CATERPILLAR MONITORING SYSTEM

Machine Model _______________________ Machine Serial No. ____________________ ECM Part No. ________________________ Date __________________________________ Machine Hours/Miles_____________________ Software Part No./Date____________________

VISUAL CHECKS: Electrical Connections SETUP MODE 0: Resettable Load Count MODE 1: Harness Code Setting MODE 6: Permanent Load Count MODE 7.7: Economy Shift Setting N/A Not Used on 777D Not Used on 777D Component Damage _________________ SPECS N/A ACTUAL

MODE 4: LOGGED RECORDS GAUGES Engine Coolant Temperature Brake Oil Temperature Tachometer Ground Speed MAX/MIN ALLOWABLE 107C (225F) 121C (250F) 2100 rpm 60.4 km/h (37.5 mph) ALERT INDICATORS ON IN MODE 4 ACTUAL

CATERPILLAR MONITORING SYSTEM

MODE 3: ACTIVE DIAGNOSTIC CODES and DESCRIPTION DIAGNOSTIC CODE DESCRIPTION CAUSE

MODE 3: INTERMITTENT DIAGNOSTIC CODES and DESCRIPTION DIAGNOSTIC CODE DESCRIPTION CAUSE

MODE 7.1: Shift Lever and Actual Gear Switch Operation NOTES:

OK

NOT OK

MODE 7.5: Hoist Lever Input and Output Signal Operation NOTES:

OK

NOT OK

MODE 7.6: Actual Gear Switch Input Signal Operation NOTES:

OK

NOT OK

MODE 7.8: Shift Lever Switch Input Signal Operation NOTES:

2

OK

NOT OK

CATERPILLAR MONITORING SYSTEM

SENSOR TESTS
Sensor Supply Voltage Actual Temperature/ Actual Signal Air Pressure/ Volts/Hz/Duty Cycle/ Fuel Level Resistance (A-B) (ET) (BC) Pull-Up Voltage (B-C)

Brake Oil Temperature Torque Converter Oil Temperature Brake Air Pressure Fuel Level Sender Alternator "R" Terminal Brake Overstroke Switch Transmission Filter Switch NOTE: N/A N/A N/A

12.4 to 14.75 DCV > 95 Hz

N/A N/A

N/A

N/A N/A

N/A N/A

Fuel level resistance: Empty--92 ohms, Full--3.5 ohms. Pull-up voltage is approx 6.2 volts. Most sensor supply voltage is 8.0 0.5 volts. Brake air sensor supply is + Battery.
3

TRUCK PRODUCTION MANAGEMENT SYSTEM (TPMS)

Machine Model ___________________ Machine Serial No. ________________ Date _________________________ Machine Hours _________________

VISUAL CHECKS: Electrical Connections Component Damage ____________

SETUP MODE 1: Truck Model Setting MODE 2: System Units Setting MODE 3: Target Weight Setting MODE 4: Truck Identification Code Setting MODE 5: System Options Setting MODE 6: System Calibration

SPECS

ACTUAL

YES NO

PAYLOAD LIGHT OPERATION Left side lights are operational: YES ________ NO _________ Right side lights are operational: YES ________ NO _________

PAYLOAD TIME CLOCK SETTING TPMS Time clock is set correctly: YES ________ NO _________

TPMS
MODE 7: ACTIVE FAULTS Description Cause

MODE 7: INTERMITTENT FAULTS Description Cause

777D OFF-HIGHWAY T RUCK E NGINE T E S T S

Machine Model ______________________ Machine Serial No. ___________________ Engine Serial No. ____________________ ECM Serial No. _____________________ Personality Module ___________________ Test Spec (ET or Eng Plate) ____________ Rated Power ________________________ Fuel Ratio Control Offset ______________ Horsepower Configuration (Rating Number): Using the Engine Information Plate and the ET Screens, ECM Summary, Logged Diagnostic Codes and the Configuration Screen, fill in the information requested. Date ________________________________ Machine Hours ________________________ Engine Hours _________________________ Throttle Pedal Configuration _____________ Personality Module Date ________________ Max Altitude__________________________ Full Load RPM________________________

E NGINE T E S T S
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.

E NGINE T E S T S
Sensor Tests Sensor
Filtered Engine Oil Pressure Unfiltered Engine Oil Pressure Coolant Temperature Aftercooler Temperature Atmospheric Pressure Crankcase Pressure Right Turbo Inlet Pressure Left Turbo Inlet Pressure Turbo Outlet Pressure Left Exhaust Temperature Right Exhaust Temperature NOTE:

Supply Voltage (A-B)

Desired Signal Volts or Duty Cycle .2 to .6 .2 to .6 .4 to 4.6 .4 to 4.6 2.2 to 4.6 2.2 to 4.6 2.2 to 4.6 2.2 to 4.6 .8 to 1.5 see below see below

Actual Signal Voltage/% (B-C)

Pull-up Actual Temperature/ Voltage Pressure (ET or VIMS) (B-C)

0 0

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 49C (120F) 10% to 21% 49 to 851C (120 to 1564F) - 22% to 88% above 851C (1564F) 88% to 90%

E NGINE T E S T S
TEST ECM Supply Voltage Throttle Sensor Supply Voltage (A-B) Throttle Sensor Low Idle Duty Cycle (B-C) Throttle Sensor High Idle Duty Cycle (B-C) Throttle Sensor Frequency (B-C) Throttle Sensor Pull-Up Voltage (B-C) Speed Sensor Supply Voltage (A-B) Speed Sensor Frequency (Cranking) (B-C) Speed Sensor Frequency (Low Idle) (B-C) Speed Sensor Frequency (High Idle) (B-C) Speed Sensor Signal Voltage (Key ON) (B-C) SPECS ACTUAL

24 8.0 0.5 16 6% Early - 48 4% Later - 85 4% 150-1000 Hz 11.5 0.5 12.5 1.0 23 - 40 Hz 140 Hz@700 rpm 385 Hz@1960 rpm less than 3.0 or greater than 10.0 2.0 to 4.0

Speed Sensor Signal Voltage (Cranking) (B-C)

E NGINE T E S T S
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTION

LOGGED DIAGNOSTIC CODES

DIAGNOSTIC CODE DESCRIPTION NUMBER FIRST OF HOUR OCCURR METER LAST HOUR METER

EVENT CODES
EVENT CODE DESCRIPTION NUMBER FIRST OF HOUR OCCURR METER LAST HOUR METER

E NGINE T E S T S
INJECTOR SOLENOID TEST: CYLINDERS OPEN CYLINDERS SHORTED

OVERRIDE PARAMETERS: ETHER INJECTION: ENGINE PRELUBE: OIL RENEWAL: OK OK OK NOT OK NOT OK NOT OK N/A N/A N/A

CURRENT TOTALS: FUEL ETHER TOTAL TIME

CYLINDER CUTOUT TEST: Injector 1: Duration: Injector 2: Duration: Injector 3: Duration: Injector 4: Duration: Injector 5: Injector 6: Injector 7: Injector 8: Duration: Duration: Duration: Duration:

Average Injection Duration Cylinders more than 10 TO 15% from Average

E NGINE T E S T S
INJECTOR CODES CALIBRATION: Injector 1: Injector 2: Injector 3: Injector 4: Code: Code: Code: Code: Injector 5: Injector 6: Injector 7: Injector 8: Code: Code: Code: Code:

NOTE: Default is 1100 NOTES:

PRESSURE SENSOR CALIBRATION: NOTES:

OK

NOT OK

TIMING CALIBRATION: NOTES:

OK

NOT OK

777D UPDATE ENGINE POWER TEST

Machine Model Machine Serial No. Engine Serial No. Rating No. ECM Serial No. _______________________ Flash File (software) ____________________ Throttle Pedal Configuration VISUAL CHECKS Oil Level Oil Filter Examination Date Machine Hours Engine Hours Rated Power Performance Spec Flash File Date

Create a Test Group on ET: 1) Using ET, choose the Engine ECM 2) In the Configuration Screen, make sure the engine is set to Rating "2" 746 kW (1000 hp) 3) In the Status Group, create a new group name "777D Engine Power Test" 4) Select the items as shown on the ET screen below:

777D UPDATE ENGINE POWER TEST

Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on the chart provided. TEST Horse Power Rating Coolant Temperature (during tests) Low Idle RPM High Idle RPM Air Filter Restriction @ TC Stall (maximum allowed) Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 10) Inlet Manifold Pressure (BOOST) @ TC Stall RPM (1605 65 rpm) Torque Converter Stall RPM Torque Converter Temperature (during stall test) SPECS "2" (1000 HP) > 71C (160F) 700 10 1937 20 25 in. of water 6.2 kPa 210 28 kPa (30 4 psi) 172 28 kPa (25 4 psi) 1540 to 1670 > 80C (175F) < 121C (250F) 170 to 600 kPa (25 to 87 psi) 365 to 600 kPa (53 to 87 psi) maximum 70 kPa (10 psi) 360 to 725 kPa (52 to 105 psi) OK ACTUAL

Engine Oil Pressure @ Low Idle

Engine Oil Pressure @ High Idle

Engine Oil Filter Differential Pressure @ High Idle

Fuel Pressure @ Torque Converter Stall Fuel Filter Status [maximum restriction 140 kPa (20 psi)]

777D UPDATE TORQUE CONVERTER TEST

Machine Model Machine Serial No. Converter Serial No. Date Machine Hours Converter Hours

Transmission ECM Flash File (Software Grp Part #) / Date VISUAL CHECKS Oil Level Air/Water in Oil? Oil Filter Examination

TEST Torque Converter Oil Temperature (during tests)

SPECS > 80C (175F) < 121C (250F)

ACTUAL

Torque Converter Inlet Pressure

Maximum at High Idle LI with Cold Oil HI 930 35 kPa (135 5 psi) STALLLI -

Torque Converter Outlet Pressure @ STALL rpm

380 to 520 kPa (55 to 75 psi)

HI STALL-

Torque Converter Stall RPM

1540 to 1670 rpm 4700 200 kPa (680 30 psi) 1725 70 kPa (250 10 psi) 1030 35 kPa (150 5 psi) 2135 70 kPa (310 10 psi) LI HI -

Parking Brake Release Pressure

Lockup Clutch Pilot Pressure (RV) NEUTRAL/LOW IDLE Lockup Clutch Primary Pressure (remove LP plug) NEUTRAL/DIRECT DRIVE/LOW IDLE Lockup Clutch Maximum Pressure NEUTRAL/DIRECT DRIVE/1300 rpm

7 7 7 D U PD A TE OFF- HIGHWA Y TRU CK TRA N S MIS S ION TES T

Machine Model ______________________________ Machine Serial Number________________________ Transmission Serial Number____________________ Date _______________________________ Machine Hours_______________________ Transmission Hours___________________

Transmission ECM Flash File (Software Grp Part #) / Date _____________________________________ VISUAL CHECKS: Oil level ___________________________________ Air/Water in Oil? ____________________________ Oil Leaks? _________________________________ Oil Viscosity ________________________ Suction Screen Debris? ________________ Oil Filter Examination _________________

SPECS LI TRANSMISSION PUMP PRESSURE minimum 2480 kPa (360 psi) 4 to 41 kPa (.5 to 6 psi) 172570 kPa (25010 psi) HI maximum 3200 kPa (465 psi) 83 to 138 kPa (12 to 20 psi) LI

ACTUAL HI

LUBE PRESSURE

PILOT PRESSURE @ Low Idle

N/A

N/A

Transmission Oil Temperature (during tests)

80 3C (160 5F)

777D

UPDATE TRA N S MIS S ION CLU TCH TES TS

PRIMARY CLUTCH PRESSURE @ L.I. Load Piston Plug Removed
STATION CLUTCH SPECS 380 KPA (55 psi) 275 KPA (40 psi) 345 KPA (50 psi) xxx 345 KPA (50 psi) 415 KPA (60 psi) 415 KPA (60 psi) 550 KPA (80 psi) xxx ACTUAL

CLUTCH CHART
SPEED CLUTCHES ENGAGED

N R 1 2 3 4 5 6 7

1 1 and 7 2 and 6 1 and 6 3 and 6 1 and 5 3 and 5 1 and 4 3 and 4

A B C D E F G H

4 2 1
xxx

5 6 7 3
xxx

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

MAXIMUM CLUTCH PRESSURE Load Piston Plug Installed

SPECS STATION CLUTCH LI xxx 2365 kPa (343 psi) 2780 kPa (403 psi) xxx xxx 2515 kPa (365 psi) 2760 kPa (400 psi) xxx HI 1425 kPa (207 psi) 2365 kPa (343 psi) 2880 kPa (418 psi) xxx 2435 kPa (373 psi) 2515 kPa (365 psi) 2760 kPa (400 psi) 1825 kPa (265 psi) LI xxx ACTUAL HI

A B C D E F G H

4 2 1
xxx

xxx xxx

xxx

5 6 7
3

xxx

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

TRANSMISSION/CHASSIS ECM
Machine Model ___________________________ Machine Serial No. ________________________ Transmission Serial No. ____________________ Flash File (Software Part #)__________________ ECM Location Code _______________________ Date _________________________________ Machine Hours _________________________ Transmission Hours _____________________ Flash File Release Date __________________ ECM Serial No. ________________________

VISUAL CHECKS: Electrical Connections Component Damage ____________________

SETUP Economy Mode (ON or OFF) Body Up Gear Limit Setting (1 to 3) Transmission Maximum Gear Setting (3 to 7) Lockup Clutch Count Permanent Load Count

DESIRED Not Used on 777D

ACTUAL Not Used on 777D

N/A N/A ACTIVE DIAGNOSTIC CODES and DESCRIPTION

Diagnostic Code

Description

Cause

TRANSMISSION/CHASSIS ECM
INTERMITTENT DIAGNOSTIC CODES Diagnostic Code and Description Number of Occurrences

First Occurrence

Last Occurrence

LOGGED EVENTS Event Code and Description Number of Occurrences

First Occurrence

Last Occurrence

7 7 7 D U P D A T E S T E E RING T E S T
Machine Model_______________________ Machine Serial No.____________________ Date ______________________________ Machine Hours _____________________

VISUAL CHECKS: Oil level Air/Water in Oil? TEST Steering Oil Temperature (during tests) Oil Viscosity _______________________ Oil Filter Examination _______________ SPECS > 38C (100F) < 121C (250F)
1. ____________________

ACTUAL

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

5.5 to 7.5 seconds

2. ____________________ 3. ____________________ AVG.

Steering Wheel turns from stop to stop @ High Idle (steer at one revolution per second) All Brakes Released approximately 3.3 turns Primary Steering Pressure @ High Idle (Steer hard against stops) Primary Steering Backup Relief Valve Pressure @ High Idle (Steer hard against stops) Low Pressure Standby @ Low Idle (Do Not Steer) Secondary Steering Pressure (Steer hard against stops) Secondary Steering Backup Relief Valve Pressure (Steer hard against stops) 1

Left to Right 1. ____________________ 2. ____________________ 3. ____________________ AVG.

Right to Left 1. ____________________ 2. ____________________ 3. ____________________ AVG.

23425 345 KPA (3400 50 PSI) 26000 400 KPA (3775 60 PSI) 2070 to 2950 KPA (300 to 430 PSI) 16880 345 KPA (2450 50 PSI) 20700 400 KPA (3000 60 PSI)

7 7 7 D U P D A T E S T E E RING T E S T

TEST Steering Pressure Switch Pressure Reducing Valve Crossover Relief Valve (Left)

SPECS 2600 + 500 - 200 KPA (375 + 70 - 30 PSI) 27200 690 KPA (3950 100 PSI) 27200 690 KPA (3950 100 PSI)

ACTUAL

Crossover Relief Valve (Right)

7 7 7 D U P D A T E HOIS T T E S T
Machine Model ____________________________ Machine Serial No. _________________________ Hoist System Enable Status___________________ Date _____________________________________ Machine Hours_____________________________ Hoist LOWER Adjustment Setting _____________

Transmission ECM Flash File (Software Grp Part #) /Date ______________________________________ VISUAL CHECKS: Oil level _________________________________ Air/Water in Oil? __________________________ Oil Viscosity ______________________________ 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 output in SNUB, pump output pressure must be less than 1725 kPa (250 psi). The hoist lever must be in HOLD when changing the setting.

7 7 7 D U P D A T E HOIS T T E S T
TEST Hoist Oil Temperature (during tests) SPECS > 65C (150F) < 121C (250F)
1. ____________________

ACTUAL

RAISE TIME @ High Idle

(Noise Reduction OFF)

14.0 to 16.0 seconds

2. ____________________ 3. ____________________ AVG.

See NOTE LOWER (POWER DOWN) TIME @ High Idle (With Snub) (Noise Reduction OFF)

1. ____________________ 2. ____________________ 3. ____________________ AVG.

10.5 to 12.5 seconds

See NOTE FLOAT TIME @ High Idle (With Snub) (Noise Reduction OFF)

1. ____________________ 2. ____________________ 3. ____________________ AVG.

10.5 to 12.5 seconds

PILOT PRESSURE (Parking Brake Retraction)

4700 200 kPa (680 30 psi) 18950 + 520 - 0 kPa (2750 + 75 - 0 psi) 3450 350 kPa (500 50 psi)

LI HI -

RAISE PRESSURE @ High Idle

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

NOTE: The FLOAT and LOWER time can be changed with the Hoist Adjustment Setting in the ET Configuration Screen

7 7 7 D U P D A T E HOIS T T E S T
Create a Test Group on ET: 1) Using ET, choose 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:

ET Setting HOIST PRESSURE IN SNUB (At Pump Tap) Maximum 1725 kPa (250 psi) Hoist Lower Solenoid Current (Hoist Output in SNUB) LI HI -

-5 LI HI -

0 LI HI -

+5

Final Programmed Value

7 7 7 D U P D A T E HOIS T T E S T
HOIST LEVER SENSOR TEST Supply Voltage Pull-Up Voltage SPECS + Battery (24 Volts) Approx 5 Volts ACTUAL

HOIST LEVER POSITION RAISE HOLD FLOAT LOWER

DUTY CYCLE (approximate)

ACTUAL DUTY CYCLE

HOIST VALVE SOLENOID SOLENOID CURRENT CURRENT % (mA) FROM ET (ET Solenoid % x 1900) ___________ mA N/A ___________ mA ___________ mA

HOIST VALVE SOLENOID CURRENT (mA) (ACTUAL)

5 - 20% 25 to 35% 40 to 70% 75 to 95%

N/A

NOTE: The current at the solenoids will be equal to the percentage shown on the ET screen x 1900 miliamps.

DRIFT TEST: OIL TEMP

MINUTES

ACCEPTABLE CYLINDER DRIFT MINUTES 12.4 9.6 7.8 6.4 5.3 4.4 3.8 3.2 2.8 OIL TEMPERATURE 38 C (100 F) 43 C (110 F) 49 C (120 F) 54 C (130 F) 60 C (140 F) 66 C (150 F) 71 C (160 F) 77 C (170 F) 82 C (180 F) CYLINDER DRIFT 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in)

777D UPDATE AIR SYSTEM AND BRAKE TEST

Machine Model_______________________ Machine Serial No.____________________ Date ______________________________ Machine Hours _____________________

VISUAL CHECKS: Hose Connections Air Leaks TEST Air Compressor Governor Setting (CUT-OUT) Air Compressor Governor Setting (CUT-IN) #1 Pressure Protection Valve (Behind Cab) (Drain Secondary Brake Tank to See Close Setting) #2 Pressure Protection Valve (ARC Relay Valve) Front Brake Ratio Valve (50/50 operation) Component Damage _________________ Oil Leaks _________________________ SPECS 830 35 kPa (120 5 psi) 655 35 kPa (95 5 psi) Open-550 kPa (80 psi) Close-480 kPa (70 psi) Open-380 kPa (55 psi) Close-310 kPa (45 psi) (below 65 psi only) 550 35 kPa (80 5 psi) 4700 200 kPa (680 30 psi) 79 to 93 C 175 to 200 F LI - min 14 kPa (2 psi) HI - max 172 kPa (25 psi) LI HI LIHIBrake Cooling Oil Temperature (during brake cooling pressure test) Brake Cooling Oil Pressure (SNUB Only) Relief Valve Setting: 585 15 kPa (85 2 psi) Open-Close-Open-Close-ACTUAL

Retarder Valve--Maximum Air Pressure

Parking Brake Release Valve

777D UPDATE AIR SYSTEM AND BRAKE TEST

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

TEST
Towing Pump Pressure (minimum) Towing pump pressure after: 1 minute: 2 minutes: 3 minutes:

SPECS 3790 kPa (550 psi)

ACTUAL

4 minutes: 5 minutes:

BRAKE CYLINDER OPERATION

TEST BRAKE AIR PRESSURE @ Brake Cylinder BRAKE OIL PRESSURE @ Slack Adjuster or Brake Caliper

Front Brake Cylinders Air/Oil Ratio (11.8 to 1) Rear Brake Cylinders Air/Oil Ratio (6.6 to 1)

777D UPDATE AIR SYSTEM AND BRAKE TEST

SLACK ADJUSTER OPERATION SLACK ADJUSTER TAP
Engaged Released

WHEEL PORT TAP

Engaged Released Residual Pressure

Left Front Wheel Front Right Front Wheel Left Rear Wheel Rear Right Rear Wheel NOTE: Low residual pressure MAY indicate a failed Slack Adjuster. High residual pressure may also indicate a failed Slack Adjuster or warped brake discs. Rotate wheel to see if pressure fluctuates. Released (residual) pressure at "S" port after releasing parking brakes: Front (oil cooled): 120 kPa (17.4 psi) Rear: 105 kPa (15.3 psi)

BRAKE HOLDING CAPACITY Service Brake Engaged Parking Brake Engaged NOTE: Minimum 1200 rpm rpm rpm Manual Retarder Engaged Secondary Brake Engaged rpm rpm

777D UPDATE AIR SYSTEM AND BRAKE TEST

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

Brake Assembly Leakage

TEST 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. Start Pressure Pressure after 5 minutes

777D UPDATE AUTO RETARDER CONTROL (ARC) TEST

Machine Model Machine Serial No. 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 Date Machine Hours

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

Maximum Air Pressure (Brake Cylinder)

Maximum Brake Oil Pressure (Slack Adjuster)

777D UPDATE AUTO RETARDER CONTROL (ARC) TEST

SETUP Control Speed Setting Control Valve Cycles Supply Valve Cycles N/A N/A ACTIVE DIAGNOSTIC CODES and DESCRIPTION Diagnostic Code Description Cause DESIRED ACTUAL

LOGGED DIAGNOSTIC AND EVENT CODES Diagnostic and Event Code and Description Number of Occurrences First Occurrence Last Occurrence

777D UPDATE AUTO RETARDER CONTROL (ARC) TEST

ARC NORMAL OPERATION FUNCTION

Activation Speed (supply solenoid ON) ARC Control Range Factory Setting

ENGINE SPEED
1850 rpm 1850 to 1950 rpm 1950 rpm

ARC OVERSPEED PROTECTION

Horn and Light Activate * Activation Speed (supply solenoid ON) ARC Control Speed ARC Shutoff Auto Upshift ** 2100 rpm 2100 rpm 2180 rpm 2075 rpm 2300 rpm

* The Horn and Light are controlled by the Engine ECM ** Auto Upshifts are controlled by the Transmission/Chassis ECM

777D UPDATE TRACTION CONTROL SYSTEM (TCS) TEST

Machine Model Machine Serial No. 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: Date Machine Hours

4) 5) 6) 7)

Run the engine at LOW IDLE Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED 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

777D UPDATE TRACTION CONTROL SYSTEM (TCS) TEST

TEST Brake Oil Temperature (during tests) SPECS > 65C (150F) 4700 200 kPa (680 30 psi) LIHIACTUAL

Parking Brake Release Pressure

Left Brake Pressure (Released) Left Brake Pressure (Engaged) Right Brake Pressure (Released) Right Brake Pressure (Engaged) ET Proportional Solenoid Percentage Proportional Solenoid Resistance/Voltage Left Selector Solenoid Resistance/Voltage Right Selector Solenoid Resistance/Voltage < 300 kPa (44 psi) 44% 12 to 22 ohms 0 to 12 Volts 18 to 45 ohms 24 Volts 18 to 45 ohms 24 Volts < 300 kPa (44 psi)

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: Wheels Turned to the LEFT: YES YES NO NO

777D UPDATE TRACTION CONTROL SYSTEM (TCS) TEST

ACTIVE DIAGNOSTIC CODES and DESCRIPTION Diagnostic Code Description Cause

LOGGED DIAGNOSTIC CODES Diagnostic Code and Description Number of Occurrences First Occurrence Last Occurrence

FRONT SUSPENSION CYLINDER CHARGING

Machine Model __________________________ Serial Number ___________________________ Date_____________________________________ Machine Hours_____________________________ 769-773: 777-793: 769-773: 777: 785-793: 25 mm (1.0 in.) 13 mm (0.5 in.) 170 mm (6.7 in.) 216 mm (8.5 in.) 265 mm (10.4 in.)

Oil Charge Dimension: _________________________

Nitrogen Charge Dimension: ____________________

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: 785-789: 793:

2400 kPa (350 psi) 2200 kPa (320 psi) 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 768C/769C - 773B/775B 776C/777C 784B/785B - 793B Shim Thickness mm/5.5 C (in./10 F) 3.2 (0.125) 5.1 (0.20) 6.4 (0.25)

REAR SUSPENSION CYLINDER CHARGING

Machine Model __________________________ Serial Number ___________________________ Date_____________________________________ Service Meter Hours________________________

Oil Charge Dimension: ___________________

769-773: 777-793:

25 mm (1.0 in.) 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: * (After Charging is Complete for future inspection)

Left Rear _____________ Right Rear ____________

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 First Charge Line Second Charge Line mm (in.) mm (in.) 128 (5.0) 124 (4.9) 102 (4.0) 104 (4.1) 108 (4.25) 121 (4.75) 140 (5.5) 137 (5.4) 114 (4.5) 117 (4.6) 121 (4.75) 133 (5.25)

Truck Model 769D/771D 773D/775D

776C/777C/776D/777D 784B/785B/C 789B/C 793B/C

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 (777D AGC00201) Enter a new document name and description (Brake cooling test with sensors at xx, xx, xxx, etc.)

DATAVIEW TOOLS
NEHS0662 131-5051 153-9630 143-4062 143-4065 143-4066 6V4144 6V2198 137-0168 137-0170 4C6824 4C4463 Software and Instruction Manual DataView Portable Tech Station Group PWM-Analog Test Group Sensor Adapter Kit 100 psi sensor 1000 psi sensor 7500 psi sensor Internal 1/4 nptf Valved Coupler (for each sensor) 18 ft. sensor extension cable Machine battery power cable 12V Cigarette Lighter power cable Carrying case for Sensors and Cables Yellow case for small parts
1

777D SENSORS IN DATAVIEW SENSOR TABLE 102-2240 - Temperature: 118-7226 - Temperature: 163-7882 - Temperature: 118-3909 - Temperature: Engine Coolant, Rear Aftercooler Coolant (analog) Brake, Torque Converter (digital) Engine Exhaust (digital) 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) 185-0600 - PWM Pressure: Air System (digital) 157-8394 - PWM Pressure: Rear Parking Brakes (digital)

Speed Sensor Teeth (PPR) Sensor Engine Output Speed (EOS) Sensor Transmission Output Speed (TOS) Sensor Traction Control System (TCS) Wheel Speed Sensors Number of Teeth 151 120

48

Engine Speed Adapter Cable

To measure the Engine Speed with DataView, a 2-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.

DIGITAL TEMPERATURE SENSOR CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION Digital Temperature Sensors TEMPERATURE -40 to -20 C (-40 to -4 F) -20 to 0 C (-4 to 32 F) 0 to 20 C (32 to 68 F) 20 to 40 C (68 to 104 F) 40 to 60 C (104 to 140 F) 60 to 80 C (140 to 176 F) 80 to 100 C (176 to 212 F) 100 to 120 C (212 to 248 F) 120 to 135 C (248 to 275 F) Tolerance is 10% SIGNAL VOLTAGE 1.1 to 1.1 DCV 1.1 to 1.4 DCV 1.4 to 1.9 DCV 1.9 to 2.9 DCV 2.9 to 4.0 DCV 4.0 to 5.1 DCV 5.1 to 5.8 DCV 5.8 to 6.3 DCV 6.3 to 6.5 DCV DUTY CYCLE 10 to 11 % 11 to 15 % 15 to 23 % 23 to 37 % 37 to 55 % 55 to 71 % 71 to 82 % 82 to 89 % 89 to 93 %

EXHAUST TEMPERATURE SENSOR CHART SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION Temperature Sensor (Exhaust) TEMPERATURE 50 to 200 C (122 to 392 F) 200 to 400 C (392 to 725 F) 400 to 600 C (725 to 1112 F) 600 to 850 C (1112 to 1562 F) Tolerance is 10% SIGNAL VOLTAGE 1.4 to 2.0 DCV 2.0 to 2.8 DCV 2.8 to 3.7 DCV 3.7 to 4.8 DCV DUTY CYCLE 22 to 33 % 35 to 50 % 50 to 67 % 67 to 88 %

REAR PARKING BRAKE RELEASE PRESSURE SENSORS CHART SENSOR DUTY CYCLE SPECIFICATION Pressure Sensors on TCS Valve ABSOLUTE PRESSURE 88.7 to 1379 kPa (0 to 200 psi) 1379 to 2759 kPa (200 to 400 psi) 2759 to 4138 kPa (400 to 600 psi) 4138 to 5517 kPa (600 to 800 psi) Tolerance is 3% AIR PRESSURE SENSOR CHARTS: Early Configurations SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION 9X5272, 161-9931, 100-4311 Pressure Sensor (AIR) Air Pressure 0 to 200 kPa (0 to 29 psi) 200 to 400 kPa (29 to 58 psi) 400 to 600 kPa (58 to 88 psi) 600 to 800 kPa (88 to 115 psi) 800 to 1000 kPa (115 to 145 psi) Later Configurations SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION 153-3962, 185-0600 Pressure Sensor (AIR) Air Pressure 0 kPa (0 psi) 140 kPa (20 psi) 275 kPa (40 psi) 415 kPa (60 psi) 550 kPa (80 psi) 690 kPa (100 psi) 825 kPa (120 psi) Tolerance is 10%
2

DUTY CYCLE 0 to 22.3 % 22.3 to 46.2 % 46.2 to 70.0 % 70.0 to 93.9 %

SIGNAL VOLTAGE 0.8 to 1.1 DCV 1.1 to 1.4 DCV 1.4 to 1.7 DCV 1.7 to 2.0 DCV 2.0 to 2.3 DCV

DUTY CYCLE 8 to 13 % 13 to 19 % 19 to 25 % 25 to 30 % 30 to 36 %

DUTY CYCLE 9.6 % 19.6 % 31.3 % 41.2 % 50.2 % 62 % 83 %