges 2 RUBBER O RINGS on valve cartridges 2 RUBBER O RINGS 2 SNAP RINGS between valve body and face plate retains filter in Static 2 RUBBER GASKETS between solenoid and harness 2 BRASS FILTERS within Static Tank orifice VALVE PACK NOTE One VALVE PACK MAINTENANCE KIT is required for each valve in the TIREBOSS MAI NT NAN KIT 2 RUBBER GASKETS between valve body and solenoid system Eg Syst trolling dri d trail ill require two VALVE MAINTENANCE KITS Part BREAKDOWN DRAWING 2 5 5 f tec manuals Service SERVICEv4 p65 V4 0807 VALVE REBUILD PROCEDURE con t Allen Screw Rubber O ring 16000 116 Valve Seat ___ Rubber O ring ___ Cartridge ____ Rubber O ring VALVE CARTRIDGE Part 16750 BREAKDOWN DRAWING 3 Exploded view for reference only parts not sold separately Rubber O ring 16000 026 Aluminium Piston Shaft_ Y FILTER Part 59 003 01 BREAKDOWN DRAWING 4 Valve Seat Poppet ___ z Y Filter exploded view for reference only parts not sold separately Aluminium End Cap 90 Pipe Fitting om 788 Clean v SSe Allen Screw filter regularly __ 300 MENS Replace seal washer f tec manuals Service SERVICEv4 p65 V4 0807 VALVE REBUILD PROCEDURE con t
37. Range Range 1 heater 14 4 Ohms 14 6 Ohms 14 2 1 heater 3 6 Ohms 3 8 Ohms 3 4 Ohms Ohms 2 heaters 1 8 Ohms 2 0 Ohms 1 6 Ohms 2 heaters 7 2 Ohms 7 4 Ohms 7 0 Ohms heaters 1 2 Ohms 1 4 Ohms 1 0 Ohms 3 heaters 4 8 Ohms 5 0 Ohms 4 6 Ohms 6 Check the VB program in the operator controller for the correct heater settings For example heaters are either unchecked on user page or have a different quantity listed than the number of valves in the system This can only be checked by TPC or their certified installers 7 Check the VB program in the operator controller to ensure the correct heater wattage is indicated in the protected parameters For example are the heaters 40 watt rather than 30 watt This can only be checked by TPC or their certified installers 3 7 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL OCU HEATER INFO SCREEN Note All Operator Control Units manufactured after the Spring 05 have a heater information screen available Factory heater settings must be activated for this function to operate To access this information test screen use the following procedures MENU 1 Push DOWN 2 Push v seven times until HEATER INFO PUSH ENTER TO ACCEPT appears on screen ENTER 3 Push The display screen should now read Heater Info OFF Voltage V 0 00 Power W 0 00 UP UP ON DOWN OFF To act
38. TIREBOSS Tire Pressure Control goce SERVICE MANUAL V4 0807 NTERNATIONAL TINE GONTNOL INTEFNATICNA_ LTD 15803 121A Ave Edmonton Alberta Canada T5V 1B1 Phone 780 451 4894 Fax 780 452 6786 Toll Free North America 1 888 338 3587 Australia 1 800 148 694 New Zealand 1 800 443 9711 E mail info tirepressurecontrol com www TIREBOSS com Part CT SRV DC TIREBOSS SERVICE Tire Pressure Control MANUAL SYSTEM DESCRIPTION i SAGE Ve AU RE O ae ii SYSTEM SCHEMATICS AND DIAGRAMS SECTION 1 System OVelVIBW cance Sede qur Give 1 1 Air and Electrical 5 cl cbs 1 2 Truck with Receiver Tank cr tite n ete SEU E Re ir kb eed RR aeg 1 3 Air and Electrical Schematic with AD IS Dryer 1 4 Wiring Diagrami 1 5 Electrical Schematic Operator Control Circuit Board 1 6 Electrical Schematic Valve Circuit Board 1393 01 1 7 Electrical Schematic Valve Circuit Board 1393 02 1 8 Valve Circuit Board Indicator Light Descriptions 1 9 Data Logger Connections gt 1 10 Valve Box Diagram i iet AX POI NR
39. The Welcome Screen will appear click on Next Enter your name and Company name click on Next The TIREBOSS Viewer by default sets up in the directory C Program Files TireBoss Viewer Leave this as the destination directory and click Next T The Start Copying Files screen will appear if the information shown is correct click Next if the information is incorrect click Back and make the required changes then click Next 8 Program will install Close the TIREBOSS Viewer screen when it appears when complete click Finish 9 Before proceeding with the following Note follow steps 1 2 amp 3 below and open the program to ensure it loads and sets up the control files folder Close the program before proceeding es m Note Before beginning the next steps to use the program the revised user file must be transferred to the Control Files folder as follows When a new file is sent by e mail to load into the controller right click on the attachment amp select Save As to save the file to the directory C Program Files TireBoss Viewer Control Files If itis replacing an existing file click Yes when the screen is displayed asking if you want to replace the file Pressure Setting File Loading On Windows desktop click on Start button Click on Programs amp select TireBoss Viewer from the list Click on TireBoss Viewer Icon 3 On the TIREBOSS Viewer screen select File amp
40. Then disconnect 5 8 air supply line and remove 909 fitting NOTE It is recommended to turn a bushing into exhaust fitting to avoid crushing during removal e Remove remaining 1 4 bolts as shown Note On three zone systems only the two front bolts and lock nuts supporting the Valve Control Module Bracket will have to be removed in order to tilt bracket to allow room for valve assembly removal D Qo This bolt will have to be removed prior to removing Exhaust Outlet Remove Remove OUTLET if equipped if equipped x Remove after remov 27 Remove Remove ing Exhaust Outlet and if equipped 9 8 Air Supply fittings Remove Remove SUPPLY BOTTOM OF BOX RIGHT SIDE OF BOX f tec manuals Service SERVICEv4 p65 V4 0807 VALVE REBUILD PROCEDURE Disconnection inside box a Remove 1 4 plastic airline from valve NOTE It may be necessary to remove line from static tank first to allow enough movement to disconnect from valve Systems with valve heaters only Cut tie strap from wire bundle and un plug heater harness Turn valve body sideways in box to allow access to solenoids Mark solenoid cables and harness posi tions to ensure they are reinstalled in original position during re assembly NOTE Red Green lead on left side and Black white lead on right side Remove solenoid harness s by removing mount screws Systems with valve heaters only Remove Robertson 2 screw on
41. Tires WARNING ALL valve cores MUST be removed for the TIREBOSS system to operate prop WV erly Failure to remove valve cores can cause unsafe or dangerous driving conditions as the TIREBOSS system will be unable to maintain proper tire pressures TRAILER Tire Removal Procedures See following Diagram C Ensure all Trailer axle TIREBOSS wheel valves are closed 2 Shut the power switch OFF on the TIREBOSS Operator Control Unit switch on back left side 3 Relieve air pressure from the TIREBOSS tire mainline by the Schrader valve 2nd from bottom Schrader marked with a T located on the right side of the TIREBOSS valve box usually located on the truck frame 4 MARK with a grease pencil one wheel stud and rim location to ensure the proper alignment of wheel hoses during reinstallation of the wheel 5 Undo TIREBOSS wheel hoses from the hub cap tee swivel fittings 6 Undo wheel nuts and remove wheel rim does not fit over hub cap tee fitting remove tee fitting by holding hub cap fitting with wrench WARNING When removing or replacing hub cap tee fitting from hub cap always use V a wrench to hold hub cap fitting Failure to do so will twist air lines inside hub cap and cause breakage and air loss of trailer tires 7 Before removing inner wheel MARK rim at same location as previously MARKED stud 8 Remove inner wheel 9 Remove TIREBOSS wheel hose from
42. Verify System Operation Check Overspeed functions Refer to Section 4 5 in Service Manual f tec manuals Service SERVICEv4 p65 V4 0807 a TIREBOSS rire Pressure Control SERVICE MANUAL SECTION 5 VALVE REBUILD PROCEDURES VALVE REBUILD PROCEDURE TIBEBUSS ONE ZONE SYSTEM TWO ZONE SYSTEM THREE ZONE SYSTEM Eg drive tire Eg drive and steer or drive drive steer and control only and trailer tire control trailer tire control TIREBOSS Tire Pressure Control systems have either 1 2 or 3 valve bodies depend ing upon the application The following pages are the rebuild procedures for a single valve body Repeat the process for each valve body if required When working with more than one valve body ensure all cable harness s and air lines are returned to the original position when reassembling the valve bodies NOTE One VALVE PACK MAINTENANCE KIT is required for each valve in the TIREBOSS system Valve Removal Close all wheel end valves to prevent loss of tire pressure during rebuild and drain wet tank Label each Y filter as to position on valve box Disconnect coupler between Y filter and 90 pipe fitting on right side of box CAUTION Air line will be pressurized Bleed line slowly until pressure is depleted Remove 909 pipe fitting from box assembly see page 5 4 On bottom of box remove 1 4 bolt to right of exhaust outlet and remove exhaust outlet See gram below
43. a faulty valve cartridge as mentioned in 1 above and will have to rebuild the valve See VALVE REBUILD PROCEDURE at the back of this manual If the leak still persists it is coming through the solenoids as mentioned in 2 above The solenoids are equipped with the manual overrides either a small blue lever or a recessed push button on solenoid Activate one then the other a few times and confirm if the leak stops Do one at a time to determine the faulty one Each valve has two solenoids NOTE ENSURE THE TRUCK SUPPLY AIR PRESSURE STAYS ABOVE 95 PSI IF THE WET TANK DROPS TO 95 PSI THE PROTECTION VALVE WILL CLOSE AND THEN THERE WILL NO LONGER BE ANY SUPPLY AIR PRESSURE TO THE SOLENOIDS AND THAT WOULD ALSO STOP ANY LEAKAGE OUT THE EXHAUST ALSO KEEP IN MIND THE TRUCK AIR GAUGES ARE ON THE SERVICE TANKS AND NOT ON THE WET TANK SO THE WET TANK COULD DROP TO 90 PSI AND THE TRUCK GAUGES WILL STILL READ SOMETHING HIGH ER E G 120 PSI 3 13 f tec manuals Service SERVICEv2 p65 V3 1105 TIREBOSS Tire Pressure Control SERVICE MANUAL If activating the manual overrides does not determine which solenoid is leaking change out one solenoid at a time replenishing the supply air each time by starting the truck and building the air supply with the TIREBOSS SYSTEM SHUT OFF at the controller You are checking the supply side of the circuit and the TIREBOSS system should be off for this portion of the test Once again this will not allo
44. actual tire pressure The upper tolerance allows for normal heat buildup in the tires All of the operating tolerances are adjustable within the programming software The system has various built in safety features to warn the driver of such things as over speed conditions or tire failures Warnings are both visual and audible See SAFETY FEATURES tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL SAFETY FEATURES The TIREBOSS Tire Pressure Control system TPCS incorporates a number of extremely important safety features to ensure the integrity of the vehicle tires and the safety of everyone on the highways These include features dealing with the following aspects of operation 1 VEHICLE OVERSPEED CONDITION If the vehicle s speed exceeds the set point for the current selected tire pressure the OVERSPEED CONDITION alert screen will be displayed and an audible alarm will sound alerting the operator of a vehicle OVERSPEED CONDITION If the vehicle OVERSPEED CONDITION persists for a specified period typically 1 minute This period is adjustable the system will automatically increase the selected pressure setting upward to the next higher tire pressure for the selected load 2 LOW AIR BRAKE SUPPLY PRESSURE A pressure protection valve and an electronic safety switch make sure that air is available for tire inflations only when vehicle system air brake pressure is above a safe level 95 p
45. alve power circuit operation When the Cab Controller is On voltage is supplied from the Cab Controller to the Valve Controller through the Orange RLY wire in the Power Data cable The RLY circuit begins at the Cab Controller circuit board connector J1 Pin 4 and ends at the Valve Controller circuit board connector strip J2 at terminal 14 marked RLY Voltage present at RLY will energize relay 1CR on the Valve Controller circuit board When 1CR is energized a voltage signal is supplied back to the Cab Controller through the Green VPS wire in the Power Data cable Voltage on the VPS wire indicates to the Cab Controller that the Valve Controller has power The VPS circuit begins on the Valve Controller circuit board at connector strip J2 at terminal 12 marked VPS and ends at connector J1 Pin 3 on the Cab Controller circuit board With the Cab Controller voltage should be present in the RLY circuit as well as the VPS circuit The absence of voltage in EITHER the RLY or VPS circuit will trigger the Valve No Power alert Trouble shooting a Valve No Power fault Perform the following trouble shooting steps in the order listed to isolate the cause of the fault 1 With the Cab Controller turned On remove the Valve Controller cover and determine that wires at terminals RLY Orange and VPS Green are tight and secure 3 9 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE
46. alve to 100 truck idling with drive hose open to atmosphere Check compressor governor operation cut out at 125 psi minimum QOOOOOOOO 000000000 96 CONTROL SYSTEM SERVICE Check valve pack box and brackets Check drive hose hangers brackets and springs Retorque manifolds on rear wheels 100 ft Ibs Retorque rotary unions Check valve heater s operation if applicable Rebuild valve customer to authorize following inspection Clean in line Y strainer s at valve box Oe Ol dg OOOOOOO ROAD TEST Verify operation of system Check over speed 5 Check air brake system and operation Steering feel and operation Check for reasonable air build up times EE OOOOO Inspection done by Date Repairs completed by Date f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Service Inspection Explanations ANNUAL AIR SUPPLY SYSTEM Visual check of compressor discharge line
47. ational Screen should dim and white lettering should glow Ensure settings and applications can be scrolled and activated as per cab cards Ensure at start up screen that OCU sound warning is operational Low air supply warning on at 75 psi Lower brake air pressure slowly LOW AIR SUPPLY warning should appear on Operator Control Unit at cut out pressure 75 psi 5 psi Allow brake air pressure to rebuild and warning should go off at cut in pressure 88 psi 5 psi Select Off hwy unloaded settings lowest pressure Select all available zones ie steer drive and trailer to lowest pressure setting s from cab cards and allow system to deflate and stabilize Select Hwy loaded settings highest pressure With truck at idle select all available zones ie steer drive and trailer to highest pressure settings from cab cards Low Air Supply Warning should NOT activate at this time Allow system to inflate and stabilize All zones should read OK on operator control unit MAIN LINES PLUMING amp ATTACHMENTS Test with tires higher pressure i e 100 psi manual valves condition operation Check valves for cracks corrosion and smooth operation hoses and hardware condition Check for rub through and cracks Ensure hose protectors are on rub points Ensure all lines are securely fastened air flow check from each tire amp control valve Refer to Section 4 3 in the Service Manual tire pressure loss war
48. d to maximum and stabilized turn off truck Close all wheel end valves at the tires for drives and frame for steers Bleed air from the main air line at the schrader valve on the side of the TIREBOSS Tire Pressure Control System Valve Box This will de pressurize the system and allow you to open and remove the metal screen from the Y Filter safely Also located on the side of the Valve Box NOTE Each tire group has its own Y filter at the side of the valve box Ensure you bleed the correct schrader valve for that group Typically the bottom Y filter and schrader is for the drive group of tires Use this opportunity to thoroughly clean the Y filter screen One by one open and close each tire wheel end valve and note the rate of the air escaping from the Y filter body Air flows should be strong and consistent If any Y filter Body tire air flows seem restricted there is a obstruction in the wheel hoses or stem Clear these obstructions as required Metal Screen Reinstall the Y filter screen and replace seal washer Seal Repeat procedure for all wheel groups i e steers and lt i D Washer trailers of QD I 3 gt 5 Y filter a o Schrader Valve fitec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Pressure Loss Warning Check Procedures In the event of a line breakage or tire failure the TIRE
49. debris in screen and cap f tec manuals Service SERVICEv4 p65 V4 0807 E a TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Pressure Control Systems Service Inspection Each Six Months Date Work Order Inspection Service Service Unit Customer Name Mileage Vehicle Make Inspected By Inspection Codes af Pass Failed gg Repairs Completed reverse for inspection explanations A OPERATION OF SYSTEMS Ensure all manual valves are open for this test 4 Comments 1 Check operation of operator control Low air supply warning on at 75 psi 4 5 brake psi 3 Select Off hwy unloaded setting lowest pressures steer tires deflated drive tires deflated ttes trailer tires deflated 4 Select Hwy loaded setting to reinflate tires steer tires inflated OOOO OOO OOOO OOO drive tires trailer tires inflated low air warning off during inflate Service Manual Page B MAIN LINES PLUMING amp ATTACHMENTS Test with tires higher pressure i e 100 psi Check steer wheel hardware manual valves c
50. dryer governor and ensure that it is set to 125psi if the air dryer governor is below 125psi remove the governor end cap Loosen the 7 16 jam nut and with a flat blade screw driver turn the set screw counter clockwise to increase the air output pressure turn only 1 8 turn at a time Tighten jam nut and check that the wet tank pressure is at 125psi by bleeding down the air system until the air compressor engages pressure rebuilds and the dryer unloads Repeat procedure until a min of 125psi is maintained reinstall the governor end cap ensure that the governors are functioning properly pump the brake pressure down no more then 20psi to ensure that the compressor engages NOTE some governors are non adjustable and will have to be changed out with an adjustable governor f tec manuals Service SERVICEv4 p65 V4 0807 2 2 TIREBOSS rire Pressure Control SERVICE MANUAL Pressure Protection Valve Adjustment System Tests after Installation is complete 1 Install a 200 p s i test pressure gauge in truck wet tank or spare inlet test port of pressure protection valve opposite port to pressure switch Adjuster cap on protection valve must be lifted away from valve to unlock 2 Close wheel end valves Remove one end of an orange drive hose at hanger T fitting 3 With the truck wet tank at zero pressure start truck turn TIREBOSS control ON and leave engine idling Air will begin flowing through pressure protection val
51. e if there is voltage present at the Power Data circular 6 pin connector on inside of rear cover where the VPS Green wire terminates If voltage is not present first check for continuity on the Green wire through the connector on the rear cover If no continuity through the two piece connector remove the cable end and check continuity through the rear cover connector If this is OK it could be a loose connection at the pin connectors where they join Using a seal pick slightly close the split barrel female socket in the cable end connector and try again If problem persists replace either the rear cover connector or cable end connector Secondly if the connectors are OK check for continuity on the green wire through the Power Data cable If no continuity through the cable repair or replace the cable If voltage is present at the circular connector then determine if voltage is present at connector J1 terminal 3 green wire on the cab controller circuit board If voltage is not present either repair or replace the Power Data connector sub assembly internal wire harness assembly If voltage is present then replace the Cab Controller or the Cab Controller circuit board 6 Remove the rear cover of the Cab Controller leaving the unit turned On with all electrical connectors in place Using a multi meter set to DC volts connect the negative lead at J1 terminal 2 black wire Using the positive multi meter lead determine if there is vol
52. e pressure increase set point pressure to match load or application reduce vehicle load OCU calibration is incorrect Speed ignition wires installed incorrectly AIR FLOW the system is cycling from inflate check that all valves are open RESTRICTION to OK to deflate several times indi check for air line kinks or restrictions cating a line restriction or a closed do air flow checks from each tire back to valve Y strainers at valve box trailer not connected to system de activate trailer circuit as per operator guide or not equipped with tire pressure control TRAILER indicates that trailer control has reactivate trailer control by pushing and hold CIRCUIT been deactivated for operating ing stop for 2 seconds DISABLED truck only with no trailer or trailer system is disconnected LOADED air bag pressure is high indicating change to loaded setting VEHICLE a loaded vehicle adjust switch to match loads OVERSPEED Vehicle exceeding programmed slow vehicle to below max speed for that set CONDITION speed settings ting change to next higher setting recalibrate OCU 3 1 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL TIREBOSS ALERTS The system has ten alert conditions The following chart indicates the cause of the alerts and some possible solutions If the problem persists contact TPC International or one of their author
53. ed Pin 5 Signal Common Ground Pin6 DSR not used Pin 7 CTS not used Pin8 RTS not used Pin9 connect 2 PIN 9 no connect PIN 8 RTS not used white PIN 7 CTS not used grey PIN 6 DSR not used purple The internal 55 OCU connections are as follows Internal J5 header TIREBOSS DB9 SUB D Pin 1 TX White Red wire Pin 2 Pin 2 RX White Green wire Pin 3 Pin 4 Signal Common Black wire Pin 5 J5 INTERNAL J5 HEADER f tec manuals Service SERVICEv4 p65 V4 0807 1 z 1 0 TIREBOSS Tire Pressure Control SERVICE MANUAL System VA LVE B OX Serial Steer Axle Static Tank if equipped DI AG RAM Number Drive Axle Static Tank Trailer Axle Static Tank if equipped Orifice Fitting Orifice Fitting Power Communication Elec trical Cable Umbilical Transducer Fittings VCM Bracket Steer Axle Valve Body Schrader Valve Steer Axle if equipped Schrader Valve Load Sense Steer or Trailer Axle if equipped Pressure Switch Schrader Valve Drive Axle if equipped Valve Solenoids Steer or Trailer Axle Valve Body see detail below Fittings to receive air pressure from Drive Axle Valve Body Air Suspension if equipped Exhaust Port closest fitting to front of valve box view from bottom of box INFLATE SOLENOID DEFLATE SOLENOID with Red
54. ent when the valve is check the connections on the corresponding inflating or deflating end on the valve board Replace the solenoid harness or solenoid HEATER the valve control detects heater check heater wiring for breaks or poor con CURRENT current when there should be no nections ERROR current or detects no heater current check all plug in connectors and ground con see page 3 4 when there should be nections test ohms resistance at heaters to determine if faulty heater or page 3 6 check VB program TPC only TEMP SENSOR thermistor valve block tem check thermistor wires at valve board ERROR perature sensor has malfunctioned change thermistor f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Pressure SERVICE MANUAL HEATER CURRENT ERROR ALERT Valve Circuit Board 1393 01 Note Valve board 1393 01 only uses 12V 30 watt heaters This alert appears on the cab controller display to indicate a problem related to the system valve heater circuit operation There are two different conditions that will cause the Heater Current Error Alert to appear The first and least common is a condition where the heaters are on and based on the ambient temperature should not be on the second and most common is the condition where the heaters are not on and based on the ambient temperature they should be on The first problem where heaters are on and sh
55. essive wear on Rotary Unions as axles travels up and down f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Drive Axle Hanger Brackets and Hose Maintenance Typical Wheel Hanger Position amp Hose Length for units NOT using tire chains Note position of hanger brackets Units not using tire chains should have the hanger brackets adjusted to the lowest possible position without going below the centre line of Rotary Unions 1 5 d 1 i 33 gt Typical Wheel Hanger Position amp Hose Length for units using tire chains Note position of hanger brackets Units using tire chains should have the hanger brackets adjusted to the highest possible position 1 5 1 5 42 Wheel hoses adjusted too close may rub tires and create wear on hose hose guard or tires Wheel hoses adjusted too far may create a snagging hazard Too close Too far f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Wheel Changing Procedures Steer Tires WARNING ALL valve cores MUST be removed for the TIREBOSS system to operate prop WV erly Failure to remove valve cores can cause unsafe or dangerous driving conditions as the TIREBOSS system will be unable to maintain proper tire pressures STEER Tire Removal Procedures See following Diagram A Ensure all Steer axle TIREBOSS wheel valves and or fra
56. g and deflating properly without WARNINGS appearing on Operator Control Unit f tec manuals Service SERVICEv4 p65 V4 0807 5 3 VALVE REBUILD PROCEDURE Y FILTER Clean metal screen insid VA LV E B DY Y filter and replace seal washer BREAKDOWN DRAWING 1 included in Valve Pack Maintenance Kit AIR SUPPLY SIDE MANIFOLD O RING INLET Red Green CHECK VALVE GASKET SOLENOID 7 8 COUPLER HERMISTOR OPTIONAL 90 PIPE FIT TING Black White SOLENOID HEATER PAPER CABLE and HAR WIRE GASKET NESS S OPTIONAL lt EXHAUST Mark cable and SIDE 1 4 AIRLINE harness positions a O RING MANIFOLD EIUS Box prior to disassembly ing fitting use ie Sidewall to ensure they are 6 point socket reinstalled in origi to prd and nal position during assembly VALVE BODY FACE PLATE View from front with Red Green with White Black Harness Harness N THERMISTOR OPTIONAL 5 4 f tec manuals Service SERVICEv4 p65 V4 0807 1 SPRING on valve car tridges 1 VALVE SEAT VALVE REBUILD PROCEDURE con t POPPET on valve cartridges 1 INLET 2 PAPER GASKETS CHECK VALVE between manifolds and box m between air sup ply manifold and valve body 4 RUBBER O RINGS between valve body and manifolds amp valve body and face plate 1 SEAL WASHER
57. hrough the two piece connector remove the cable end and check continuity through the rear cover connector If this is OK it could be a loose connection at the pin connectors where they join Using a seal pick slightly close the split barrel female socket in the cable end connector and try again If problem persists replace either the rear cover connector or cable end connector Secondly if the connectors are OK check for continuity on the green wire through the Power Data cable If no continuity through the cable repair or replace the cable If voltage is present at the circular connector then determine if voltage is present at connector J1 terminal 3 green wire on the cab controller circuit board If voltage is not present either repair or replace the Power Data connector sub assembly internal wire harness assembly If voltage is present then replace the Cab Controller or the Cab Controller circuit board 6 Remove the rear cover of the Cab Controller leaving the unit turned On with all electrical connectors in place Using a multi meter set to DC volts connect the negative lead at J1 terminal 2 black wire Using the positive multi meter lead determine if there is voltage present at the Power Data board connector J1 terminal 4 Orange wire If voltage is not present at pin 4 on the J1 connector then replace the Cab Controller or Cab Controller circuit board If voltage is present at this point then move to the rear cover ci
58. imary Tank eeeeeeee pneumatic control lines Secondary Tank main air supply lines electronic signal lines 1 2 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS rire Pressure Control SERVICE MANUAL Install Temporary Gauge Here to set Dryer Governor to 125psi Pressure Protection Valve Internal Relief Valve One Way TIREBOSS VALVE BOX mounted inside wet tank TO Adjusted to 100 psi v Internal Standpipe Check Valve 5 8 AIRBRAKE TUBE SUPPLY LINE nan 2 DRYER GOVERNOR SENSING Y U VV AN 12 TEFLON with 16 5 cfm compressor 16 TEFLON with 30 cfm compressor COMPRESSOR GOVERNOR unload at 135 psi Lu Temporary 7 Inline Gauge Here to set Compressor Governor to 135psi 5 8 AIRBRAKE TUBE FACTORY RECEIVER TANK NOTE Compressor Governor must be adjusted to 135 psi first then adjust Dryer Governor to 125 psi See Truck Air Compressor Gover nor Adjustment in Service Manual for details Air Drying System HEATER 1 4 AIRBRAKE TUBE UNLOADER LINE UNLOADER LINE lt DRYER GOVERNOR unload at 125 psi PLUMBING SCHEMATIC NOTE If vehicle is equipped with only one D2 governor then RU WIT H the compressor Sensing line must be located at the truck wet tank and the dryers unloader line located at the unloader R
59. ing Diaqram A 1 Re install wheel matching up the previously MARKED stud and rim 2 Tighten and torque wheel nuts to manufacturers specifications 3 If hose adaptor fitting was removed apply thread sealing compound and re install using a wrench to hold the hub cap fitting WARNING When removing or replacing hose adaptor fitting from hub cap always use V a wrench to hold hub cap fitting Failure to do so will twist air lines inside hub cap and cause breakage and air loss of front tires 4 Remove valve core and install wheel hose onto valve stem Do not overtighten the nut it should be just snug 5 Using a small amount of anti seize compound reattach the wheel hose to the hose adaptor fitting ensuring the hub cap fitting does not turn 6 Open all steer axle wheel and frame valves 7 Turn the TIREBOSS Operator Control Unit and run truck until steer tire pressures stabilize at the highest pressure setting HIGHWAY LOADED Soap water test all steer wheel fittings to ensure no leaks are present If equipped with TIREBOSS hub protectors remove 4 wheel nuts to allow for mounting Tighten and torque wheel nuts as per manufacturer specifications 59 59 4 8 f tec manuals Service SERVICEv4 p65 4 0807 TIREBOSS Tire Pressure SERVICE MANUAL Tire Wheel Changing Procedures Drive Tires erly Failure to remove valve cores can cause unsafe or dangerous driving conditions as WV WARNING ALL
60. irs Completed 4l Bi See reverse for inspection explanations A MAIN LINES PLUMING amp ATTACHMENTS Test with tires higher pressure i e 100 psi Service amp comments Manual 1 Check steer wheel hardware Page manual valves condition operation L1 gg hoses and hardware condition 10 0 air flow check from each tire amp control valve ggg 4 3 tire pressure loss warning Ooo 4 4 sali IBaKS son 2 Check drive wheel hardware manual valves condition operation 00 hoses and hardware condition air flow check from each tire amp control valve LI L1 LJ 4 3 tire pressure loss warning operation 4 4 xal leaks 00g 3 Check trailer hardware manual valves condition operation hoses and hardware condition Ooo air flow check from each tire amp control valve 4 3 tire pressure loss warning Ooo 4 4 leaks siae e Ete A OP pP M ated ggg B AIR SUPPLY SYSTEM 1 Check dryers unloading OK check with TPCS off 0 L 2 Drain wet tank comment on moisture
61. ivate heaters push A This will temporarily turn the heaters on for the test procedure Heaters will automatically return to normal function operation when Info Screen in exited The display screen should now read Heater Info ON Voltage V 12 89 example only for a 2 zone 40watt heater Power W 89 60 example only for a 2 zone 40watt heater UP DOWN OFF If the screen does not show as example the following problems may exist If Voltage V shows a reading ie 12 89 and Power W reads 0 the heater is not functioning check heater wires and connection or replace heater pad If Voltage V reads 0 and Power W reads 0 the 10 Amp fuse on the Valve Circuit board may be faulty replace push in fuse on Valve Circuit Board see Valve Circuit Board Schematic for location To determine if the heaters are within the acceptable working range you will need to know the number of ohms To determine the number of ohms use the following formulas step one Power W Voltage V step two Amps A Voltage V Amps step three Compare ohms reading to chart in the HEATER CURRENT ERROR Alert section in the service manual If the ohms are not within the acceptable ranges inspect wires power source and connections To test a single heater disconnect all but one heater and repeat above procedure for each This will identify the faulty heater circuit if it exists Replace faulty heater if necessary
62. ized installers and speak to a service technician ALERT CAUSE POSSIBLE SOLUTIONS CAB UNIT the supply voltage to the Operator check fuse and connections at main power LOW VOLTS Control Unit is less than 8 0 V on supply battery and at ignition power supply 12V systems or less than 20V on check ground connections at frame or battery 24V systems must have a good ground connection check wiring at Operator Control Unit for breaks or poor connections check all plug in connectors and ground con nections VALVE UNIT the supply voltage to the check fuse and connections at main power LOW VOLTS control is less than 8 0 V on 12V supply battery systems or less than 20V on 24V check ground connections at frame or battery Systems check wiring at valve control for breaks or poor connections check all plug in connectors and ground con nections COM ERROR Operator Control Unit not check cable connections plug on back of op receiving proper communications from valve control erator control or wiring within valve control unit check for broken heat damaged or worn Operator Control Unit cable between controller and valve box VALVE POWER Valve control detects valve cur check wiring at valve control for breaks or ERROR rent when no current should be poor connections present Valve control detects no check all plug in connectors and ground con valve current when current should nections
63. l SERVICE MANUAL Trucks with dual D2 air governors a 0 200psi gauge must be installed inline between the D2 compressor governor and the receiver air tank sense line Refer to Plumbing Schematic Truck With Receiver Tank section in this manu al a 0 200psi gauge must be installed into the available 1 4 NPT port on the Pressure Protection Valve opposite of the electric pressure switch Refer to Pressure Protection Valve Adjustment sec tion in this manual with the TIREBOSS Operator Control Unit turned off first ensure truck air compressor is set to 135psi the pressure that is maintained after the dryer has unloaded and pressure has stabilized If truck air compressor is set to 135psi then check that the wet tank pressure is set at 125psi the pressure at which the dryer unloads If the pressures are not at the above settings follow the pro cedures listed below these adjustments must be done with the TIREBOSS Operator Control Unit turned off first ensure that the compressor governor is set to 135psi if the truck air compressor is below 135psi Remove the compressor governor end cap Loosen the 7 16 jam nut and with a flat blade screw driver turn the set screw counter clockwise to increase the air compressor output pressure turn only 1 8 turn at a time Tighten jam nut and check the air compressor output pressure Repeat procedure until 135psi is maintained reinstall the governor end cap then locate the air
64. l of the tire 7 Open all trailer axle wheel valves 8 Turn the TIREBOSS Operator Control Unit ON and run truck until trailer tire pressures stabilize at the highest pressure setting HIGHWAY LOADED 9 Soap water test all trailer wheel fittings to ensure no leaks are present 4 10 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Wheel Changing Procedures Diagrams Rotary Union Compres To Valve Stem sion Fitting Manifold S wivel Fitting Wheel Hose Swivel Fitting Hose Adaptor Fitting Hub Cap Fitting Caution always hold this fitting Wheel with wrench when removing or Lot H installing fittings into hub cap Sue Manifold Assembly DRIVE AXLE HARDWARE P d Rotary Union Diagram B STEER AXLE HARDWARE Diagram A H To inner dual valve stem Inner Wheel Hose in t To outer dual Hub Cap Tee valve stem gt Hub Cap Fittin Caution always a this at EN Outer Wheel Hose with wrench when removing or Wheel Valve installing fittings into hub cap TRAILER AXLE HARDWARE Diagram C 4 11 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Pressure Control Systems Service Inspection MONTHLY Date Work Order Customer Name Unit Mileage Vehicle Make Inspected By Inspection Codes Pass Failed Repa
65. l valve cores are removed Reinstall the wheel hose onto valve stem Do not overtighten the nut it should be just snug Soapwater test for leaks Inner wheel uses the straight wheel hose fitting and when installed the rubber hose protector should be slid to the base of the valve stem Outer wheel uses the curved wheel hose Outer wheel valve stem should be turned into the rim to avoid damage to wheel hose or valve stem 2 Reinstall inner wheel matching up previously MARKED stud and rim 3 Reinstall outer wheel by inserting inner wheel hose into appropriate rim hole and matching up the previously MARKED stud and rim 4 Tighten and torque wheel nuts as per manufacturers specifications 5 Using a small amount of anti seize compound reattach the wheel hoses to the TIREBOSS manifold swivel fitting ensuring valve handles are parallel with the side wall of the tire 6 Using oil on rotary union compression fitting threads and sleeve reattach the orange drive hose orange drive hose should be approximately 2 away from the tire side wall 7 Open all drive axle wheel valves 8 Turn the TIREBOSS Operator Control Unit ON and run truck until drive tire pressures stabilize at the highest setting HIGHWAY LOADED 9 Soap water test all drive wheel fittings to ensure no leaks are present f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Tire Wheel Changing Procedures Trailer
66. le is moving See SYSTEM OVERVIEW The control valves are supplied with air pressure from the vehicle s air brake system The air brake system always has priority over the tire pressure system and is protected by two safety systems First a pneumatic pressure protection valve closes air supply to the tire pressure system if brake tank pressure falls below 95 PSI An electronic pressure switch that opens the electronic circuit if the brake tank pressure drops to 75 PSI backs this up This switch also activates an alert LOW AIR SUPPLY on the OCU and electronically prevents any inflation or deflation of the tire pressure system The system will resume operation once air pressure builds above the safe limits Tire pressures are controlled to specific set points dependent on vehicle load and speed Typical tire pressures change from a maximum of 110 PSI when fully loaded at highway speeds down to 27 PSI when empty at reduced off highway speeds These pressure ranges are typical for truck transport vehicles that operate with a standard air supply system and adhere to guidelines set by the tire manufacturer for automotive applications The upper amp lower limits for air pressure control are 150 PSI and 10 PSI respectively and are based on the air supply capacity pressure transducer limits and application The control valves can ac commodate up to 75 CFM Tire pressure control amp display is accurate within a nominal range of 2 psi of
67. ll appear push ENTER for different exit a menu option screen Application Screens Will re enable disabled Will allow Operator 10 trailer circuit when held enter apply settings f r 2 seconds enter apply applications enter apply menu options Will dim LED display and white lettering on OCU will illuminate TRAILER CIRCUIT OVERRIDE FUNCTION This function is used only when pulling a trailer that is not equipped with TIREBOSS Tire Pressure Control or when not pulling a trailer Non equipped or non connected trailers will cause the TRAILER AIR FLOW RESTRICTION alert to activate Push amp Hold the CANCEL button for 2 seconds until a single beep is heard The alert stops amp the trailer circuit will be de activated trailer STATUS flashes To resume normal operation Push amp Hold the STOP button for 2 seconds f tec manuals Service SERVICEv4 p65 V4 0807 1 1 2 TIREBOSS rire Pressure Control OPERATOR CONTROL UNIT OCU SELECTION SEQUENCES The following information and selection screens can be accessed by using the following selection sequences TO ACCESS CHANGING SETTING within an APPLICATION APPLICATION CHANGING APPLICATION SPEED FREQ SET UP CAB SET UP FILE CAB PROGRAM VERSION VALVE PROGRAM VERSION TPC SYSTEM SERIAL NUM BER TIREBOSS VERSION HEATER INFO not available with all software versions PROGRAM MODE PUSH
68. ller display to indicate a problem related to the system valve heater circuit operation There are two different conditions that will cause the Heater Current Error Alert to appear The first and least common is a condition where the heaters are on and based on the ambient temperature should not be on the second and most common is the condition where the heaters are not on and based on the ambient temperature they should be on The first problem where heaters are on and should not be is pretty easy to diagnose and is typically caused by a defective or failed relay relay failed in an on state as if energized The second problem where heaters should be on but are not could be any one or a combination of the following Blown heater circuit fuse Failed heater circuit control relay relay is off and will not energize Broken heater wire s or loose heater wire connections Failed heater element s Incorrect heater s installed Cab controller is not set up properly for the number of installed heaters Cab controller is not set up properly for the wattage rating of installed heaters Short description of the valve heater circuit operation Valve heater s are installed on vehicles used in locations where at times the ambient temperatures may be be low freezing Freezing temperatures can prevent proper operation of the system control valve s due to moisture contained in the air supply freezing inside the valve s The system
69. me valves are closed 2 Shut the power switch OFF on the TIREBOSS Operator Control Unit switch on back left side 3 Relieve air pressure from the TIREBOSS tire mainline by the Schrader top Schrader marked with an S located on the right side of the TIREBOSS valve box usually located on the truck frame 4 MARK with a grease pencil one wheel stud and rim location to ensure the proper alignment of wheel hoses during re installation of the wheel 5 If equipped with TIREBOSS hub protectors remove the 4 wheel nuts holding it in place and set hub protectors aside for reinstallation at a later time 6 Undo TIREBOSS wheel hose from the hub cap Hold hose adaptor fitting with a wrench and undo swivel fitting attached to wheel hose CAUTION Steer wheel hose is pressurized 7 Undo wheel hose at the valve stem fitting and insert a valve core into the valve stem 8 Undo wheel nuts and remove wheel If rim does not fit over hose adaptor fitting remove by holding hubcap fitting with wrench WARNING When removing or replacing hose adaptor fitting from hub cap always use V a wrench to hold hub cap fitting Failure to do so will twist air lines inside hub cap and cause breakage and air loss of front tires 9 Repair or replace tire as required If rim is changed MARK new rim in same location as old rim as orientated from the valve stem Typical STEER Tire Re installation Procedures See follow
70. ming out of it and is mounted to the side of one of the valves The TEMP SENSOR wires are connected at Terminal Strip J2 at terminal 7 marked TH1 and terminal 8 marked TH2 Note that connection of the HEATER 3 6 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire PressureControl SERVICE MANUAL PAD or TEMP SENSOR wiring is not polarity sensitive can be connected either way The TEMP SENSOR will call for the heaters to be turned on only when the sensed temperature is 3 Degrees C 38 Degrees F or lower Note that a Heater Current Error alert will not be caused by a defective TEMP SENSOR or its related wiring Any problem related to the TEMP SENSOR its circuit will cause a Temp Sensor Error alert to appear on the operator control screen Trouble shooting a Heater Current Error fault Perform the following trouble shooting steps in the order listed to isolate the cause of the fault 1 Check to ensure that the main Power and Ground wire connections to the heaters at terminals HT COM and 28V OR 14V are tight 2 Using multi meter connect the negative lead at the VBAT terminal and check to ensure there is voltage present on both sides of Fuse 22 11 15V on a 12 volt system 22 30V on 24 volt system 3 With the Cab Controller on and the TEMP SENSOR activated again using a multi meter with the negative lead connected at the VBAT terminal check to ensure there is 11 15V 22 30V present at terminal HT
71. ning operation Refer to Section 4 4 in the Service Manual air leaks Soap water test all hoses hardware and pneumatic connections with system at 100 psi f tec manuals Service SERVICEv4 p65 V4 0807 P a TIREBOSS Tire Pressure Control SERVICE MANUAL Tire pressure Control Systems Service Inspection B Annual Complete this inspection in addition to the A six month inspection Inspection Codes 4 Pass Failed Repairs Completed See reverse for inspection explanations Comments Service Manual AIR SUPPLY SYSTEM Page of Visual check of compressor discharge line fittings Check wet tank drain Drain wet tank comment on moisture content Drain secondary air tanks comment on moisture content Check air dryer s amp alcohol injector s it applicable MOUNTING and hoses 2 service required to be authorized following inspection change dryer cartridge s change unloader 5 change turbo boost valve s L change outlet check 5 drain alcohol injector s eene refill alcohol injector s seasonal 6 Adjust Pressure Protection V
72. ol or strong cleaners Rubber will swell and deteriorate Assemble valve cartridge with new O rings four in total replacing valve seat poppet If valve seat or body is damaged replace the entire valve cartridge part 16750 VY CAUTION Take care not to over tighten allen head screw as damage to valve piston shaft may occur Carndge Body Replace O rin Allen Screw Brass End Joe Spring Valve Piston Shaft Valve Seat Poppe Replace O rings Spring Washer 5 2 f tec manuals Service SERVICEv4 p65 V4 0807 VALVE REBUILD PROCEDURE con t Disassembly and Replacement of Orifice Filters a Using two wrenches remove Static Tank Orifice located on top of static tank Remove and replace 2 snap rings and filters supplied in valve pack maintenance kit VY CAUTION When re installing do not over tighten as brass fittings may split Valve Reassembly Cut away showing snap rings amp filters VY NOTE Torque all valve body 1 4 bolts to 8 ft Ibs a On assembled valve cartridge lightly lubricate O rings brass bushing at end of cartridges and valve body bore with a light O ring lube DOW CORNING 111 Valve Lubricant amp Sealant Insert cartridge into bore of valve body Starting at a slight angle then aligning straight to insert gently into bore Ensure free movement open and close by manually moving piston end Any interference in movement must be rectified CAUTION Take extra care not to damage O rings when in
73. ondition operation hoses and hardware E air flow check from each tire amp control valve tire pressure loss warning air l aKS 2 Check drive wheel hardware manual valves condition operation hoses and hardware condition 5 E air flow check from each tire amp control valve tire pressure loss warning salt leaks E 3 Checktrailer hardware manual valves condition operation hoses and hardware air flow check from each tire amp control valve tire pressure loss warning 3alldeaks iii en DOUCE DAC gt dagad OOOOO PIEIEIEIEI a 9 Inspection done by Repairs completed by Date f tec manuals Service SERVICEv4 p65 V4 0807 4 3 4 3 4 4 4 3 TIREBOSS Tire Pressure Control SERVICE MANUAL Service Inspection Explanations SIX MONTH OPERATION OF SYSTEM Ensure all manual valves are open for this test Check operation of Operator Control Unit Check that dimming function in oper
74. ould be done on an annual basis 1 Ensure good speed signal by following this procedure On the Operator Control Unit press MENU then the DOWN ARROW and ENTER The display will now show the hertz reading with vehicle at full stop hertz should read 0 now drive vehicle at a steady speed i e 15mph 21kph and hertz should stay constant and should not fluctuate as long as you are at that same speed it takes a few seconds to process the signal press CANCEL if hertz are not fluctuating WV If hertz do not read O at full stop or are fluctuating a pulse speed sender may have to be installed speed board turned and system calibrated 2 Ensure proper Overspeed Function by following this procedure With Operator Control Unit on lowest speed setting Refer to Speed Setting Chart on Cab Card drive truck at a speed just below maximum speed for that setting for 30 seconds i e if setting is 10mph 14kph drive truck at 8mph 12kph The Overspeed Alert should not activate With Operator Control Unit still on same setting drive truck at a speed just above maximum speed for that setting i e if setting is 10mph 14kph drive truck at 12mph 16kph The Overspeed Alert should now activate with an audible beep and a warning message on the Operator Control Screen VEHICLE OVERSPEED CONDITION SLOW VEHICLE DOWN OR CHANGE TO NEXT SETTING This warning will appear 3 times in approx 30 second time span Allow warning to activate until
75. ould not be is pretty easy to diagnose and is typically caused by a defective or failed relay relay failed in an on state as if energized The second problem where heaters should be on but are not could be any one or a combination of the following Blown heater circuit fuse Failed heater circuit control relay relay is off and will not energize Broken heater wire s or loose heater wire connections Failed heater element s Incorrect heater s installed Cab controller is not set up properly for the number of installed heaters Cab controller is not set up properly for the wattage rating of installed heaters Short description of the valve heater circuit operation Valve heater s are installed on vehicles used in locations where at times the ambient temperatures may be be low freezing Freezing temperatures can prevent proper operation of the system control valve s due to moisture contained in the air supply freezing inside the valve s The system valve s are located inside of the valve box which is typically mounted on the truck frame behind the cab There is a heater element attached to the bottom side of each valve The heaters are resistive elements contained in a flat pad with two wires exiting the pad for electrical connection to the circuit Also inside the valve box is the valve controller circuit board mounted inside its own enclosure The circuit which controls turning the heaters on and off is located on the valve con
76. psi when parking decreases to 75 psi when starting 2 Through the solenoids mounted on the valve This would allow supply air from protection valve wet tank to vent through the solenoids into the same exhaust port Normally when the solenoids are in neutral they are seated and prevent any air flow through their seat A leak here would not drop tire pressures but would allow the wet tank pressure to drop but only to the closing pressure of the pressure protection valve setting of approx 95 100 psi The source of the leak can be determined by pulling ONLY the exhaust manifold off the valve as sembly and determining which valve steer drive or trailer is leaking The system can still be aired up and operated with this manifold removed To remove the exhaust manifold first remove the exhaust port elbow from the bottom of the box Next remove the two bolts also at bottom of box holding the manifold in the box Now remove the bolts holding the manifold to the valve assembly inside the box Once it is determined which valve s are leaking indicated by the passage of air out of the ex haust port in the valve body perform the following procedures Close all the wheel valves shut the truck off once it has reached the unloading pressure of the compressor e g 125 psi and disconnect 1 air line from the side of the valve that is leaking This ensures there is no pressure on the tire side of the valve If the leak stops you have
77. rcular 6 pin connector and determine if voltage is present at the terminal where the RLY Orange wire terminates If voltage is present at this location first check for continuity on the Orange wire through the connector on the rear cover If no continuity through the two piece connector remove the cable end and check continuity through the rear cover connector If this is OK it could be a loose connection at the pin connectors where they join Using a seal pick slightly close the split barrel female socket in the cable end connector and try again If problem persists replace either the rear cover connector or cable end connector Secondly if the connectors OK check for continuity on the orange wire through the Power Data cable no continuity through the cable either repair or replace the cable 3 12 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL SLIGHT AIR LEAK THROUGH EXHAUST PORT Note A slight air leak as referenced here can be identified by holding your hand over the exhaust port bottom of the valve box assembly and detecting a slow build up of pressure A slight leak through the exhaust port can come from one of two places 1 Feeding back from the tires through the valve cartridge seat and out the exhaust port This would allow a pressure drop in the tire circuit when parking overnight You would notice a decrease in tire pressure on the cab controller e g 90
78. si If the air brake pressure falls below a safe level the LOW AIR SUPPLY alert will be displayed and the air supply is shut off to the TPCS The supply of compressed air to the vehicle air brake system always has priority over the TPCS 3 LOSS OF TIRE PRESSURE When an unexplained drop in tire pressure takes place in any of the zones an audible alarm will sound The tire pres sure status display on the operator control unit will flash the zone display in which the loss of tire pressure has occurred and it will alternate with the TIRE PRESSURE LOSS alert The source of the pressure drop must be located prior to continuing operation so that appropriate action may be taken such as isolating the problem tire from the rest of those in the zone through the use of manual shutoff valves 4 AIR FLOW RESTRICTION The TIREBOSS system is designed to work normally with all wheel valves open maintaining constant monitoring amp control of tire pressures If the valves are left in a closed position the system only senses line pressure and begins inflating amp deflating past the set point pressure This repetitive action will cause the AIR FLOW RESTRICTION ALERT to be activated This alert will continue until the valves are re opened allowing normal operation to resume 5 TIRE OVER PRESSURE The TIREBOSS system automatically assigns upper and lower limits to the programmable set points The system will trim the tire pressures for a preset time after
79. stalling cartridge NOTE Use anti seize paste on all bolts and screws in valve assembly Liquid Pipe thread sealer should be used in moderation on all pipe fittings Do not use teflon tape With rebuilt cartridges in place replace 2 small o rings and 2 spool valve o rings Bolt on face plate with three 1 4 bolts Install 2 new solenoid gaskets and reinstall solenoids NOTE Do not over tighten solenoid screws Install new inlet check valve Supplied in maintenance kit Ensure no liquid pipe thread sealer is on the inner face Reinstall 1 4 airline fitting into valve body Install side manifolds with new o rings Tighten bolts only finger tight at this time With side manifolds in position place assembly upright on work bench While pushing down on valve body tighten side manifold bolts This will ensure proper alignment of manifolds and valve body NOTE Torque all valve body 1 4 bolts to 8 ft Ibs Install valve body into box and reinstall thermistor wire systems with valve heaters only Plug in solenoid harness on each solenoid with new square gaskets Ensure these are installed to original position and valve as marked NOTE Red Green wire to left side and White Black wire to right side Install and tighten all side 1 4 valve body bolts to box Now install and tighten bottom 1 4 body bolts to box Install 1 4 air line on valve body NOTE Torque all valve body 1 4 bolts to 8 ft lb NOTE On
80. sure Control SERVICE MANUAL SECTION 4 MAINTENANCE PROCEDURES TIREBOSS Tire Pressure Control SERVICE MANUAL System Maintenance Overview Attached is the information required to properly maintain your TTREBOSS Tire Pressure Control system for optimum performance DAILY Drain wet tank Observe moisture content Walk around the truck give system and wheel ends a visual inspection WEEKLY Inspect Rotary Unions see attached Rotary Union Maintenance Instructions for basic guidelines MONTHLY Complete and diarize the attached Monthly Service Inspection sheet 6 MONTHS Complete and diarize the attached Six Month Service Inspection sheet Check air supply system ANNUALLY Complete and diarize the attached Annual Service Inspection sheet This needs to include the rebuilding of the valve pack s and fully servicing your air drying system as outlined on the Inspection Sheet Valve rebuild kits are available through our parts department We recommend that this procedure is coordinated with your servicing in the fall This way your air drying system will be fully serviced before the winter months providing optimal performance f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Rotary Union Maintenance Instructions Testing Rotary Unions For Excessive Wear or Leaks With the drive wheel valves open move rotary union up and down and spray base with soapy wa
81. tage present at the Power Data board connector J1 terminal 4 Orange wire If voltage is not present at pin 4 on the J1 connector then replace the Cab Controller or Cab Controller ircuit board If voltage is present at this point then move to the rear cover circular 6 pin connector and determine if voltage is present at the terminal where the RLY Orange wire terminates If voltage is present at this location first check for continuity on the Orange wire through the connector on the rear cover If no continuity through the two piece connector remove the cable end and check continuity through the rear cover connector If this is OK it could be a loose connection at the pin connectors where they join Using a seal pick slightly close the split barrel female socket in the cable end connector and try again If problem persists replace either the rear cover connector or cable end connector Secondly if the connectors are OK check for continuity on the orange wire through the Power Data cable If no continuity through the cable either repair or replace the cable 3 10 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL VALVE NO POWER ALERT Valve Circuit Board 1393 02 This alert appears on the Cab Controller display to indicate an existing problem related to the system Valve Controller circuit board power Notes i In the following descriptions RLY is Relay and VPS
82. ter Worn or leaking unions should be replaced NOTE Short Rotary Unions used on Hub Reduction wheel ends do not have grease fittings and do not require greasing For Rotary Unions that have grease fittings regular greasing will optimize the operation and life of the Rotary Unions Basic Guidelines AMOUNT OF GREASE Re lubricate sparingly only enough grease should be applied one pump to replace that grease which has been dissipated Over greasing be damaging to the Rotary Union Do not use power greasers TYPE OF GREASE We recommend the Rotary Unions be serviced with Red Ram Complex A grease which is available through your local TTREBOSS parts distributor or our distribution warehouse 1 888 338 3587 FREQUENCY Operating on roads that are Every 2 500 km frequently salted sanded or or 1 500 miles calcium applied Operating on clean and clear Every 5 000 km roads or 3 000 miles NOTE All Rotary Unions that are internal on Trailer and Steer axles do not require greasing 4 2 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure SERVICE MANUAL Air Flow Check Procedures Regular checks of tire air flow will ensure good passage of air into and out of the tires keeping in flate and deflate times to a minimum Air flow checks should be done regularly on a monthly basis 1 With the TIREBOSS Tire Pressure Control System at a maximum setting and tires inflate
83. the corresponding number of heaters should be within 2 Ohm of the values listed in the following table Note that all heaters connected together to a common pair of wires going to the valve board HT 1 amp HT 2 If only 1 heater is in the circuit and the measured resistance is outside of the acceptable range replace the heater If more than 1 heater is in the circuit then separate the heaters and check each individual heater to determine which one is faulty 12V 30W HEATERS Ideal Acceptable Range 1 heater 4 8 Ohms 5 0 Ohms 4 6 Ohms 2 heaters 2 4 Ohms 2 6 Ohms 2 2 Ohms heaters 1 6 Ohms 1 8 Ohms 1 4 Ohms Check the VB program in the operator controller for the correct heater settings For example heaters are either unchecked on user page or have a different quantity listed than the number of valves in the system This can only be checked by TPC or their certified installers Check the VB program in the operator controller to ensure the correct heater wattage is indicated in the protected parameters For example are the heaters 40 watt rather than 30 watt This can only be checked by TPC or their certified installers 3 5 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire PressureControl SERVICE MANUAL HEATER CURRENT ERROR ALERT Valve Circuit Board 1393 02 Note Valve board 1393 02 accommodates both 12V and 24V systems This alert appears on the cab contro
84. the electronic circuit for each LED SN e x In the event of a faulty circuit a fault may exist in the following areas 2 low battery power supply lt er MS lt e replaceable fuses heater battery or ignition fuse QV S ES poor terminal connections 3 F av valve circuit board or OCU circuit board 4 NS 4 NN Ss abraded wires i wo aN lt eost a9 SD SKK UP e Se CO D ss SU 9 S SS gat e Qd s 22227 m m A e e VALVE CONTROL MODULE CIRCUIT 2CR Control 12 24 VDC REMOTE ALARM POSITIVE SUPPLY f tec manuals Service SERVICEv4 p65 4 0807 1 9 TIREBOSS Tire Pressure Control SERVICE MANUAL Data Logger Connections to TIREBOSS POWER DATA The Data Logger port is located on the im back of the Operator Control Unit OCU DATA LOGGER TERFACE PORT It is a standard DB9 Serial port male connector and is labelled COM A or DATALOGGER SPEED IGNITION has the molded female sockets The pin connectors are as follows BACK OF COMMA DB9 SUB D view from inside cover PIN 1 no connect PIN 2 TX DATA white red PIN 3 RX DATA white green PIN 4 not used blue PIN 5 Signal Common Ground black TIREBOSS DB9 SUB D Connections Pin 1 connect Pin2 TXDATA Pin3 RX DATA Pin 4 DTR not us
85. thermistor to detach from valve body Remove valve assembly from box WV NOTE On three zone systems only the two front bolts and lock nuts on the Valve Control Module Bracket will have to be removed in order to allow room to remove valve assembly see page 1 Valve Disassembly WV CAUTION Systems with valve heaters only Do not damage valve heater and foil on bottom of valve Do not submerse in cleaning fluid as this will damage heater Remove solenoids from valve and discard O rings See parts BREAKDOWN DRAWING 1 Remove 1 4 bolts to disassemble face plate from valve body and discard rubber o rings Pull valve cartridges from valve body using needle nose vice grips on centre allen screw and put aside for cleaning at a later stage Remove 1 4 manifold bolts on side of valve body and discard o rings Remove inlet check valve and 1 4 air line fitting using a 6 point socket only CAUTION Use caution when removing these fittings Do not damage push to lock Remove paper gaskets from valve body Clean valve body and manifolds Blow air through all passages Ensure all passages are free of debris and completely free of any cleaning materials before reassembly begins Ms Valve Cartridges Using two allen wrenches for old style or allen wrench and two 1 4 bolts for new style disassemble valve cartridges Clean all parts See parts BREAKDOWN DRAWING 3 VY NOTE Do not soak rubber components in vars
86. three zone systems only with a small amount of silicone to seal reinstall the two front bolts and lock nuts on the Valve Control Module Bracket as removed on page 5 2 Box Assembly Install exhaust and air supply fittings on bottom of box Remove temporary bushing from inside exhaust port NOTE Install exhaust port prior to installing 1 4 bolt on right side of fitting Systems with valve heaters only Install heater connection harness and tie strap wire bundle together Air up wet tank to approx 120 psi and ensure that there are no leaks through the valve body assembly Install 900 pipe fitting on side of box using liquid pipe thread sealer With metal screen removed from Y filter check airflows by opening and closing each wheel end valve to ensure good airflow from wheels to valve box 6 After cleaning metal screen inside Y filter replace seal washer Supplied in maintenance kit and reinstall Y filter plug See parts BREAKDOWN DRAWING 4 Reconnect to original position the Y filter assembly to 909 fitting on side of box Final Check Open all wheel valves and ensure that there is no air leaking at the exhaust outlet With the engine running turn on the Operator Control Unit Change setting to highest tire pressure setting and allow tire pressures to build to this setting Leak check all air connections and valve pack assembly using soapy water Test system functions by changing settings and ensuring system is inflatin
87. troller circuit board Refer to drawing on page 1 7 for location of the following components on valve circuit board Heater power positive 12V is supplied through fuse F2 10 Amp Mini ATO and control relay 3CR located on the valve controller circuit board The 12V connection for the heater s is then supplied on Terminal Strip J2 at terminal 15 marked HT 1 The ground side connection for the heater s is supplied at terminal 16 marked HT 2 Power is only available at HT 1 with the 10 amp fuse in place and the Relay 3CR energized This relay is activated by the operator controller after receiving a low temperature message from a temperature sensing element Each system has one TEMP SENSOR regardless of the number of valves heaters used in the system The TEMP SEN SOR looks like an electrical ring terminal with two wires coming out of it and is mounted to the side of one of the valves The TEMP SENSOR wires are connected at Terminal Strip J2 at terminal 7 marked TH1 and terminal 8 marked TH2 Note that connection of the HEATER PAD or TEMP SENSOR wiring is not polarity sensitive can be connected either way The TEMP SENSOR will call for the heaters to be turned on only when the sensed temperature is 3 Degrees C 38 Degrees F or lower 3 4 f tec manuals Service SERVICEv4 p65 V4 0807 TIREBOSS Tire Pressure Control SERVICE MANUAL Note that a Heater Current Error alert will not be caused by a defective TEMP SENSOR or its related
88. valve reads 50 psi example only and the operator controller reads 0 psi it means either the transducer is no longer functioning or it is calibrated incorrectly 3 You may either change the transducer or attempt to RE CALIBRATING TRANSDUCERS To recalibrate transducers you will require a multi meter that can read DC volts The transducers require 5 volts and are calibrated based on 5 volts which is supplied by the CPU circuit board If the supply voltage changes then it could leave the transducers out of range Once adjusted to that input voltage then the transducers should begin to function properly See schematic on following page 1 Turn on the TIREBOSS system at the operator control unit 2 Inside the TIREBOSS Valve Box remove cover of Valve Control Module by removing the eight screws 3 Remove the airline to the transducer at push to lock fitting on side of Valve Control Module 4 Set the multi meter to DC Volts Attach the multi meter BLACK probe to the terminal marked TP6 This is the ground terminal to the transducer 5 Touch the multi meter RED probe to the terminal marked VS This is the soldered pin attached to the transducers red wire You might need to scrape the solder pin before getting a reading as it has a protective coating 6 Record the input voltage reading 7 Now you need to get an accurate output voltage reading from the transducer With the BLACK probe still attached to the TP6
89. valve s are located inside of the valve box which is typically mounted on the truck frame behind the cab There is a heater element attached to the bottom side of each valve The heaters are resistive elements contained in a flat pad with two wires exiting the pad for electrical connection to the circuit Also inside the valve box is the valve controller circuit board mounted inside its own enclosure The circuit which controls turning the heaters on and off is located on the valve controller circuit board Refer to drawing on page 1 8 for location of the following components on valve circuit board Heater power positive 12V 24V is supplied through fuse F2 10 Amp Mini ATO and control relay 3CR located on the valve controller circuit board The 12V 24V connection for the heater s is then supplied on Terminal Strip J2 at terminal 15 marked HT COM The ground side connection for the heater s is different based on the system voltage For 24V systems heater ground is at terminal 16 marked HT 28V For 12V systems heater ground is at terminal 17 marked HT 14V Power is only available at HT COM with the 10 amp fuse in place and the Relay energized This relay is activated by the operator controller after receiving a low temperature message from a temperature sensing element Each system has one TEMP SENSOR regardless of the number of valves heat ers used in the system The TEMP SENSOR looks like an electrical ring terminal with two wires co
90. ve and out of hanger at open T fitting 4 Pressure Protection Valves are backed off completely and need to be set after installation to the truck 5 Turn the pressure protection valve adjuster cap until the pressure in the wet tank is maintained to 100 psi with a steady flow of air coming from the hanger T fitting When approaching final pressure turn adjuster gradually 1 4 turn at a time Allow time for pressures to stabilize 6 Reduce brake pressure to 80 psi no lower and reconfirm pressure rebuilds and is maintained to 100 psi in wet tank with truck idling and air flow out hanger end Reinstall orange drive hose 7 Open all wheel valves and let stabilize at lowest pressure setting When dryers unload at idle select the highest pressure setting and confirm that the pressure does not drop below 80 p s i It is normal for the tank pressure to swing below the 100 p s i setting and then rebuild and stabilize again If pressure drops to 75 p s i it will trigger a Low Air Supply alert on the Operator Control Unit If this happens increase the protection valve setting slightly by 2 3 p s i 102 p s i and repeat step 7 Push down to lock adjuster cap 8 Confirm proper operation of Low Air Supply warning on Operator Control display screen This Low Air Supply warning should only be activated when truck wet tank pressure is lowered to 75 psi by several brake applications Operator Control Unit must be on for this test 9
91. w a tire pressure drop as it is independent of the tire supply circuit Please note that although the solenoids are supposed to be air tight a slight leak here will not cause any operational problems with the tire pressure control or the air brake system It would never be noticed with the truck running but would allow a slow leak down of the wet tank pressure overnight but only down to the set point of the TIREBOSS pressure protection valve approx 95 100 psi For a final test hook up all of the air lines that were removed leaving the exhaust manifold off open the wheel valves and start the truck with the TIREBOSS controller off If there are no leaks turn the controller on and allow the tire pressures to stabilize NOT INFLAT ING OR DEFLATING so the solenoids are in the NEUTRAL CLOSED POSITION If there are no leaks install the exhaust manifold 3 14 f tec manuals Service SERVICEv2 p6e5 V3 1105 TIREBOSS Tire Pressure Control SERVICE MANUAL TRANS RANGE ERROR ALERT This alert appears on the operator control unit display to indicate a problem related to the systems transducer TROUBLE SHOOTING TRANSDUCERS 1 Compare the air pressure at the Y strainer schrader valve located on the side of the valve box to the pressure indicated on the operator control unit display Ensure you are reading the same schrader valve and controller zone i e drives schrader valve and drives display on controller 2 If the schrader

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