Spicer TPCS ® (Tire Pressure Control System) Troubleshooting Guide AXTS0020 April 2007
General Information Warnings and Cautions The descriptions and specifications contained in this service publication are current at the time of printing. Dana reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. 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.
Table of Contents Service Procedures 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 . . . . . . . . . . . . . . . . . . .
General Information Tire Pressure Control System 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.
General Information Component Description Tire Pressure Control System Components Driver Display Module (DDM) OR mph kph Tire bar Pres psi sure Cont rol L/U SELE Component Description Wheel Valve CT HWY OFF HWY EMER RUN FLA T Operator Control Panel (OCP) Speed Sensor (or Alternate Speed Inputs) Pressure Switch Trailer Connector Pneumatic Control Unit (shown with optional 3rd channel) Electronic Control Unit 2
General Information Wheel Valve Vehicle Speed 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. Speed is read from the vehicle data link or a separate speed sensor.
General Information Simplified System Schematic Tire Tire Wheel Valve Rotary Joint Compressor Rotary Joint Wheel Valve User Interface Speed Sensor Air Dryer To Primary and Secondary Tanks Pressure Switch Supply Tank Electronic Control Unit Pneumatic Control Unit PCU Sensor Simplified System Schematic Trailer Connector Seal Assembly Wheel Valve Seal Assembly Tire Wheel Valve Tire Seal Assembly Wheel Valve Tire Seal Assembly Wheel Valve Tire System Key Pneumatic Electrical 4
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 Display Module (DDM) is illustrated below and the following section explains the features and use. 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 tire is not holding pressure.
Operator Instructions 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: • Highway (Hy) - For travel on paved surfaces at higher speeds. • Off Highway (OH) - For reduced speed operation on secondary roads and unpaved surfaces. • Emergency (E) - For selection of extremely low tire pressures to help free a stuck vehicle.
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.
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 section explains the features and use. 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 tire is not holding pressure.
Operator Instructions System Operation • mph kph bar psi Channel Indicators - The OCP display includes rings inside the tires of the truck graphic. The pressure shown in the display reflects the channel with the lighted rings. SELECT Tire Pressure Control mph kph L /U • • • HWY OFF HWY EMER bar RUN FLAT Display - The OCP uses a graphic display to indicate the selection for both terrain mode and vehicle load.
Operator Instructions Tire Pressure Control System Programming To program the system, follow these steps: 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 to "Operator Control Panel Programming Sequence" for sample procedure. 2.
Operator Instructions Operator Control Panel Programming Sequence Example for Step 1 Programming (see OCP Programming Chart) Tire Pressure Control + SELECT L /U mph kph bar Press at the same time to enter programming down arrow psi Flashing "bar" or "psi" indicates you have entered programming up arrow Tire Pressure Control or L /U EMER SELECT mph kph bar Toggle between metric and English Press to record a selection in memory and move to the next step psi Make selection + SELECT L /U Pr
Operator Instructions OCP Programming Chart Step Setting Metric SpeedTerrain Arrows English Indicator Indicator Loaded OCP Channel Indicator Arrow HWY OFF HWY EMER Front 1 Metric / English 2 Highway Over Speed 3 Highway Loaded Front Pressure On On 4 Highway Loaded Rear Pressure On On 5* Highway Loaded Trailer Pressure On On 6 Highway Unloaded Front Pressure On 7 Highway Unloaded Rear Pressure On 8* Highway Unloaded Trailer Pressure On 9 Off-Highway Over Speed 10 Rear Trail
Diagnostics Diagnostics This section covers the equipment and procedures used to find and correct Tire Pressure Control System problems. Service Codes Test Equipment 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. Tire Pressure Control System troubleshooting can be performed at three levels: 1. PC diagnostics. 2. Handheld tester.
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.
Diagnostics Handheld Tester Multimeter 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. 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.
Diagnostics Troubleshooting Tips This checklist outlines some general hints and guidelines that will be helpful in tracking down and correcting operating problems. Operator Control Panel only displays one active code. Only the most recent service code displays on the Operator Control Panel. In troubleshooting, be alert for related codes. Use of a diagnostic tool offers the advantages of spotting multiple active codes as well as retrieving historical codes.
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 receiving expected messages on J1708 data link 77 Normal Operation J1939 Speed Message - not receiving expected messages on data link 4C! 15 Inflate Only Display Control Communications - ECU not receiving communication
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 check (multiple attempts) 43 Inflate Only Tire Leak, Trailer - not passing tire pressure confirm check (multiple attempts) 44 Pressure Check Only Tire Leak, Front - tire pressure imbalance or line leak 45 Pressure Check Only Tire Leak, Rear - tire pressure imbalance or line lea
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.
Service Codes Group: 1C! (Code 17) Power (Code 17) With ignition switched on and engine running, measure battery voltage across battery terminals. Is voltage reading > 32 volts? Yes Base vehicle power is out of range. Refer to Service Manual No With ignition switched on but engine not running, measure battery voltage across battery terminals. Is voltage reading < 9 volts? Yes Base vehicle power is out of range. Refer to Service Manual No Switch off ignition. Disconnect ECU connector.
Service Codes Group: 3C! (Codes 18, 76, 77) Type: Speed Signal System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Normal Operation No speed signal - ECU power cycled 50 times without vehicle being moved. - Sensor disconnected or loose plug. - Either speed sensor wire is open (broken wire). - Either speed sensor wire is shorted to ground (bare wire is touching the frame). - Faulty speed sensor. - Sensor actuation failure. - Tang drive broken/disconnected on mechanical sensor.
Service Codes Speed Signal (Codes 18, 76, 77) This fault is set when ECU power has been cycled 50 times without sensing any speed input. Move vehicle at greater than 5 mph. Did fault clear? Yes Complete No Group: 3C! (Codes 18, 76, 77) Determine type of speed sensor input: Digital (TTL signal from engine ECU or speedometer) Analog (pole sensor or VR type) Data Link (SAE J1708/1587 or SAE J1939) Check adjustment on threaded pencil speed sensor or drive tang on mechanical speed sensor.
Service Codes Group: 4C! (Code 15) Type: Display Control Communications System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Inflate Only Blank Display - No power to Driver Interface. - No ground connection to Driver Interface. - System voltage out of range (9-19 volts DC). Inflate Only Operator Control Panel displays logo only - No power or ground to ECU. - Driver Interface to Electronic Control Unit lines open.
Service Codes Display Control Communications (Code 15) Turn on ignition. With vehicle running, measure battery voltage across battery terminals. Is voltage reading > 19 volts? Yes Yes Is driver interface completely blank? Base vehicle power is out of range. Refer to Service Manual No Switch ignition off. Disconnect ECU connector. Disconnect driver interface connector. Switch ignition on.
Service Codes Group: 5C! (Codes 33, 34) Type: PCU Sensor System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) No operation No PCU sensor reading - PCU Sensor electrically disconnected. - PCU Sensor signal wire open. - PCU Sensor signal wire shorted to ground. - PCU Sensor XDCR VREF wire open. - PCU Sensor XDCR VREF wire shorted to ground. - PCU Sensor XDCR COMMON wire open. - Faulty PCU Sensor. - Faulty Electronic Control Unit.
Service Codes With ignition off, inspect socket connections at ECU connector and at PCU sensor 3-way. Replace ECU. Repair conditions as necessary. Are connections mechanically and electrically sound? No Disconnect the ECU connector and the PCU sensor connector. Check continuity between the following points: Is there continuity? PCU Sensor Harness Pin C B A No ECU Harness Connector Pin H1 H2 H3 No Note: ECUs are not a typical cause of problems.
Service Codes Group: 12C! (Codes 51, 52, 53, 54, 55, 56) Type: PCU Solenoids • Front (51) • Rear (52) • Trailer (53) • Supply (54) • Deflate (55) • Control (56) System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) No operation Pneumatic Control Unit solenoid failed electrical diagnostic test - Connector unplugged or faulty wiring. - Solenoid wire open. - Solenoid wire shorted to ground. - Solenoid wire shorted to power. - Faulty solenoid.
Service Codes PCU Solenoids (Codes 51, 52, 53, 54, 55, 56) Code 12C! Indicates one or more solenoid faults. Use service tool to determine the specific solenoid. When the troubleshooting instructions refer to connector test points, use chart select the pin test point for use with the particular fault code you are diagnosing.
Service Codes Group: 1P! (Codes 11, 12, 13, 16, 22) Type: No Deflate Signal System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Inflate Only Inadequate vacuum in the Pneumatic Control Unit - Plugged or restricted Pneumatic Control Unit vent line. - Faulty Pneumatic Control Unit. Inflate Only No sustained vacuum in control lines - Line leaks. - Air seals, oil lip seals.
Service Codes No Deflate Signal (Codes 11, 12, 13, 16, 22) Using the diagnostic tool, test vacuum in isolated PCU. Is the vacuum < 6" Hg? No Yes No Replace PCU and recheck system. Refer to Service Manual Yes Initiate deflate mode on the steer channel. Record the reading. Initiate pressure check and hold on steer channel. Check all air lines and fittings for leaks as well as exhaust port of wheel valves. Make repairs to faulty components.
Service Codes Group: 2P! (Code 14) Type: Deflate Trend System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Inflate Only Pressure increased or failed - Plugged or restricted control lines. to drop appropriately - Plugged or restricted Pneumatic Unit vent line. - Plugged or restricted wheel valve exhaust port. - Faulty Pneumatic Control Unit. Code Description Group 2P! is the result of a deflate that did not occur properly.
Service Codes Group: 2P! (Code 14) Deflate Trend (Code 14) Use diagnostic tool to manually deflate the tires on each channel. All tires on each channel deflate? No Check for conditions preventing vacuum reaching tires: Restrictions in valve stems (valve cores, filters, rubber, etc.) Restricted PCU vent line Loss of vacuum on channel (see 1P! flowchart) Inoperative or restricted wheel valve Yes Replace or clean PCU. Caution: Verify clean (no oil), dry air system on vehicle.
Service Codes Group: 3P! (Code 21) Type: Vacuum Fault System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Inflate Only Inappropriate vacuum generation - Faulty or contaminated Pneumatic Control Unit. Code Description Group 3P! displays when the system is generating a vacuum at a time when the Electronic Control Unit (ECU) is not requesting a vacuum. Creation of an unexpected vacuum is highly unlikely.
Service Codes Vacuum Fault (Code 21) Verify the problem. Replace or clean PCU. Group: 3P! (Code 21) Caution: Verify clean (no oil), dry air system on vehicle. This condition can be caused by contamination in PCU. Reference PCU Cleaning and Inspection for cleaning procedure. Verify the repair.
Service Codes Group: 4P! (Codes 23, 24, 25) Type: Channel Between Modes System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Pressure Check Only Slow Inflate - Faulty compressor. - Restricted flow at wheel valve air filters or tire valve stems. - Crimped or plugged lines. Slow Deflate - Restricted flow at wheel valve air filters or tire valve stems. - Plugged or restricted Pneumatic Control Unit vent port. - Leaking lines. - Plugged or restricted wheel valve exhaust port.
Service Codes Channel Between Modes (Codes 23, 24, 25) Verify Tire Pressure Control System air system capacity by checking air system pressure buildup. Does the air system build up to at least 125 psi? No Repair air system and retest system. Refer to Service Manual Yes Using the diagnostic tool, check faults to identify the faulty channel: Front (23) Rear (24) Trailer (25) Group: 4P! (Codes 23, 24, 25) Initiate deflate mode on the identified channel.
Service Codes Group: 5P! (Codes 26, 27, 28) Type: Low Pressure Reading System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Pressure Check Only Extreme pressure loss - Leaking axle seals. - Open line between Pneumatic Control Unit to channel. - Crimped or plugged line between supply tank and Pneumatic Control Unit. - Pressure switch failure, shorted closed. - Pneumatic Control Unit failure, supply or control off. - Faulty pressure transducer.
Service Codes Group: 5P! (Codes 26, 27, 28) Low Pressure Reading (Codes 26, 27, 28) Using the diagnostic tool, check faults to identify the faulty channel: Front (26) Rear (27) Trailer (28) Initiate inflate mode for the faulty channel. Is there a restricted line between the wet tank and PCU? Is there extreme pressure loss? Yes Identify cause of air loss, repair and recheck system.
Service Codes Group: 7P! (Codes 31, 32) Type: Low Air Supply System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Pressure check only Pressure switch won’t close (32) - Compressor governor cut-out set too low. - Air dryer needs service. - Pressure switch unplugged. - Open or broken line from supply tank to Pneumatic Control Unit. - Crimped or plugged line from supply tank to Pneumatic Control Unit. - Faulty pressure switch. - Faulty compressor.
Service Codes Low Air Supply (Codes 31, 32) Use diagnostic tool to determine type of fault. Pressure switch failed. Open or closed? Open Is the governor cutout pressure set at 120-125 psig? Verify wiring: Switch off ignition. Disconnect ECU harness connector and supply tank pressure switch connector. Check for shorts between ECU harness connector pins G3 and K2. Yes No Is the pressure switch plugged in? Repair harness and retest.
Service Codes Group: 8P! (Code 35) Type: Atmospheric System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Pressure check only Pneumatic Control Unit pressure out of range - Faulty PCU Sensor. - Faulty Pneumatic Control Unit. - Faulty Electronic Control Unit. Air Pressure Check Code Description The Tire Pressure Control System is not continuously pressurized; pressure checks occur on a periodic basis.
Service Codes Atmospheric (Code 35) Using the diagnostic tool, read the atmospheric pressure. Is the reading between 8 and 20 psia? No Is any audible air flowing through the PCU? Yes Yes Service code is not active. Reverify flowchart steps and wait for fault to reoccur. See service code No Code for audible air leak in PCU. No See service code 5C! PCU sensor and follow troubleshooting chart.
Service Codes Group: 9P! (Codes 36, 37, 38) Type: Inflate Trend System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Channel inoperative Loss of channel pressure in inflate mode - Damaged or leaking tire. - Leaking lines. - Leaking seals. - Leaking wheel valve. - Faulty Pneumatic Control Unit. - Faulty Electronic Control Unit. Code Description Group 9P! displays when system pressure is dropping while in inflate mode.
Service Codes Group: 9P! (Codes 36, 37, 38) Inflate Trend (Codes 36, 37, 38) Using the diagnostic tool, check faults to identify the faulty channel: Front (36) Rear (37) Trailer (38) Is there a damaged tire on the identified channel? Yes Repair tire and retest system. No Initiate inflate mode on the faulty channel. Are there any leaks in the channel’s control lines or seals? Is there a leaking hose between a tire and wheel valve? Yes Yes Repair leak and retest.
Service Codes Group: 10P! (Codes 41, 42, 43) Type: Tire Leak (Confirm) System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Inflate only Channel confirmation failure - Damaged or leaking tire. - Leaking line between wheel valve and tire. - Air passage restriction. - Wheel Valve shut off failure. Air Pressure Check The Tire Pressure Control System is not continuously pressurized; pressure checks occur on a periodic basis.
Service Codes Tire Leak (Confirm) (Codes 41, 42, 43) Stop vehicle and connect the diagnostic tool to the system. Group: 10P! (Codes 41, 42, 43) Identify affected channels: Front (41) Rear (42) Trailer (43) Tire or air line leak Spray soap solution on tires, bead area, wheel valve and wheel valve hose. Repair all leaks and perform checkout test.
Service Codes Group: 11P! (Codes 44, 45, 46) Type: Tire Leak (Imbalance) System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Channel only checks pressure Tire pressure lower on one tire than others on same channel - Minor tire leakage at start-up (leaked down overnight). - Severe tire damage or leaks. - Leaking lines. - Contaminated wheel valve filters. - Restricted tire valve stem. - Leaking seals. - Leaking wheel valve. - Crimped or restricted control lines.
Service Codes Tire Leak (Imbalance) (Codes 44, 45, 46) Use diagnostic tool to verify proper vehicle configuration selection. Using the diagnostic tool, identify the faulty channel: Front (44) Rear (45) Trailer (46) Manually check the tire pressures at the wheel valves on the faulty channel. Are any wheel readings low? Yes No Yes Group: 11P! (Codes 44, 45, 46) Check for a blocked wheel valve exhaust or plugged wheel valve filter. Make repairs to faulty components and recheck the system.
Service Codes Group: 12P! (Codes 61, 62, 63, 64, 65, 66) Type: Wheel Valve Shut Off System Mode Condition Possible Causes (Listed in Likely Order of Occurrence) Normal Operation Loss of pressure during shut off - Wheel Valve shut off failure. - Air passage restriction. Air Pressure Check Code Description The Tire Pressure Control System is not continuously pressurized; pressure checks occur on a periodic basis.
Service Codes Group: 12P! (Codes 61, 62, 63, 64, 65, 66) Wheel Valve Shut Off (Codes 61, 62, 63, 64, 65, 66) Stop vehicle and connect the diagnostic tool to the system. Which codes are identified? Codes 64, 65, 66 Codes: Front (64) Rear (65) Trailer (66) Wheel valve closure (major) Codes 61, 62, 63 Codes: Front (61) Rear (62) Trailer (63) Wheel valve closure (minor) Check airflow and look for restrictions between the wheel valve and PCU. Replace wheel valve and perform checkout test.
Service Codes Code: No Code Type: Miscellaneous Although the Tire Pressure Control System is self-diagnosing, there are some problems that may not trigger a service code. The following chart lists these conditions along with possible causes and solutions: Condition Operating problems that do not trigger a service code. Possible Causes* Since a service code was not set, these conditions may be universal and not call for a troubleshooting routine.
Service Codes Condition Operating problems that do not trigger a service code. Possible Causes* Since a service code was not set, these conditions may be universal and not call for a troubleshooting routine. Service Where fault codes appear, refer to the troubleshooting procedures listed under that code. Display shows tires at higher pressure than target, yet system does not attempt to deflate. No apparent inflate or deflate.
Service Codes Condition Operating problems that do not trigger a service code. Possible Causes* Since a service code was not set, these conditions may be universal and not call for a troubleshooting routine. Service Where fault codes appear, refer to the troubleshooting procedures listed under that code. Apparent continuous operation, or slow inflates or deflates. - Tire(s) leakage. - Between mode. - Trend fault. Follow troubleshooting for 4P!, 9P!, and 10P! group.
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Service Procedures Final System Checkout Test Requirements This test requires use of a diagnostic tool (PC or handheld) to control and monitor the functions of the Spicer TPCS, and an accurate tire pressure gauge. Select Highway-Loaded. Upon successfully achieving Highway-Loaded, verify tire pressures are within ± psig of desired pressure.
Service Procedures Use Diagnostic tool to MONITOR SYSTEM. • Deflate the system by selecting Highway-Unloaded. Upon successfully achieving Highway-Unloaded, use pressure gauge to verify tire pressures are within ±3 psig of desired pressure. • Select Highway-Loaded. Upon successfully achieving Highway-Loaded, use pressure gauge to verify tire pressures are within ±3 psig of desired pressure. • Drive vehicle and verify diagnostic tool display coincides with vehicle speedometer.
Service Procedures Pneumatic Control Unit - Cleaning and Inspection The following describes the procedure for disassembly, cleaning, and inspection of the Spicer Tire Pressure Control System Pneumatic Control Unit (P/N 673336, and 673316). Components requiring replacement can be found in the Illustrated Parts List (AXIP-0010). CAUTION Do not use cleaning solvents which are not compatible with elastomer or rubber components.
Service Procedures PCU - Cleaning and Inspection Note: It is necessary to position both covers on the body at the same time. 18. Carefully tighten cover screws ensuring that wires are not pinched between cover and body. Torque screws 40 to 45 in. lbs. 19. Reinstall Pneumatic Control Unit in vehicle. 20. Conduct TPC system checkout to verify integrity of cleaning/assembly.
Service Procedures Solenoid Assembly and Cartridge Typical Pneumatic Control Unit Assembly Optional Trailer Channel 7a 7c 3c 6 3a 7b 3b 8 2 10d 1 8 10e 9 10b 10a 10e 59 10c
Service Procedures Typical Solenoid Assembly PCU Cleaning & Inspection 16 Solenoid Assembly & Cartridge 11 12 15 14 13 Typical Cartridge PISTON 0-RING (-114) CARTRIDGE 0-RING (-020) 60
Service Procedures Service Guidelines The Tire Pressure Control System requires normal maintenance much the same as other systems on the vehicle. Following are some general rules that apply to Tire Pressure Control System service: Clean and Dry Air Supply The Spicer Tire Pressure Control System requires a constant supply of clean dry air. An adequately sized and properly maintained air dryer is critical for continued proper operation of the Tire Pressure Control System.
Service Procedures Air Filter Change prevent air loss (SAE 37 degree flare plug, 3/8" tube size, 9/16-18 thread). The "Air Filter Change" illustration shows the location of the air filter in each wheel valve. This filter must be replaced whenever the tire or wheel valve is serviced. Use the illustration as a reference in completing the air filter replacement as follows: WARNING Be sure to use appropriate eye and ear protection. 2. Remove the adapter fitting from the tire port. 3.
Service Procedures Troubleshooting Wheel End Seals Perform an air seal pressure check as follows (refer to "Wheel End Seals" illustration). 1. Connect a hose from a pressure reservoir, 2" ID x 12" long with 2' long 3/8" hose (or equivalent volume), to the inlet tube. 2. Plug hub air port with a 3/8" pipe plug or 9/16-18 straight thread O-ring plug, as appropriate. 3. Open the valve from the air supply line and stabilize the pressure in the reservoir to 100 PSI minimum. Close air supply valve.
Service Procedures Shop Air Supply Wheel End Seals Wheel End Seals Reservoir 2" I.D. Pipe, 12" Long Air Port Plugged for Test Oil Fill Plug 2' Long, 3/8" I.D.
Service Procedures Hose and Supply Tank Selection Chart CAUTION The following hose lengths and sizes are necessary for correct TPCS operation. Any deviations may cause the system to function incorrectly and may reduce the ability to detect low tires. Front Channel Plumbing Requirements Standard Front (1 Axle) Dual Front (2 Axle) Both Non-Driven Dual Front (2 Axle) 1 Driven, 1 Non-Driven Min. Tank Size Main Run Jounce 1400 in3 18' to 20' 5/8" OD 6' to 8' per axle 5/16" ID Only (6 gal.
Service Procedures Trailer Channel Plumbing Requirements (Tractor) PCU to Glad Hand* Min. Tank Size Main Run N/A 16' to 22' 5/8" OD Jounce 19' to 25' 13/32" I D 22' to 30' 1/2" OD Single Trailer (2 to 3 Axles) Dual Trailers (4 to 5 Axles) 35' to 40' 1/2" OD 7' to 9' per axle 5/16" ID Only (6 gal.) 40' to 50' 5/16" ID 7' to 9' per axle 5/16" ID Only 2800 in3 60' to 85' 1/2" OD 7' to 9' per axle 5/16" ID Only (12 gal.
Wire Harness Connector Illustrations (All views shown looking into connector) Harness Connectors OCP Diagnostics ECU 9-Pin 5 6 8 9 10 J1939 / Can Link F G H J K F G H J K F G H J K A B C D E A B C D E A B C D E DDM Load Switch 3 2 1 D E F 6-Pin C B B A A E J DDM Terrain Switch DDM Display 5 6 4 7 2A 3 8 2B 2 9 1 10 7 9 7 9 4 1 4 1 5A 2A 5A 5B 2B 5B 6 3 6 3 8 10 8 10 Harness and Component Connectors Harness Pressure Switch Component A B B A A B B
Wire Harness Electrical Schematic Note: Schematic is shown for "point- to-point" troubleshooting only. Actual OEM implementations may vary with bulkhead connectors, etc. ECU Connector SPEED A SPEED B SPEED F3 SPEED F2 SPEED SENSOR INPUT or CONDITIONED SPEED INPUT COND SPEED COND SPEED F1 DIMMER DIMMER J1 DIMMER INPUT (0V= Dim, 12V = Bright) Note: Not used with DDM.
Wire Harness Driver Interface Options Driver Display Module (DDM) GROUND 4 POWER 5 COMM+ 7 COMM- 6 3 Display 1 DIMMER 2 DIMMER 8 COMM+ DIMMER 7 COMM- POWER 1 GROUND GROUND 3 POWER GROUND 9 LAMP/DIMMER GROUND Load Switch 10 2B 2B Or Operator Control Panel (OCP) COMM+ 9 COMM- 10 GROUND 6 POWER 5 LAMP/DIMMER 8 NO CONNECTION 7 69 GROUND 10 GROUND 9 GROUND 3 POWER 1 DIMMER 7 DIMMER 8 Terrain Switch
Wire Harness Configuration Connections Configuration Connections CONFIG 0 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D A B C D OR WITH OPTIONAL TRAILER: OR CONFIG 1 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D (BOTH STEERS NON-DRIVEN) OR A B C D WITH OPTIONAL TRAILER: OR CONFIG 2 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D (1 STEER DRIVEN, 1 STEER NON-DRIVEN) OR A B C D WITH OPTIONAL TRAILER: OR CONFIG 3 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2
Wire Harness Configuration Connections CONFIG 5 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D A B C D WITH OPTIONAL TRAILER: OR CONFIG 6 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D A B C D CONFIG 7 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D A B C D (Reserved) (BOTH STEERS NON-DRIVEN) OR WITH OPTIONAL TRAILER: OR CONFIG 8 HARNESS CONNECTOR GROUND CONFIG 1 POWER CONFIG 2 A B C D A B C D (1 STEER DRIVEN, 1 STEER NON-DRIVEN) OR WITH OPTIONAL TRAILER: OR 7
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For spec‘ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.com Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee, Ohio, USA 43537 www.dana.com All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation.
