Spicer TPCS Troubleshooting Guide

Spicer

TPCS

(

Tire Pressure Control System

Troubleshooting Guide

AXTS0020

)

April 2007

Warnings and Cautions

General Information

The descriptions and specifications contained in this service publication are current at the time of printing.

Dana reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.

IMPORTANT NOTICE

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used.

WARNING: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.

CAUTION: Failure to follow indicated procedures may cause component damage or malfunction.

IMPORTANT: Highly recommended procedures for proper service of this unit.

Note: Additional service information not covered in the service procedures.

Always use genuine Spicer replacement parts.

Every effort has been made to ensure the accuracy of all information in this guide. However, Dana Commercial Vehicle

Systems Division makes no expressed or implied warranty or representation based on the enclosed information.

Any errors or omissions may be reported to: Marketing Services Dana Commercial Vehicle Systems Division P.O. Box 4097 Kalamazoo, MI. 49003

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Table of Contents

General Information

Tire Pressure Control System 1

Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Component Description . . . . . . . . . . . . . . . . . . . . . . . . 2

Simplified System Schematic . . . . . . . . . . . . . . . . . . . . 4

Operator Instructions

Driver Display Module (DDM) . . . . . . . . . . . . . . . . . . . 5

Operator Control Panel (OCP) . . . . . . . . . . . . . . . . . . . 8

OCP Programming Chart . . . . . . . . . . . . . . . . . . . . . . 12

Diagnostics

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service Code Summary . . . . . . . . . . . . . . . . . . . . . . . 17

Service Codes

Group: 1C! (Code 17) . . . . . . . . . . . . . . . . . . . . . . . . . 19

Group: 3C! (Codes 18, 76, 77) . . . . . . . . . . . . . . . . . . 21

Group: 4C! (Code 15) . . . . . . . . . . . . . . . . . . . . . . . . . 23

Group: 5C! (Codes 33, 34) . . . . . . . . . . . . . . . . . . . . . 25

Group: 12C! (Codes 51, 52, 53, 54, 55, 56) . . . . . . . . 27

Group: 1P! (Codes 11, 12, 13, 16, 22) . . . . . . . . . . . . 29

Group: 2P! (Code 14) . . . . . . . . . . . . . . . . . . . . . . . . . 31

Group: 3P! (Code 21) . . . . . . . . . . . . . . . . . . . . . . . . . 33

Group: 4P! (Codes 23, 24, 25) . . . . . . . . . . . . . . . . . . 35

Group: 5P! (Codes 26, 27, 28) . . . . . . . . . . . . . . . . . . 37

Group: 7P! (Codes 31, 32) . . . . . . . . . . . . . . . . . . . . . 39

Group: 8P! (Code 35) . . . . . . . . . . . . . . . . . . . . . . . . . 41

Group: 9P! (Codes 36, 37, 38) . . . . . . . . . . . . . . . . . . 43

Group: 10P! (Codes 41, 42, 43) . . . . . . . . . . . . . . . . . 45

Group: 11P! (Codes 44, 45, 46) . . . . . . . . . . . . . . . . . 47

Group: 12P! (Codes 61, 62, 63, 64, 65, 66) . . . . . . . . 49

Code: No Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Service Procedures

Final System Checkout . . . . . . . . . . . . . . . . . . . . . . . .55

Pneumatic Control Unit - Cleaning and Inspection . . .57

Solenoid Assembly and Cartridge . . . . . . . . . . . . . . . .59

Service Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Joint Compounds and Fittings . . . . . . . . . . . . . . . . . . .61

Air Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Troubleshooting Wheel End Seals . . . . . . . . . . . . . . . .63

Hose and Supply Tank Selection Chart . . . . . . . . . . . .65

Wire Harness

Connector Illustrations . . . . . . . . . . . . . . . . . . . . . . . .67

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Configuration Connections . . . . . . . . . . . . . . . . . . . . .70

Table of Contents

Tire Pressure Control System

General Information

Spicer Tire Pressure Control System features driver control of tire air pressure through:

• Simple push button operation.

• Independent Front, Rear, and Trailer operation.

• Electronic braking priority for air system.

• Vehicle speed sensing and response capability.

• Self-diagnostics.

Key Features

Depressurized Control Lines

The only time the system is pressurized is when changing tire pressures or during pressure checks. Wheel valves isolate the tires from the rest of the system.

Electronic Braking Priority

A pressure switch, installed in the supply tank, controls the TPCS’s use of air. This optimizes and protects the brake system’s primary tank pressures during system operation.

Self-Diagnostic and Auto Shut-Down

The Spicer TPCS provides self-diagnosis during operation. If the system detects a problem, it will display a service code on the driver interface to alert the driver. If necessary, it will close the wheel valves and shut down.

Diagnostic Capability

The Spicer TPCS provides for easy troubleshooting using PCbased or industry standard tools. PC-supported diagnostics improve troubleshooting, reduce maintenance time, provide manual control of TPCS test sequences, and give historical and active service code data.

Speed / Pressure Control and Warning

If truck speed exceeds the maximum allowable speed for a given setting, a warning is activated by TPCS to alert the driver. If speed is not reduced, the system automatically inflates the tires to the appropriate pressure.

Manual Tire Inflation / Deflation

A valve stem has been included on each wheel valve and may be used for manual inflation, deflation or measurement of tire pressures.

Run Flat Operation

The TPCS normally checks tire pressures at intervals of 15 minutes. If possible tire damage is detected, the system will activate Auto RUN FLAT. RUN FLAT reduces the pressure check interval to 15 seconds, helping to assure that the tire will remain inflated despite minor tire damage.

Component Description

Tire Pressure Control System Components

Wheel Valve

General Information

Driver Display Module (DDM)

mph

kph

L/U HWY OFF HWY

bar psi

Tire Pressure Control

EMER RUN FLAT

Operator Control Panel (OCP)

SELECT

Component Description

Pressure Switch

Trailer Connector

Speed Sensor (or Alternate Speed Inputs)

Pneumatic Control Unit (shown with optional 3rd channel)

Electronic Control Unit

General Information

Wheel Valve

All axles use a Wheel Valve (WV) at each end. Dual wheels are typically connected through one WV to provide tire pressure balance, although individual wheel valves for each tire may be installed. When the system is idle, the wheel valve isolates the tire(s), ensuring fail-safe operation. A standard valve stem is included on the WV for manual inflation / deflation / pressure checking.

Electronic Control Unit (ECU)

The Electronic Control Unit (ECU) is the control center for the entire Tire Pressure Control System. The ECU receives commands from the driver through the Driver (DDM) or Operator Control Panel (OCP) and transmits and monitors appropriate signals throughout the system.

Display Module

Driver Interface

Options are available for the TPCS driver interface. The Driver Display Module (DDM) includes two rocker switches and a multi-function display. The Operator Control Panel (OCP) uses a six-button keypad and graphic display.

Vehicle Speed

Speed is read from the vehicle data link or a separate speed sensor.

Pressure Switch

The Pressure Switch (PS) acts as an electronic brake priority switch. It prevents the Tire Pressure Control System from using air from the supply tank until the brake system is fully charged. The PS also ensures that enough pressure exists for the system to operate properly.

Air Lines

The Tire Pressure Control System uses a dedicated pneumatic system plumbed from the vehicle’s existing supply tank.

Wiring

A wiring harness (Dana or OEM supplied) provides for electrical signals between appropriate components.

Pneumatic Control Unit (PCU)

The Pneumatic Control Unit (PCU) is a solenoid controlled manifold that controls the air system. It also contains the Pressure Sensor (transducer) which reads tire pressures.

Simplified System Schematic

General Information

TireTire

To Primary

and Secondary

Tanks

Wheel

Valve

Compressor

Air Dryer

Supply Tank

Wheel

Valve

Rotary

Joint

Pressure

Switch

Connector

Seal

Assembly

Trailer

User

Interface

Speed Sensor

Electronic

Control Unit

Pneumatic

Control

Unit

PCU

Sensor

Rotary

Joint

Seal

Assembly

Wheel

Valve

Simplified System

Schematic

Wheel

Valve

Wheel

Valve

System Key

Seal

Assembly

Pneumatic

Electrical

Seal

Assembly

TireTire

Wheel

Valve

TireTire

Operator Instructions

Operator Instructions - Driver Display Module (DDM)

TPCS may be equipped with one of two driver interface devices: a Driver Display Module (DDM) or an Operator Control Panel (OCP). The Driver Disp trated below and the following sec and use.

lay Module (DDM) is illus-

tion explains the features

Warning Icons

TPCS includes two distinct warnings to report possible tire problems and inappropriate vehicle operation. You must take immediate action to either reduce vehicle speed or check tire condition whenever these warnings are displayed.

Reduce Vehicle Speed

CAUTION

Failure to respond may result in overheated tires and possible tire failure.

This signal reports that the vehicle speed is too fast for the

sure selected. You must either reduce speed or select a

pres higher pressure by pressing the appropriate key. Continued operation in this mode will result in the system automatically selecting a more appropriate pressure setting.

Check Tire Condition

This signal reports that one or more tires may be at a significantly lower pressure than the others and could indicate that a

is not holding pressure. Stop the vehicle immediately in a

tire safe place and identify the extent of tire damage.

IMPORTANT

Tires can still go flat! Although the Tire Pressure Control

is designed to identify under-inflated tires and fill

System these tires to the desired operating pressure, you can still expect that tires will occasionally be punctured or otherwise damaged during normal use and no longer retain air

liably. A daily walk-around inspection of the vehicle at the

re start of the day, including a manual check of the tires, is still an important responsibility of the vehicle operator. Tire damage is more apparent after the vehicle has been idle overnight and will be more difficult to detect visually once the TPCS equipped vehicle is in operation. Although observation of excessive inflation periods through the driver

terface can help identify a tire problem, you should have

in damaged tires replaced prior to placing the vehicle in operation.

Terrain and Load Pressure Selection

Operator Instructions

Driver Display Module

CAUTION

TPCS displays both the selected terrain and load, and may be configured to display numerical tire pressures in PSI, if desired. Tire pressures for the following terrain modes can be

programmed and may be selected by the operator:

• Highw

• Off Highway (

• Em

The Emergency selection is for extreme conditions only and

ld not be used for normal driving.

shou

ay (Hy) - For travel on paved surfaces at

higher speeds.

OH) - For reduced speed operation on

secondary roads and unpaved surfaces.

ergency (E) - For selection of extremely low tire

pressures to help free a stuck vehicle.

CAUTION

System Operation

Operating a loaded vehicle at unloaded tire pressures may

sult in tire overheating and reduced tire life or blowout.

• Pressure Display - If the terrain switch

up position for >5 seconds, numerical tire pressures (in PSI) for each channel will alternate in the display with the selected mode.

Note: The system

due to heat buildup during vehicle use. This system will not automatically deflate these pressure buildups— lower pressure mode selection by the operator must be selected to initiate a deflate.

is designed to allow tire pressure increase

is held in the

• Display - The DDM uses a multi-function display to

indicate the current selections. The display will show HY for highway pressures, OH for off-highway pressures, and E for emergency pressures.

errain Selection - The terrain selection is changed

• T

by depressing the terrain rocker switch, up to increase pressures and down to decrease pressures. Any switch operation which does not change pressures will command the system to do a pressure check.

• Loa

d Selection - Vehicle load selection is repre-

sented by a horizontal bar graph under the mode display. Depress the load rocker switch to change the selection, up for increasing load and dow decreasing load.

n for

• Chann

el Indicators - The DDM indicates FRT, RR or

TLR respectively for front, rear or trailer axle groups. If a channel indicator is on continuously, that channel has achieved the target pressure.

Operator Instructions

• Service Code Indication - The DDM will not display

service codes directly but will exhibit two dashes if service is required. (Accessing the service codes will require a diagnostic tool).

Note: See the Service Codes Section to diagnose and repair.

• RUN FLAT Indicator - If the TPC System determines

that a tire or tires may not be holding air, it may reduce the pressure check interval to minimize the possibility of air loss from the tire by switching to RUN FLAT operation. (See RUN FLAT in the Key Features section).

If RUN FLAT is activated, the DDM will alternate the display of the terrain setting and RF and the CHECK TIRE indicator will be illuminated.

Tire Pressure Control System Programming

Spicer's Tire Pressure Control System is fully programmable, allowing the technician to program tire pressures for each channel (axle group) and maximum speeds for each terrain mode. If equip programming must be done with a diagnostic tool.

Programmable settings include:

• Individual pressure settings for the front, rear, and

• Loaded and unloaded axle group programming for

• Over speed warning threshold for highway,

ped with

trailer axle groups.

highway, off-highway, and emergency conditions.

off-highway and emergency conditions.

the Driver Display Module (DDM),

CHECKTIRE

Operator Instructions

Operator Instructions - Operator Control Panel (OCP)

TPCS may be equipped with one of two driver interface devices: a Driver Display Module (DDM) or an Operator Control Panel (OCP). The Operator Control Panel (OCP) is illustrated below and the following sec

tion explains the features

and use.

mph

kph

L/ U HWY OFF HWY EMER RUN FLAT

bar psi

SELECT

Warning Icons

Reduce Vehicle Speed

CAUTION

Failure to respond may result in overheated tires and possible tire failure.

Check Tire Condition

This signal reports that one or more tires may be at a significantly lower pressure than the others and could indicate that a

is not holding pressure. Stop the vehicle immediately in a

tire safe place and identify the extent of tire damage.

IMPORTANT

Tires can still go flat! Although the Tire Pressure Control

is designed to identify under-inflated tires and fill

System these tires to the desired operating pressure, you can still expect that tires will occasionally be punctured or otherwise damaged during normal use and no longer retain air

liably. A daily walk-around inspection of the vehicle at the

terface can help identify a tire problem, you should have

in damaged tires replaced prior to placing the vehicle in operation.

Operator Control Panel

This signal reports that the vehicle speed is too fast for the

sure selected. You must either reduce speed or select a

pres higher pressure by pressing the appropriate key. Continued operation in this mode will result in the system automatically selecting a more appropriate pressure setting.

mph

kph

Terrain and Load Pressure Selection

TPCS displays both the selected terrain and load, and may be configured to display numerical tire pressures in PSI, if desired. Tire pressures for the following terrain modes can be programmed and may be selected by the operator:

• HWY - For

speeds.

• OFF HWY

secondary roads and unpaved

• EM

ER - For selection of extremely low tire pressures

to help free a stuck vehicle.

The EMER key is for extreme conditions only and should not

used for normal driving.

travel on paved surfaces at higher

- For reduced speed operation on surfaces.

CAUTION

Operator Instructions

System Operation

mph

kph

L/ U HWY OFF HWY EMER RUN FLAT

• Display - The OCP uses a graphic display to indicate

the selection for both terrain mode and vehicle load. Above the selector keys labeled HWY (highway), OFF HWY (off-highway), and EMER (emergency), an illuminated arrow designates the current selection.

• T

by depressing the desired mode on the keypad. When the system is actively changing tire pressure, the arrow above the target mode will flash. Pressing the key for a current mode will command a pressure check.

• Loa

represented by an arrow above the rear w graphic display. Depress the keypad button labeled L/U to change from loaded to unlo

Operating a loaded vehicle at unloaded tire pressures may

sult in tire overheating and reduced tire life or blowout.

• Pressure Display

Select is pressed after vehicle start, numerical pressures will be displayed sequentially for each active channel. Subsequent actuation of the lock the display on individual channels, or turn it off again.

Note: The sys

due to heat buildup during vehicle use. This system will not automatically deflate these pressure buildups— lower pressure mode selection by the operator must be selected to initiate a deflate.

bar psi

SELECT

errain Selection - The terrain selection is changed

d Selection - Vehicle load selection is

heels in the

aded.

CAUTION

- If the keypad button labeled

Select key will

tem is designed to allow tire pressure increase

• Chann

inside the tires of the truck graphic. The pressure shown in the display reflects the channel with the lighted rings.

mph

kph

rvice Code Indication - The OCP will display ser-

• Se

vice codes using a number and letter combination followed by an excla

Note: See the Ser

etric/English Indicator - The OCP may be pro-

• M

grammed to display pressure in metric (BAR) or English (PSI) units

• RUN F

If RUN FLAT is activated, an asterisk (*) will be illuminated in the display of the OCP. This asterisk matches the symbol on the RUN FLA indicates that the RUN FLAT feature is selected. The OCP also allows the driver to select RUN FLAT, by depressing that key, to manually reduce the pressure check interval. This may be desirable when operating under conditions (i.e. sharp rocks or construction debris) where tire punctures may be anticipated. The RUN FLAT feature will automatically de-select after 10 minutes, but may be re-selected.

mph

kph

el Indicators - The OCP display includes rings

Tire Pressure Control

bar psi

mation point (!).

vice Codes Section to diagnose and repair.

(see Programming section).

LAT Indicator - If the TPC System determines

T key and it

bar psi

SELECT

RUN FLATL /U HWY OFF HWY EMER

mph

kph

bar psi

Operator Instructions

Tire Pressure Control System Programming

Spicer's Tire Pressure Control System is fully programmable, allowing the technician to program tire pressures for each channel (axle group) and maximum speeds for each terrain mode. The system allows programming directly through the Operator Control Panel, or with a diagnostic tool.

Programmable settings include:

• Individual pressure settings for the front, rear, and trailer axle groups.

• Loaded and unloaded axle group programming for highway, off-highway, and emergency conditions.

• Over speed warning threshold for highway, off-highway and emergency conditions.

To program the system, follow these steps:

1. Enter the Tire Pressure Control System programming sequence by pressing the SELECT and L/U buttons at the same time. A flashing bar or PSI verifies that you are in the programming mode and also indicates that the first selection, English or metric values, is ready for programming. Refer

Panel Programming Sequence" for sample

Control procedure.

2. Press the up/down arrows (on the L/U and EMER keys) to select options or change settings (pressure or speed) and press the SELECT button to record a selection in memory and move to the next step.

3. Press the SELECT button repeatedly to move through the program steps, one step for each time the SELECT button is pressed. Refer to the programming reference chart for specific Tire Pressure Control System pressure and speed programming steps.

4. To complete the programming sequence, or exit the programming mode, continue to press the SELECT button to step through to the end of the procedure, or press the SELECT and L/U buttons at the same time.

to "Operator

Operator Control Panel

Note: If no buttons are pressed for more than one minute, the

Operator Control Panel will end the programming sequence, saving any changes made during programming.

Operator Instructions

Operator Control Panel Programming Sequence

Example for Step 1 Programming (see OCP Programming Chart)

L/U

SELECT

mph

kph

bar psi

Tire Pressure Control

Press at the same

time to enter

programming

down arrow

arrow

L/U

between metric

and English

EMER

Toggle

L/U

Press at the same

time to exit

programming

SELECT

Flashing "bar" or "psi"

indicates you have

entered programming

mph

kph

bar psi

Make selection

Tire Pressure Control

SELECT

Press to record a selection in memory and move to the next step

Example for Step 7 Programming (see OCP Programming Chart)

L/U

Enter programming

SELECT

+ +

SELECT

Press SELECT six times to go to step 7

SELECT

L/U

Exit programming

SELECT

SELECT+SELECT

down arrow

SELECT

L/U

arrow

EMER

Press to set highway

unloaded drive pressure

OCP Programming Chart

Operator Instructions

Step Setting Metric

English Indicator

1 Metric / English On

2 Highway Over Speed On On

3 Highway Loaded Front Pressure On On On

4 Highway Loaded Rear Pressure On On On

5* Highway Loaded Trailer Pressure On On On

6 Highway Unloaded Front Pressure On On

7 Highway Unloaded Rear Pressure On On

8* Highway Unloaded Trailer

Pressure

9 Off-Highway Over Speed On On On On

10 Off-Highway Loaded Front

Pressure

11 Off-Highway Loaded Rear

Pressure

SpeedIndicator

Terrain Arrows Loaded

Arrow

HWY OFF HWY EMER Front Rear Trailer

On On

On On On

On On

OCP Channel Indicator

OCP Programming Chart

12* Off-Highway Loaded Trailer

Pressure

13 Off-Highway Unloaded Front

Pressure

14 Off-Highway Unloaded Rear

Pressure

15* Off-Highway Unloaded Trailer

Pressure

16 Emergency Over Speed On On

17 Emergency Loaded Front Pressure On On On

18 Emergency Loaded Rear Pressure On On On

19* Emergency Loaded Trailer

Pressure

20 Emergency Unloaded Front

Pressure

21 Emergency Unloaded Rear

Pressure

22* Emergency Unloaded Trailer

Pressure

On On

On On On

On On

* 3 Channel Only

Diagnostics

This section covers the equipment and procedures used to find and correct Tire Pressure Control System problems.

Test Equipment

Tire Pressure Control System troubleshooting can be performed at three levels:

1. PC diagnostics.

2. Handheld tester.

3. Operator Control Panel service codes (if vehicle is equipped with an OCP).

Regardless of the testing equipment used, the troubleshooting procedures will be based upon the diagnostic service codes. Diagnostic tools offer the advantages of computeraided testing without interpreting service codes.

Tire Pressure Control System Diagnostics

The onboard system diagnostics are an important feature of Spicer’s Tire Pressure Control System. This section describes the use of service codes to identify Tire Pressure Control System operating problems.

Service Codes

The Service Codes are described in the Troubleshooting section. Some service codes also identify the component that is associated with the problem. A list of possible causes is shown in order of most likely occurrence.

Test Modes

Diagnostic tools allow the system to be placed in several diagnostic modes:

Info - Display ECU information and configuration.

Codes - Active and historic codes are listed as reported by the

ECU.

Monitor (Normal) - TPCS operates normally, while status of system components is observed.

Test - The following operations can be performed on each channel (axle group):

• Check & Hold - System checks and

displays the pressures, then holds pressure in air lines (quick test of control line and seal integrity).

The Tire Pressure Control System uses a code to identify service issues. The codes can be extracted from the ECU memory using a diagnostic service tool appropriate Operator Control Panel (OCP) will report codes directly on the display. Refer to the service code chart for more detailed information on service codes.

software. In addition, systems equipped with an

equipped with the

Historical Service Codes

Any time a fault occurs the system will log a fault in memory of the ECU. If the system becomes inoperative, the Driver Display Module (DDM) will report two dashes (- -) or an actual service code will be displayed on the Operator Control Panel. (Only the most recent code is displayed by the Operator Control Panel). Historical codes are stored in memory. Historical codes can only be accessed by a diagnostic tool. Historical codes are automatically cleared after 50 ECU resets with no active faults.

• Deflate - System "manually" deflates (test the

deflation signal).

• Inflate - System "manually" inflates (test for large

leaks).

• Hold - Pressure is held in control lines (test for small

leaks).

Setup - Allows the technician to modify parameters such as target tire pressures, etc.

Diagnostics

PC Diagnostics

CAUTION

A battery charger is not an adequate source of power.

Visit www.dana.com for free download of Dana Diagnostic Tool (DDT).

PC diagnostics are easy to use and provide the quickest diagnostic capabilities.

• Retrieve historical data, faults and tire pressures.

• Pressurize system to detect leaks.

• Access troubleshooting flowcharts and service

procedures.

Attach computer to RP1210A communications box.

Download free Dana Diagnostic Tool from dana.com.

To use this program, an RP1210A compatible interface box and cables are needed to connect the PC to the vehicle.

For these types of interface boxes to work with the Dana Diagnostic Tool program, you must install a "RP1210 driver" program provided by the manufacturer of the interface box. If you do not have this program, it can normally be obtained from the manufacturer's web site. Please contact the manufacturer of your interface box if you have any questions regarding this process.

Connect to diagnostic connector.

Diagnostics

Note: Program requires

Windows 98 or newer.

Follow on-screen instructions.

Diagnostics

Handheld Tester

A Prolink handheld tester may be used to read and clear service codes and to obtain a short description of failures. The tester can initiate test sequences for controller outputs and can also read system parameters when equipped with the Dana program card.

KENT-MOORE

MICRO PROCESSOR SYSTEMS INC.

Pro-Link

7 8

4 5

2 3

ENTER

FUNC

Multimeter

Based upon system schematics and aided by component specific service codes, a multimeter can be used to check sensor and solenoid resistances and to find wiring harness faults. The multimeter can be used to check the Tire Pressure Control System wiring and components for:

• Continuity

• Ground

• Broken wires

• Open circuits

• Shorted circuits

• Incorrect battery voltage

Troubleshooting Tips

Diagnostics

This checklist outlines some general hints and guidelines that will be helpful in tracking down and correcting operating problems.

Operator Control Panel only displays one active code.

Only the most recent service code Control Panel. In troubleshooting, be alert for related codes. Use of a diagnostic tool offers the advantages of spotting multiple active codes as well as retrieving historical codes.

A cleared code alone does not indicate a corrected problem.

A code is set by a specific fault condition and may be cleared

switching the ignition off. It's possible to clear a code (i.e.,

by remove it from the driver interface) only to have it display again when the fault condition reoccurs. To ensure that a problem is fixed, you must run the system through the same operating modes that caused the problem and verify that the service code does not appear.

Disconnect the Electronic Control Unit connector with ignition off.

To avoid setting electrical service codes, make sure that the ignition is at the Electronic Control Unit module.

Reconnect the connector before switching on the ignition.

off before unplugging the wire harness connection

displays on the Operator

C! Service Codes are often connection problems.

The most likely cause of component faults will be damaged wires or co service codes, switch off vehicle ignition, then disconnect applicable connectors and inspect for damage. (Switching off the ignition is required before disconnecting the harness at the Electronic Control Unit, but is also a recommended practice before all other electrical system disconnections.) Clean or repair all

System is not continually pressurized.

When troubleshooting P! service code faults, keep in mind that ple, in the inflate mode). This means that such checking for leaks require the system to be in an active, pressurized state. This can be accomplished most easily by using

Basic vehicle air and power systems guide.

The Tire Pressure Control System requires air pressure and electrical power Diagnosis and service of these systems is outside the scope

this manual.

Some faults will halt inflate or deflate sequences.

Upon sensing some service codes, the Tire Pressure Control System will immediately go cause mode arrows to stop flashing before the system has

actually attained the pressures for the indicated mode.

nnections. As a first step in troubleshooting all C!

suspicious connections before proceeding.

the air system is only pressurized as needed (for exam-

procedures as

a diagnostic tool.

are not covered in this

supply from the base vehicle systems.

to the "maintain" mode. This may

Troubleshooting Tips

Diagnostics

Service Code Summary

Group Code System Status Description

1C! 17 No Operation Power - battery voltage out of range at the ECU

3C! 18 Normal Operation Speed Signal - no speed detected during multiple ignition cycles

76 Normal Operation J1587 Speed Message - not

77 Normal Operation J1939 Speed Message - not

4C! 15 Inflate Only Display Control Communications - ECU not receiving

interface

5C! 33 No Operation PCU Sensor - signal voltage too high

34 No Operation PCU Sensor - connector unplugged; signal voltage too low

12C! 51 No Operation PCU Solenoid, Front - connector unplugged; faulty wiring or solenoid

52 No Operation PCU Solenoid, Rear - connector unplugged; faulty wiring or solenoid

53 No Operation PCU Solenoid, Trailer - connector unplugged; faulty wiring or solenoid

54 No Operation PCU Supply Solenoid - connector unplugged; faulty wiring or solenoid

55 No Operation PCU Deflate Solenoid - connector unplugged; faulty wiring or solenoid

56 No Operation PCU Control Solenoid - connector unplugged; faulty wiring or solenoid

1P! 11 No Deflation Deflate Signal, Front - could not generate a

12 No Deflation Deflate Signal, Rear - could not generate a vacuum in control lines

13 No Deflation Deflate Signal, Trailer - could not generate a vacuum in control lines

16 Normal Operation Deflate Signal - could not generate a vacuum in one or

22 Inflate Only Deflate Signal, PCU - could not generate

receiving expected messages on J1708 data link

receiving expected messages on data link

communications from user

vacuum in control lines

more channel's control lines

a vacuum in pneumatic control unit

2P! 14 Inflate Only Deflate Trend - tire pressure did not decrease properly

3P! 21 Inflate Only Vacuum - unintentional vacuum in PCU

4P! 23 Pressure Check Only Between Modes, Front - inflated or

24 Pressure Check Only Between Modes, Rear - inflated or deflated too slowly

25 Pressure Check Only Between Modes, Trailer - inflated or deflated too slowly

5P! 26 Pressure Check Only Low Pressure, Front - open line or large seal leak

27 Pressure Check Only Low Pressure, Rear - open line or large seal leak

28 Pressure Check Only Low Pressure, Trailer - open line or large seal leak

7P! 31 Pressure Check Only Pressure Switch - failed closed or wiring shorted

32 Pressure Check Only Low Air Supply - pressure switch did not close

8P! 35 Pressure Check Only Atmospheric - PCU sensor reading out of range

9P! 36 Channel Inoperative Inflate Trend, Front - tire pressure decreased

37 Channel Inoperative Inflate Trend, Rear - tire pressure

38 Channel Inoperative Inflate Trend, Trailer - tire pressure decrea

deflated too slowly

during an inflate

decreased during an inflate

sed during an inflate

during deflate

Diagnostics

Group Code System Status Description

10P! 41 Inflate Only Tire Leak, Front - not passing tire pressure confirm check (multiple attempts)

42 Inflate Only Tire Leak, Rear - not passing tire pressure confirm c

43 Inflate Only Tire Leak, Trailer - not passing tire pressure confirm check (multiple attempts)

11P! 44 Pressure Check Only Tire Leak, Front - tire pressure imbalance or line leak

45 Pressure Check Only Tire Leak, Rear - tire pressure imbalance or line leak

46 Pressure Check Only Tire Leak, Trailer - tire pressure imbalance or line leak

12P! 61 Normal Operation Sluggish Shut Off, Front - lost minor pressure during wheel valve

62 Normal Operation Sluggish Shut Off, Rear - lost

63 Normal Operation Sluggish Shut Off, Trailer - lost minor pressure

64 Normal Operation Shut Off Failure, Front - cannot close wheel valve(s) and vent lines

65 Normal Operation Shut Off Failure, Rear - cannot close wheel valve(s) and vent lines

66 Normal Operation Shut Off Failure, Trailer - cannot

- 47-48 Reserved (47, 48)

57 Spare #1 - connector unplugged; faulty wiring or component

58 Spare #2 - connector unplugged; faulty wiring or component

67-68 Reserved (67, 68)

71-75 Reserved (71-75)

78 Reserved (78)

minor pressure during wheel valve shut off

close wheel valve(s) and vent lines

heck (multiple attempts)

during wheel valve shut off

shut off

Service Code Summary

Service Codes

Group: 1C! (Code 17)

Type: Power

System Mode Condition Possible Causes

(Listed in Likely Order of Occurrence)

No Operation Power out of range - Low battery voltage.

- Poor ground connection to Electronic Control Unit.

- Poor switched ignition connection to Electronic Control Unit.

- High vehicle electrical system voltage.

- Faulty Electronic Control Unit.

Code Description

Group 1C! (17) indicates a power fault and sets when the system power is outside the acceptable range of 9 to 32 volts.

fault could be caused by low battery power or some other

The problem with the basic vehicle electrical system.

If the vehicle power system checks out possible causes include bad Electronic Control Unit (ECU) connections, or a faulty Electronic Control Unit.

In inspecting circuits and connections for a Code 1C! fault, pay part be causing the fault.

See "Troubleshooting Tips" for general diagnostics.

icular attention to a bad ground connection that could

satisfactorily, other

guidelines on system

ECU Harness Connector

ABB

GHJK

HJJKK

3 2 1

Power (Code 17)

Service Codes

Group: 1C! (Code 17)

With ignition switched on and engine running,

measure battery voltage across battery terminals.

Is voltage

reading > 32

volts?

With ignition switched on but engine not running,

measure battery voltage across battery terminals.

Is voltage

reading

< 9 volts?

Switch off ignition. Disconnect ECU connector. Switch on ignition. Check SWACC circuit by measuring voltage between ECU harness connector pins K1 and K2.

Yes

Base vehicle power is out of range.

Refer to Service Manual

Base vehicle power is out of range.

Refer to Service Manual

Does

measured

voltage match battery voltage

reading obtained in

step?

Yes

Is code 1C!

fault cleared?

Yes

Complete

Inspect for failure in SWACC circuit including

vehicle power panel and/or ground

connections. Repair or replace as indicated.

Inspect wire sockets and ECU pins.

If okay, replace ECU.

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