TPC TIREBOSS 2 User manual

TIREBOSS 2
Tire Pressure Control
®
TB2 Service Manual
Version 2.0 | Current as of August, 2022
TECHNICAL - documents | DOCUMENTS | SERVICE MANUAL | Service Manual - V 2._
15803-121A Ave., Edmonton, Alberta, Canada T5V 1B1
Toll Free Phone: North America 1-888-338-3587
New Zealand 1-800-443-971 | Australia 1-800-148-694
Phone: [phone] | Fax: [phone]
Email: [e-mail]
This is a working document that is
subject to change without notice
Contact TPC International with any inquries at;

I
Service ManualTire Pressure Control
Table of Contents
Safety Information & Disclaimers
System Descriptions
Safety Systems
Chapter 1 - System Schematics;
Truck Overview ....................................................................................................................
System Overview ................................................................................................................
Electrical Overview ...........................................................................................................
Air Supply Pneumatics - Standard Dryer .........................................................
Air Supply Pneumatics - ADIS Dryer ....................................................................
Air Supply Pneumatics - Dual Dryer ....................................................................
Chapter 2 - Adjustments, Settings & Maintenance;
Monthly Service Inspection ........................................................................................
Annual Service Inspection ..........................................................................................
Adjusting the Pressure Protection Valve [PPV] ............................................
Adjusting the Air Compressor Governor ............................................................
Rotary Union Maintenance ........................................................................................
WEV Plate Maintenance ..............................................................................................
Valve Rebuild Procedure ..............................................................................................
Chapter 3 - Operations;
Operators Control Unit [OCU] Controls ..............................................................
Selecting Applications ...................................................................................................
Enabling / Disabling Applications .........................................................................
Connecting OCU to Wifi ...............................................................................................
Adding a New Network to OCU ................................................................
Connecting as ‘TPC-Tech’ ..............................................................................
Creating a ‘TPC-Tech’ Hotspot on IOS Devices ...............................
Creating a ‘TPC-Tech’ Hotspot on Android Devices ....................
Chapter 4 - Programming & Updates;
Field OCU & SCU Replacements .............................................................................
Firmware / Software Updates ..................................................................................
Chapter 5 - Trouble-Shooting Guide;
Wiring Pinout .......................................................................................................................
Alarm Code Diagnostic Chart ..................................................................................
OCU Diagnostic Lights ..................................................................................................
SCU Alive Diagnostic Plug ..........................................................................................
SCU Diagnostic Plug .......................................................................................................
I
IV
V
1-1
1-2
1-4
1-5
1-6
1-7
2-1
2-2
2-4
2-7
2-11
2-15
2-18
3-1
3-3
3-3
3-5
3-6
3-6
3-7
3-7
4-1
4-2
5-1
5-6
5-18
5-20
5-21

Service ManualTire Pressure Control
II
Before you begin;
Read, Understand and Comply with;
- All Instructions and procedures,
- Companies maintenance intervals, service
routines, installation and diagnostic procedures
- Vehicle manufacturers safety instructions when
working on vehicles,
- Vehicle manufacturers safety and best practice
guidelines not included or described in service
procedure,
- Local safety regulations
During Service;
- Work should only be carried out by trained
personnel
- Use only recommended parts, tools, and
procedures
Upon Completing Service;
- All vehicles should be thoroughly tested and
inspected before being released back into
service
- Ensure the date and service type is noted on
the log sheet located inside of the SCU cover
Safety Notice;
Proper maintenance, service and repair is
importantforthereliableandsafeoperationof Tire
Pressure Control International Ltd.’s [henceforth
known as “TPC International”] TIREBOSS®2
Tire Pressure Control system. Systems that lack
or have poor service and maintenance intervals
have a higher potential for failure with potentially
devastating circumstances. Failure of the control
system could place additional stress on different
systems within the vehicle causing them to be
worn in ways they were not designed for and
creating a dangerous situation. This includes,
but is not limited to, vehicle tires, suspension
system, pneumatic system, electrical system,
etc. The procedures outlined in this guide are
preventive and should be considered as part
of regular maintenance in order to ensure the
health and good operation of the system. Due to
the technical nature of the procedure outlined
in this guide, service should be performed with
extreme caution by trained individuals only.
Disclaimer;
The description and specifications outlined in
this service procedure are current as of the date
indicated on the front cover. TPC International
reserves the right to modify, revise, or discontinue
components that may be used throughout
the procedure without notice to customers.
This right will be reserved for instances where
the technical development team at TPC
International devises a solution it deems to be
more appropriate. Contact TPC International
if you believe a change has been made to your
system (since the date of this procedure). Any
reference to brand names seen in this publication
are made as an example of the recommended
products used and should not be considered as
an endorsement. Alternative’s to these products
can be used as long they are verified to be of a) a
similar chemical composition, b) will not damage
existing hardware, and c) will serve the same
purpose as the recommended product. Only
genuine TIREBOSS®2 replacement parts can
be used in order to maintain warranty. Failure
to use genuine TIREBOSS®2 replacement parts
can also have adverse effects and create critical
issues within the system. Every effort has been
made to ensure the accuracy of the following
procedure, however TPC International makes
no expressed or implied warranty claims based
on the enclosed information. TPC International
will also not be liable for any incidental or indirect
damages or consequential damages incurred by
following this procedure.
Contact TPC International;
Email: [e-mail]
Phone Number: [phone]
Toll Free:
1 [phone] [North America]
1 (800) 148 694 [Australia]
0 (800) 443 971 [New Zealand]
0 (8000) 155 612 [United Kingdom]

III
Service ManualTire Pressure Control
CAUTION
System must be serviced by
QUALIFIED PERSONNEL ONLY
DO NOT connect or disconnect any
part of this electrical system when
controller is on
Before WELDING on vehicle, battery
cables must be DISCONNECTED or
serious damage to electrical system
may result
AVOID direct high pressure wash
TIREBOSS
®
Important Information
The TIREBOSS 2 system is a Tire Pressure Control System that monitors and
controls tire pressures.
- References to system components contained within this manual are
as follows;
OCU - Operator Control Unit
SCU - System Control Unit
VCU - Valve Control Unit
WEV - Wheel End Valve
- The OCU must remain on at all times while the vehicle is in motion.
- Ensure all manual wheel end valves are opened before moving the vehicle.
- If service work is being performed that requires the removal of wheels &
tires, ensure valve core stems are removed prior to reconnecting the
TIREBOSS system.

Service ManualTire Pressure Control
IV
System Description
INTRODUCTION
The Tireboss 2 system is a second generation of the TIREBOSS® product, that provides the
ability to change tire pressure in one or more groups of tires while the vehicle is in operation.
The primary improvements in Tireboss 2 over the original Tireboss 1 system are:
• The algorithm by which it measures and controls the tire pressure. This is a significant
advancement by effectively learning how the vehicle air supply and tire groups
are configured and optimizing the inflation and deflation control of the tires, while
continually learning and tuning these parameters during normal operation.
• It also offers the ability to autonomously control tire pressures without operator
intervention where that functionality is required.
• The ability to perform updates and upgrades remotely through Wi-Fi is also incorporated
in Tireboss 2.
OVERVIEW
The Tireboss 2 system consists of the Operator Control Unit (OCU), the System Control Unit
(SCU), and one or more Valve Control Units (VCUs)
The OCU provides the operator interface to the system allowing configuration, selection of
operating modes, reporting of alarm conditions, data logging, remote access and system
maintenance functions. It displays system parameters in a convenient, user-friendly
manner. It is basically a specialized touchscreen computer.
The OCU provides GPS information to the system, most importantly for vehicle speed
(which is used to monitor speed limits for various tire pressures and loads, and initiate auto
inflations in the case of over speed conditions for the current selections), as well as location
information and time for logging purposes. It has an RS-485 interface to the System
Controller, as well as a Wi-Fi radio for data transfer and program updates. The OCU receives
switched power from the vehicle.
The SCU is the heart of the system. It coordinates all aspects of system operation, accepting
commands from and reporting to the OCU as well as controlling the other system
components. It measures air pressures from both the vehicle air supply (for safety purposes)
and from the suspension air bags (if the vehicle is so equipped) for load sensing, providing
Standard Autonomous Operation capability. It also serves as a “black box” data recorder for
critical system information and provides the interface to an optional external data logger.
One or more VCUs control pressure in defined group(s) of tires. The VCUs communicate
with the SCU over a daisy-chained Local Interconnect Network (LIN) bus. The system can
currently accommodate up to 4 valves. Each VCU provides pressure control and monitoring,
automatic heater control (to prevent valve icing in cold temperatures) and fault handling for
one group of tires.

V
Service ManualTire Pressure Control
Safety Features
The TIREBOSS 2 Tire Pressure Control system [TPCS] incorporates a number of extremely important
safety features to ensure the integrity of the vehicle, tires and the safety of everyone on the highways.
These include features dealing with the following aspect of operation.
1. VEHICLE OVERSPEED CONDITION
If the vehicle’s speed exceeds the set point for the current selected tire pressure, the OVERSPEED
CONDITION alert screen will be displayed and an audible alarm will sound alerting the operator of a
vehicle OVERSPEED CONDITION. If the vehicle OVERSPEED CONDITION persists for a specified period,
typically 30 seconds (this period is adjustable), the system will automatically increase the selected
pressure setting upward to the next higher tire pressure for the selected load.
2. LOW AIR BRAKE SUPPLY PRESSURE
A pressure protection valve and an electronic safety switch make sure that air is available for tire
inflations only when vehicle system air brake pressure is above a safe level (95 psi). If the air brake
pressure falls below a safe level, the LOW BRAKE AIR PRESSURE alert will be dislayed and the air supply
shut off to the TPCS. The supply of compressed air to the veicle air brake system always has priority over
the TPCS.
3. LOSS OF TIRE PRESSURE
When an unexplained drop in tire pressure takes place in any of the zones, an audible alarm will sound.
The tire pressure status display on the operator control unit will highlight the zone display in which the
loss of tire pressure has occured and it will display the TIRE PRESSURE LOSS alert continuously. The
source of pressure drop must be located prior to continuing operation so that the appropriate action
may be taken, such as isolating the problem tire from the rest of those in the zone, through the use of
manual shutoff valves.
4. AIR FLOW RESTRICTION
The TIREBOSS 2 system is designed to work normally with all wheel end valves open maintaining
constant monitoring & control of tire pressures. If the valves are left in a closed position, the system only
senses line pressures and begins inflating & deflating past the set point pressure. The repetitive action
will cause the AIR FLOW RESTRICTION alert to be activated. This alert will continue until the valves are
re-opened allowing normal operation to resume.
5. TIRE OVER-PRESSURE
The TIREBOSS system automatically assigns upper limits to the programmable set points. The system
will trim the tire pressures for a preset time, after a new selection is made, to hone in on the new
setting. Following the initial “trimming” time, the tire pressures are allowed to increase above the trim
tolerance to allow for normal heat build up. If the tire pressure exceeds a maximum limit, the TIRE
OVER-PRESSURE ALERT will be displayed indicating an overheat condition in the tire which may be
caused from impropoer pressure settings or a failure of other vehicle components, such as the brakes
overheating.
6. LOAD SENSING FEATURE (      )
Vehicles equipped with air suspension on the drive axles can be fitted with a load sensing option. A
load sensing pressure switch indicates to the control system when the vehicle is loaded and will not
allow any of the unloaded settings to be selected. This feature limits the selections to the driver and
ensures only the appropriate tire pressures are being used for the current vehicle load.
In addition to the system safety features outlined above, it should be noted that the TIREBOSS 2
systems use only quality components, such as DOT approved drive axle air hosing. The TPCS computer
continously monitors tire pressure and controls the inflating, deflating, or maintaining of a preselected
target tire pressure. The systems carry operational decaling, which is further explained in the operators
manual carried in each vehicle.

SECTION 1
SYSTEM SCHEMATICS

1-1
Service ManualTire Pressure Control
Control System
[SCU & VCU’s]
*Mounting location will vary*
TPC Wet Tank
*Optional*
OCU
*Located in the truck cabin*
Steer Axle
Drive Axle(s)
Drive Axle
Hose Hanger
Drive Axle
Drop Lines
WEV Plate
Manual Shuttoff
valves
*On the lines between
WEV plate and tire*
Steer Axle Y-Fitting
Steer Axle Main Line
*Optional*
Main Data Cable
*TPC PN: 1000-420*
SCU Power Cale
*TPC PN: 1000-400*
Pressure Protection Valve
*Sometimes Remote Mounted*
Drive Axle Y-Fitting
Drive Axle Main Lines
Truck Overview Schematic
OCU Ignition Cable

Service ManualTire Pressure Control
1-2
* Not required with newer *
TIREBOSS 2 systems
* USE EXTREME CAUTION for correct *
positioning of connectors into SCU
Switched Ignition
Connect Red wire to ignition switched power inside cab.
Connect Black wire to clean, strong ground in cab or on
re wall.
If Master Power Switch
present;
Ensure TIREBOSS 2
system is connected
after pwer switch
(I.e. no power when
switched o󰀨)
Diagnostic Plug
Optional for testing Port B
System Overview Schematic

1-3
Service ManualTire Pressure Control

Service ManualTire Pressure Control
1-4
4
1
6
5
2
7
3
*Optional* Remote Alarm Wiring
Intened to only be used in situations
where a remote alarm is required
*Optional* Remote
Load Sense Switch
Switched Power Source
OCU
SCU
VCU's
BOM ID Description TPC Part Number Qty
1OCU Power Cable - 15' CABLE 1000-120 1
2SCU Power Cable - 30' CABLE 1000-400 1
3Main Communications Cable - 50' CABLE 1000-420 1
4VCU Jumper - 3' CABLE 1000-440 1
5GPS Antenna *Optional* 1528-1170-ND 1
615 Amp Push In Style Fuse ATC-15 1
72 Amp Push In Style Mini Fuse ATM-2 1
This page displays a high level schematic breakdown of the electrical system of
your TIREBOSS 2 equipped truck. a further breakdown of each cable including
appropraite voltage ranges per pin can be found on page 5-1 in the troubleshooting
section of this manual.
General Electrical Schematic

1-5
Service ManualTire Pressure Control
Conventional Pneumatic Schematic
Purge Tank
Air Compressor Feed
Suspension
Sense Line
Main
Tire line
Brake Pressure
Sense Line
Truck
Wet Tank
SCU
VCU
Primary
Wet Tank
Air Dryer
Governor
Unloader Lines
to compressor
VCU
Exhaust
TIREBOSS 2
Supply line
Secondary
Wet Tank

Service ManualTire Pressure Control
1-6
ADIS Dryer Pneumatic Schematic
Suspension
Sense Line
Main Tire
Line
Feed from air
Compressor
Unloader Line
Brake Pressure
Sense Line
TPC
Wet Tank *
SCU
VCU
ADIS Dryer
Primary
Wet Tank
Secondary
Wet Tank
VCU
Exhaust
TIREBOSS 2
Supply line
*In ADIS systems, TPC Wet Tanks are an optional
component with the PPV being remote mounted

1-7
Service ManualTire Pressure Control
Dual Dryer Pneumatic Schematic
Suspension
Sense Line
Unloader Line
To Purge Tank
Feed From Air
Compressor
Brake Pressure
Sense Line
Alcohol Injector
TPC
Wet Tank
SCU
VCU
Governor
Air Dryer Primary
Wet Tank
Secondary
Wet Tank
Main Tire
Line
VCU
Exhaust

SECTION 2
ADJUSTMENTS, SETTINGS, &
MAINTENANCE PROCEDURES

2-1
Service ManualTire Pressure Control
Steer Wheel Hardware, Check;
- Manual wheel valves for condition & operation ...
- Hoses & hardware for condition & operation ..........
- Air flow from each tire to control valve .......................
- Tire pressure loss warning operation ...........................
- Air leaks (Use soapy water on all connections)......
Drive Wheel Hardware, Check;
- Manual wheel valves for condition & operation ...
- Hoses & hardware for condition & operation ..........
- Air flow from each tire to control valve .......................
- Tire pressure loss warning operation ...........................
- Air leaks (Use soapy water on all connections)......
Trailer Hardware, Check;
- Manual wheel valves for condition & operation ...
- Hoses & hardware for condition & operation ..........
- Air flow from each tire to control valve .......................
- Tire pressure loss warning operation ...........................
- Air leaks (Use soapy water on all connections)......
- Clean in line Y-Strainer (if equipped) ............................
Verify Max & Min pressures on wheel end plates
and VCU. Compare to values given by OCU ..................
Main Lines, Fittings & Attachments
Air Supply System
- Check dryers unloading OK (with TPCS off) ............
- Check Wet-Tank Drain Operation ..................................
- Drain Wet-Tank (Comment on moisture) .................
- Drain Secondary Tanks (Comment on moisture)
Comments
Tireboss 2 Service Inspection - Monthly
Customer Name:
TB2 Serial Number:
Work Order #:
Vehicle Mileage:
Inspected by:
Vehicle Make:
Repairs completed by: Date:
Inspected by: Date:
Unit #:Date:

Service ManualTire Pressure Control
2-2
Correct operation of OCU .......................................................................
Low air supply warning at 75 (+/- 5) brake PSI .........................
Adjust PPV to specification (min. 95 PSI with open outlet) .
Check compressor governor (110 PSI Cut in) ..................
Select Lowest Pressure Setting, Check;
- Steer tires deflated ...............................................................................
- Drive tires deflated ...............................................................................
- Trailer tires deflated .............................................................................
Select Highest Pressure Setting, Check;
- Steer tires inflating ...............................................................................
- Drive tires inflating ...............................................................................
- Trailer tires inflating .............................................................................
Low air warning off during inflation ...............................................
System Operations
Main Lines, Fittings & Attachments
Check steer wheel hardware;
- Manual wheel valves condition/ operation ........................
- Hoses and hardware condition ...................................................
- Air flow check valve from each tire to valve .......................
- Tire pressure loss warning operation ......................................
- Auto wheel end valve (locks air in tires when main
line is removed) .......................................................................................
- Air leaks (Use soapy water on all connections)........
Check drive wheel hardware;
- Manual wheel valves condition/ operation ........................
- Hoses and hardware condition ...................................................
- Air flow check valve from each tire to valve .......................
- Tire pressure loss warning operation ......................................
- Auto wheel end valve (locks air in tires when main
line is removed) .......................................................................................
- Air leaks (Use soapy water on all connections)........
Comments
Tireboss 2 Service Inspection - Annual
Date:
Customer Name:
TB2 Serial Number:
Work Order #:
Vehicle Mileage:
Inspected by:
Vehicle Make:
Unit #:

2-3
Service ManualTire Pressure Control
Check trailer wheel hardware;
- Manual wheel valves condition/ operation ..........................
- Hoses and hardware condition ...................................................
- Air flow check valve from each tire to valve ........................
- Tire pressure loss warning operation .......................................
- Air leaks (Use soapy water on all connections) ........
Verify Max & Min pressures on wheel end plates
and VCU's. Compare to values given by the OCU .....
Visual check of compressor discharge lines .............................
Check wet tank drain operation .......................................................
Drain Wet tank (Comment on moisture) ....................................
Drain Secondary tank (Comment on moisture) ....................
Check air dryer(s) & alcohol injector(s);
- Mounting and hoses ...........................................................................
- Service required ......................................................................................
- Change dryer cartridge(s) ...................................................
- Change unloader valve (s) ..................................................
- Change turbo boost valve(s) .............................................
- Change outlet check valve(s) ............................................
- Drain alcohol injector(s) ........................................................
- Refill alcohol injector(s) .........................................................
Air Supply System
Check valves & brackets .................................................................
Check drive hose hangers & brackets .................................
Re-torque manifolds on rear wheels ...................................
Re-torque rotary unions ................................................................
Check valve heater(s) operations ...........................................
Rebuild valves ........................................................................................
Clean in-line Y-strainer (Trailer Only) ...................................
Control System Service
Verify system operation ................................................................
Check over-speed functions ......................................................
Check air brake system & operation ...................................
Steering feel & operation .............................................................
Check for reasonable air build up times ..........................
Road Test
Repairs completed by: Date:
Inspected by: Date:

Service ManualTire Pressure Control
2-4
Before beginning the service;
- Ensure all manual wheel end valves are closed
- With the truck turned off, depress the brake pedal to ensure that
no air is remaining in the wet tank or AD-IS/ AD-HF dryer
Warning;
- Never use thread tape! Use Locktite 5452 pipe sealant on all
external threaded fittings.
Required Parts;
- Locktite 5452 Pipe Thread Sealant
Required Tools;
- 3/16” Hex Key
- 1/2” [13mm] Wrench
- 9/16” [14mm] Wrench
- External Pressure Gauge with 1/4” Fitting [Only for AD-IS &
AD-HF equipped trucks]
CONTAINED WITHIN THIS GUIDE ARE INSTRUCTIONS FOR SETTING THE
FAILSAFE VALUES ON THE PRESSURE PROTECTION VALVE.
FOR TRUCKS EQUIPPED WITH CONVENTIONAL DRYER SYSTEMS,
FOLLOW THE STEPS BEGINNING ON PAGE 2-5
FOR TRUCKS EQUIPPED WITH AD-IS & AD-HF DRYER SYSTEMS,
FOLLOW THE STEPS BEGINNING ON PAGE 2-6
Adjusting the Pressure Protection Valve [PPV]