roll sensor troubleshooting guide

roll sensor troubleshooting guide
ROLL SENSOR TROUBLESHOOTING GUIDE
WARNING
Service the roll sensor(s) only if you are an authorized technician.
The roll sensor triggers airbags and seat restraints. Accidental
deployment could cause serious injury and property damage.
Never remove the roll sensor with cables connected. Removing the
roll sensor may deploy the airbags and seat restraints.
Never connect harness to an unmounted roll sensor.
o
Devices could be activated! The sensor is mounted
to the inside of roof and should NOT be removed except for
replacement.
Cylinders contain explosives and pressurized gas that can be
dangerous if punctured, damaged, cut or drilled into.
The roll sensor must be disconnected when welding on the vehicle.
MAKE sure battery switch is OFF before connecting or disconnecting
roll sensor.
TO PERFORM DIAGNOSTIC TROUBLESHOOTING, the following additional
items may be required:
1. Either of the following diagnostic tools. The troubleshooting procedure will vary
depending on the diagnostic tool used.
a. RollTek Diagnostic software and cable for a laptop computer.
b. SAE J1587 heavy-duty truck cartridge diagnostics with Pro Link reader or lap
top. Other cartridges or software that are capable of picking up automatic MIDs
can also be used. The cartridge must be able to read MID values up to 254.
(DDEC, WTEC, Cummins and other ECU specific cartridges will NOT work.)
2. Digital Voltmeter (DVM)
3. Roll System Wiring Diagram
ROLL SENSOR FAULT LIGHT FUNCTIONALITY:
The indicator lamp normally remains on for approximately 5 seconds after the vehicle
ignition power is applied. During these 5 seconds, internal tests verify system
functionality.
If the cab is raised, the vehicle is moving, and/or experiences heavy vibration during the
5-second initialization period, internal sensor tests may fault. The fault light will
activate, and the system will remain inactive. The power must then be cycled when the
truck is in a stationary level position for the fault to clear.
If roll sensor is unplugged, the connector shorts “Warning Lamp GND” to “Warning
Lamp Out”, thus activating the warning indicator.
The vehicle can be operated while the warning lamp is on.
The roll system may or may not be operational, but this will not affect the vehicle
operations.
ROLL SENSOR FUNCTIONALITY:
Sensor diagnostics continuously monitor internal functions such as the power supply,
accelerometer, angular rate sensor, microprocessor, and memory operation.
The sensor also monitors external connections to power and the active restraints.
Fault conditions are indicated via the Roll System Fault warning lamp and the SAE J1708
diagnostic bus.
Normal operating voltage: 9-16 VDC ignition power. (If available, wired to auxiliary
battery)
Operating Current: 200Ma at 14 VDC
Temperature Range: -40 to +85C
The roll sensor has a minimum power reserve of 1 second in case of loss of power during
a roll.
The electrical connections to the roll sensor are made with a special AMP connector.
The connector is designed for use with pyrotechnic squibs in the activation of
vehicle airbag and similar occupant protection devices.
The connector pins to these squibs short together when the connector becomes
disengaged. This design is to reduce the possibility of accidentally deploying
devices during installation.
The connector has a secondary red locking tab that must be pushed forward to
lock or pulled back to unlock the connector. This tab must have mild pressure
applied to remove the connector from the module.
When connecting, gently tug on connector when seated in place to verify locking
mechanism has been latched, and apply secondary lock.
The indicator light should remain active if the roll sensor is disconnected and the battery
switch is ON.
Always disconnect power before connecting or disconnecting harness to roll sensor.
LARGE SAFETY SYSTEM APPLICATIONS:
If more than eight safety system devices are required in an application, an extra “Slave”
roll sensor may be linked to the “Master” roll sensor. The “master” sensor then signals
the “slave” sensor when a roll event occurs. The sensor communications are thru the
harness via Type II I/O (+/-) communications.
MID 254 identifies master sensor. MID 232 identifies slave sensor. The 9 pin diagnostic
port for these sensors is under the dash.
SQUIB DEVICES:
Outputs to the squib devices are closed loop. The power and ground both must be given
to the pyrotechnic device to activate it.
If a safety device is not used, a terminating resistor is installed at the connector end of the
harness in place of that position. The resistor used is 2.2 ohm, 5%, ¼ watt minimum.
IF THE INDICATOR LAMP REMAINS ILLUMINATED:
If the fault light remains lit, or does not light during vehicle prove out, the vehicle should
be brought to an authorized service facility. In certain cases, turning OFF the ignition and
vehicle power and then turning them back ON may reset the fault light. The roll sensor(s)
record all fault codes, which may be read with a diagnostic reader at an authorized
service facility.
TROUBLESHOOTING PROCEDURE WITH ROLLTEK DIAG:
If a fault occurs, system diagnostics must be performed to determine the source of the
fault. Diagnostics will be performed with a laptop computer using RollTek Diagnostic
software and supplied cables. For troubleshooting using Pro-Link reader, see procedure
at the end of this document.
Park the vehicle in a level, stationary position.
Turn ignition switch off.
To start testing a RollTek system in a vehicle, install the RollTek Diag software on a
laptop or other personal computer that can be located near the vehicle. When installed
and started, the startup screen should appear:
Choose the RollTek system that best matches the vehicle you are troubleshooting, and
press “Select”. You should then see this screen:
The operating screen will then appear:
Apply power with the vehicle ignition switch. The red light on the Gateway will
illuminate and RollTek system will be energized.
Use the Comm Port pull-down menu to chose the correct port. If the program has
established communications with the SAE Gateway, the status window will read
“Ready”. Click on “Read Sensors” to check for faults. As the Master and Slave Sensors
and SAE Gateway respond, the circle indicators will blink green. If these indicators do
not blink, the component is not communicating. Check the wiring and power
connections.
If the status window reads "Check connections" or "Comm timeout", there may be a
problem with the wiring setup. Check that the cables are connected, the correct
communications port is selected, and power is applied to the SAE Gateway and the
RollTek system.
Once the RollTek Diag program has connected to the RollTek system, it is ready to check
sensor faults.
IGNITER CIRCUIT FAULTS
RollTek Diag displays sensor faults in a graphical format. Click “Read Sensors” to check
for faults. Currently active faults light up red, while stored faults are blue. The system
below has an active open circuit fault on the driver door (F1) and a stored short circuit on
the left outside rear facing seat (M1). The master sensor is also illuminating the warning
lamp. Refer to the vehicle’s RollTek wiring diagram to determine the wiring details.
Stored faults may be due to an intermittent wiring issue, so the wiring should be checked
before putting the vehicle into service.
WARNING
Before correcting any faults, deactivate the roll sensor by turning off
the ignition and battery switch. Do NOT perform service to a live
system. Accidental deployment could cause serious injury and
property damage.
Identify the source of the open or short circuit. After the wiring is repaired, the fault
indicator will change from red to blue. Click “Clear Stored Faults”. Warning light will
not deactivate until active and inactive codes are cleared. Verify fault light operation.
Note: The connectors going to the squib devices and roll sensor are shorting when
disconnected. If a terminating resistor is used in place of a seating position, the resistor
used is 2.2 ohm, 5%, ¼ watt minimum.
ADDITIONAL FAULT CODE MESSAGES
Internal faults
This fault could indicate a faulty component in the sensor. An internal fault can also be
created when the cab is tilted for servicing, or if there are excessive vibrations at the
sensor location. If the sensors are mounted firmly and the internal fault indicator remains
on after cycling the power, continue below.
A slave sensor can generate this fault code if the communication is lost between the
Master and Slave. Check the Type II I/O (+/-) wiring circuits between the modules (Pins
A12 and A13). Also check the connections to the Master and Slave. Then try to clear the
fault.
If the fault will not clear, the module must be replaced and returned to the manufacturer.
UNPLUG roll sensor before attempting to remove from vehicle. Moving an activated
roll sensor could deploy safety devices.
Trigger
This indicates that a trigger is stored in program memory. The roll sensor will transmit
the status message following a roll or frontal crash trigger every 15 seconds. Contact
IMMI for assistance. Trigger events cannot be cleared with standard diagnostic tools.
IMMI has proprietary diagnostic software for roll event data extraction. Additional
information is recorded in the sensor. IMMI has proprietary diagnostic software for roll
event data extraction. Please contact IMMI for assistance to reconstruct roll events.
The roll sensor is designed to activate once. If the system is activated or damaged,
trained authorized personnel must replace the unit.
TROUBLESHOOTING PROCEDURE WITH PRO-LINK:
If a fault occurs, system diagnostics must be performed to determine the source of the
fault. Diagnostics will be performed with an SAE J1587 module, such as PRO-LINK.
1. Park the vehicle in a level, stationary position.
2. Turn ignition switch off.
3. Connect diagnostic reader with heavy-duty cartridge to roll sensor diagnostic
port below cab dash. Turn ignition switch “on.” The diagnostic module
should power up, and the “Roll Sensor Fault” dash light should illuminate
brighter. The light will remain on if a fault is present, the roll sensor is
disconnected, or power to the roll sensor power is lost. The light will
deactivate if no faults exist.
4. Set the diagnostic module to automatically scan for all Message Identification
Character (MID)’s. It should find MID 254 (Master) and MID 232 if a slave
controller is used. Check both for active and inactive faults in the Rollover
Protection system. Check, Subsystem Identification (SID), Parameter
Identification Character (PID), and/or Failure Mode Identifier (FMI) faults
with the tables below.
5. Before correcting any faults, deactivate the roll sensor by turning off the
ignition and battery switch. Do NOT perform service to a live system!
6. After troubleshooting is complete, clear all stored faults and cycle ignition
power. Warning light will not deactivate until active and inactive codes are
cleared.
7. If the lamp continues to remain illuminated, contact an authorized service
facility to further diagnose and repair the rollover protection system.
Diagnostic Codes for Igniter Circuits (Master, MID 254 Only)
SID
FMI
Description
1
5
Device 1, F2 Seat Igniter Open Circuit
1
6
Device 1, F2 Seat Igniter Short Circuit
2
5
Device 2, M4 Seat Igniter Open Circuit
2
6
Device 2, M4 Seat Igniter Short Circuit
3
5
Device 3, M4 Wall Igniter Open Circuit
3
6
Device 3, M4 Wall Igniter Short Circuit
4
5
Device 4, F2 Door Igniter Open Circuit
4
6
Device 4, F2 Door Igniter Short Circuit
8
5
Device 5, M1 Seat Igniter Open Circuit
8
6
Device 5, M1 Seat Igniter Short Circuit
SID
FMI
Description
9
5
Device 6, F1 Seat Igniter Open Circuit
9
6
Device 6, F1 Seat Igniter Short Circuit
11
5
Device 7, M1 Wall Igniter Open Circuit
11
6
Device 7, M1 Wall Igniter Short Circuit
12
5
Device 8, F1 Door Igniter Open Circuit
12
6
Device 8, F1 Door Igniter Short Circuit
Identify the source of the open or short circuit, repair, clear codes. Verify fault light
operation.
The connectors going to the squib devices and roll sensor are shorting when
disconnected. If a terminating resistor is used in place of a seating position, the resistor
used is 2.2 ohm, 5%, ¼ watt minimum.
Diagnostic Codes for Igniter Circuits (Master, MID 254 with Slave)
SID
FMI
Description
1
5
Device 1, M1 Seat Igniter Open Circuit
1
6
Device 1, M1 Seat Igniter Short Circuit
2
5
Device 2, F1 Seat Igniter Open Circuit
2
6
Device 2, F1 Seat Igniter Short Circuit
3
5
Device 3, M1 Wall Igniter Open Circuit
3
6
Device 3, M1 Wall Igniter Short Circuit
4
5
Device 4, F1 Door Igniter Open Circuit
4
6
Device 4, F1 Door Igniter Short Circuit
8
5
Device 5, R2 Seat Igniter Open Circuit
8
6
Device 5, R2 Seat Igniter Short Circuit
9
5
Device 6, R1 Seat Igniter Open Circuit
9
6
Device 6, R1 Seat Igniter Short Circuit
11
5
Device 7, R1 Wall Igniter Open Circuit
11
6
Device 7, R1 Wall Igniter Short Circuit
12
5
Device 8, Terminating Resistor Open Circuit
12
6
Device 8, Terminating Resistor Short Circuit
Diagnostic Codes for Igniter Circuits (Slave, MID 232 )
SID
FMI
Description
1
5
Device 1, R3 Seat Igniter Open Circuit
1
6
Device 1, R3 Seat Igniter Short Circuit
2
5
Device 2, R4 Seat Igniter Open Circuit
2
6
Device 2, R4 Seat Igniter Short Circuit
3
5
Device 3, R4 Wall Igniter Open Circuit
3
6
Device 3, R4 Wall Igniter Short Circuit
4
5
Device 4, M4 Wall Igniter Open Circuit
4
6
Device 4, M4 Wall Igniter Short Circuit
8
5
Device 5, M4 Seat Igniter Open Circuit
8
6
Device 5, M4 Seat Igniter Short Circuit
9
5
Device 6, F2 Seat Igniter Open Circuit
9
6
Device 6, F2 Seat Igniter Short Circuit
11
5
Device 7, F2 Door Igniter Open Circuit
11
6
Device 7, F2 Door Igniter Short Circuit
ADDITIONAL FAULT CODE MESSAGES
Internal faults
MID
SID
Description
FMI
Description
254 or 232
Controller #1
12
Bad Device or Component
254
This fault could indicate a faulty component in the sensor. A slave sensor can generate
this fault code if the communication is lost between the Master and Slave. Check the
Type II I/O (+/-) wiring circuits between the modules (Pins A12 and A13). Also check
the connections to the Master and Slave. Then try to clear the fault. If the fault will not
clear, trained authorized personnel must replace the module, then return it to the
manufacturer. Turn battery switch OFF and UNPLUG roll sensor before attempting to
remove from vehicle. Activated roll sensor could deploy safety devices.
Trigger Event Stored
MID
SID
Description
FMI
Description
254 or 232
14
Special Instructions
240
Program
Memory
This indicates that a trigger is stored in program memory. The roll sensor will transmit
the status message following a roll or frontal crash trigger every 15 seconds. If the
diagnostic module is capable, further trigger status information may be read. Contact
IMMI for assistance. Trigger events cannot be cleared with standard diagnostic tools.
IMMI has proprietary diagnostic software for roll event data extraction. The roll sensor
is designed to activate once. If the system is activated or damaged, trained authorized
personnel must replace the unit.
Additional information is recorded in the sensor. IMMI has proprietary diagnostic
software for roll event data extraction. Please contact IMMI for assistance to reconstruct
roll events.
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