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. Devices may
deploy and cause serious injury or property damage.
 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 are required. The troubleshooting procedure will vary slightly depending on the
diagnostic tools used.

1. RollTek® Diagnostic software and cable for a laptop computer. The laptop computer
must have Windows XP or higher operating system with 1G RAM. RP1210A
compliant product with drivers installed into the laptop computer.
2. Digital Voltmeter (DVM) - optional
3. RollTek® System Wiring Diagram - optional

ROLL SENSOR FAULT LAMP FUNCTIONALITY:

The fault 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 and/or the sensor experiences heavy vibration during the 5-second
initialization period, the sensor may fault. The fault lamp 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 fault lamp.

If fault lamp is on, system may NOT be operational and vehicle is operable, but
issues should be diagnosed immediately.

ROLL SENSOR FUNCTIONALITY:

The sensor monitors connections to power and the active restraints.

Fault conditions are indicated via the roll system fault lamp and the SAE J1939
diagnostic bus.

Normal operating voltage: 9-16 VDC ignition power.

Operating Current: 275mA at 14 VDC
Temperature Range: -40°C to +85°C

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 TYCO/AMP
connector.
 The connector is designed for use with pyrotechnic squibs in the activation of
vehicle air bag 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 fault lamp 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.
Source address for master sensor is 83. Source address of slave sensor is 88. The
location of the 9 pin diagnostic port that these sensors are connected to may vary with
manufacturer, please consult your wiring diagram to locate the appropriate diagnostic
port.

PYROTECHNIC DEVICES:
If a pyrotechnic device (pretensioner, S4S, side roll airbag) is not used, a 2.2 ohm (5%, ¼
watt minimum) terminating resistor is installed at the connector end of the harness in
place of that position. These terminating resistors are available through IMMI.

IF THE FAULT LAMP REMAINS ILLUMINATED:

If the fault lamp remains lit, or does not light during vehicle start up, the vehicle should
be serviced by authorized technician. In certain cases, turning OFF the ignition and
vehicle power and then turning them back ON may reset the fault lamp.

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 an RP1210A complaint adaptor. Before attempting troubleshooting
procedures, the adaptor driver must be installed in the laptop computer. The RollTek
Diagnostic software must also be installed in the laptop computer.
Before starting the RollTek Diagnostics software, the following procedure must be
followed:
1. Park the vehicle in a level, stationary position.
2. Turn ignition switch off.
3. Connect adaptor to the J1939 diagnostic port that the sensors are connected to.
4. Connect the other end of the adaptor to the laptop.
5. Turn ignition switch on.
To start troubleshooting using RollTek Diagnostics, start the application by double
clicking the RollTek Diagnostics Icon. The following startup screen appears (Fig 1):

Figure 1: RollTek Diagnostic Software Start Screen

Choose the “Run Diagnostics” radio button, then press “Select”

You should then see this screen:

Figure 2: RollTek Diagnostics Software Choose Adaptor Screen

In Figure 2, all the RP1210A compliant adapters drivers installed in your computer are
displayed inside the adapter list. Select the adaptor that is physically connected between
the sensor and the computer, then press “Continue”

If you receive an error window after this procedure, there is problem with your adaptor.
Please contact your adaptor manufacturer with the error code to resolve the issue before
continuing to the next step.
The operating screen appears as shown in Figure 3. Please note the green manufacturer
name on top left corner (1) and the green ID (2) for each sensor. Record the ID numbers
under each sensor for future use. The Message Window (3) shows the status of
communications between the program and the sensors.

Figure 3: Operating Screen

If you don’t see the ID numbers in area 2 or area 1 is red in color and states “Not
Connected”, the software cannot communicate to the sensors. This can be caused by the
followings:
1. J1939 bus error. Use a J1939 scan tool to evaluate its performance.

2. Connected to wrong J1939 diagnostic port. There can be multiple J1939 bus in
your vehicle. Consult your wiring diagram to confirm that you are connected to
the correct diagnostic port.
3. No power to the sensors. Consult your wiring diagram to make sure there is
power supplied to the sensors and that the fuse is not blown.
 4. Adaptor not connected to the computer. Make sure the Adaptor is connected, not
used by other software, and ready to be used by this software. Usually, you can
monitor its status using Device Manager.

5. Lack of activity on the J1939 bus. Cycling the power may re-establish bus
communications.

Areas 1 and 2 must be green in color and sensor IDs must be recorded before proceeding
to the next step. If you experience problems, call technical support after you have
verified the following:

1. Proper operation of the adaptor

2. No bus errors
3. Correct diagnostic port

Select the radio button that suits your vehicle type. Selecting different Vehicle Type will
cause the pictorial representation of the application to change.

Figure 4: Fire Truck selected Figure 5: Heavy Truck selected

Press the “Read Sensor” button, located at the top left corner, to start communicating
with the sensors.

Figure 6: Read Sensor button

The Warning Lamp under each sensor shows status of the fault lamp. If this status is not
the same as the physical fault lamp in the vehicle, check the wiring to the fault lamp
before proceeding to the next step.
Figure 7: Warning Lamp ON Figure 8: Warning Lamp Off

After retrieving information from the sensor(s), you should see a screen similar to the
following diagram (Fig 9) for a fire truck application.

Figure 9: Fire truck with DTCs screen

Figure 10: Heavy Truck with DTC screen
Description of each area

1. Active DTC: this area shows all the active Diagnostic Trouble Codes (DTC). The
sensor’s DTC are also displayed graphically through the picture to the left. The
sensor broadcasting the fault is also shown in the area, along with the occurrence
count.

2. Stored DTC: this area shows all the DTC’s that were previously active. The
sensor’s stored DTCs are also displayed graphically through the picture to the left.

3. Red box: a red box illustrates an active DTC. The text inside this box represents
its fault state. “Open” means there’s an open in the firing loop circuit at this
location. “Short” means there’s a short between the two leads in the firing loop
circuit at this location.
 4. Blue box: a blue box represents a stored DTC. The text inside this box represents
its previously active fault state.

5. Seat: this is a graphical representation of the location of each potential firing loop.
Note that not all vehicles have all seating locations.

6. Internal Fault: An internal fault can be created when the cab is tilted for
servicing, or if there are excessive vibrations at the sensor location.

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. After ensuring proper connections, clear the fault(s) by pressing the “Clear
Stored Faults” button.

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.

7. Trigger: This indicates that a trigger is stored in program memory. Contact IMMI
for assistance. Trigger events cannot be cleared with standard diagnostic tools.
The roll sensor is designed to activate once. If the system is activated or
damaged, authorized technician must replace the unit.

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. Press “Clear Stored Faults”. Warning light will
not deactivate until active and inactive codes are cleared. Verify that vehicle fault lamp
matches diagnostic warning lamp status
Note: The connectors going to the pyrotechnic devices and roll sensor are shorted when
disconnected. If a digital volt meter is connected to a shorted plug it will not provide an
accurate indication of component status.
ELECTRICAL CONNECTIONS

The electrical connections to the AB10 sensor are application dependent. Refer to
customer drawing for application specific pin assignments. Wiring harness with twisted
pairs (≥ 1 turn/in) must be used for device outputs, communication lines, and power
supply input. Wire should be 20 AWG, stranded.

Use only approved crimped tool and extraction tool when repair of wiring harness is
necessary. Follow the instructions as illustrated below when repairing a contact. The
following table includes part numbers of the connector mating to the AB10 Master
sensor.

Location Manufacturer Tool used

and Part
number
Connector A Tyco 1924685-1 N/A
Housing
Connector B Tyco 1438618-1 N/A
Housing
Contacts for A and Tyco 1393365-1 Crimp tool : 6-1393462-5 Get B
B Extraction tool: 3-1579007-6
Table 1: AB10 Master sensor mating connector and contact information
Below instructions on how to extract pins from its connector housing (Information
provided by Tyco Electronics)
 Figure
Figure 11: AB10 Connector A terminal
12: AB10 Connector B terminal numbers
numbers

Figure 13: AB10 Master Sensor Connector A terminal removal instructions

Figure 14: AB10 Master sensor Connector A terminal insertion instructions
Figure 11: AB10 Master sensor connector B terminal removal instructions
 Figure 16: AB10 Master sensor connector B terminal insertion instructions

The following table includes terminal and contact information for AB10 Slave sensor.

Location Manufacturer Tool used

and Part
number
Connector A Tyco 1326018-1 N/A
Housing
Connector B Tyco 1326018-2 N/A
Housing
Contacts for A and Tyco 1326028-1 Crimp tool: 91338-1
B Extraction tool: 0.8 – 1.0 mm flat blade
screwdriver
TPA removal tool: 1.0 – 1.2 mm flat blade
screwdriver
Table 2: AB10 Slave sensor mating connector and contact information
 Figure 12: Slave sensor wire insertion side terminal number
The following procedure illustrates the proper way to insert and remove terminals from
the above connector housings (information provided by Tyco Electronics).

1. Connector must be unmated and strain relief must be removed. Before removing
contacts from the housing, the TPA lock must be moved back into open position.
See the following diagram to remove TPA lock.
2. Insert a 1.0 – 1.2 mm flat blade screwdriver into the circular hole.
3. Using the edge of the housing shroud as a pivot, rotate the screwdriver toward the
wire bundle. Rotate the screwdriver until the retention latch is above the mating
face of the plug assembly.
Figure 138: AB10 Slave sensor connector TPA removal procedures (from Tyco Electronics)
4. Insert a 0.8 – 1.0 mm flat blade screwdriver into the selected exposed contact
cavity.
5. Hold the wire of the contact to be removed and push the contact forward until it
stops.
6. Using the 0.8 – 1.0 mm flat blade screwdriver, gently deflect the retention finger.
7. Simultaneously pull wire and contact from the plug housing.
 Figure 14: AB10 Slave sensor contact removal procedures (from Tyco Electronics)

CONNECTING OR DISCONNECTING RollTek Module

NEVER remove SRS sensor from mounted location if connected.

Air bag deployment and/or seat belt retraction may result from Failure to follow
this procedure.
BEFORE disconnecting AB10 sensor:
1. Turn battery switch OFF and WAIT 1 minute.
2. Apply anti-static grounding strap from wrist to vehicle grounding surface
3. Disconnect SRS sensor connector(s).
To connect SRS system, follow procedure in reverse order.

Sensor must be firmly installed in vehicle before making electrical connection.

Inadvertent deployment could cause serious injury and property damage.

Fault Code Table

SPN SPN FMI FMI FMI Description Sensor Pin Location Note
(Dec) (Hex) (Dec) (Hex)
4822 12D6 03 03 Short to Vbat Master A-11 Buckle
04 04 Short to Ground A-12 Pretensioner,
05 05 Open Line Front Driver
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4823 12D7 03 03 Short to Vbat Master A-9 Buckle
04 04 Short to Ground A-10 Pretensioner,
SPN SPN FMI FMI FMI Description Sensor Pin Location Note
(Dec) (Hex) (Dec) (Hex)
05 05 Open Line Front Passenger
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4824 12D8 03 03 Short to Vbat Master B-17 F1-SRA/IHC
04 04 Short to Ground B-18
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4826 12DA 03 03 Short to Vbat Master B-9 F2-SRA/IHC
04 04 Short to Ground B-10
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4828 12DC 03 03 Short to Vbat Master B-19 Slave #1 This output is available for Master and
04 04 Short to Ground B-20 Slave configuration. In Master only
05 05 Open Line configurations (Frontal Only, Roll
06 06 Short Line Master Only), this output is not
available.
31 1F Cross Coupling
14 0E Configuration
4834 12E2 03 03 Short to Vbat Slave B-25 M1-Buckle In Master and Slave Configuration.
04 04 Short to Ground B-26 Pretensioner

05 05 Open Line Master B19 In Master Roll Only Configuration

06 06 Short Line B20
31 1F Cross Coupling
14 0E Configuration
4830 12DE 03 03 Short to Vbat Master B-1 M1-SRA/IHC
04 04 Short to Ground B-2
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4831 12DF 03 03 Short to Vbat Master B-11 M4-SRA/IHC
04 04 Short to Ground B-12
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4832 12E0 03 03 Short to Vbat Master A-7 Slave 2 This output is available for Master and
04 04 Short to Ground A-8 Slave configuration. In Master only
05 05 Open Line configurations (Frontal Only, Roll
06 06 Short Line Master Only), this output is not
available.
31 1F Cross Coupling
14 0E Configuration
4835 12E1 03 03 Short to Vbat Slave B-31 M4-Buckle In Master and Slave Configuration.
04 04 Short to Ground B-32 Pretensioner
05 05 Open Line
Master A7 In Master Roll Only Configuration
A8
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4829 12DD 03 03 Short to Vbat Master B-7 R1-SRA/IHC
04 04 Short to Ground B-8
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
SPN SPN FMI FMI FMI Description Sensor Pin Location Note
(Dec) (Hex) (Dec) (Hex)
4833 12E1 03 03 Short to Vbat Master B-15 R4-SRA/IHC
04 04 Short to Ground B-16
05 05 Open Line
06 06 Short Line
31 1F Cross Coupling
14 0E Configuration
4836 12E4 05 05 Open Line Slave B-1 R1 Buckle
06 06 Short Line B-2 Pretensioner
4837 12E5 05 05 Open Line Slave B-3 R2 Buckle
06 06 Short Line B-4 Pretensioner
4838 12E6 05 05 Open Line Slave B-5 R3 Buckle
06 06 Short Line B-6 Pretensioner
4839 12E7 05 05 Open Line Slave B-7 R4 Buckle
06 06 Short Line B-8 Pretensioner
4840 12E8 05 05 Open Line Slave B-27 M2 Buckle
06 06 Short Line B-28 Pretensioner
4841 12E9 05 05 Open Line Slave B-29 M3 Buckle
06 06 Short Line B-30 Pretensioner
624 270 03 03 Short to Vbat Master A-1 Warning Lamp Warning Lamp In, to Slave Pin A11
04 04 Short to Ground output
05 05 Open Line
06 06 Short Line Warning Lamp
Slave A-3 output To Warning Lamp Indicator
31 1F Cross Coupling
14 0E Configuration
61696 F100 03 03 Vbat Too High Master A-24 Power Supply Power Supply and Ground
04 04 Vbat too Low A-2
49267 C073 11 0B CAN Busoff Master A19 CAN-H and
A-20 CAN-L
4973 136D 14 0E Deployment Master
Fault
36590 8EEE 12 0C Internal fault Master
254 FE 12 0C Internal Fault Slave
240 F0 14 0E Program Memory Slave
 Gather info (all info needs to be available before
Purpose:
starting troubleshooting procedures):
1. Gather General Information about the problematic vehicle and personel
Manufacturer Name
2. Help solve routine problems without Engineering assistance
Vehicle manufacture year
Part #
Name and Title
Phone #
Have wiring diagram handy?

RollTek
N Diagnostic
Software
Installed
Park vehicle in a
Turn ignition Off level stationary
position
RP1210A
Tru
Fir

N device driver
ck
e

installed and
hardware
available
Locate diagnostic
SPN Location Location port

4818 F1-Airbag Driver-Airbag

4819 F2-Airbag Pass-Airbag
4822 F1-Belt Driver-Belt
4823 F2-Belt Pass-Belt
Turn Ignition On Press Read
4824 F1-SRA/IHC Driver-SideAir Sensor button
4825 N/A N/A
4826 F2-SRA/IHC Pass-SideAir
4828 M2-Belt SIL1 N
4829 M1-Belt SIL2 Check
Wait… N
4830 M1-SRA/IHC SIL3 Connect adaptor
Green Adaptor
Check Adaptor connection
to Diagnostic port connection several times
4831 M4-SRA/IHC SIL4 Name
already?
4832 M3-Belt SIL5
4833 M4-Belt SIL6
4834 R1-SRA/IHC SIL7
4835 R4-SRA/IHC SIL8 Start RollTek
Diagnostic See Green Text
4836 R1-Belt SIL9 Software above sensor
4837 R2-Belt SIL10 “Connected”

4838 R3-Belt SIL11

4839 R4-Belt SIL12
Table 1: SPN to Location
Choose Manual Provide Serial
Mode, hit Continue numbers

Choose the
Red solid Dot Check wiring to
adaptor you’re
under either N the diagnostic
using, then hit OK
sensor? lamp

Wait…
N Operating Any Red DTC
Error window Any Blue DTC N
Window Under N
appears under message
message
window?
window

Contact Adaptor Choose “Truck” or

Manufacturer “Fire” Copy Red DTC,
under message Press Clear Stored
window Faults

Resolve issue then

restart process Pick 1 Red DTC Press Read
SPN, FMI Sensors Button

Reference Table1 Any Blue

for their location Stored DTC?

N
Forward call to Any Blue Press Read Press Clear Stored N More Red
Engineering Stored DTC? Sensors Button Faults DTC?

N
SPN in Table 1 Problem Solved
N

N The DTC
Problem Solved
disappeared
Identify FMI

Forward call to
Engineering

Press Read FMI = 5 FMI = 6

Sensors Open Short

Turn off
Ignition and
Battery switch
before attempting
Fix problem
any repair

Find location of the

wires identified
above
Check 2.2 ohm
resistor connection

Check connection
to Ignitor
N Firing loop Consult wiring
exists? diagram