1

V VI I T TA AL L I I N NF FO OR RM MA AT TI I O ON N M MA AN NA AG GE EM ME EN NT T S SY YS ST TE EM M
( ( V VI I M MS S) )
Machine Model______________________________ Date ______________________________
Machine Serial No.___________________________ Machine Hours _____________________
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 (ATTACH) Used to
recognize if RAC module is present
0 NO
4 - YES
Languages
PRI:
SEC:
Configuration Type
Operator ID
2
V VI I M MS S
PAYLOAD
PROGRAM CODE DESIRED ACTUAL
PAYCAL (729225) YES/NO
RAC (722) Set Haul Road Severity
0 OFF
1 low
2 medium
3 - high
ESET (3738) Customize Payload Overload
Events
PAYCONF (7292663)
Max Payload Weight:
Last Pass Indicator:
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
3
V VI I M MS S
EACK (3225): ACTIVE EVENTS
EVENT
HOUR METER
START
LENGTH OF TIME
CATEGORY
LEVEL
ELIST (35478): INTERMITTENT EVENTS
EVENT
HOUR METER
START
LENGTH OF TIME CATEGORY
LEVEL
4
V VI I M MS S
Sensor Tests
Sensor
Supply
Voltage
Actual Temperature/
Pressure/ Fuel Level
Actual Signal
Volts/Hz/Duty Cycle/
Resistance
Pull-up
Voltage
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
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 Sender
NOTE: Sensor supply voltage is 8.0 0.5 or 24.8 to 29.5
5
VIMS KEYPAD OPERATIONS
PAYCONF 7292663 Configure Payload Monitor
(requires VIMS PC connection)
PAYCAL 729225 Calibrate Payload Monitor
TOT 868 Show Payload Cycle Resettable Totals
RESET 73738 Reset Displayed Data
ESET 3738 Customize Payload Overload Events
(requires VIMS PC connection)
SVCLIT 782548 Reset Service Light
SVCSET 782738 Service Light Set
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 RAC module is present (0 NO, 4 YES)
RAC 722 Set Haul Road Severity
(0 - OFF, 1 - low, 2 - medium, 3 high)
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).
1
7 77 77 7D D- -7 79 93 3C C O OF FF F- -H HI IG GH HW WA AY Y T TR RU UC CK K
E EN NG GI IN NE E T TE ES ST TS S
Machine Model ______________________ Date_________________________________
Machine Serial No. ___________________ Machine Hours ________________________
Engine Serial No. _____________________ Engine Hours__________________________
ECM Serial No. ______________________ ECM Location Code ___________________
Personality Module ___________________ Personality Module Date_________________
Performance Spec ____________________ Max Altitude __________________________
Gross Power _________________________ Full Load RPM________________________
T E S T S P E C S A C T U A L
ECM Supply Voltage 24
Throttle Sensor Supply Voltage 8.0 0.5
Throttle Sensor Low Idle Duty Cycle 16 6%
Throttle Sensor High Idle Duty Cycle
Early - 48 4%
Later - 85 4%
Throttle Sensor Frequency 150-1000 Hz
Throttle Sensor Pull-Up Voltage 11.5 0.5
Speed Sensor Supply Voltage 12.5 1.0
Speed Sensor Frequency (Cranking) 23 - 40 Hz
Speed Sensor Frequency (Low Idle) 140 Hz@700 rpm
Speed Sensor Frequency (High Idle) 385 Hz@1960 rpm
Speed Sensor Signal Voltage (Key ON)
less than 3.0
or
greater than 10.0
Speed Sensor Signal Voltage (Cranking) 2.0 to 4.0
2
E EN NG GI IN NE E T TE ES ST TS S
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink Select ECM and choose 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.
3
E EN NG GI IN NE E T TE ES ST TS S
Sensor Tests
Sensor Supply
Voltage
Desired
Signal Volts
Actual Signal
Voltage
Actual
Temperature/
Pressure
Pull-up
Voltage
Filtered Engine Oil
Pressure
.2 to .6
Unfiltered Engine Oil
Pressure
.2 to .6
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
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 5.00.5
Desired signal voltages are at Key ON.
Exhaust Temperature Sensor Duty Cycles: below 49C (120F) - 10% to 21%
49 to 851C (120 to 1564F) - 22% to 88%
above 851C (1564F) - 88% to 90%
4
E EN NG GI IN NE E T TE ES ST TS S
ACTIVE FAULT CODES
FAULT CODE DESCRIPTION
NUMBER
OF
OCCURR
FIRST
HOUR
METER
LAST
HOUR
METER
LOGGED FAULT CODES
FAULT CODE DESCRIPTION
NUMBER
OF
OCCURR
FIRST
HOUR
METER
LAST
HOUR
METER
EVENT CODES
FAULT CODE DESCRIPTION
NUMBER
OF
OCCURR
FIRST
HOUR
METER
LAST
HOUR
METER
5
E EN NG GI IN NE E T TE ES ST TS S
INJECTOR SOLENOID TEST:
CYLINDERS OPEN
CYLINDERS SHORTED
NOTES:


OVERRIDE PARAMETERS:
ETHER INJECTION: OK NOT OK
ENGINE PRELUBE: OK NOT OK
WASTEGATE: Override % Volts Current (miliamps)
0%
25%
50%
75%
100%
NOTES:


6
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 100 from Average
NOTES:


CURRENT TOTALS:
FUEL TOTAL TIME
ETHER
7
E EN NG GI IN NE E T TE ES ST TS S
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:


1
785C Eng Power Test.doc
7 78 85 5C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
Machine Model Date
Machine Serial No. Machine Hours
Engine Serial No. Engine Hours
Rating No. Rated Power
Flash File/Date
Throttle Pedal Configuration
VISUAL CHECKS
Oil Level Oil Filter Examination
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink Select ECM and choose 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
2
785C Eng Power Test.doc
7 78 85 5C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the
information on the chart provided.
T E S T S P E C S A C T U A L
Coolant Temperature (during tests) > 71C (160F)
Low Idle RPM 700 10
High Idle RPM 1935 30
Air Filter Restriction @ TC Stall (maximum allowed)
25 in. of water
6.2 kPa
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10)
182 30 kPa
(26 5 psi)
Inlet Manifold Pressure (BOOST)
@ TC Stall RPM (1640 65 rpm)
178 30 kPa
(26 5 psi)
Torque Converter Stall RPM 1640 65
Torque Converter Temperature (during stall test)
> 80C (175F)
< 121C (250F)
Engine Oil Pressure @ LI
170 to 600 kPa
(25 to 87 psi)
Engine Oil Pressure @ HI
365 to 600 kPa
(53 to 87 psi)
Engine Oil Filter Differential Pressure @ HI
maximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall
360 to 725 kPa
(52 to 105 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 110F over ambient
*2 Should be 8 to 20F less than Top Tank Temp/thermostat open (> 88C/190F)
1
789C Eng Power Test.doc
7 78 89 9C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
Machine Model Date
Machine Serial No. Machine Hours
Engine Serial No. Engine Hours
Rating No. Rated Power
Flash File/Date
Throttle Pedal Configuration
VISUAL CHECKS
Oil Level Oil Filter Examination
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink Select ECM and choose 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
2
789C Eng Power Test.doc
7 78 89 9C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the
information on the chart provided.
T E S T S P E C S A C T U A L
Coolant Temperature (during tests) > 71C (160F)
Low Idle RPM 700 10
High Idle RPM 1935 30
Air Filter Restriction @ TC Stall (maximum allowed)
25 in. of water
6.2 kPa
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10)
178 30 kPa
(26 5 psi)
Inlet Manifold Pressure (BOOST)
@ TC Stall RPM (1715 65 rpm)
178 30 kPa
(26 5 psi)
Torque Converter Stall RPM 1715 65
Torque Converter Temperature (during stall test)
> 80C (175F)
< 121C (250F)
Engine Oil Pressure @ LI
170 to 600 kPa
(25 to 87 psi)
Engine Oil Pressure @ HI
365 to 600 kPa
(53 to 87 psi)
Engine Oil Filter Differential Pressure @ HI
maximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall
360 to 725 kPa
(52 to 105 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 110F over ambient
*2 Should be 8 to 20F less than Top Tank Temp/thermostat open (> 88C/190F)
1
793C EngPowerTest.doc
7 79 93 3C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
Machine Model Date
Machine Serial No. Machine Hours
Engine Serial No. Engine Hours
Rating No. Rated Power
Flash File/Date
Throttle Pedal Configuration
Horsepower Configuration (Rating Selection):
Dual Horsepower (2160 hp only) Multi-Torque (2160/2300 hp)
VISUAL CHECKS
Oil Level Oil Filter Examination
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink Select ECM and choose 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
2
793C EngPowerTest.doc
7 79 93 3C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T ( ( 7 7T TR R w wa as s t t e eg ga at t e e) )
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the
information on the chart provided.
T E S T S P E C S A C T U A L
Coolant Temperature (during tests) > 71C (160F)
Low Idle RPM 700 10
High Idle RPM 1965 10
Air Filter Restriction @ TC Stall (maximum allowed)
25 in. of water
6.2 kPa
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10)
207 35 kPa
(30 5 psi)
Inlet Manifold Pressure (BOOST)
@ TC Stall RPM (1672 65 rpm)
_______ 30 kPa
(_______ 5 psi)
Torque Converter Stall RPM 1672 65
Torque Converter Temperature (during stall test)
> 80C (175F)
< 121C (250F)
Engine Oil Pressure @ LI
193 to 600 kPa
(28 to 87 psi)
Engine Oil Pressure @ HI
324 to 600 kPa
(47 to 87 psi)
Engine Oil Filter Differential Pressure @ HI
maximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall
303 to 600 kPa
(44 to 87 psi)
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)]
OK
Wastegate %
< 60 %
LI -
HI -
Stall -
3
793C EngPowerTest.doc
7 79 93 3C C E EN NG GI I N NE E P PO OW WE ER R T TE ES ST T
( ( 8 8W WM M H HD D - - n no o w wa as s t t e eg ga at t e e) )
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the
information on the chart provided.
T E S T S P E C S A C T U A L
Coolant Temperature (during tests) > 71C (160F)
Low Idle RPM 700 10
High Idle RPM 1965 20
Air Filter Restriction @ TC Stall (maximum allowed)
25 in. of water
6.2 kPa
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10)
191 35 kPa
(28 5 psi)
Inlet Manifold Pressure (BOOST)
@ TC Stall RPM (1672 65 rpm)
_______ 30 kPa
(_______ 5 psi)
Torque Converter Stall RPM 1672 65
Torque Converter Temperature (during stall test)
> 80C (175F)
< 121C (250F)
Engine Oil Pressure @ LI
220 to 600 kPa
(32 to 87 psi)
Engine Oil Pressure @ HI
324 to 600 kPa
(47 to 87 psi)
Engine Oil Filter Differential Pressure @ HI
maximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall
317 to 634 kPa
(46 to 92 psi)
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)]
OK
1
785C-793C Conv Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C T TO OR RQ QU UE E C CO ON NV VE ER RT TE ER R T TE ES ST T
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) On the ET screen toolbar, click Datalink Select ECM and choose 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:
Converter Clutch Slip Engine Speed TC Out Speed
Torque Converter Output RPM vs Engine RPM
CONVERTER DRIVE
700 rpm
1300 rpm
1950 rpm
Torque Converter Output RPM vs Engine RPM
DIRECT DRIVE
700 rpm
1300 rpm
1950 rpm
2
785C-793C Conv Test.doc
7 78 85 5C C/ / 7 78 89 9C C T TO OR RQ QU UE E C CO ON NV VE ER RT TE ER R T TE ES ST T
T E S T SPECS A C T U A L
Torque Converter Oil Temperature (during tests)
> 80C (175F)
< 121C (250F)
Torque Converter Charge Filter Restriction
Max Restriction
140 15 kPa
(20 2 psi)
LI -
HI -
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--1640 65 rpm
789C--1715 65 rpm
Parking Brake Release Pressure
4700 200 kPa
(680 30 psi)
LI-
HI-
Lockup Clutch Pilot Pressure (RV)
NEUTRAL/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)
3
785C-793C Conv Test.doc
7 79 93 3C C T TO OR RQ QU UE E C CO ON NV VE ER RT TE ER R T TE ES ST T
T E S T SPECS A C T U A L
Torque Converter Oil Temperature (during tests)
> 80C (175F)
< 121C (250F)
Torque Converter Charge Filter Restriction
Max Restriction
140 15 kPa
(20 2 psi)
LI -
HI -
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 1672 65 rpm
Transmission Charge Pressure
LI > 2515 kPa
(365 psi)
1750 rpm < 3065 kPa
(445 psi)
LI -
1750 rpm
1300 -
Dir Drv
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)
1
7 7 8 8 5 5 C C/ / 7 7 8 8 9 9 C C T TR RA AN NS S M MI IS S S S I IO ON N T TE ES S T T
Machine Model _____________________________ Date ________________________________
Machine Serial No. __________________________ Machine Hours _______________________
Transmission S/N ___________________________ Transmission Hours ___________________
Transmission/Chassis Flash File/Release Date
VISUAL CHECKS:
Oil level Oil Viscosity _______________________
Air/Water in Oil? Oil Filter Examination ________________
DUAL STAGE
RELIEF
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)
> 82C (180F)
< 121C (250F)
DUAL STAGE
RELIEF
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
ALL CLUTCH PRESSURES
xxx
2020 + 240 - 100 kPa
(293 + 35 - 15 psi)
xxx
2
7 7 8 8 5 5 C C/ / 7 7 8 8 9 9 C C T TR RA AN NS S M MI IS S S S I IO ON N C CL LU UT TC CH H T TE ES S T TS S
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 approximatley 1380 kPa (200 psi)
1
7 7 9 9 3 3 C C T TR RA AN NS S M MI IS S S S I IO ON N T TE ES S T T
Machine Model ___________________________ Date _______________________________
Machine Serial No. ________________________ Machine Hours_______________________
Transmission S/N_________________________ Transmission Hours___________________
Transmission/Chassis Flash File/Release Date
VISUAL CHECKS:
Oil level Oil Viscosity _______________________
Air/Water in Oil? Oil Filter Examination ________________
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)
> 82C (180F)
< 121C (250F)
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)
STATION "D" PRESSURE
xxx
Adjust station "D" to
get correct rail
(clutch) pressures
ALL CLUTCH PRESSURES
xxx 1620 70 kPa
(235 10 psi)
2
7 7 9 9 3 3 C C T TR RA AN NS S M MI IS S S S I IO ON N C CL LU UT TC CH H T TE ES S T TS S
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
1
T TR RA AN NS SM MI I S SS SI I O ON N/ / C CH HA AS SS SI I S S E EC CM M
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 DESIRED ACTUAL
Body Up Gear Limit Setting
Transmission Maximum Gear Setting
Lockup Clutch Count N/A
Permanent Load Count N/A
ACTIVE FAULT CODES and DESCRIPTION
Fault Code Description Cause
2
T TR RA AN NS SM MI I S SS SI I O ON N/ / C CH HA AS SS SI I S S E EC CM M
INTERMITTENT FAULT CODES
Fault Code
and
Description
Number of
Occurrences First Occurrence Last Occurrence
LOGGED EVENTS
Event Code
and
Description
Number of
Occurrences First Occurrence Last Occurrence
1
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C O OF FF F- - H HI I G GH HW WA AY Y T TR RU UC CK K
S ST TE EE ER RI IN NG G T TE ES ST T
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)
> 60C (150F)
< 121C (250F)
Cycle Time @ High Idle
(steer at one revolution per second)
From Left to Right and Right to Left Combined
7.0 to 9.0
seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
Steering wheel turns from stop to stop
785C: ________ turns
789C: 3.0 to 4.0 turns
793C: ________ turns
Left to Right
1. ____________________
2. ____________________
3. ____________________
AVG.
Right to Left
1. ____________________
2. ____________________
3. ____________________
AVG.
785C Pump Compensator Valve Pressure
Cut-out - 17580 345 kPa (2550 50 psi)
Cut-in - 13950 kPa (2025 psi)
Cut-out -
Cut-in -
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)
2
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C S ST TE EE ER RI IN NG G T TE ES ST T
TEST SPECS ACTUAL
Pump Low Pressure Standby Pressure @ Low Idle
(789C/793C only)
2067 to 3617 kPa
(300 to 525 psi)
Cycle time from Cut-out to Cut-in greater than
15 seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
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
785C: 20670 400 kPa (3000 60 psi)
789C: 22740 345 kPa (3300 50 psi)
793C: 26000 400 kPa (3775 60 psi)
Relief/Makeup Valve Pressure (Right Turn)
785C: 18270 345 kPa (2650 50 psi)
789C: 28000 1000 kPa (4065 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)
Relief/Makeup Valve Pressure (Left Turn)
785C: 18270 345 kPa (2650 50 psi)
789C: 28000 1000 kPa (4065 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)
1. Accumulator Nitrogen Charge Pressure
@ 21C (70F)
785C: 8270 0 kPa (1200 0 psi)
789C: 5512 345 kPa (800 50 psi)
793C: 6545 345 kPa (950 50 psi)
2. Accumulator Nitrogen Charge Pressure
@ 21C (70F)
785C: 8270 0 kPa (1200 0 psi)
789C: 5512 345 kPa (800 50 psi)
793C: 6545 345 kPa (950 50 psi)
1
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C H HO OI IS ST T T TE ES ST T
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 Enable Status 2. The Hoist Enable Status 2 is a test mode only and
will prevent the hoist cylinders from accidentally being activated. After the body is installed, change the Hoist Enable
Status to 1 for the hoist system to function properly. Shown below are the three Hoist Enable Statuses.
Hoist System Enable Status:
0 - hoist system is not installed
1 - hoist system is installed and enabled (normal operation)
2 - hoist system is installed but disabled
Make sure the engine is not running and the truck is not moving. 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 lever in FLOAT, pump output pressure must be less than
1725 kPa (250 psi). The hoist lever must be in HOLD when changing the setting.
2
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C H HO OI IS ST T T TE ES ST T
TEST SPECS ACTUAL
Hoist Oil Temperature
(during tests)
> 65C (150F)
< 121C (250F)
DRIFT
(See Chart on Page 4)
RAISE TIME @ High Idle
785C: 17.0 to 19.0 seconds
789C: 18.0 to 20.0 seconds
793C: 18.0 to 20.0 seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
LOWER TIME @ High Idle
785C: ________ to ________ seconds
789C: 16.0 to 17.0 seconds
793C: ________ to ________ seconds
________ seconds
(not including snub)
________ seconds
(including snub)
1. ____________________
2. ____________________
3. ____________________
AVG.
FLOAT TIME @ High Idle
785C: ________ to ________ seconds
789C: 16.0 to 18.0 seconds
793C: ________ to ________ seconds
________ seconds
(not including snub)
________ seconds
(including snub)
1. ____________________
2. ____________________
3. ____________________
AVG.
PILOT PRESSURE
(Parking Brake Retraction)
4700 200 kPa
(680 30 psi)
LI -
HI -
RAISE PRESSURE @ High Idle
785C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)
789C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)
793C: 20370 + 700 - 0 kPa (2955 + 100 - 0 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 FLOAT
Maximum 1725 kPa (250 psi)
LI -
HI -
LI -
HI -
LI -
HI -
Final Programmed Value
3
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C H HO OI IS ST T T TE ES ST T
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink Select ECM and choose 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 %
4
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C H HO OI IS ST T T TE ES ST T
HOIST
LEVER
POSITION
DUTY CYCLE
(approximate)
ACTUAL
DUTY
CYCLE
HOIST VALVE
SOLENOID
CURRENT %
HOIST VALVE
SOLENOID
CURRENT (mA)
(Solenoid% x 1900)
HOIST VALVE
SOLENOID
CURRENT (mA)
(ACTUAL)
RAISE 5 - 20%
___________ mA
HOLD 25 to 35%
N/A N/A N/A
FLOAT 40 to 70%
___________ mA
LOWER 75 to 95%
___________ mA
NOTE: The current at the solenoids will be equal to the percentage shown on the ET screen x 1900 miliamps.
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)
1
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C A AI I R R S SY YS ST TE EM M A AN ND D B BR RA AK KE E T TE ES ST T
Machine Model_______________________ Date ______________________________
Machine Serial No.____________________ Machine Hours _____________________
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
55035 kPa
(80 5 psi)
Parking Brake Retraction Valve
4700200 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 -
2
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C A AI I R R S SY YS ST TE EM M A AN ND D B BR RA AK KE E T TE ES ST T
Brake Cooling Oil Pressure (Body Down in Float)
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 (793C Hoist Front)
LI -
HI -
LI -
HI -
Right Front Wheel (793C Hoist Rear)
LI -
HI -
LI -
HI -
Left Rear Wheel (793C Rear Oil Cooler)
LI -
HI -
LI -
HI -
Right Rear Wheel
LI -
HI -
LI -
HI -
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
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C A AI I R R S SY YS ST TE EM M A AN ND D B BR RA AK KE E T TE ES ST T
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
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C A AI I R R S SY YS ST TE EM M A AN ND D B BR RA AK KE E T TE ES ST T
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: Minimum 1200 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 40 seconds or less. If the time recorded is greater than 40 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
1
C-Series ARC Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
A AU UT TO O R RE ET TA AR RD DE ER R C CO ON NT TR RO OL L ( ( A AR RC C) ) T TE ES ST T
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)
2
C-Series ARC Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
A AU UT TO O R RE ET TA AR RD DE ER R C CO ON NT TR RO OL L ( ( A AR RC C) ) T TE ES ST T
SETUP DESIRED ACTUAL
Control Speed Setting
Control Valve Cycles
Supply Valve Cycles
ACTIVE FAULT CODES and DESCRIPTION
Fault Code Description Cause
LOGGED FAULT AND EVENT CODES
Fault Code and
Description
Number of
Occurrences
First Occurrence Last Occurrence
3
C-Series ARC Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
A AU UT TO O R RE ET TA AR RD DE ER R C CO ON NT TR RO OL L ( ( A AR RC C) ) T TE ES ST T
ARC OVERSPEED PROTECTION
Horn and Light Activate *
Activation Speed
(supply solenoid ON)
ARC Shutoff
Auto Upshift **
2100 rpm
2180 rpm
2100 rpm
2075 rpm
2300 rpm
ARC Control Speed
ARC NORMAL OPERATION
FUNCTION ENGINE SPEED
Activation 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
** Auto Upshifts are controlled by the Transmission/Chassis ECM
1
785C-793C TCS Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
T TR RA AC CT TI I O ON N C CO ON NT TR RO OL L S SY YS ST TE EM M ( ( T TC CS S) ) T TE ES ST T
Machine Model Date
Machine Serial No. Machine Hours
Brake ECM Flash File/Date
TEST 1 : Perform TCS test using the TCS TEST SWITCH:
1) On the ET screen toolbar, select Datalink Select ECM and choose 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
2
785C-793C TCS Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
T TR RA AC CT TI I O ON N C CO ON NT TR RO OL L S SY YS ST TE EM M ( ( T TC CS S) ) T TE ES ST T
TEST SPECS ACTUAL
Brake Oil Temperature (during tests) > 65C (150F)
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), then gradually decrease. This is the function of the proportional solenoid
and orifices.
TEST 2 : FUNCTIONAL TEST
Remove all test pressure gauges and run the engine at Low Idle.
Engage First Gear, Low Idle, Brakes Released with the TCS Test Switch Depressed; Brakes
ENGAGE and RELEASE intermittently?
Wheels Turned to the RIGHT: YES NO
Wheels Turned to the LEFT: YES NO
3
785C-793C TCS Test.doc
7 78 85 5C C/ / 7 78 89 9C C/ / 7 79 93 3C C
T TR RA AC CT TI I O ON N C CO ON NT TR RO OL L S SY YS ST TE EM M ( ( T TC CS S) ) T TE ES ST T
ACTIVE FAULT CODES and DESCRIPTION
Fault Code Description Cause
LOGGED FAULT CODES
Fault Code and
Description
Number of
Occurrences
First Occurrence Last Occurrence
F FR RO ON NT T S SU US SP PE EN NS SI I O ON N C CY YL LI I N ND DE ER R C CH HA AR RG GI I N NG G
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)
768C/769C - 773B/775B 3.2 (0.125)
776C/777C 5.1 (0.20)
784B/785B - 793B 6.4 (0.25)
R RE EA AR R S SU US SP PE EN NS SI I O ON N C CY YL LI I N ND DE ER R C CH HA AR RG GI I N NG G
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)
773D/775D 124 (4.9) 137 (5.4)
776C/777C/776D/777D 102 (4.0) 114 (4.5)
784B/785B/C 104 (4.1) 117 (4.6)
789B/C 108 (4.25) 121 (4.75)
793B/C 121 (4.75) 133 (5.25)
1 Sensor Specs.doc
TEMPERATURE SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
Temperature Sensors
TEMPERATURE SIGNAL VOLTAGE DUTY CYCLE
-40 to -20 C (-40 to -4 F) 1.1 to 1.1 DCV 10 to 11 %
-20 to 0 C (-4 to 32 F) 1.1 to 1.4 DCV 11 to 15 %
0 to 20 C (32 to 68 F) 1.4 to 1.9 DCV 15 to 23 %
20 to 40 C (68 to 104 F) 1.9 to 2.9 DCV 23 to 37 %
40 to 60 C (104 to 140 F) 2.9 to 4.0 DCV 37 to 55 %
60 to 80 C (140 to 176 F) 4.0 to 5.1 DCV 55 to 71 %
80 to 100 C (176 to 212 F) 5.1 to 5.8 DCV 71 to 82 %
100 to 120 C (212 to 248 F) 5.8 to 6.3 DCV 82 to 89 %
120 to 135 C (248 to 275 F) 6.3 to 6.5 DCV 89 to 93 %
Tolerance is 10%
EXHAUST TEMPERATURE SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
Temperature Sensor (Exhaust)
TEMPERATURE SIGNAL VOLTAGE DUTY CYCLE
50 to 200 C (122 to 392 F) 1.4 to 2.0 DCV 22 to 33 %
200 to 400 C (392 to 725 F) 2.0 to 2.8 DCV 35 to 50 %
400 to 600 C (725 to 1112 F) 2.8 to 3.7 DCV 50 to 67 %
600 to 850 C (1112 to 1562 F) 3.7 to 4.8 DCV 67 to 88 %
Tolerance is 10%
2 Sensor Specs.doc
REAR PARKING BRAKE RELEASE PRESSURE SENSORS CHART
SENSOR DUTY CYCLE SPECIFICATION
Pressure Sensors on TCS Valve
ABSOLUTE PRESSURE DUTY CYCLE
88.7 to 1379 kPa (0 to 200 psi) 0 to 22.3 %
1379 to 2759 kPa (200 to 400 psi) 22.3 to 46.2 %
2759 to 4138 kPa (400 to 600 psi) 46.2 to 70.0 %
4138 to 5517 kPa (600 to 800 psi) 70.0 to 93.9 %
Tolerance is 3%
AIR PRESSURE SENSOR CHARTS:
Early Configurations
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
Pressure Sensor (AIR)
Air Pressure SIGNAL VOLTAGE DUTY CYCLE
0 to 200 kPa (0 to 29 psi) 0.8 to 1.1 DCV 8 to 13 %
200 to 400 kPa (29 to 58 psi) 1.1 to 1.4 DCV 13 to 19 %
400 to 600 kPa (58 to 88 psi) 1.4 to 1.7 DCV 19 to 25 %
600 to 800 kPa (88 to 115 psi) 1.7 to 2.0 DCV 25 to 30 %
800 to 1000 kPa (115 to 145 psi) 2.0 to 2.3 DCV 30 to 36 %
Later Configurations
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
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%
3 Sensor Specs.doc
ULTRASONIC FUEL LEVEL SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
Ultrasonic Fuel Level Sensor
Depth of Fuel (Shallow Tank)
SIGNAL
VOLTAGE
DUTY CYCLE
0 to 250 mm (0 to 9.9 inch) 0.6 to 1.9 DCV 6 to 25 %
250 to 500 mm (9.9 to 19.7 inch) 1.9 to 3.2 DCV 25 to 45 %
500 to 750 mm (19.7 to 29.6 inch) 3.2 to 4.5 DCV 45 to 64 %
750 to 1000 mm (29.6 to 39.4 inch) 4.5 to 5.7 DCV 64 to 84 %
Tolerance is 10%