Spicer TIMS (Tire Inflation and Monitor System) for Trailers. Installation Guide. AXIG-0025 October 2007

Transcription

1 Spicer TIMS (Tire Inflation and Monitor System) for Trailers Installation Guide XIG-0025 October 2007

2 Warnings and Cautions Warnings and Cautions The descriptions and specifications contained in this service publication are current at the time of printing. Dana Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. ny 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. IMPORTNT 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. WRNING: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician. CUTION: Failure to follow indicated procedures may cause component damage or malfunction. IMPORTNT: Highly recommended procedures for proper service of this unit. Note: dditional service information not covered in the service procedures. Tip: Helpful removal and installation procedures to aid in the service of this unit. lways use genuine Spicer replacement parts. This device complies with part 15 of the FCC rules and with RSS-210 of Industry Canada. Operation is subject to the following conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. 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. ny errors or omissions may be reported to: Marketing Services Dana Commercial Vehicle Systems Division P.O. Box 321 Toledo, Ohio

3 Table of Contents General Information bout this Manual Product Family Importance of Maintaining Proper Tire Pressure System Overview Features Data Logging System Specifications Component Weights Operation System Operation Manually Checking Tire Pressure Warning Lamp Description Two Seconds On at Power-Up Multiple Flashes at Power-Up Lamp on Continuously How the System Operates Component Description Tire Hose (with integral check valve) Rotary Joint (RJ) Manifold Electronic Control Unit (ECU) Controller ssembly Tire Maintenance System Components System Setup Setting Tire Pressure Target System Learn Method Troubleshooting Learn Mode Service Tool Method Troubleshooting Troubleshooting Introduction Blink Code Diagnostics Blink Code Description Warning Lamp Status Chart (Normal Mode) Warning Lamp Status Chart (Program Mode) Glossary Glossary ppendix Tire Maintenance System Performance at 100 psig Tire Maintenance System Schematic Connector Chart Table of Contents Installation Installation Materials and Supplies Installation Introduction xle Preparation Component Installation xle Hose Installation Spindle Plug Installation Spindle Plug, Plug Driver, and Rubber Collar Identification Chart Rotary Joint ssembly Installation of Rotary Joint Hubcap ssembly Controller ssembly Installation Wiring Harness Installation xle Vent Installation Control Line Installation dditional xles Tire Hose Installation Configuration, Clocking, and Tire Hose Selection Chart Label Locations

4 General Information General Information bout this Manual This manual is provided to support the Spicer Tire Maintenance System. The manual provides the following information: General Information Operation Components Installation System Set-up Glossary dditional information on the Spicer Tire Maintenance System is available in the following publications: Operator Instructions (CDR-0003) Troubleshooting and Service (XTS-0025) Product Family Spicer s Tire Maintenance System is one of a family of tire pressure management products that improve the productivity of commercial vehicles. Spicer s family of tire pressure management products include: Tire Maintenance System This system senses when one or more tires are below the desired cold pressure setting and reinflates the tires to the desired setting. The system alerts the vehicle operator, via a warning lamp, when tires are significantly below the desired pressure. Mobility Systems These systems are used in military and on/off-highway commercial applications. Spicer s mobility systems are capable of controlling tire pressure over a wide range of operating conditions. In addition to providing the benefits of the systems described above, these systems can lower tire pressure significantly to maximize the area of the tire footprint and greatly improve vehicle mobility under soft surface conditions. 1

5 General Information Importance of Maintaining Proper Tire Pressure Maintaining proper tire pressures can result in significant benefits for owners as well as operators. Tires are second only to fuel as a maintenance cost. They account for the majority of road failures, primarily as a result of underinflation. Tires represent a fleet s number one labor maintenance cost, contributing to over half of the total maintenance dollars spent. System Overview The Spicer Tire Maintenance System is designed to automatically inflate tires that are below their cold tire pressure setting using compressed air from the brake supply tank. ir seals and hoses remain non-pressurized when the system is not actively checking or inflating the tires. warning lamp will turn on when one or more tire pressure(s) is low by 10% or more. The lamp will not turn on for minimal inflation requirements of less than 10%, thus avoiding operator distraction when no action is required. If a tire is low, the remaining tires are protected from pressure loss by integral check-valves located in each tire hose. In addition, should system or tire maintenance be required (i.e. leaky tire resulting in excessive inflation), the lamp will flash multiple times at power-up indicating service is required. General Information Under Inflation Over Inflation Normal Inflation 218UX005 2

6 General Information Features Lamp on when tires 10% low (programmable) Checks tire pressure every 10 minutes Non-pressurized lines and seals when not inflating Warning lamp on only when service is required (not every inflation) Does not pressurize axle tube (prevents contamination of air seals) Seal and line leaks will not pressurize wheel ends No venting at wheel end prevents contamination from entering hubcap Check-valves located in tire hoses Industry standard data link (SE J1587) for communications and service Historical information retained through power-ups Leaky tire detection utomatic pressure target learn mode Serviceable filter at manifold keeps lines and seals clean System detects and logs service code if no supply air for greater than 24 hours Data Logging ctive and historical service codes (clear after 50 resets without reoccurrence) Count of inflation events Total inflation time Total hold time (pressurized) Count of power resets Total powered time Inflation time histogram data Pressure below target histogram data System Specifications Tire pressure setting range: psi Pressure sensor accuracy: +/- 1% Pressure resolution: 0.5 psi Pressure protection valve: 80 +/- 5 psi Pressure check interval: 10 minutes Power requirement (at 12 VDC): <85 ma idle, 1.2 amps inflating Minimum operating voltage: 9 volts Warning lamp current range: ma Inflate capacity (1 tire): 10 psi in approximately 2 minutes Component Weights Controller assembly: 5.5 lbs. Wheel end hardware: 1.5 lbs./end Misc. fittings and air line: 2.0 lbs. Wire harness: 2.0 lbs. 3

7 Operation Operation System Operation Manually Checking Tire Pressure To ensure that the system is functioning, the operator should verify that a 2 second warning lamp bulb check occurs when the unit is powered. The system is powered from the blue circuit on the 7 pin trailer connector. Once powered, the brake supply tank must be charged before the system will operate. The system will then pressurize the lines and measure the tire pressure. If one or more tires are low, the system automatically inflates the low tire(s) to the cold tire pressure setting. The remaining tires are protected from pressure loss by check-valves located in each tire hose. If one or more tires are low by 10% or more, the warning lamp will turn on and remain on until the tire(s) are reinflated. Once the tires are at the proper pressure, the seals and hoses will be depressurized, preventing unnecessary wear on the seals. The system rechecks tire pressure every 10 minutes by momentarily pressurizing the lines and measuring tire pressure as described above. If the warning lamp flashes multiple times on powerup, the system has stored a service code and may be unable to properly check or maintain tire pressure. The operator should manually check tire pressures to ensure that it is safe to operate the vehicle and should seek service at the next opportunity. If the warning lamp remains on, the system is attempting to inflate the tires but may not be able to adequately maintain proper tire pressure. The operator should stop and check the tires to determine if it is safe to continue to operate the vehicle and should seek service at the next opportunity. WRNING: To prevent injury, always wear eye protection when maintaining or servicing the vehicle. Note: Check valves in the tire hoses prevent tire pressure loss when a tire hose is removed. You may, however, experience air flow at the open line and a low tire indication on the warning lamp if the tire hose is disconnected and the system is powered. To manually check tire pressure: Disconnect tire hose from tee or straight fitting at hubcap, or disconnect from valve stem. Use a conventional gage to measure tire pressure at hose end or at valve stem. See illustration below. Reattach and firmly hand-tighten tire hose. CUTION: Do not overtighten tire hose or the seal may be damaged! Ensure tire hoses are not stretched or rubbing on the wheel! Tire Pressure Gage Tire Hose Operation CUTION: ll hoses must be connected for system to operate properly. If any of the hoses are removed or damaged, the system cannot inflate any low tire(s). 218UX046 4

8 Operation Warning Lamp Description Two Seconds On at Power-Up This is a system verification and warning lamp bulb check. If there is no bulb check at power-up, the system may not be functioning. Verify proper power is applied to the system. Note: The maintenance system utilizes the trailer s blue circuit for power. Some early model tractors do not power this circuit resulting in no power to the system. Multiple Flashes at Power-Up If the warning lamp flashes multiple times on power-up, the system has stored a service code. service code indicates the need for tire or system maintenance. If this occurs, the system may be unable to properly check or maintain tire pressure. Verify that all tires are inflated properly, and have the system serviced at the next opportunity. Note: Only active service codes will cause the warning lamp to blink multiple times at power up. How the System Operates The system checks the tire pressures on a ten-minute interval. To measure the tire pressure, the system charges the air lines with a series of pulses. If the line pressure has not increased to the target tire pressure after a specified period of time, the system will begin to inflate the low tire(s). If the measured tire pressure is 10% or more below the target tire pressure, the warning lamp will illuminate while the system is inflating the tire(s) to inform the driver of a potential tire leak. Once the target tire pressure is achieved, the system performs an additional check to verify that the control lines have depressurized and turns off the lamp. To prevent air from leaking while the control lines are not pressurized, there is a check valve (no spring valve core) in each of the tire hoses. If the warning lamp is on, the driver should check all the tires for damage and take corrective actions if applicable. Lamp on Continuously The lamp will light if the measured pressure of one or more tires is 10% or more below the cold pressure setting. The lamp will remain on until the tires are reinflated to the proper tire pressure. If the lamp is on, the operator should stop the vehicle and check the tires for damage. Under some conditions of normal operation, you may find that the warning lamp illuminates when no visible damage is apparent. This may be due to changes in ambient temperature while the trailer is idle. When the system is first powered on a trailer at a temperature significantly lower than when previously operated, cooling of the tires may result in a drop of pressure below 10% of the target pressure, thus illuminating the lamp. Refer to the Tire Maintenance System Performance at 100 psig on page 33 for examples of temperature effects on tire pressure. In addition, the lamp may turn on solid as the result of a significant air line leak, the system failing to depressurize, or because a new ECU has not had a target programmed yet. CUTION: Extended periods of use with the lamp illuminated may decrease the life of the rotary air seals. Typical Trailer Mounted TMS Warning Light 218UX006 5

9 Components Component Description Tire Hose (with integral check valve) Provides an air passage from the hubcap tee or straight fitting to the tire. Integral check valves in the tire hoses allow the air lines and seals to remain non-pressurized when the system is not checking or inflating the tires. No modification to the standard valve stem or core is required. Rotary Joint (RJ) Provides a means to allow the air to flow from a nonrotating axle spindle to the rotating hubcap. The RJ is composed of seals and bearings. The air seal prevents leakage from the rotating shaft and the oil seal guards against contamination. Provides a vent for air pressure in the hubcap during normal use and in the event of rotary joint damage. Under normal operation, the RJ will be nonpressurized for the majority of the time. Manifold Solenoids control the flow of air to tires. Pressure sensor reads tire pressure. Serviceable inlet filter reduces contamination from the air source. Electronic Control Unit (ECU) Controls the manifold to read and maintain tire pressures. Performs a lamp check to inform the driver that the system is powered and operational. Turns on the warning lamp when the measured tire pressure drops more than 10% (typical value) below the target pressure. Detects faults and displays service codes via the warning lamp. Provides on-board diagnostic support over a industry standard SE J1708/J1587 communication interface. Provides diagnostics support via blink-codes. Stores historical data for future use. Components Controller ssembly Manifold ECU Mounting bracket 6

10 Components Tire Maintenance System Components TMS Warning Lamp Diagnostic Port Main Power Harness To BS Controller ssembly Hubcap & Hose ssembly Mounting Bracket ECU Pressure Sensor Hose ssembly "T" Fitting Check Valve Check Valve Hose ssembly Manifold Rotary Joint 218UX002 7

11 Installation Installation Installation Materials and Supplies Installation Introduction In addition to hardware provided by Dana, the installer shall provide the following: Hubcaps, unless pre-installed on dressed axle. Pressure protection valve. Spindle plug driver and handle, unless plugs are already installed in axle. ir lines and fittings. Warning lamp and wire. 115 psi shop air or PC/hand-held tool to set tire pressure target. Optional J560 to 5-pin extension harness if trailer is pre-bs. Controller assembly mounting bolts. Identify the bullet item below that describes the condition of the trailer axles and proceed as directed. If the maintenance system hardware is already installed on a fully dressed axle, skip to Controller ssembly Installation. If tire maintenance system axle hose and spindle plugs are already installed on the axle, skip to Rotary Joint ssembly. If the axles have been pre-drilled, but no hardware has been installed, skip to Component Installation. For retrofit installations start with the following procedures. Installation 8

12 Installation xle Preparation The following describes the procedure for preparing a trailer axle for system installation. The Spicer Tire Maintenance System is designed to be used on trailer axles with hollow tapered (D22 series) or hollow parallel (P22 series) spindles with inside diameter machined to a minimum depth of 1.0". Some trailer axles have a solid web inside the spindle under the inner bearing that may be modified to allow for a hose to be routed through the obstruction. Consult with the axle manufacturer for approval to modify the axle before installation of the Dana Spicer Tire Maintenance System. The Spicer Tire Maintenance System does not require the removal of the wheel assemblies. However, the tires must be blocked and the trailer supported to prevent movement during installation. WRNING: Block all wheels before beginning this installation procedure. Never work under a vehicle supported by a jack. 1. Block tires to keep the trailer from moving. D22-Style Tapered Spindle OR 218UX008 P22-Style Parallel Spindle 218UX007 CUTION: Do not weld on axles with hoses installed as hoses may be damaged. Note: The Maintenance System cannot be installed on solid spindle trailer axles. Note: The Maintenance System is not compatible with xilok or cotter pin locked spindle nuts. Use of the 3-piece jam nut system with the maintenance system is recommended. Pro-Torque nuts may require use of an optional hubcap spacer. 2. If the trailer is equipped with an air suspension system, deflate the air springs or support the trailer frame to prevent settling during installation. 3. If the wheel end is oil lubricated, drain the oil from the hubcap and discard. 4. Remove the hubcap bolts and hubcap. 5. Remove the spindle plug from the end of the spindle. 6. Inspect spindle plug bore and remove any burrs or sealant. 7. Check the inside of the spindle to insure that there is a passage through the axle to allow installation of the air line. 8. Locate the three 1/4" pipe plugs on the top of the axle tube near the center and remove. If the axle was not prepared at the factory with the three 1/4" pipe thread holes, proceed to step Proceed to the Component Installation section. 9

13 Installation Note: Follow the axle manufacturer s recommendations for the location and process to modify axle. Failure to follow the recommendations may reduce the life or load carrying capacity of the trailer. Note: On Hendrickson axle/suspensions, only drill in window area (consult manufacturer for details). 10. On the top of the axle under the trailer, locate the center and mark. From the center mark just created, measure to the left and right an equal distance of 13-1/2" or greater (within suspension brackets) and mark. 11. Drill and tap 1/4" NPT holes in axle beam to prepare for component installation. Mount drilling fixture on trailer axle in proper location (13.5" from center and at 12:00). Install the 1/2" x 1/2" long drill bushing in the fixture. Install the 3/16 x 3/4" long drill bushing in the first bushing. Drill though the axle tube with a 3/16" boron steel drill bit. Do not exceed 300 RPM. Note: Cutting oil is recommended. Note: lever may be necessary to produce enough force to cut the material. Reduce force on lever before the bit goes through to prevent breaking the bit. Remove the 3/16" and 1/2" drill bushings from the fixture. Install the 7/16 x 1/2" long drill bushing in the fixture. Drill through the axle tube with a 7/16" boron steel drill bit. Do not exceed 300 RPM. Remove fixture and ream hole with a tapered reamer for a 1/4" tapered pipe. Reinstall fixture and install tapping bushing. Tap hole with a 1/4" male pipe tap. Clean debris from the axle generated during the drilling and tapping operations. Check the size of the threads created. 12. Proceed to the Component Installation section. Component Installation Refer to the following assembly procedures to complete the installation of the Spicer Tire Maintenance System. Component installation procedures include: xle Hose Installation Spindle Plug Installation Rotary Joint ssembly and Installation of Rotary Joint Hubcap ssembly Controller ssembly Wiring Harness Installation xle Vent and Control Line Installation Tire Hose Installation Installation 10

14 Installation xle Hose Installation 1. In the left 1/4" pipe hole located on the top of the axle tube, route the small covered end of the metal braided hose into the axle. Note: Make sure that the braided hose heads toward the spindle end. 2. Making sure that the hose is going toward the correct wheel end, continue feeding the metallic covered hose into the trailer axle until the small end of the hose exits the spindle end. 3. Thread the large adapter end of the axle hose assembly into the axle and tighten to 20 lbs. ft. (27.1 N m). 4. Remove protective coverings from end of the axle hose assembly and blow air through it to remove any debris. 5. Repeat steps 1 through 4 for the opposite side of the axle. Hose Routing in xle Route Braided Hose Into xle Route Braided Hose Into xle D22-Style Spindle OR P22-Style Spindle 218UX009 Thread dapter Into xle Thread dapter Into xle D22-Style Spindle OR P22-Style Spindle 218UX010 11

15 Installation Spindle Plug Installation 1. Route the end of the left axle hose assembly through the center of the left spindle plug assembly. 2. With the breather hole of the spindle plug assembly located in the 12 o clock position, place the plug assembly at the spindle end. 3. Route the braided hose assembly through the slot in the end of the plug driver and press the plug into the spindle until the driver bottoms on the end of the spindle. Note: The driver regulates the correct installation depth. 4. Repeat steps 1 through 3 for the right side of the axle. Spindle Plug with Small Hole and "Flat" at 12 O'Clock Position D22 Spindle D22-Style Spindle Braided Hose Installation Plug Driver Handle Plug Driver P22 Spindle P22-Style Spindle Braided Hose Spindle Plug with Small Hole and "Flat" at 12 O'Clock Position Plug Driver Handle Plug Driver 218UX011 12

16 Installation Spindle Plug, Plug Driver, and Rubber Collar Identification Chart Model Spindle Identification* Spindle Plug Plug Driver** Rubber Collar D22 (Tapered) 1.750" P22 (Parallel) 2.500" P22 (Parallel) 2.753" *NOTE: minimum bore depth of 1.0" required. **NOTE: Use standard drive handle (ex: Kent Moore J-8092) with appropriate plug driver. 13

17 Installation Rotary Joint ssembly Install rotary joint in appropriate rubber collar. See the Spindle Plug, Plug Driver, and Rubber Collar Identification Chart on page 13. Take care to align the TOP breather groove on the rubber collar with the flat on the rotary joint. CUTION: Install the rubber collar onto the outboard side of the rotary joint such that the label and part number face out. Installation of Rotary Joint Note: Install hubs and drums according to manufacturers specifications before installing the rotary joint assemblies. 1. Place the stepless ear clamp onto the axle hose assembly end sticking out of the end of the spindle. 2. Slide the smooth barbed end of the rotary joint assembly into the end of the axle hose assembly until the hose bottoms on the rotary joint s body. Back Vie w "Top" Notch Flat "Top" Notch 3. Using a crimping tool (Oetiker pliers), squeeze the clamp to tighten the hose to the rotary joint. 4. Check the orientation of the breather grooves in rubber collar to insure the top one aligns itself with flat on the rotary joint body. Orient the flat on the rotary joint body (located near the clamp) to the 12 o clock position and press the rotary joint assembly into the spindle bore. The assembly is seated when the outer edge is almost flush with the end of the spindle. Installation T O P "Top" Note: For ease of installation, apply lubricant (grease or oil) to inside bore of axle spindle prior to installing rotary joint assembly. Fr ont View Press ONLY Here When Inserting Into xle End CUTION: Do not push on brass colored air tube when inserting rotary joint assembly into spindle. Carefully push only on face of rotary joint where it meets the rubber collar. IMPORTNT: Rubber Collar Fits s Shown T O P Face of Rotary Joint is Behind the Lip of the Mounting Cylinder 5. fter assembly, verify proper installation by grasping the brass colored tube at the center of the rotary joint. Using fingers only, pull firmly outward on the joint assembly. properly installed and seated rotary joint will not be removed with hand pressure alone. T O P Grasp brass colored tube at center as illustrated Pull firmly straight out to verify proper installation 14

18 Installation Braided Hose Crimping Tool Rotary Joint ssembly Position "Flat" on Top Spindle ssemble Parts and Crimp 218UX012 Braided Hose Spindle 218UX013 15

19 Installation Hubcap ssembly 1. Place hubcap gasket over rotary joint s exit tube and bulkhead adapter. 2. Lubricate o-ring on the rotary joint s bulkhead adapter. 3. From the inside, insert the bulkhead adapter through the hole in the hubcap marked ir. Be sure to align the flat on the bulkhead adapter to the flat inside the hubcap. ttach the jam nut and hand tighten. When properly seated, the top of the bulkhead adapter will be flush with the top of the jam nut. Braided Hose Installation Nut Hubcap Spindle 218UX014 CUTION: If wheels are installed, refer to Tire Hose Installation on page 24 and Configuration, Clocking, and Tire Hose Selection Chart on page 25 to determine correct clocking of hubcap. Wheel must be properly clocked to hubcap to prevent hoses rubbing on the wheel. Failure to properly clock hubcap may result in hose failure. 4. lign the hubcap and gasket and install the 6 bolts. Torque to the values listed in the Torque Values Chart per manufacturers recommendations. 5. Torque the rotary joint's jam nut to lbs. ft. 6. Install lubricant in wheel end to the correct level. Torque Values Chart Hub Material Bolt Grade Bolt Size Torque Iron 5 5/ lbs. ft. Iron 8 5/ lbs. ft. luminum 5 & 8 5/ lbs. ft. CUTION: Use of Pro-Torque spindle nuts may require a hubcap spacer to prevent interference. 16

20 Installation Controller ssembly Installation 1. Locate the controller assembly such that it can conveniently connect to the brake supply tank. 2. Drill two holes on 4" centers to accommodate the mounting bracket. ttach the controller assembly with two 5/16" fasteners. See illustration below. CUTION: The controller assembly must be mounted vertically with ECU connector down to prevent damage. See illustration below. CUTION: Do not weld on bracket without first removing both ECU & Manifold from the bracket. CUTION: Cover Controller ssembly prior to painting or undercoating trailer to prevent plugging of manifold and ECU vents. Cross Member 5/16" Mounting Bolts 218UX028 17

21 Installation Wiring Harness Installation 1. Plug the Power Input connector side of Dana's Tire Maintenance System harness into the 5 pin Packard connector coming from the J560 interface. See illustration below. 2. Plug the cable from the BS wire harness into the 5- pin Packard BS connector on the Tire Maintenance System harness. 3. Route the harness to connect to the ECU, Manifold, and Pressure Sensor located on the maintenance controller assembly. 4. Mount the diagnostic connector to the side of the trailer, typically in front of the tires. For slider applications, make sure to allow for adequate movement of the slider. 5. Mount the lamp on the front corner or side of the trailer within view of the operators side view mirror. On applications with tractors utilizing large wind fairings, locating the lamp near the left rear wheels (near the BS warning lamp) may be preferred. Connect one side of the lamp to ground. 6. Route the lamp power wire (16 WG minimum) and connect to the 0.156" female bullet connector of the Tire Maintenance System harness. 7. Secure harness as required. Note: For pre-bs equipped trailer retrofits, a power harness is also available. When using this harness, cut the cable length as required and connect to the vehicle power at the SE J560 connector. J560 5 Pin Packard Power Input 5 Pin Packard To BS Male Bullet Warning Lamp Warning Lamp Male Bullet Provided by Trailer Manufacturer Valve Pressure Sensor 1587 Diagnostic Provided by Dana Installation ECU To BS 218UX016 18

22 Installation xle Vent Installation 1. Install a 1/4" NPT male to 3/8" NT fitting in the 1/4" pipe thread located on the axle for venting. 2. Run 3/8" OD Nylon ir Brake Tubing to the frame and position the end facing down to prevent contamination. See illustration below. 3. Secure tubing as required. Vent Fitting 1/4" NTP to 3/8" Nylon Tubing dapter Trailer Frame Rail Front of Trailer xle Vent Hose (minimum 3/8" OD nylon air brake tubing) Trailer xle CUTION: Position the end of the vent tube down to prevent contamination of the axle. Control Line Installation pressure protection value (PPV) is recommended between the trailer air supply tank and the Tire Maintenance System controller assembly. n existing suspension PPV can also be used to supply air to the suspension as well as the Tire Maintenance System. Proper Tire Maintenance System operation requires correct air line diameters and lengths. The following diagrams show air brake tubing lengths and sizes and associated fittings required to complete the system installation. CUTION: To prevent twisting air line inside axle when tightening fittings to the axle hose fitting, use a wrench to hold the axle hose fitting. CUTION: Proper Tire Maintenance System operation requires correct air line diameters and lengths. Installation sizes and lengths must be within limits shown. CUTION: Proper Tire Maintenance System operation requires correct air line connections. ll junctions of two or more 1/4" lines MUST upsize to 3/8" line for adequate flow. CUTION: To prevent contamination of the Tire Maintenance System, do not install fitting on the bottom of the air supply tank. dditional xles For systems with 3 or 4 axles, observe the installation requirements as shown in the following diagrams. Extend the main 3/ 8" run as necessary. However, all total line lengths must still remain within the limits listed on the diagrams. CUTION: Failure to properly install axle vent may result in wheel end pressurization and/or water ingestion which could cause wheel end failure. 19

23 Installation Typical Maintenance System Plumbing - 3/8 and 1/4 Lines with Junction Manifold J D Supply Tank E G F IN OUT Controller ssembly Front B C D OR B H Plug D Installation J To dditional xles Item Description ir Line B ir Line C ir Line D xle Connector E Pressure Protection Valve F Controller In Fitting G Controller Out Fitting H Junction Manifold J xle Vent Fitting 3/8" OD Nylon ir Brake Tubing: any length 3/8" OD Nylon ir Brake Tubing: 0-8 feet total 1/4" OD Nylon ir Brake Tubing: 6-50 feet total 1/8" NPT male to 1/4" NT NPT to 3/8" NT 3/8" NPT male to 3/8" NT 3/8" NPT male to 3/8" NT 3/8" NT inlet, 1/4" NT outlets 1/4" NPT male to 3/8" NT NT = Nylon Tubing dapter 218UX004 20

24 Installation Typical Maintenance System Plumbing - 3/8 and 1/4 Lines without Junction Manifold J D C Supply Tank C I E Front B F IN Controller ssembly G OUT C B I C D J Item Description ir Line B ir Line C ir Line D xle Connector E Pressure Protection Valve F Controller In Fitting G Controller Out Fitting I Tee(s) J xle Vent Fitting 3/8" OD Nylon ir Brake Tubing: any length 3/8" OD Nylon ir Brake Tubing: 0-8 feet total 1/4" OD Nylon ir Brake Tubing: 6-50 feet total 1/8" NPT male to 1/4" NT NPT to 3/8" NT 3/8" NPT male to 3/8" NT run tee: 3/8" NPT male, 3/8" NT, 3/8" NT 3/8" NT inlet, 1/4" NT outlets 1/4" NPT male to 3/8" NT NT = Nylon Tubing dapter 218UX041 21

25 Installation Typical Maintenance System Plumbing - 3/8 Lines Only J D B I B Supply Tank E Front G F IN OUT Controller ssembly B I D B Installation J Item Description ir Line B ir Line D xle Connector E Pressure Protection Valve F Controller In Fitting G Controller Out Fitting I Tee(s) J xle Vent Fitting 3/8" OD Nylon ir Brake Tubing: any length 3/8" OD Nylon ir Brake Tubing: 3-30 feet total 1/8" NPT male to 3/8" NT NPT to 3/8" NT 3/8" NPT male to 3/8" NT run tee: 3/8" NPT male, 3/8" NT, 3/8" NT 3/8" NT inlet, 3/8" NT outlets 1/4" NPT male to 3/8" NT NT = Nylon Tubing dapter 218UX040 22

26 Installation Typical Maintenance System Plumbing - Single xle with 1/4" or 3/8" Lines Supply Tank E Front F IN OUT Controller ssembly B G D J Item Description ir Line B ir Line D xle Connector E Pressure Protection Valve F Controller In Fitting G Controller Out Fitting J xle Vent Fitting 3/8" OD Nylon ir Brake Tubing: any length 3/8" OD Nylon ir Brake Tubing: 4-30 feet total OR 1/4" OD Nylon air Brake Tubing: 8-50 feet total 1/8" NPT male to 3/8" or 1/4" NT (depends on axle hose fitting and air line B) NPT to 3/8" NT 3/8" NPT male to 3/8" NT NT = Nylon Tubing dapter run tee: 3/8" NPT male, 3/8" NT, 3/8" NT OR run tee: 3/8" NPT male, 1/4" NT, 1/4" NT (depends on air line B) 1/4" NPT male to 3/8" NT 218UX042 23

27 Installation Tire Hose Installation 1. Position the hubcap and wheel so the hoses will not stretch or rub on the wheel. See the Configuration, Clocking, and Tire Hose Selection Chart on page 25. CUTION: Wheel must be properly clocked to hubcap to prevent hoses rubbing on the wheel. Failure to do so may result in hose failure. 2. Screw the inverted flare nut on the tire hose tee fitting into the rotary joint s bulkhead adapter and tighten finger tight. Tighten with a wrench an additional 1/4 turn. See illustration below. 3. ttach tire hose and check valve assemblies to the tee fitting. 4. Install tire hoses on the tire valves and tighten with fingers. 5. Tighten the tee or straight fitting to the tire hoses. CUTION: Using a wrench or pliers to tighten the tire hose to the valve stem, tee, or straight fitting may damage the gasket causing a leak or decreased performance. Straight Fitting for Singles Installation Check Valve OR Outer Wheel Hose ssembly Check Valve "T" Fitting For Duals Inner Wheel Hose ssembly 218UX047 24

28 Installation Configuration, Clocking, and Tire Hose Selection Chart Clock "" 5-Hole or 5-Spoked Wheel Installation (17.5" or 22.5" Wheel) Clock "B" 5-Hole or 5-Spoked Wheel Installation (19.5" or 24.5" Wheel) Clock "C" 2-Hole or 4/6 Spoked Wheel Installation (any size wheel) Wheel Size Hole Config Hose Inner Hose Outer Clock X X X C 17.5 X X X 19.5 X X X C 19.5 X X X B 22.5 X X X C 22.5 X X X 24.5 X X X C 24.5 X X X B Single n/a n/a X n/a n/a n/a n/a 25

29 Installation Label Locations 1. Install the Tire Monitor System label at either the left front or the left rear side of the trailer. 2. Install the Check Tires label near the warning lamp at the left front of the trailer. Place at Easily Visible Location Place at Easily Visible Location Near Warning Lamp Installation Controller ssembly 218UX038 26

30 System Set-up Setting Tire Pressure Target fter completing the installation, the system s tire pressure target must be set before using the trailer. On power-up, the lamp will remain on as an indication that the target pressure has not been set. There are two methods for setting the system s tire pressure target: System Learn Method all tire pressures are set to the cold tire pressure setting and the system reads the tire pressure target Service Tool Method a service tool (PC-based or hand-held) is used to download the target over the data link. Short Pins and E and Release 3 Times to Enter Learn Mode F B E D C 218UX017 System Learn Method In order to set the target tire pressure using this method, all the tires must be verified to be at the target pressure for an accurate setting. Use the procedure in How to Manually Check Tire Pressures to measure and set the cold tire target pressure for all tires. 1. pply 12 volt power to the trailer at the SE J560 connector. 2. Provide adequate pressure to the brake supply tank. (Minimum of desired tire target pressure +5 psi or 90 psi, whichever is greater.) Note: Older systems with ECU P/N require a minimum supply of 110 psi to program. 3. Remove the weather cap from the diagnostic connector. Short pins and E in the following sequence: short the pins three times, maintaining the short for approximately 1 second on and waiting 1 second off. The pins to be shorted can be easily identified by the interconnecting slot in the shell, allowing convenient use of a coin or screwdriver tip to short the pins together. 4. Upon entering learn mode, the warning lamp will turn on for 2 seconds twice and will then flash once every 10 seconds to acknowledge that the learn mode is active. 5. The system will pressurize the air lines for several seconds, and then wait for the pressure to stabilize. 6. The tire pressure read will be stored as the target pressure. Once the target pressure is established, the warning lamp will turn ON continuous for 5 seconds and then flash out the target pressure. For example, if the tire pressure is 102 psi, the light will turn ON continuous for 5 seconds and then flash 1 time, pause and then flash 10 more times, pause and then flash 2 more times (0 is represented by 10 flashes). If the value flashed is lower than the desired target pressure, verify that all the tires are set to the proper pressure and that no line leaks are present. 7. fter the system has determined the target pressure, it will remain pressurized for up to 2 minutes (or until power is cycled). During this time, a manual check for air leaks should be made. If a line leak is detected, the system will not pro gram a target pressure and warning lamp will turn on solid. If this occurs, correct the leak(s) and then set all tires to the target pressure and conduct the learn sequence again. Note: The system is only pressurized for two minutes following the attempted target learn. leak will only be audible during this time. 27

31 System Set-up Troubleshooting Learn Mode Several faults may cause the system not to learn the target. The following is a list of the most common occurrences. CUTION: Use of a battery charger as the power supply may result in the system not functioning properly. Condition Possible Causes Lamp does not illuminate during power-up System remains in learn mode (Lamp flashes once every 10 seconds) The lamp remains illuminated after the learn mode The system reads the tire pressure low Poor electrical connection, power below 9 volts, or burned out lamp Supply pressure is below 90 psi minimum fault has occurred, refer to the blink code diagnostics or PC tool ir leaks, supply pressure too low, air line leaks, kinked or restricted supply line, or not plumbed per installation guidelines. Service Tool Method When using a PC or other supported service tool connected to the diagnostic port, follow the instructions included with the service tool. 1. pply 12 volt power to the trailer at the SE J560 connector. 2. Enter the desired cold temperature tire pressure target into the ECU using the service tool and then remove power from the trailer. 3. Reapply power and verify proper operation by selecting the manual operation mode in the Diagnostic Tool. Select pressure check and hold to check for leaks in the system. 4. Watch for a drop in manifold pressure and listen for any audible leaks. If a leak is found, take corrective actions. 5. If any faults have occurred during programming, clear all historical faults. System Set-up 28

32 Troubleshooting Troubleshooting Troubleshooting Introduction The system identifies certain conditions and reports them via the trailer mounted warning lamp. In normal mode, the operator is informed whenever a tire is low enough to require service (typically 10%) or there is a fault in the system. For troubleshooting, additional information can be obtained either through blink-codes, or through use of service tools connected to the diagnostic connector. Blink Code Diagnostics Blink codes provide a means to determine what service codes exist without requiring any special tools. pply power to system. To activate blink-codes, remove the weather cap from the diagnostic connector and electrically short pins "" and "E" together until warning lamp changes state (approximately 5 seconds). The pins to be shorted can be easily identified by the interconnecting slot in the shell, allowing convenient use of a coin or screwdriver tip to short the pins together. The warning lamp will turn on for 5 seconds upon entering the diagnostics mode, and will then flash a 2 digit service code. See the Warning Lamp Status Chart (Diagnostic Mode) for service code descriptions. Should more than one fault exist, there will be a 2 second pause between each flash sequence. If no faults are present or all the faults have been flashed, the system will flash a code 5-5. It is not necessary to short the diagnostic connector to obtain blink-codes when a service tool is used for troubleshooting. Follow the instructions included with the service tool. Blink Code Description Low Tire - Low tire pressure is indicated by a solid warning lamp. This service code will be set when one or more tire pressures drops a predetermined amount (typically 10%) below the target pressure. Inspect the tires to verify there is no tire damage. This fault can also be set as a result of a large line leak. System Fault - system fault is set when a problem has been detected with the system. System service codes include memory reset, internal atmospheric sensor fault, or other pneumatic faults. Code This indicates the end of the service code list. If this is the only code received, then no service codes exist. Short Pins and E Until Lamp Changes State (approximately 5 seconds) and Release to ccess Blink Codes F B E D C 218UX034 29

33 Troubleshooting Warning Lamp Status Chart (Normal Mode) Warning Lamp Status ECU in Normal Operating Mode System Condition Troubleshooting 2 seconds ON at power-up* Normal operation (lamp check) Multiple flashes at power-up Continuous ON ctive service code stored in ECU Low pressure in one or more tires Substantial air line leak Failure to depressurize the system No tire pressure target programmed (new ECU) Note: If the vehicle is powered and the supply air tank pressure is not at a minimum of 90 psi the system will not check or inflate the tires. *Note: The maintenance system utilizes the trailer's blue circuit for power. Some early model tractors do not power this circuit resulting in no power to the system. 218UX023 Warning Lamp Status Chart (Program Mode) ECU in Learn Mode Warning Lamp Status System Condition 2 seconds ON twice when learn mode is selected cknowledges that the learn mode has been activated 1/2 second ON every 10 seconds Learn mode active - inadequate supply pressure to determine tire pressure target 5 seconds ON, then multiple 1/2 second ON cknowledges that a tire pressure target has flashes separated by 2 seconds OFF been determined by the ECU (each series of flashes represents 1 digit of new tire pressure target - example: 9 flashes, 2 sec. pause, 5 flashes = target of 95 psig) Note: a zero is indicated by 10 flashes. 218UX024 30

34 Troubleshooting ECU in Diagnostic Mode (Blink Codes)* 1st Digit 2nd Digit Description Possible Causes 1 Leaking tire** Repeated inflates of a slow leak in tire or wheel assembly 1 2 Tire pressure low** Tire pressure more than 10% (typical) below target pressure; Significant air line leak or hose disconnected Line leak Supply pressure low 6 Maximum inflate time ir line is leaking between manifold and wheel-end; Very low tire Supply pressure inadequate to check tire pressures for greater than 24 hours System has been continuously inflating for over 2 hours but has not reached target 7 System vent failure System unable to depressurize air lines. Check valve or manifold contamination. Pressure sensor ground wire disconnected. Pressure target out of range Programmed tire pressure target is outside allowable range ( psig) 1 ECU memory failure Faulty ECU (possible lost historical data) tmospheric reading System defaults to 14.5 psi reference pressure 2 failure 4 3 No target pressure New installation-target pressure must be programmed 4 No sensor signal Pressure sensor wiring disconnected or faulty 5 Low voltage Trailer supply voltage too low for normal operation End of service code 5 5 listing 1 Lamp-open circuit Disconnected or faulty wire harness, lamp or ECU 2 Lamp-short circuit Faulty wire harness, lamp or ECU 6 3 Solenoid 1-open circuit Disconnected or faulty wire harness, solenoid or ECU 4 Solenoid 1-short circuit Faulty wire harness, solenoid or ECU 5 Solenoid 2-open circuit Disconnected or faulty wire harness, solenoid or ECU 6 Solenoid-2-short circuit Faulty wire harness, solenoid or ECU *Note: The warning lamp will turn ON continuously for 5 seconds when entering the diagnostic mode. The lamp will then flash any active two-digit blink codes. **Note: Following repair of the leaking tire, check all other tires manually for correct tire pressure. If the system has been maintaining pressure in a leaking tire for an extended period of time, the other tires may now be slightly above target pressure. 31

35 Glossary Glossary Spicer Tire Maintenance System Manifold Electronic Control Unit (ECU) Rotary Joint Target Pressure system that maintains the pressure of selected tires and activates a warning to alert the vehicle operator if the pressure drops by more than 10%. Receives signals from the Electronic Control Unit (ECU) and directs air flow to either maintain or inflate the tires to keep them at their target pressure. The ECU is programmed with the target pressure and directs the manifold to supply air to the tires when needed. significant drop in tire pressure causes the ECU to light the warning lamp. Rotary air seal assembly that allows air transfer from wheel end to tire(s) while vehicle is in motion. Only pressurized while system is checking tire pressure or inflating. The desired cold temperature tire pressure for the tires. Glossary 32

36 ppendix Tire Maintenance System Performance at 100 psig MBIENT TEMPERTURE T WHICH THE TIRE PRESSURE IS SET TO THE TRGET PRESSURE Target Pressure: 100 psi 218UX TIRE PRESSURE VS. TEMPERTURE Drops to 90 psig at 20 F: Warning lamp goes on Set 100 PSIG at 70 F Pressure (PSIG) Temperature (F) 218UX018 33

37 ppendix Tire Maintenance System Schematic dditional Harness Required for Non-BS Trailers E B C D B C D E To Maintanance System Harness Power Ground J560 Blue J560 White 1 7 SE J560 Trailer Connector (Viewed from Back Side) E C B D From SE J560 B C D E Note: ll connector views are shown looking into the harness connector unless otherwise noted. Note: Older systems have pressure sensor ground (Pin ) spliced to harness ground (ECU Pin 7) and not connected to ECU Pin 2. Female Bullet Connector Stop Light Power Power BS Trailer Warning Lamp Ground OEM Supplied Trailer-Mounted Warning Light Ground Supply Signal B C D E B C E B To BS ECU B C C D Pressure Sensor ppendix Supply Solenoid Switched Ignition Control Solenoid B C B C ECU Connector Pressure Sensor Supply Pressure Sensor Ground 2 Switched Ignition 3 SE J1587 (+) 4 SE J1587 (-) 5 Pressure Sensor Signal 6 Ground 7 Supply Solenoid 8 Spare Input 9 Optional Warning Lamp 10 Control Solenoid 11 Fault Output 12 Optional B C D E F Manifold Solenoids F B E D C Diagnostic Connector 218UX001 34