Vims 793C

VVIITTAALL IINNFFOORRMMAATTIIOONN MMAANNAAGGEEMMEENNTT SSYYSSTTEEMM

((VVIIMMSS))

Machine Model______________________________ Date ______________________________

Machine Serial No.___________________________ Machine Hours _____________________

Machine Miles ______________________________

VISUAL CHECKS:

Electrical Connections ________________________ Component Damage ________________

MSTAT (67828) - MACHINE STATISTICS

PARAMETER DESIRED ACTUAL

Source Code S:

Configuration Code C:

Hardware H:

Model Number

Serial Number

Equipment Number

Attachment Code (see chart on page 5)

Languages PRI: SEC:

Configuration Type

Operator ID

ATTACH (288224) (see chart on page 5)

1

VVIIMMSS

PAYLOAD

PROGRAM CODE DESIRED ACTUAL

PAYCAL (729225) YES/NO

RAC (722) - Set Haul Road Severity 0 – OFF 1 – high 2 – medium 3 - low

PAYCONF (7292663) Max Payload Weight: Last Pass Indicator: Overload Limit % (105 to 120): Enhanced Scrbrd MSG: - Disabled - Reweigh Only - Count Up - Count Down

Second Gear Reweigh Option:

TOT (868) Load Count: Total Payload: Travel Distance: Travel Time: RESET (73738) YES/NO

LUBSET (582738) - AUTO LUBE SETTINGS

PARAMETER DESIRED ACTUAL

Autolube Cycle Time

Autolube Duration

ESTAT (37828) - EVENT STATISTICS

EVENT

SYSTEM

MACHINE

2

VVIIMMSS

EACK (3225) ACTIVE EVENTS

EVENT HOUR

METER START

LENGTH OF TIME

CATEGORY LEVEL LIMIT WORST

ELIST (35478) INTERMITTENT EVENTS

EVENT HOUR

METER START

LENGTH OF TIME

CATEGORY LEVEL LIMIT WORST

3

VVIIMMSS Use a Multimeter and check the Supply Voltage, Signal Output, and Pull-Up Voltages. Use the test group below to record the actual values of the sensor outputs. All measurements are taken with Key On and Engine OFF.

Sensor Tests

Sensor

Supply Voltage

(A-B)

Actual Temperature/ Pressure/ Fuel Level

(ET or VIMS)

Actual Signal Volts/Hz/Duty Cycle/

Resistance (B-C)

Pull-up Voltage

(B-C)

Ambient Air Temp

Aftercooler Level

Jacket Water Level

System Air Pressure

Auto Lube Pressure

Steering Oil Level

Steering Oil Temp

Steering Pressure (High) N/A N/A

Steering Pressure (Low) N/A N/A

Brake Temperature--LF

Brake Temperature--RF

Brake Temperature--LR

Brake Temperature--RR

Strut Pressure--LF

Strut Pressure--RF

Strut Pressure--LR

Strut Pressure--RR

Alternator "R" Terminal N/A 12.4 to 14.75 DCV

> 95 Hz

N/A

Fuel Level Sensor

4

VIMS ATTACHMENT CODES

785C/789C/793C ATTACHMENT CODES

Attachment Code RAC Enabled TKPH or TMPH Enabled

0 No No

4 Yes No

5 No Yes

6 Yes Yes

Road Analysis Control (RAC) Tonne-Kilometer Per Hour (TKPH) Ton-Mile Per Hour (TMPH)

5

VIMS KEYPAD OPERATIONS

PAYCONF 7292663 Configure Payload Monitor (requires VIMS PC connection) PAYCAL 729225 Calibrate Payload Monitor (requires VIMS PC connection) TOT 868 Show Payload Cycle Resettable Totals RESET 73738 Reset Displayed Payload Data ESET 3738 Customize Events (requires VIMS PC connection) SVCLIT 782548 Turn OFF Service Light SVCSET 782738 Service Light Set (requires VIMS PC connection) TEST 8378 Self-Test Instrumentation MSTAT 67828 Show Machine Statistics (source and config codes) LUBSET 582738 Set Lube Cycle Times LUBMAN 582626 Manual Lube EACK 3225 Show Acknowledged Events (Active) ESTAT 37828 Show Event Statistics ELIST 35478 Show Event List (Intermittent) EREC 3732 Start Event Recorder ERSET 37738 Configure 1 Event Recorder (requires VIMS PC connection) DLOG 3564 Start/Stop Data Logger DLRES 35737 Reset Data Logger LA 52 Change Language UN 86 Change Units ODO 636 Odometer Set/Reset (requires VIMS PC connection) BLT 258 Change Backlight CON 266 Change Display Contrast ATTACH 288224 see chart on page 5 (requires VIMS PC connection) RAC 722 Set Haul Road Severity (0 - OFF, 1 - high, 2 - medium, 3 – low) (requires VIMS PC connection) OK Key--Used to complete keypad entries and to acknowledge events. Acknowledging an event will remove the event from the display temporarily. Severe events cannot be acknowledged. GAUGE key--Displays parameters monitored by VIMS. Depressing the arrow keys will scroll through the parameters. Entering the parameter number and the GAUGE key selects that parameter. F1 Key--Provides additional information on the current event being displayed. For MAINTENANCE (SYSTEM) events, the MID, CID, FMI is displayed. For DATA (MACHINE) events, the current parameter value is displayed (temperature, pressure, rpm).

6

VIMS KEYPAD GAUGE PARAMETERS 100 ENG SPD 105 BOOST PRES 106 LT EXH TEMP 107 RT-LT EXH TEMP 108 RT EXH TEMP 111 F AFTRCLR TEMP 112 R AFTRCLR TEMP 116 COLD MODE 117 ENG DERATE % 118 AIR FLTR IN-H20 121 ENG LOAD % 122 FUEL FLTR 129 ENG FUEL RATE GAL/HR 130 ENG OIL LVL 131 ENG OIL PRES 135 ENG COOL TEMP 140 SYS VOLTAGE 197 ENG FAN SPD #1 198 ENG FAN SPD #2 199 RT-LT FAN SPD 200 ENG FAN TEMP 313 TC OUT TEMP 325 DIFF TEMP 328 DIFF LUBE PRES 350 TRN LUBE TEMP 403 FAN DRIVE FLTR 416 LT PARKBK PRES 417 RT PARKBK PRES 444 STRG OIL TEMP 452 BRK/AIR PRES 460 LT F BRK TEMP 461 LT R BRK TEMP 462 RT F BRK TEMP 463 RT R BRK TEMP 724 BODY ANGLE DEG 790 ATMOS PRES 791 AMB AIR TEMP 799 HOIST STATUS NOTE: Shown are the most commonly used parameters.

7

778855CC--779933CC OOFFFF--HHIIGGHHWWAAYY TTRRUUCCKK EENNGGIINNEE TTEESSTTSS

Machine Model ______________________ Date_________________________________ Machine Serial No. ___________________ Machine Hours ________________________ Engine Serial No._____________________ Engine Hours _________________________ ECM Serial No. _____________________ Throttle Pedal Configuration _____________ Personality Module ___________________ Personality Module Date ________________ Performance Spec (eng plate) ___________ Max Altitude __________________________ Gross Power_________________________ Full Load RPM ________________________ Fuel Ratio Control Offset (-25 to 0) ________________________________________________ Dual Horsepower (2160 hp only) Multi-Torque (2160/2300 hp)

Using the Engine Information Plate and the ET Screens, ECM Summary, Logged Diagnostic Codes and the Configuration Screen, fill in the information requested.

1

EENNGGIINNEE TTEESSTTSS

Create a Test Group on ET: 1) Using ET, choose the Engine ECM 2) In the Status Group, create a new group name "Engine Test" 3) Select the items as shown on the ET screen below:

With the engine NOT running, record the information on the chart provided.

2


Sensor Tests

Sensor Supply Voltage

(A-B)

Desired Signal Volts

or Duty Cycle

Actual Signal Voltage/%

(B-C)

Actual Temperature/

Pressure (ET or VIMS)

Pull-up Voltage

(B-C)

Filtered Engine Oil Pressure

.2 to .6 0

Unfiltered Engine Oil Pressure

.2 to .6 0

Coolant Temperature .4 to 4.6

Aftercooler Temperature

.4 to 4.6

Atmospheric Pressure 2.2 to 4.6

Crankcase Pressure 2.2 to 4.6 0

Right Turbo Inlet Pressure

2.2 to 4.6

Left Turbo Inlet Pressure

2.2 to 4.6

Turbo Outlet Pressure .8 to 1.5

Left Exhaust Temperature

see below

Right Exhaust Temperature

see below

NOTE: Analog supply voltage is 5.0 ± 0.5 Digital supply voltage is 8.0 ± 0.5 Desired signal voltages are at Key ON. Exhaust Temperature Sensor Duty Cycles: below 49°C (120°F) - 10% to 21% 49 to 851°C (120 to 1564°F) - 22% to 88% above 851°C (1564°F) - 88% to 90%

3


T E S T S P E C S A C T U A L

ECM Supply Voltage 24

Throttle Sensor Supply Voltage (A-B) 8.0 ± 0.5

Throttle Sensor Low Idle Duty Cycle (B-C) 16 ± 6%

Throttle Sensor High Idle Duty Cycle (B-C) Early - 48 ± 4% Later - 85 ± 4%

Throttle Sensor Frequency (B-C) 150-1000 Hz

Throttle Sensor Pull-Up Voltage (B-C) 11.5 ± 0.5

Speed Sensor Supply Voltage (A-B) 12.5 ± 1.0

Speed Sensor Frequency (Cranking) (B-C) ≈ 23 - 40 Hz

Speed Sensor Frequency (Low Idle) (B-C) 140 Hz@700 rpm

Speed Sensor Frequency (High Idle) (B-C) 385 Hz@1960 rpm

Speed Sensor Signal Voltage (Key ON) (B-C) less than 3.0

or greater than 10.0

Speed Sensor Signal Voltage (Cranking) (B-C) 2.0 to 4.0

4


ACTIVE DIAGNOSTIC CODES

DIAGNOSTIC CODE DESCRIPTION

LOGGED DIAGNOSTIC CODES

DIAGNOSTIC CODE DESCRIPTION NUMBER

OF OCCURR

FIRST HOUR

METER

LAST HOUR

METER

EVENT CODES

EVENT CODE DESCRIPTION NUMBER

OF OCCURR

FIRST HOUR

METER

LAST HOUR

METER

5


INJECTOR SOLENOID TEST: CYLINDERS OPEN CYLINDERS SHORTED NOTES: OVERRIDE PARAMETERS: ETHER INJECTION: OK NOT OK N/A ENGINE PRELUBE: OK NOT OK N/A OIL RENEWAL: OK NOT OK N/A

WASTEGATE: Override % Volts Current (miliamps)

(793 only) 0%

25%

50%

75%

100% NOTES:

6

EENNGGIINNEE TTEESSTTSS CYLINDER CUTOUT TEST: Injector 1: Duration: Injector 9: Duration: Injector 2: Duration: Injector 10: Duration: Injector 3: Duration: Injector 11: Duration: Injector 4: Duration: Injector 12: Duration: Injector 5: Duration: Injector 13: Duration: Injector 6: Duration: Injector 14: Duration: Injector 7: Duration: Injector 15: Duration: Injector 8: Duration: Injector 16: Duration: Average Injection Duration Cylinders more than 10 TO 15% from Average NOTES: CURRENT TOTALS: FUEL TOTAL TIME ETHER

7


INJECTOR CODES CALIBRATION: Injector 1: Code: Injector 9: Code: Injector 2: Code: Injector 10: Code: Injector 3: Code: Injector 11: Code: Injector 4: Code: Injector 12: Code: Injector 5: Code: Injector 13: Code: Injector 6: Code: Injector 14: Code: Injector 7: Code: Injector 15: Code: Injector 8: Code: Injector 16: Code: NOTE: Default is 1100 NOTES: PRESSURE SENSOR CALIBRATION: OK NOT OK NOTES: TIMING CALIBRATION: OK NOT OK NOTES:

8

778855CC EENNGGIINNEE PPOOWWEERR TTEESSTT Machine Model Date Machine Serial No. Machine Hours Engine Serial No. Engine Hours Performance Spec Rated Power Throttle Pedal Config Fuel Ratio Control Offset Flash File/Date

VISUAL CHECKS Oil Level Oil Filter Examination Create a Test Group on ET: 1) Using ET, choose the Engine ECM 2) In the Status Group, create a new group name "Engine Power Test" 3) Select the items as shown on the ET screen below:

NOTE: 151 flywheel gear teeth for magnetic pickup engine speed

1

778855CC EENNGGIINNEE PPOOWWEERR TTEESSTT Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on the chart provided.


Coolant Temperature (during tests) > 71°C (160°F) Start:

Stop:

Low Idle RPM 700 ± 10

High Idle RPM 1937 ± 10

Air Filter Restriction @ TC Stall (maximum allowed) 25 in. of water

Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 ± 10)

194 ± 30 kPa (28.2 ± 4.3 psi)

Inlet Manifold Pressure (BOOST) @ TC Stall RPM (1642 ± 65 rpm)

206 ± 30 kPa (29.8 ± 4.3 psi)

Torque Converter Stall RPM 1642 ± 65

Torque Converter Temperature (during stall test) > 80°C (175°F) < 121°C (250°F)

Engine Oil Pressure @ LI 200 to 600 kPa (29 to 87 psi)

Engine Oil Pressure @ HI 345 to 600 kPa (50 to 87 psi)

Engine Oil Filter Differential Pressure @ HI maximum 70 kPa (10 psi)

Fuel Pressure @ Torque Converter Stall 338 to 682 kPa (49 to 99 psi)

Fuel Filter Status [maximum restriction 140 kPa (20 psi)] OK

Coolant Conditioner Concentration (% or PPM) 3 - 6 % or 1200 ppm

Coolant Minimum Temperature Protection

*1 Radiator Top Tank Temperature @ TC Stall

*2 Water Pump Outlet Temperature @ TC Stall *1 Should be less than 110°F over ambient *2 Should be 8° to 20°F less than Top Tank Temp/thermostat open (> 88°C/190°F)

2

778899CC EENNGGIINNEE PPOOWWEERR TTEESSTT Machine Model Date Machine Serial No. Machine Hours Engine Serial No. Engine Hours Performance Spec Rated Power Throttle Pedal Config Fuel Ratio Control Offset Flash File/Date



1

778899CC EENNGGIINNEE PPOOWWEERR TTEESSTT Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on the chart provided.



Stop:




Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 ± 10)

198 ± 30 kPa (28.8 ± 4.3 psi)

Inlet Manifold Pressure (BOOST) @ TC Stall RPM (1718 ± 65 rpm)

194 ± 30 kPa (28.2 ± 4.3 psi)







Fuel Filter Status [maximum restriction 140 kPa (20 psi)] OK

Coolant Conditioner Concentration (% or PPM) 3 - 6 % or 1200 ppm

Coolant Minimum Temperature Protection

*1 Radiator Top Tank Temperature @ TC Stall

*2 Water Pump Outlet Temperature @ TC Stall *1 Should be less than 110°F over ambient *2 Should be 8° to 20°F less than Top Tank Temp/thermostat open (> 88°C/190°F)

2

793C ENGINE POWER TEST Machine Model Date Machine Serial No. Machine Hours Engine Serial No. Engine Hours Performance Spec Rated Power Throttle Pedal Config Fuel Ratio Control Offset Flash File/Date Horsepower Configuration (Rating Selection): Dual Horsepower (2160 hp only) Multi-Torque (2160/2300 hp)



1

793C (4AR, 4GZ, ATY) ENGINE POWER TEST (7TR with Wastegate)

Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on the chart provided.



Stop:




Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 ± 10) – DIRECT DRIVE

207 ± 31 kPa (30.1 ± 4.5 psi)

Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 ± 10) – CONV DRIVE

181 ± 27 kPa (26.3 ± 4 psi)

*







Fuel Filter Status [max restriction 140 kPa (20 psi)] OK

Wastegate %

< 60 %

LI -

HI -

Stall - * Use Torque Stall for Class

2

793C (4AR, 4GZ, ATY) ENGINE POWER TEST (8WM HD - No Wastegate)




Stop:





188 ± 28 kPa (27.2 ± 4.1 psi)


171 ± 26 kPa (24.8 ± 3.7 psi)

*







Fuel Filter Status [maximum restriction 140 kPa (20 psi)]

OK

* Use Torque Stall for Class

3

793C (CBR) ENGINE POWER TEST (SOUND TRUCK)




Stop:





189 ± 28 kPa (27.4 ± 4 psi)


184 ± 28 kPa (26.7 ± 4 psi)

*







Fuel Filter Status [maximum restriction 140 kPa (20 psi)]

OK

* Use Torque Stall for Class NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP. Converter Stall must be ran in FIRST FORWARD with the Body DOWN.

4

793C HYDRAULIC FAN TEST Machine Model Date Machine Serial No. Machine Hours Brake ECM Flash File/Date Create a Test Group on ET: 1) On the ET screen, choose the Brake ECM 2) In the Status Group, create a new group named "793C Fan Test" 3) Select the items as shown on the ET screen below from the Brake ECM, the Engine ECM

and the VIMS ECM:

NOTE: The Air Conditioner must be OFF during all tests except the A/C Test. Use the VIMS Data Logger to capture additional information during the fan tests. NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of the pump and motors before starting the engine.

1

779933CC HHYYDDRRAAUULLIICC FFAANN TTEESSTT With COLD temperatures and LOW IDLE, the fan drive pump should be turned OFF. Fan speed will be approximately 100 rpm. Using the "Fan Speed Override" function of ET, perform the following Fan Test: TEST 1: HYDRAULIC FAN OVERRIDE Tools 1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView 2) Laptop with ET During the test, fan speed will be overridden to 200, 300, 400, 500, 625, 700 rpm and the solenoid disconnected. Fan Speed Override Procedure: 1) On the ET screen toolbar, click on Diagnostics – Override Parameters 2) Select "Desired Engine Cooling Fan Speed Override" and change the value to the

required rpm (see ET screens below) 3) Using DataView, VIMS or ET, observe the Fan Speeds

2

779933CC HHYYDDRRAAUULLIICC FFAANN TTEESSTT

Run the engine at LOW IDLE and HIGH IDLE. Using DataView, VIMS or the ET "793C Fan Test" group and a pressure gauge, record the data into the chart. NOTE: When accelerating from LOW IDLE to HIGH IDLE, the fan drive pressure will spike to start the fan rotation. The spike pressure may be the pump High Pressure Cut-off setting of 27000 ± 345 kPa (3920 ± 50 psi) at sea level. The high pressure cut-off valve setting must be set lower at higher altitudes. If the fan drive pump solenoid is disconnected and the engine is run at high idle, the fan would overspeed if the high pressure cut-off valve setting is too high.

3

TEST TEMPERATURES

Jacket Water Coolant

After Cooler Coolant

Brake Oil Fan Drive Oil

HYDRAULIC FAN OVERRIDE

Engine Speed

Fan Override Speed

Left Fan Speed

Right Fan Speed

Desired Pump

Pressure

Actual Pump Pressure

200 rpm

300 rpm

400 rpm

500 rpm

625 rpm

700 rpm

Low Idle

Neutral

DISCONNECT SOLENOID

HYDRAULIC FAN OVERRIDE

Engine Speed

Fan Override Speed

Left Fan Speed

Right Fan Speed

Desired Pump

Pressure

Actual Pump Pressure

200 rpm

300 rpm

400 rpm

500 rpm

625 rpm

700 rpm

High Idle

Neutral

DISCONNECT SOLENOID

4

TEST 2: HYDRAULIC FAN HIGH PRESSURE CUT-OFF Tools 1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView 2) Fan Pump Port Cover Plate (5P0048) 3) Cover Plate Seal (1P3704) High Pressure Cut-Off Test Procedure: To determine the high pressure cut-off setting at the current altitude, use ET to override the hydraulic fan speed to 625 rpm, raise the engine speed to HIGH IDLE and record the pump pressure and fan speeds. We now know what pressure is required to rotate the fans at 625 rpm at the current altitude. For example, at our current altitude it required approximately 16675 kPa (2420 psi) to rotate the fans at 625 rpm. Pump cut-off pressure should be set a minimum of 2070 kPa (300 psi) above the pressure required to maintain maximum fan speed (625 rpm) with the solenoid unplugged. This will vary with the elevation above sea level. So, at this altitude we should set the pump cut-off pressure to a minimum of 18740 kPa (2720 psi). 1) Install the 5P0048 cover plate at the pump discharge port. 2) Operate the truck at LOW IDLE. The pump should be at the cut-off pressure. 3) At sea level, adjust the cut-off pressure to 27000 ± 345 kPa (3920 ± 50 psi). At higher

altitudes a lower cut-off pressure may be desired.

HYDRAULIC FAN HIGH PRESSURE CUT-OFF

Engine Speed @

LOW IDLE PUMP PRESSURE

TEST TEMPERATURES

Jacket Water Coolant

After Cooler Coolant

Brake Oil Fan Drive Oil

NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of the pump and motors before starting the engine.

5

TEST 3: HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY Tools 1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView 2) Laptop with ET 3) Fan Motor Port Cover Plate (5P0048) x 2 4) Cover Plate Seal (1P3704) x 2 optional 1) Bolt (8T4910) x 8 -- M12 x 1.75 x 60mm 2) Washer (8T4223) x 8 3) Cover (7I7133) x 2 Pump and Motor Efficiency Test Procedure: 1) Install two 5P0048 port cover plates in the Left Fan Motor supply and return ports to

completely block the Left Fan Motor (or at the manifold block between the two fan motors). Blocking the flow of oil to one of the motors will isolate all of the pump flow to one motor.

2) Unplug the pump solenoid and operate the truck at LOW IDLE. 3) Remove the cover plates from the Left Fan Motor and install them in the Right Fan Motor.

Repeat the above low idle check. If the pump and motor both have acceptable volumetric efficiencies, the fan speed should be a minimum of 510 rpm. If both fan speeds are about the same, but the fan speeds are too low, then the pump may have a problem supplying the required flow. If only one fan speed is too low, then the slow fan motor may be failing.

HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY

Pump Pressure LEFT Motor

Fan Speed (Minimum 510 rpm)

Right Motor Blocked

Engine Speed @

LOW IDLE

HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY

Pump Pressure RIGHT Motor

Fan Speed (Minimum 510 rpm)

Left Motor Blocked

Engine Speed @

LOW IDLE

6

779933CC HHYYDDRRAAUULLIICC FFAANN TTEESSTT TEST 4: AIR CONDITIONING TEST Air Conditioning Test Procedure: 1) Turn the Air Conditioner Switch ON. When the Compressor turns ON, the Fan Speed is set

to Maximum. Record the Fan Speed at Low and High Idle.

AIR CONDITIONING TEST

Engine Speed Compressor OFFFan Speed

Compressor ON Fan Speed

Left Right Left Right

LOW IDLE:

HIGH IDLE:

FAN SPEED VERSUS PUMP SOLENOID CURRENT

00

100200300400500600700800

100 200 300 400 500 600 700 800

PUMP SOLENOID CURRENT (mA)

LOW IDLE FAN SPEED HIGH IDLE FAN SPEED

FAN

SPE

ED (R

PM)

7

779933CC HHYYDDRRAAUULLIICC FFAANN TTEESSTT

ENGINE FAN CONTROL °C (°F)

JACKET WATER TEMPERATURE

AFTERCOOLER TEMPERATURE

BRAKE TEMPERATURE

FAN CONTROL

< 88 (190) < 78 (172) < 102 (215) BASE TEMP OFF

> 88 (190)< 98 (208)

> 98 (208)

> 78 (172) < 88 (190)

> 88 (190)

> 102 (215)< 107 (225)

> 107 (225)

MODULATE TO TEMP CHART

MAXIMUM

DESIRED ENGINE FAN SPEEDS

COOLANT TEMPERATURE

ABOVE BASE TEMP

ENGINE RPM

700 1200 1750 1950

1°C (1.8°F)

2°C (3.6°F)

3°C (5.4°F)

4°C (7.2°F)

5°C (9°F)

0

0

0

0

0

0

0 0

150 150

150

6°C (10.8°F)

7°C (12.6°F)

8°C (14.4°F)

9°C (16.2°F)

10°C (18°F)

BRAKE TEMPERATURE

ABOVE BASE TEMP

.5°C (1°F)

1°C (2°F)

1.5°C (3°F)

2°C (4°F)

2.5°C (5°F)

3°C (6°F)

3.5°C (7°F)

4°C (8°F)

4.5°C (9°F)

5°C (10°F)

186 208

171 249 277

1920 280 312

150 235 342 381

162 277 405 451

186 320 466 520

208 363 529 589

224 384 560 624

8

778855CC//778899CC//779933CC TTOORRQQUUEE CCOONNVVEERRTTEERR TTEESSTT

Machine Model Date Machine Serial No. Machine Hours Converter Serial No. Converter Hours Transmission/Chassis ECM Flash File/Date

VISUAL CHECKS

Oil Level Oil Filter Examination Create a Test Group on ET: 1) Using ET, choose the Transmission ECM 2) In the Status Group, create a new group name "Torque Converter Test" 3) Select the items as shown on the ET screen below:

1

778855CC//778899CC TTOORRQQUUEE CCOONNVVEERRTTEERR TTEESSTT

T E S T SPECS A C T U A L

Torque Converter Oil Temperature (during tests) > 80°C (175°F) < 121°C (250°F)

Torque Converter Inlet Pressure Maximum at High Idle

with Cold Oil

930 ± 35 kPa (135 ± 5 psi)

LI -

HI –

STALL-

Torque Converter Outlet Pressure @ STALL rpm 345 to 550 kPa (50 to 80 psi)

LI -

HI –

STALL-

Torque Converter Stall RPM 785C--1642 ± 65 rpm 789C--1718 ± 65 rpm

Parking Brake Release Pressure 4700 ± 200 kPa (680 ± 30 psi)

LI-

HI-

Lockup Clutch Pilot Pressure (RV) NEUTRAL/DIRECT DRIVE/LOW IDLE

1725 ± 70 kPa (250 ± 10 psi)

Lockup Clutch Signal Pressure (from Lockup Solenoid)NEUTRAL/DIRECT DRIVE/1300 rpm

1445 to 2240 kPa (210 to 325 psi)

Lockup Clutch Primary Pressure NEUTRAL/DIRECT DRIVE/LOW IDLE

1030 ± 35 kPa (150 ± 5 psi)

Lockup Clutch Maximum Pressure NEUTRAL/DIRECT DRIVE/1300 rpm

2135 ± 70 kPa (310 ± 10 psi)

2

779933CC TTOORRQQUUEE CCOONNVVEERRTTEERR TTEESSTT

T E S T SPECS A C T U A L

Torque Converter Oil Temperature (during tests) > 80°C (175°F) < 121°C (250°F)

Torque Converter Inlet Pressure Maximum at High Idle

with Cold Oil

930 ± 35 kPa (135 ± 5 psi)

LI -

HI –

STALL-

Torque Converter Outlet Pressure @ STALL rpm 345 to 550 kPa (50 to 80 psi)

LI -

HI –

STALL-

Torque Converter Stall RPM 4AR, 4GZ, ATY – 1672 ± 65 rpm CBR – 1640 ± 65 rpm

Transmission Charge Pressure (Converter Drive)

LI: > 2515 kPa (365 psi) HI: < 3065 kPa (445 psi)

LI -

HI –

Transmission Charge Pressure (Direct Drive) 2310 ± 70 kPa (335 ± 10 psi) @ 1300 rpm

Lockup Clutch Pilot Pressure (RV) NEUTRAL/DIRECT DRIVE/LOW IDLE

1725 ± 70 kPa (250 ± 10 psi)

Lockup Clutch Signal Pressure (from Lockup Solenoid)NEUTRAL/DIRECT DRIVE/1300 rpm

1445 to 2240 kPa (210 to 325 psi)

Lockup Clutch Primary Pressure NEUTRAL/DIRECT DRIVE/LOW IDLE

1030 ± 35 kPa (150 ± 5 psi)

Lockup Clutch Maximum Pressure NEUTRAL/DIRECT DRIVE/1300 rpm

2150 to 2350 kPa (310 to 340 psi)

NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP. Converter Stall must be ran in FIRST FORWARD with the Body DOWN.

3

778855CC//778899CC TTRRAANNSSMMIISSSSIIOONN TTEESSTT

Machine Model ____________________________ Date _______________________________

Machine Serial No. _________________________ Machine Hours_______________________

Transmission S/N___________________________ Transmission Hours ___________________

Transmission/Chassis Flash File/Release Date

CONVERTER DRIVE PRESSURES

LOCKUP SOLENOID DE-ENERGIZED

SPECS ACTUAL LI HI LI HI

PUMP PRESSURE 2515 kPa (365 psi) (minimum)

3175 kPa (460 psi) (maximum)

LUBE PRESSURE

4 kPa (.6 psi) (minimum)

140 to 205 kPa 20 to 30 psi)

PILOT PRESSURE

1755 ± 35 kPa (255 ± 5 psi)

xxx xxx

Transmission Oil Temperature (during tests) > 82°C (180°F) < 121°C (250°F)

DIRECT DRIVE PRESSURES

LOCKUP SOLENOID ENERGIZED (plug signal line to lockup clutch valve)

SPECS ACTUAL LI 1300 RPM LI 1300 RPM

PUMP PRESSURE xxx 2100 ± 100 kPa (305 ± 15 psi)

xxx

STATION "D"

PRESSURE

xxx Adjust station "D" to get correct pump and

clutch pressures

xxx

NEUTRAL CLUTCH PRESSURE STATION "C"

xxx 2020 + 240 - 100 kPa(293 + 35 - 15 psi)

xxx

1

778855CC//778899CC TTRRAANNSSMMIISSSSIIOONN CCLLUUTTCCHH TTEESSTTSS

CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I.

Load Piston Plug Removed

SPEED CLUTCHES ENGAGED

STATION CLUTCH SPECS ACTUAL

N 3 A 2 525 KPA (76 psi)

R 1 and 6 B 1 475 KPA (69 psi)

1 1 and 5 C 3 480 KPA (70 psi)

2 2 and 5 D DUAL RELIEF xxx xxx

3 1 and 4 E 4 425 KPA (62 psi)

4 2 and 4 F 5 450 KPA (65 psi)

5 1 and 3 G 6 425 KPA (62 psi)

6 2 and 3 H xxx xxx xxx

Primary Clutch Pressure Tolerance: +50 -35 kPa (+7 -5 psi)

MAXIMUM CLUTCH PRESSURE Load Piston Plug Installed

SPECS ACTUAL

STATION CLUTCH LI HI LockUp @ 1300 RPM LI HI LockUp @

1300 RPM

A 2 xxx xxx 2020 kPa (293 psi) xxx xxx

B 1 2760 kPa (400 psi)

2890 kPa (419 psi)

2020 kPa (293 psi)

C 3 2470 kPa (358 psi)

2470 kPa (358 psi)

2020 kPa (293 psi)

D DUAL RELIEF

Adjust station "D" to get correct clutch pressures during lockup xxx xxx

E 4 xxx xxx 2020 kPa (293 psi) xxx xxx

F 5 2705 kPa (392 psi)

2705 kPa (392 psi)

2020 kPa (293 psi)

G 6 2760 kPa (400 psi)

2805 kPa (407 psi)

2020 kPa (293 psi)

H xxx xxx xxx xxx xxx xxx xxx

Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi) "D" station pressure will be approximately 1380 kPa (200 psi)

2

779933CC TTRRAANNSSMMIISSSSIIOONN TTEESSTT

Machine Model ____________________________ Date _______________________________

Machine Serial No.__________________________ Machine Hours _______________________

Transmission S/N___________________________ Transmission Hours ___________________

Transmission/Chassis Flash File/Release Date

CONVERTER DRIVE PRESSURES

LOCKUP SOLENOID DE-ENERGIZED

SPECS ACTUAL LI HI LI HI

PUMP PRESSURE (Adjust with Transmission Relief Valve)

2515 kPa (365 psi) (minimum)

3065 kPa (445 psi) (maximum)

LUBE PRESSURE

5 to 65 kPa (.5 to 10 psi)

160 ± 50 kPa 23 ± 7 psi)

PILOT PRESSURE (Result of setting Direct Drive Pump Pressure)

2410 to 2755 kPa (350 to 400 psi) xxx xxx

Transmission Oil Temperature (during tests) > 82°C (180°F) < 121°C (250°F)

DIRECT DRIVE

PRESSURES

LOCKUP SOLENOID ENERGIZED (plug signal line to lockup clutch valve)

SPECS ACTUAL LI 1300 RPM LI 1300 RPM

PUMP PRESSURE (Adjust with Priority Reducing Valve)

xxx 2310 ± 70 kPa (335 ± 10 psi)

xxx

STATION "D"

PRESSURE

xxx Adjust station "D" to get correct rail

(clutch) pressures

xxx

NEUTRAL CLUTCH PRESSURE STATION "C"

xxx 1620 ± 70 kPa (235 ± 10 psi)

xxx

1

779933CC TTRRAANNSSMMIISSSSIIOONN CCLLUUTTCCHH TTEESSTTSS

CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I. Load Piston Plug Removed

SPEED CLUTCHES ENGAGED

STATION CLUTCH SPECS ACTUAL

N 3 A 2 525 KPA (76 psi)

R 1 and 6 B 1 475 KPA (69 psi)

1 1 and 5 C 3 480 KPA (70 psi)

2 2 and 5 D DUAL RELIEF xxx xxx

3 1 and 4 E 4 425 KPA (62 psi)

4 2 and 4 F 5 450 KPA (65 psi)

5 1 and 3 G 6 425 KPA (62 psi)

6 2 and 3 H xxx xxx xxx

Primary Clutch Pressure Tolerance: +50 -35 kPa (+7 -5 psi)

MAXIMUM CLUTCH PRESSURE

Load Piston Plug Installed SPECS ACTUAL

STATION CLUTCH LI HI LockUp @ 1300 RPM LI HI LockUp @

1300 RPM

A 2 xxx xxx 1620 kPa (235 psi) xxx xxx

B 1 2400 kPa (348 psi)

2425 kPa (352 psi)

1620 kPa (235 psi)

C 3 2470 kPa (358 psi)

2470 kPa (358 psi)

1620 kPa (235 psi)

D DUAL RELIEF

Adjust station "D" to get correct clutch pressures during lockup xxx xxx

E 4 xxx xxx 1620 kPa (235 psi) xxx xxx

F 5 2585 kPa (375 psi)

2720 kPa (395 psi)

1620 kPa (235 psi)

G 6 2585 kPa (375 psi)

2805 kPa (407 psi)

1620 kPa (235 psi)

H xxx xxx xxx xxx xxx xxx xxx

Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi)

NOTE: During LockUp test, plug lockup signal hose to lockup valve

"D" station pressure will be approximately 965 kPa (140 psi)

2

TTRRAANNSSMMIISSSSIIOONN//CCHHAASSSSIISS EECCMM

Machine Model ___________________________ Date _________________________________

Machine Serial No. ________________________ Machine Hours_________________________

Transmission Serial No. ____________________ Transmission Hours _____________________

Flash File________________________________ Flash File Release Date __________________

ECM Location Code ______________________ ECM Serial No. ________________________

VISUAL CHECKS:

Electrical Connections Component Damage ____________________

SETUP or COUNT DESIRED ACTUAL

Body Up Gear Limit Setting

Transmission Maximum Gear Setting

Lockup Clutch Count N/A

Resettable Load Count N/A

Permanent Load Count N/A

ACTIVE DIAGNOSTIC CODES

Diagnostic Code Description Cause

1

TTRRAANNSSMMIISSSSIIOONN//CCHHAASSSSIISS EECCMM


Diagnostic Code and

Description

Number of

Occurrences

First Occurrence

Last Occurrence

LOGGED EVENTS

Event Code and

Description

Number of

Occurrences

First Occurrence

Last Occurrence

2

778855CC OOFFFF--HHIIGGHHWWAAYY TTRRUUCCKK SSTTEEEERRIINNGG TTEESSTT

Machine Model_______________________ Date ______________________________

Machine Serial No.____________________ Machine Hours _____________________

VISUAL CHECKS:

Oil level Oil Viscosity _______________________

Air/Water in Oil? Oil Filter Examination _______________

TEST SPECS ACTUAL

Steering Oil Temperature (during tests) > 60°C (150°F) < 121°C (250°F)

Cycle Time @ High Idle From Left to Right and Right to Left Combined All Brakes Released

7.0 to 9.0 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

Steering wheel turns from stop to stop @ High Idle All Brakes Released (steer at one revolution per second)

3.0 to 4.0 turns

Left to Right

1. ____________________

2. ____________________

3. ____________________

AVG.

Right to Left

1. ____________________

2. ____________________

3. ____________________

AVG.

Pump Compensator Valve Pressure 17580 ± 345 kPa (2550 ± 50 psi)

Backup Relief Valve Pressure @ Low Idle 20670 ± 400 kPa (3000 ± 60 psi)

Crossover Relief Valve Pressure (Right Turn) 18270 ± 345 kPa (2650 ± 50 psi)

Crossover Relief Valve Pressure (Left Turn) 18270 ± 345 kPa (2650 ± 50 psi)

RH Accumulator Nitrogen Charge Pressure @ 21°C (70°F)

8270 ± 0 kPa (1200 ± 0 psi)

LH Accumulator Nitrogen Charge Pressure @ 21°C (70°F)

8270 ± 0 kPa (1200 ± 0 psi)

1

778855CC OOFFFF--HHIIGGHHWWAAYY TTRRUUCCKK SSTTEEEERRIINNGG TTEESSTT

Pump Compensator Valve Pressure Test: Put a 34450 kPa (5000 psi) gauge on the pressure tap at the bottom of the left steering accumulator In order to use the 785C pump controller as a pressure compensator, the low-pressure standby adjustment screw (screw furthest from pump body) must be turned all the way in. This will block the margin spool from moving and allow the high-pressure cutoff spool to control the pump outlet pressure. Pump low-pressure standby is not used on the 785C Trucks. Start the engine and leave it at Low Idle. As the accumulators fill, the pressure of the oil through the pump outlet increases. The pump supply pressure will increase until the pressure of the oil in the pump compensator valve is high enough to overcome the spring force on the compensator (high pressure cutoff) spool. The spool then moves and opens the passage to the minimum angle actuator piston. This movement occurs when the outlet oil pressure is approximately 17580 ± 345 kPa (2550 ± 50 psi). The pressure setting can be adjusted with the high-pressure cutoff adjustment screw (screw closest to pump body). Backup Relief Valve Pressure Test: The back-up relief valve must be adjusted only on a test bench. The pressure setting of the back-up relief valve can be changed by adjusting the spring force that keeps the relief valve seated (closed). To change the relief valve setting, remove the protective cap and turn the adjustment screw clockwise to increase or counterclockwise to decrease the pressure setting. One revolution of the setscrew will change the pressure setting 3800 kPa (550 psi). A functional test of the back-up relief valve can be performed on the machine by installing a manual hydraulic pump at the location of the Auxiliary Power Unit (APU) connector and installing blocker plates to prevent oil from flowing to the accumulators. See the service manual for more detailed information. Crossover Relief Valve Pressure Test: Put two 34450 kPa (5000 psi) gauges on the pressure taps on the crossover relief valve housing on the left frame rail in the engine compartment. The crossover relief valve housing contains two pressure taps where steering system pressure can be measured. One tap shows pressure during a left turn and the other tap shows pressure during a right turn. To check the steering system pressure, turn the steering wheel completely in either direction. Operate the engine at LOW IDLE. Continue to turn the steering wheel after the wheels have stopped and the pressure will increase to the pump compensator valve setting. Check the steering pressure while turning in both directions. The pump compensator valve setting should be observed on the gauge in both directions. If the pressure readings are different, one of the crossover relief valve settings is probably incorrect. A misadjusted valve must be removed and readjusted on a test bench.

2

778899CC//779933CC OOFFFF--HHIIGGHHWWAAYY TTRRUUCCKK SSTTEEEERRIINNGG TTEESSTT

Machine Model_______________________ Date ______________________________


VISUAL CHECKS:

Oil level Oil Viscosity _______________________

Air/Water in Oil? Oil Filter Examination _______________

TEST SPECS ACTUAL

Steering Oil Temperature (during tests) > 60°C (150°F) < 121°C (250°F)

Cycle Time @ High Idle From Left to Right and Right to Left Combined All Brakes Released

7.0 to 9.0 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

Steering wheel turns from stop to stop @ High IdleAll Brakes Released (steer at one revolution per second) 789C: 3.0 to 4.0 turns 793C: 4.0 to 5.0 turns

Left to Right

1. ____________________

2. ____________________

3. ____________________

AVG.

Right to Left

1. ____________________

2. ____________________

3. ____________________

AVG.

Accumulator Charge Valve Pressure @ Low Idle Cut-out 789C: 18300 ± 345 kPa (2655 ± 50 psi) 793C: 21400 ± 345 kPa (3100 ± 50 psi)

Accumulator Charge Valve Pressure @ Low Idle Cut-in 789C: 16470 ± 345 kPa (2390 ± 50 psi) 793C: 19200 ± 315 kPa (2785 ± 45 psi)

Cycle time from Cut-out to Cut-in

greater than 15 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

1

778899CC//779933CC SSTTEEEERRIINNGG TTEESSTT

TEST SPECS ACTUAL

Pump Low Pressure Standby Pressure @ Low Idle 2067 to 3617 kPa (300 to 525 psi)

Pump High Pressure Cut-off @ Low Idle 789C: 20000 ± 345 kPa (2900 ± 50 psi) 793C: 23100 ± 345 kPa (3350 ± 50 psi)

Backup Relief Valve Pressure @ Low Idle 789C: 22740 ± 345 kPa (3300 ± 50 psi) 793C: 26000 ± 400 kPa (3775 ± 60 psi)

Relief/Makeup Valve Pressure (Right Turn) 789C: 28000 ± 1000 kPa (4065 ± 150 psi) 793C: 27000 to 29000 kPa (3920 to 4210 psi)

Relief/Makeup Valve Pressure (Left Turn) 789C: 28000 ± 1000 kPa (4065 ± 150 psi) 793C: 27000 to 29000 kPa (3920 to 4210 psi)

1. Accumulator Nitrogen Charge Pressure @ 21°C (70°F) 789C: 5512 ± 345 kPa (800 ± 50 psi) 793C: 6545 ± 345 kPa (950 ± 50 psi)

2. Accumulator Nitrogen Charge Pressure @ 21°C (70°F) 789C: 5512 ± 345 kPa (800 ± 50 psi) 793C: 6545 ± 345 kPa (950 ± 50 psi)

2

778855CC//778899CC//779933CC HHOOIISSTT TTEESSTT Machine Model _____________________________ Date______________________________________ Machine Serial No. __________________________ Machine Hours _____________________________

Hoist System Enable Status ___________________ Hoist LOWER Adjustment Setting______________ Transmission/Chassis ECM Flash File/Date __________________________________________________

VISUAL CHECKS:

Oil level __________________________________ Oil Viscosity ______________________________ Air/Water in Oil? ___________________________ Oil Filter Examination _______________________ The hoist system can be enabled or disabled in the Transmission/Chassis ECM using ET. All trucks shipped from the factory without bodies installed are set at the Hoist Disabled Status. The Hoist Disabled Status is a test mode only and will prevent the hoist cylinders from accidentally being moved. After the body is installed, enable the Hoist Status for the hoist system to function properly. Shown below are the three Hoist Statuses. Hoist System Enable Status: - hoist system is not installed - hoist system is installed and enabled (normal operation) - hoist system is installed but disabled Make sure the engine is not running and the truck is not moving. Transmission Output Speed (TOS) needs to be zero to change this parameter. When the engine is running there is sometimes some jitter on the TOS signal, which could keep the parameter from changing. The hoist valve LOWER position is an adjustable parameter in the Transmission/Chassis ECM using ET. The slight adjustment provides a means to compensate for valve differences. The adjustment range is from -5 to +5 with zero as the default. A negative number will decrease the lower speed and a positive number will increase the lower speed. With the engine at HIGH IDLE and the hoist output in SNUB, pump output pressure must be less than 1725 kPa (250 psi). The hoist output must be in HOLD when changing the setting.

1

778855CC//778899CC//779933CC HHOOIISSTT TTEESSTT

TEST SPECS ACTUAL

Hoist Oil Temperature (during tests)

> 65°C (150°F) < 121°C (250°F)

RAISE TIME @ High Idle 785C: 14.0 to 16.0 seconds 789C: 17.0 to 19.0 seconds 793C: 19.0 to 21.0 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

LOWER TIME @ High Idle (including snub)

785C: 15 to 17 seconds 789C: 14.0 to 16.0 seconds 793C: 17.0 to 19.0 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

FLOAT TIME @ High Idle (including snub)

785C: 15 to 17 seconds 789C: 14.0 to 16.0 seconds 793C: 17.0 to 19.0 seconds

1. ____________________

2. ____________________

3. ____________________

AVG.

PILOT PRESSURE (Parking Brake Retraction)

4700 ± 200 kPa (680 ± 30 psi)

LI - HI -

RAISE PRESSURE @ High Idle 785C: 17225 ± 345 kPa (2500 ± 50 psi) 789C: 17225 ± 345 kPa (2500 ± 50 psi) 789C: 18950 ± 345 kPa (2750 ± 50 psi) (cast pump)793C: 20370 ± 345 kPa (2955 ± 50 psi)

F Tap: R Tap:

LOWER PRESSURE @ High Idle (Body Switch in RAISE Position)

3450 + 350 – 0 kPa(500 + 50 – 0 psi)

F Tap: R Tap:

ET Setting -5 0 +5

HOIST PRESSURE IN SNUB Maximum 1725 kPa (250 psi)

LI -

HI -

LI -

HI -

LI -

HI -

Hoist LOWER Solenoid Current %

Final Programmed Value

2


Create a Test Group on ET: 1) On the ET screen, select the Transmission ECM 2) In the Status Group, create a new group name "Hoist Test" 3) Select the items as shown on the ET screen below:

HOIST LEVER SENSOR

TEST SPECS ACTUAL

Supply Voltage + Battery (24 Volts)

Pull-Up Voltage Approx 5 Volts

Signal Duty Cycle % Full Raise to Full Lower 5 to 95 %

BODY POSITION SENSOR ANGLE

TEST Hoist LOWER Solenoid Current %

BODY POSITION ANGLE

Body Full RAISE N/A

FLOAT to SNUB

3


HOIST LEVER

POSITION

DUTY CYCLE (approximate)

ACTUAL DUTY CYCLE

SOLENOID CURRENT %

FROM ET

HOIST VALVE SOLENOID CURRENT

(mA)

(ET Solenoid % x 1900)

HOIST VALVE SOLENOID

CURRENT (mA)

(ACTUAL)

RAISE 1 - 18% ___________ mA

HOLD 24 to 48% N/A N/A N/A

FLOAT 55 to 71% ___________ mA

LOWER 80 to 96% ___________ mA

SNUB N/A N/A ___________ mA

NOTE: The current at the solenoids will be equal to the percentage shown on the ET screen x 1900 milliamps. DRIFT TEST: OIL TEMP MINUTES

ACCEPTABLE CYLINDER DRIFT

MINUTES OIL TEMPERATURE CYLINDER DRIFT

12.4 38 °C (100 °F) 6.40 mm (0.25 in)

9.6 43 °C (110 °F) 6.40 mm (0.25 in)

7.8 49 °C (120 °F) 6.40 mm (0.25 in)

6.4 54 °C (130 °F) 6.40 mm (0.25 in)

5.3 60 °C (140 °F) 6.40 mm (0.25 in)

4.4 66 °C (150 °F) 6.40 mm (0.25 in)

3.8 71 °C (160 °F) 6.40 mm (0.25 in)

3.2 77 °C (170 °F) 6.40 mm (0.25 in)

2.8 82 °C (180 °F) 6.40 mm (0.25 in)

4

778855CC//778899CC//779933CC AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT

Machine Model ______________________ Date ______________________________


VISUAL CHECKS:

Hose Connections Component Damage _________________

Air Leaks Oil Leaks _________________________

TEST SPECS ACTUAL

Air Compressor Governor Setting (CUT-OUT)

830 ± 35 kPa (120 ± 5 psi)

Air Compressor Governor Setting (CUT-IN)

655 ± 35 kPa (95 ± 5 psi)

#1 Pressure Protection Valve (Behind Cab) (Drain Secondary Brake Tank to See Close Setting)

Open-- 550 kPa (80 psi) Close-- 480 kPa (70 psi)

Open-- Close--

#2 Pressure Protection Valve

(ARC Relay Valve)

Open-- 380 kPa (55 psi) Close-- 310 kPa (45 psi)

Open-- Close--

Retarder Valve--Maximum Air Pressure 550±35 kPa (80 ± 5 psi)

Parking Brake Retraction Valve 4700±200 kPa (680 ± 30 psi)

LI-

HI-

Towing Pump Pressure 4481 kPa (650 psi)

Towing pump pressure after:

1 minute – 4 minutes -

2 minutes – 5 minutes -

3 minutes -

1


Brake Cooling Oil Pressure At Wheels (Body Down in SNUB) AT WHEEL INLET: Low Idle Minimum – 14 kPa (2 psi) High Idle Maximum - 172 kPa (25 psi)

Brake Cooling Oil Temperature (during brake cooling pressure test)

79 to 93 °C (175 to 200 °F)

TEST Brake Inlet Tap Brake Outlet Tap

Left Front Wheel LI - HI -

LI - HI -

Right Front Wheel LI - HI -

LI - HI -

Left Rear Wheel LI - HI -

LI - HI -

Right Rear Wheel LI - HI -

LI - HI -

793C Brake Cooling Oil Pressure (Body Down in SNUB)

Brake Cooling Oil Temperature (during brake cooling pressure test)

79 to 93 °C (175 to 200 °F)

TEST RETARDER ENGAGED RETARDER RELEASED

Hoist Pump Front (front brake oil cooling) LI - HI -

LI - HI -

Hoist Pump Rear (front brake oil cooling) LI - HI -

LI - HI -

Rear Brake Oil Cooler LI - HI -

LI - HI -

NOTE: 793C Hoist Pump (front oil cooling) and Rear Oil Cooler Relief Valve settings are 790 kPa (115 psi)

2


BRAKE CYLINDER OPERATION (Apply Service Brake Pedal)

TEST AIR PRESSURE @ Brake Cylinder

OIL PRESSURE @ Slack Adjuster

Brake Cylinder Air/Oil Ratio 6.6 to 1

Front Brake Cylinders: XXXX XXXX

Brake Cylinder #1

Brake Cylinder #2

Rear Brake Cylinders: XXXX XXXX

Brake Cylinder #3

Brake Cylinder #4

3


SLACK ADJUSTER OPERATION

SLACK ADJUSTER TAP WHEEL PORT TAP

Engaged Released

Engaged Released

Residual Pressure

Left Front Wheel

Front

Right Front Wheel

Left Rear Wheel

Rear

Right Rear Wheel

Released (residual) pressure at "S" port after releasing parking brakes: 785 front - 103 kPa (14.9 psi) 785 rear - 59 kPa (8.6 psi) 789 front - 106 kPa (15.3 psi) 789 rear - 65 kPa (9.5 psi) 793 front - 59 kPa (8.6 psi) 793 rear - 68 kPa (9.9 psi) NOTE: Low residual pressure MAY indicate a failed Slack Adjuster. High residual pressure MAY indicate warped brake discs. Rotate wheel to see if pressure fluctuates.

Brake Assembly Leakage

TEST Start Pressure Pressure after 5 minutes

Left Front Wheel

Right Front Wheel

Left Rear Wheel

Right Rear Wheel

Block the brake cooling ports and pressurize each brake assembly to a maximum of 138 kPa (20 psi). Close off the air supply source and observe the pressure trapped in the brake assembly for five minutes. The trapped pressure should not decrease.

4


BRAKE OIL MAKEUP TANK REFILL OPERATION Flow into the makeup tank is acceptable: YES ________ NO _________

BRAKE HOLDING CAPACITY

Service Brake Engaged rpm Manual Retarder Engaged rpm Parking Brake Engaged rpm Secondary Brake Engaged rpm

NOTE: 785C/789C Minimum 1200 rpm 793C Minimum 1300 rpm

AIR COMPRESSOR TEST

To test the air compressor efficiency, lower the air system pressure to 480 kPa (70 psi). Start the engine and raise the engine speed to HIGH IDLE. When the air system pressure reaches 585 kPa (85 psi), measure the time that it takes to build system pressure from 585 kPa (85 psi) to 690 kPa (100 psi). The time to raise the pressure should be 50 seconds or less. If the time recorded is greater than 50 seconds, check for leaks or a restriction in the system. If no leaks or restrictions are found, the air compressor may have a problem. Time to charge system: seconds

5

AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT Machine Model Date Machine Serial No. Machine Hours Brake ECM Flash File/Date Perform ARC test using ET diagnostics: 1) Connect 0-1000 psi gauges to the Front and Rear Slack Adjusters 2) On the ET screen toolbar, select Diagnostics – Diagnostics Tests – Auto Retarder Test 3) Switch ON the ARC ON/OFF switch 4) Click the Start button and the Auto Retarder Test will be turned ON 5) The ARC Control Solenoid Current will sweep from 0 –100% 6) The ARC Pressure Switch Status will toggle between ‘Low’ and ‘High’ 7) Observe the Front & Rear Slack Adjusters pressure increase and decrease accordingly

Functional Test Maximum Air Pressure

(Brake Cylinder) Maximum Brake Oil

Pressure (Slack Adjuster)

Front Brake Cylinder Air/Oil Ratio (6.6 to 1)

Rear Brake Cylinder Air/Oil Ratio (6.6 to 1)

1

AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT

SETUP DESIRED ACTUAL

Control Speed Setting

Control Valve Cycles N/A

Supply Valve Cycles N/A

ACTIVE DIAGNOSTIC CODES and DESCRIPTION

Diagnostic Code Description Cause

LOGGED DIAGNOSTIC AND EVENT CODES

Diagnostic and Event Code and Description

Number of Occurrences First Occurrence Last Occurrence

2

AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT

ARC OVERSPEED PROTECTION

Horn and Light Activate *

Activation Speed(supply solenoid ON)

ARC Shutoff

Auto Upshift **

2100 rpm

2125 rpm

2100 rpm

2075 rpm

2300 rpm

ARC Control Speed

ARC NORMAL OPERATION

FUNCTION ENGINE SPEEDActivation Speed(supply solenoid ON) 1850 rpm

ARC Control Range

Factory Setting

1850 to 1950 rpm

1950 rpm

* The Horn and Light are controlled by the Engine ECM** The Auto Upshift is controlled by the Transmission ECM

3

TTRRAACCTTIIOONN CCOONNTTRROOLL SSYYSSTTEEMM ((TTCCSS)) TTEESSTT Machine Model Date Machine Serial No. Machine Hours Brake ECM Flash File/Date TEST 1: Perform TCS test using the TCS TEST SWITCH: 1) Using ET, choose the Brake ECM 2) In the Status Group, create a new group name "TCS Test" 3) Select the items as shown on the ET screen below:

4) Run the engine at LOW IDLE 5) Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON 6) Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED 7) Depress the TCS Test Switch and observe the TCS Proportional Solenoid signal sweep

between 0-44% 8) At the same time, the Left & Right Rear Brake Solenoid will toggle between On & Off and

the Left & Right Parking Brake Oil Pressure will increase and decrease accordingly 9) Record the data into the chart

1

TRACTION CONTROL SYSTEM (TCS) TEST

TEST SPECS ACTUAL

Brake Oil Temperature (during tests) > 65°C (150°F)

Parking Brake Release Pressure 4700 ± 200 kPa (680 ± 30 psi)

LI-

HI-

Left Brake Pressure (Released)

Left Brake Pressure (Engaged) < 300 kPa (44 psi)

Right Brake Pressure (Released)

Right Brake Pressure (Engaged) < 300 kPa (44 psi)

ET Proportional Solenoid Percentage 44%

Proportional Solenoid Resistance/Voltage

12 to 22 ohms 0 to 12 Volts

Left Selector Solenoid Resistance/Voltage

18 to 45 ohms 24 Volts

Right Selector Solenoid Resistance/Voltage

18 to 45 ohms 24 Volts

NOTE: When the brakes are ENGAGED, gauge pressure will drop quickly to approximately 1380 kPa (200 psi), and then gradually decrease. This is the function of the proportional solenoid and orifices.

TEST 2: FUNCTIONAL TEST Run the engine at Low Idle. Engage FIRST GEAR and release the brakes. With the TCS Test Switch Depressed, do the brakes ENGAGE and RELEASE intermittently? Wheels Turned to the RIGHT: YES NO Wheels Turned to the LEFT: YES NO

2

TTRRAACCTTIIOONN CCOONNTTRROOLL SSYYSSTTEEMM ((TTCCSS)) TTEESSTT

ACTIVE DIAGNOSTIC CODES and DESCRIPTION

Fault Code Description Cause


Diagnostic Code and Description

Number of Occurrences First Occurrence Last Occurrence

3

FFRROONNTT SSUUSSPPEENNSSIIOONN CCYYLLIINNDDEERR CCHHAARRGGIINNGG Machine Model __________________________ Date_____________________________________ Serial Number ___________________________ Machine Hours_____________________________ Oil Charge Dimension: _________________________ 769-773: 25 mm (1.0 in.) 777-793: 13 mm (0.5 in.) Nitrogen Charge Dimension: ____________________ 769-773: 170 mm (6.7 in.) 777: 216 mm (8.5 in.) 785-793: 265 mm (10.4 in.) Nitrogen Charge Dimension Temperature Correction: Shop Temperature ________ Outside Temperature _________ Temperature Difference _________ Temperature Difference X (see chart) = Shim Thickness ____________________ Corrected Nitrogen Charge Dimension _______________ Nitrogen Charge Pressure: _______________________ 769-777: 2400 kPa (350 psi) 785-789: 2200 kPa (320 psi) 793: 2300 kPa (335 psi) Chrome Length Measurement After Gauge Block is Removed: * Left Front _____________ Right Front ____________ Wiped Chrome Dimension After Operation: Left Front _____________ Right Front ____________ * dimension between top of spindle and bottom of cylinder housing

SHIMS FOR TEMPERATURE CORRECTION

Truck Model

Shim Thickness mm/5.5 °C (in./10 °F)

768D/769D/771D773E/775E 3.2 (0.125)

776D/777D 5.1 (0.20)

784C/785C/789C/793C 6.4 (0.25)

RREEAARR SSUUSSPPEENNSSIIOONN CCYYLLIINNDDEERR CCHHAARRGGIINNGG Machine Model __________________________ Date_____________________________________ Serial Number ___________________________ Service Meter Hours________________________ Oil Charge Dimension: ___________________ 769-773: 25 mm (1.0 in.) 777-793: 13 mm (0.5 in.) Nitrogen Charge Dimensions: (see chart) First Charge Line _____________________ Second Charge Line ____________________ Nitrogen Charge Dimension Temperature Correction: Shop Temperature ________ Outside Temperature _________ Temperature Difference _________ Temperature Difference X 2.5 mm/5.5 °C (.10 in./10 °F) = Additional Length ________________ Corrected Nitrogen Charge Dimensions: First Charge Line _______________ Second Charge Line _____________ Pin to Pin Measurement: * Left Rear _____________ Right Rear ____________ (After Charging is Complete for future inspection) Wiped Chrome Dimension After Operation: Left Rear _____________ Right Rear ____________ * dimension between the center line of the top mounting pin and the bottom mounting pin

NITROGEN CHARGE DIMENSIONS Distance Below Top Of

Suspension Cylinder Housing

Truck Model First Charge Line

mm (in.) Second Charge Line

mm (in.)

769D/771D 128 (5.0) 140 (5.5)

773E/775E 124 (4.9) 137 (5.4)

776D/777D 102 (4.0) 114 (4.5)

784C/785C 104 (4.1) 117 (4.6)

789C 108 (4.25) 121 (4.75)

793C 121 (4.75) 133 (5.25)

DataView Users Guide 1. Install DataView Software in Laptop (NEHS0662) or STW – NETG5030 2. Connect DataView Box to Laptop printer port with cable provided 3. Connect sensors and cables to Machine and DataView Box. (Max possible is 9, 6 analog and

3 frequency). 4. Power On DataView Box 5. Start DataView Application on Laptop (Setup screen will pop up with channels displayed) 6. Select each channel and Double Click the channel to define it (put in a long name and short name).

When done select OK. 7. Select each Pressure Channel and click on the 0.0 Icon (second icon from right) to Zero each

sensor 8. For speed sensors, enter the number of teeth or Pulses Per Revolution (PPR) 9. When using PWM/Analog Sensor adapter kit (153-9630) make sure NOT to use small black PWM

sensor adapter box with analog sensors 10. Click on Clock Icon (Setup Logger Tool) (third icon from left) 11. Select all channels 12. Click on 5th Icon from the right (Setup Logger) (looks like a cassette tape) 13. Set Sample Rate (usually leave alone) and Log Time Before and After Trigger (make sure time

After is longer than test will take i.e. 10 min) 14. Set a Trigger pressure or No Trigger Channel for Manual 15. Send Configuration 16. Raise Trigger Switch for Manual Logging. Lower Trigger Switch for Auto Logging. 17. Click on 2nd Icon from left (graph) to view Sensor Status Real Time while logging 18. Raise Trigger Switch again to Stop Logging manually 19. Click on 4th Icon from left (Graph Viewer Tool) and select one of the data sources 20. Move four sensors from Available to Selected and select next to set ranges and select Finish.

Select Add Graph to see a second graph at same time with more sensors. Select OK to see graphs. Use mouse to select area of graph.

After Data Logging is complete, Select File and Download Data Log from pull-down menu Open a New File and Name it the Machine Serial Number (789C 2BW00201) Enter a new document name and description (Brake cooling test with sensors at xx, xx, xxx, etc.)

DATAVIEW TOOLS NEHS0662 Software and Instruction Manual JERD2163 Software Updates 131-5051 DataView Portable Tech Station Group 153-9630 PWM-Analog Test Group Sensor Adapter Kit 213-3274 100 psi sensor 213-3275 1000 psi sensor 213-3276 7500 psi sensor 6V4144 Internal 1/4 nptf Valved Coupler (for each sensor) 6V2198 18 ft. sensor extension cable 137-0168 Machine battery power cable 137-0170 12V Cigarette Lighter power cable 4C4463 Yellow case for small parts

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C-SERIES SENSORS IN DATAVIEW SENSOR TABLE 100-3055 - Temperature: Brake, Differential, Torque Converter, Transmission (digital) 163-7882 - Temperature: Engine Exhaust (digital) 102-2240 - Temperature: Engine Coolant, Rear Aftercooler Coolant (analog) 118-7226 - Temperature: Front Aftercooler Coolant (VIMS), Steering (digital) 118-3909 - Temperature: Ambient (digital) 161-9926 - Pressure: Atmospheric, Turbo Inlet, Crankcase (analog) 194-6724 - Pressure: Turbo Out (Boost) (analog) (was 161-9929) 194-6725 - Pressure: Engine Oil (analog) (was 161-9931) 176-1602 - PWM Position: Throttle (digital) 141-5746 - PWM Pressure: Air System (digital) 157-8394 - PWM Pressure: Rear Parking Brakes (digital) 160-1582 - PWM Pressure: Rear Axle Oil (digital)

Speed Sensor Teeth (PPR)

Sensor Number of Teeth

Engine Output Speed (EOS) Sensor 151

Fan Motor Output Speed Sensor 67

Transmission Output Speed (TOS) Sensor 120

Traction Control System (TCS) Wheel Speed Sensors

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Engine and Fan Speed Adapter Cable To measure the Engine and Fan Speeds with DataView, a two-pin adapter T-cable will need to be made from either a 153-9626 3-pin HD-10 Adapter cable or a 153-9627 3-pin DT Adapter cable. Remove the 3-pin plug and receptacle from the T-cable. Cut the red wire. The red wire is not needed with the 2-pin passive speed sensors. Using a 102-8802 2-pin DT receptacle kit and a 155-2270 2-pin DT plug kit, install the white wires in pin location 1 and install the black wires in pin location 2.

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Shown is a DataView screen while running the hydraulic fan override test.

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ANALOG TEMPERATURE SENSOR CHARTS

SENSOR VOLTAGE SPECIFICATION

ENGINE JACKET WATER, REAR AFTERCOOLER and FUEL Analog Temperature Sensors

TEMPERATURE SIGNAL VOLTAGE -40 to -20 °C (-40 to -4 °F) .5 to .57 DCV -20 to 0 °C (-4 to 32 °F) .57 to .75 DCV 0 to 20 °C (32 to 68 °F) .75 to 1.16 DCV 20 to 40 °C (68 to 104 °F) 1.16 to 1.86 DCV 40 to 60 °C (104 to 140 °F) 1.86 to 2.74 DCV 60 to 80 °C (140 to 176 °F) 2.74 to 3.53 DCV 80 to 100 °C (176 to 212 °F) 3.53 to 4.1 DCV 100 to 120 °C (212 to 248 °F) 4.1 to 4.46 DCV

Tolerance is ± 10%


ENGINE OIL Analog Temperature Sensor

TEMPERATURE SIGNAL VOLTAGE -40 to -20 °C (-40 to -4 °F) .2 to .57 DCV -20 to 0 °C (-4 to 32 °F) .57 to 1.12 DCV 0 to 20 °C (32 to 68 °F) 1.12 to 1.71 DCV 20 to 40 °C (68 to 104 °F) 1.71 to 2.31 DCV 40 to 60 °C (104 to 140 °F) 2.31 to 2.94 DCV 60 to 80 °C (140 to 176 °F) 2.94 to 3.55 DCV 80 to 100 °C (176 to 212 °F) 3.55 to 4.0 DCV 100 to 120 °C (212 to 248 °F) 4.0 to 4.37 DCV

Tolerance is ± 10%

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ANALOG PRESSURE SENSOR CHARTS


ATMOSPHERIC and TURBO INLET PRESSURE Analog Pressure Sensor

ABSOLUTE PRESSURE SIGNAL VOLTAGE 0 to 20.7 kPa (0 to 3 psi) 0 to .89 DCV 20.7 to 41.3 kPa (3 to 6 psi) .89 to 1.78 DCV 41.3 to 62 kPa (6 to 9 psi) 1.78 to 2.67 DCV 62 to 82.7 kPa (9 to 12 psi) 2.67 to 3.56 DCV 82.7 to 103 kPa (12 to 15 psi) 3.56 to 4.44 DCV

Tolerance is ± 3%


TURBO OULET PRESSURE Analog Pressure Sensor

ABSOLUTE PRESSURE SIGNAL VOLTAGE 0 to 34.5 kPa (0 to 5 psi) 0 to .33 DCV 34.5 to 68.9 kPa (5 to 10 psi) .33 to .66 DCV 68.9 to 103.4 kPa (10 to 15 psi) .66 to .99 DCV 103.4 to 137.8 kPa (15 to 20 psi) .99 to 1.32 DCV 137.8 to 172.3 kPa (20 to 25 psi) 1.32 to 1.65 DCV 172.3 to 206.7 kPa (25 to 30 psi) 1.65 to 1.98 DCV 206.7 to 241.2 kPa (30 to 35 psi) 1.98 to 2.31 DCV 241.2 to 275.6 kPa (35 to 40 psi) 2.31 to 2.64 DCV

Tolerance is ± 3%

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ENGINE OIL PRESSURE Analog Pressure Sensor

ABSOLUTE PRESSURE SIGNAL VOLTAGE 0 to 137.8 kPa (0 to 20 psi) 0 to .6 DCV 137.8 to 275.6 kPa (20 to 40 psi) .6 to 1.2 DCV 275.6 to 413.4 kPa (40 to 60 psi) 1.2 to 1.8 DCV 413.4 to 551.2 kPa (60 to 80 psi) 1.8 to 2.4 DCV 551.2 to 689 kPa (80 to 100 psi) 2.4 to 3.0 DCV 689 to 826.8 kPa (100 to 120 psi) 3.0 to 3.6 DCV 826.8 to 964.6 kPa (120 to 140 psi) 3.6 to 4.2 DCV

Tolerance is ± 3%

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DIGITAL TEMPERATURE SENSOR CHARTS

SENSOR DUTY CYCLE SPECIFICATION

BRAKE, DIFFERENTIAL, CONVERTER, TRANSMISSION, STEERING, FRONT AFTERCOOLER and FAN DRIVE

Digital Temperature Sensors TEMPERATURE DUTY CYCLE

-40 to -20 °C (-40 to -4 °F) 10 to 11.3 % -20 to 0 °C (-4 to 32 °F) 11.3 to 15 % 0 to 20 °C (32 to 68 °F) 15 to 23.2 % 20 to 40 °C (68 to 104 °F) 23.2 to 37.2 % 40 to 60 °C (104 to 140 °F) 37.2 to 54.7 % 60 to 80 °C (140 to 176 °F) 54.7 to 70.6 % 80 to 100 °C (176 to 212 °F) 70.6 to 82 % 100 to 120 °C (212 to 248 °F) 82 to 89.3 %

Tolerance is ± 10%


AMBIENT TEMPERATURE Digital Temperature Sensor

TEMPERATURE DUTY CYCLE -60 to -40 °C (-76 to -40 °F) 1 to 4 % -40 to -20 °C (-40 to -4 °F) 4 to 11.3 % -20 to 0 °C (-4 to 32 °F) 11.3 to 22.3 % 0 to 20 °C (32 to 68 °F) 22.3 to 34.2 % 20 to 40 °C (68 to 104 °F) 34.2 to 46.2 % 40 to 60 °C (104 to 140 °F) 46.2 to 58.8 % 60 to 80 °C (140 to 176 °F) 58.8 to 70.9 % 80 to 100 °C (176 to 212 °F) 70.9 to 80.6 % 100 to 120 °C (212 to 248 °F) 80.6 to 87.4 %

Tolerance is ± 10%

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EXHAUST TEMPERATURE SENSOR CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION

Digital Temperature Sensor (Exhaust) TEMPERATURE DUTY CYCLE

50 to 200 °C (122 to 392 °F) 22 to 33.2 % 200 to 400 °C (392 to 725 °F) 33.2 to 50 % 400 to 600 °C (725 to 1112 °F) 50 to 67 % 600 to 850 °C (1112 to 1562 °F) 67 to 88.4 %

Tolerance is ± 10%

REAR PARKING BRAKE RELEASE PRESSURE SENSOR CHART


Digital Pressure Sensor on TCS Valve

ABSOLUTE PRESSURE DUTY CYCLE 0 to 1378 kPa (0 to 200 psi) 0 to 22.3 % 1378 to 2756 kPa (200 to 400 psi) 22.3 to 46.1 % 2756 to 4134 kPa (400 to 600 psi) 46.1 to 70.0 % 4134 to 5512 kPa (600 to 800 psi) 70.0 to 93.8 %

Tolerance is ± 3%

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DIFFERENTIAL PRESSURE SENSOR CHART


Digital Pressure Sensor on Rear Axle Valve

ABSOLUTE PRESSURE DUTY CYCLE 0 to 137.8 kPa (0 to 20 psi) 0 to 13.6 % 137.8 to 275.6 kPa (20 to 40 psi) 13.6 to 29.6 % 275.6 to 413.4 kPa (40 to 60 psi) 29.6 to 45.6 % 413.4 to 551.2 kPa (60 to 80 psi) 45.6 to 61.6 % 551.2 to 689 kPa (80 to 100 psi) 61.6 to 77.6 % 689 to 826.8 kPa (100 to 120 psi) 77.6 to 93.6 %

Tolerance is ± 3%

ULTRASONIC FUEL LEVEL SENSOR CHART


Ultrasonic Fuel Level Sensor Depth of Fuel (Shallow Tank) DUTY CYCLE 0 to 250 mm (0 to 9.9 inch) 6 to 25 % 250 to 500 mm (9.9 to 19.7 inch) 25 to 45 % 500 to 750 mm (19.7 to 29.6 inch) 45 to 64 % 750 to 1000 mm (29.6 to 39.4 inch) 64 to 84 %

Tolerance is ± 10%

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AIR PRESSURE SENSOR CHARTS:

Early Configurations


9X5272, 100-4311 Pressure Sensor (AIR) Air Pressure DUTY CYCLE

0 to 200 kPa (0 to 29 psi) 8 to 13 % 200 to 400 kPa (29 to 58 psi) 13 to 19 % 400 to 600 kPa (58 to 88 psi) 19 to 25 % 600 to 800 kPa (88 to 115 psi) 25 to 30 % 800 to 1000 kPa (115 to 145 psi) 30 to 36 %

Later Configurations


141-5746, 185-0600 Pressure Sensor (AIR) Air Pressure DUTY CYCLE

117 kPa (17 psi) 10.7 % 140 kPa (20 psi) 13.3 % 275 kPa (40 psi) 26.4 % 415 kPa (60 psi) 39.7 % 550 kPa (80 psi) 53.0 % 690 kPa (100 psi) 66.4 % 825 kPa (120 psi) 79.7 %

Tolerance is ± 10%

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Vims 793C

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