777 d test charts
TRANSCRIPT
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CC AA TT EE RR PP II LL LL AA RR MM OO NN II TT OO RR II NN GG SS YY SS TT EE MM
Machine Model _______________________ Date __________________________________
Machine Serial No. ____________________ Machine Hours/Miles_____________________
ECM Part No. ________________________ Software Part No./Date____________________
VISUAL CHECKS:
Electrical Connections Component Damage _________________
SETUP SPECS ACTUAL
MODE 0: Resettable Load Count N/A
MODE 1: Harness Code Setting
MODE 6: Permanent Load Count N/A
MODE 7.7: Economy Shift Setting Not Used on 777D Not Used on 777D
MODE 4: LOGGED RECORDS
GAUGES MAX/MIN ALLOWABLE ACTUAL
Engine Coolant Temperature 107°C (225°F)
Brake Oil Temperature 121°C (250°F)
Tachometer 2100 rpm
Ground Speed 60.4 km/h (37.5 mph)
ALERT INDICATORS ON IN MODE 4
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CC AA TT EE RR PP II LL LL AA RR MM OO NN II TT OO RR II NN GG SS YY SS TT EE MM
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 OK NOT OK
NOTES:
MODE 7.5: Hoist Lever Input and Output Signal Operation OK NOT OK
NOTES:
MODE 7.6: Actual Gear Switch Input Signal Operation OK NOT OK
NOTES:
MODE 7.8: Shift Lever Switch Input Signal Operation OK NOT OK
NOTES:
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CC AA TT EE RR PP II LL LL AA RR MM OO NN II TT OO RR II NN GG SS YY SS TT EE MM
SENSOR TESTS
SensorSupply Voltage
(A-B)
Actual Temperature/Air Pressure/Fuel Level
(ET)
Actual SignalVolts/Hz/Duty Cycle/
Resistance(B–C)
Pull-UpVoltage
(B-C)
Brake Oil Temperature
Torque Converter OilTemperature
Brake Air Pressure
Fuel Level Sender N/A N/A
Alternator "R"Terminal N/A
12.4 to 14.75 DCV
> 95 HzN/A
Brake OverstrokeSwitch N/A N/A N/A
Transmission FilterSwitch N/A N/A N/A
NOTE: 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.
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Machine Model ___________________ Date _________________________
Machine Serial No. ________________ Machine Hours _________________
VISUAL CHECKS:
Electrical Connections Component Damage ____________
SETUP SPECS ACTUAL
MODE 1: Truck Model Setting
MODE 2: System Units Setting
MODE 3: Target Weight Setting
MODE 4: Truck Identification CodeSetting
MODE 5: System Options Setting
MODE 6: System Calibration 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 _________
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TT PPMM SS
MODE 7: ACTIVE FAULTS
Description Cause
MODE 7: INTERMITTENT FAULTS
Description Cause
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777777DD OOFFFF--HHIIGGHHWWAAYY TTRRUUCCKKEENNGGIINNEE 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 ________________
Test Spec (ET or Eng Plate) ____________ Max Altitude__________________________
Rated Power ________________________ Full Load RPM________________________
Fuel Ratio Control Offset ______________
Horsepower Configuration (Rating Number):
Using the Engine Information Plate and the ET Screens, ECM Summary, Logged Diagnostic Codes andthe Configuration Screen, fill in the information requested.
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EENNGGIINNEE TTEESSTTSS
Create a Test Group on ET:1) Using ET, choose the Engine ECM2) 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.
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EENNGGIINNEE TTEESSTTSS
Sensor Tests
SensorSupplyVoltage
(A-B)
DesiredSignal Volts
orDuty Cycle
Actual SignalVoltage/%
(B-C)
ActualTemperature/
Pressure(ET or VIMS)
Pull-upVoltage
(B-C)Filtered Engine OilPressure .2 to .6 0
Unfiltered Engine OilPressure .2 to .6 0
Coolant Temperature.4 to 4.6
AftercoolerTemperature .4 to 4.6
Atmospheric Pressure2.2 to 4.6
Crankcase Pressure2.2 to 4.6 0
Right Turbo InletPressure 2.2 to 4.6
Left Turbo InletPressure 2.2 to 4.6
Turbo Outlet Pressure.8 to 1.5
Left ExhaustTemperature see below
Right ExhaustTemperature see below
NOTE: Analog supply voltage is 5.0 ± 0.5Digital supply voltage is 8.0 ± 0.5Desired 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%
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EENNGGIINNEE TTEESSTTSS
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
orgreater than 10.0
Speed Sensor Signal Voltage (Cranking) (B-C) 2.0 to 4.0
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EENNGGIINNEE TTEESSTTSS
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTION
LOGGED DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTIONNUMBER
OFOCCURR
FIRSTHOUR
METER
LASTHOUR
METER
EVENT CODES
EVENT CODE DESCRIPTIONNUMBER
OFOCCURR
FIRSTHOUR
METER
LASTHOUR
METER
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EENNGGIINNEE TTEESSTTSS
INJECTOR SOLENOID TEST:
CYLINDERS OPEN
CYLINDERS SHORTED
OVERRIDE PARAMETERS:
ETHER INJECTION: OK NOT OK N/A
ENGINE PRELUBE: OK NOT OK N/A
OIL RENEWAL: OK NOT OK N/A
CURRENT TOTALS:
FUEL TOTAL TIME
ETHER
CYLINDER CUTOUT TEST:
Injector 1: Duration: Injector 5: Duration:
Injector 2: Duration: Injector 6: Duration:
Injector 3: Duration: Injector 7: Duration:
Injector 4: Duration: Injector 8: Duration:
Average Injection Duration
Cylinders more than 10 TO 15% from Average
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EENNGGIINNEE TTEESSTTSS
INJECTOR CODES CALIBRATION:
Injector 1: Code: Injector 5: Code:
Injector 2: Code: Injector 6: Code:
Injector 3: Code: Injector 7: Code:
Injector 4: Code: Injector 8: Code:
NOTE: Default is 1100
NOTES:
PRESSURE SENSOR CALIBRATION: OK NOT OK
NOTES:
TIMING CALIBRATION: OK NOT OK
NOTES:
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777777DD UUPPDDAATTEE EENNGGIINNEE PPOOWWEERR TTEESSTT
Machine Model Date
Machine Serial No. Machine Hours
Engine Serial No. Engine Hours
Rating No. Rated Power
ECM Serial No. _______________________ Performance Spec
Flash File (software) ____________________ Flash File Date
Throttle Pedal Configuration
VISUAL CHECKS
Oil Level Oil Filter Examination
Create a Test Group on ET:1) Using ET, choose the Engine ECM2) 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:
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777777DD UUPPDDAATTEE EENNGGIINNEE PPOOWWEERR TTEESSTT
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information onthe chart provided.
T E S T S P E C S A C T U A L
Horse Power Rating "2" (1000 HP)
Coolant Temperature (during tests) > 71°C (160°F)
Low Idle RPM 700 ± 10
High Idle RPM 1937 ± 20
Air Filter Restriction @ TC Stall (maximum allowed)25 in. of water
6.2 kPa
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 ± 10)
210 ± 28 kPa
(30 ± 4 psi)
Inlet Manifold Pressure (BOOST)
@ TC Stall RPM (1605 ± 65 rpm)
172 ± 28 kPa
(25 ± 4 psi)
Torque Converter Stall RPM 1540 to 1670
Torque Converter Temperature (during stall test)> 80°C (175°F)
< 121°C (250°F)
Engine Oil Pressure @ Low Idle170 to 600 kPa
(25 to 87 psi)
Engine Oil Pressure @ High Idle365 to 600 kPa
(53 to 87 psi)
Engine Oil Filter Differential Pressure @ High Idlemaximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall360 to 725 kPa
(52 to 105 psi)
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)]OK
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77 77 77 DD UU PP DD AA TT EE TT OO RR QQ UU EE CC OO NN VV EE RR TT EE RR TT EE SS TT
Machine Model Date
Machine Serial No. Machine Hours
Converter Serial No. Converter Hours
Transmission ECM Flash File (Software Grp Part #) / Date
VISUAL CHECKS
Oil Level Air/Water in Oil? Oil Filter Examination
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 PressureMaximum at High Idle
with Cold Oil
930 ± 35 kPa(135 ± 5 psi)
LI -
HI –
STALL-
Torque Converter Outlet Pressure @ STALL rpm380 to 520 kPa(55 to 75 psi)
LI -
HI –
STALL-
Torque Converter Stall RPM 1540 to 1670 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 Primary Pressure (remove LP plug)NEUTRAL/DIRECT DRIVE/LOW IDLE
1030 ± 35 kPa(150 ± 5 psi)
Lockup Clutch Maximum PressureNEUTRAL/DIRECT DRIVE/1300 rpm
2135 ± 70 kPa(310 ± 10 psi)
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77 77 77 DD UU PPDD AA TTEE OOFFFF-- HHIIGGHHWWAA YY TTRRUU CCKK
TTRRAA NN SS MMIISS SS IIOONN TTEESS TT
Machine Model ______________________________ Date _______________________________
Machine Serial Number________________________ Machine Hours_______________________
Transmission Serial Number____________________ Transmission Hours___________________
Transmission ECM Flash File (Software Grp Part #) / Date _____________________________________
VISUAL CHECKS:
Oil level ___________________________________ Oil Viscosity ________________________
Air/Water in Oil? ____________________________ Suction Screen Debris? ________________
Oil Leaks? _________________________________ Oil Filter Examination _________________
SPECS ACTUAL
LI HI LI HI
TRANSMISSIONPUMP PRESSURE
minimum
2480 kPa
(360 psi)
maximum
3200 kPa
(465 psi)
LUBE PRESSURE 4 to 41 kPa
(.5 to 6 psi)
83 to 138 kPa (12
to 20 psi)
PILOT PRESSURE
@ Low Idle1725±70 kPa
(250±10 psi)N/A N/A
Transmission Oil Temperature (during tests) 80 ± 3°C
(160 ± 5°F)
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77 77 77 DD UU PP DD AA TT EE TT RR AA NN SS MM II SS SS II OO NN CC LL UU TT CC HH TT EE SS TT SS
CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I.
Load Piston Plug Removed
SPEED CLUTCHES
ENGAGED
STATION CLUTCH SPECS ACTUAL
N 1 A 4 380 KPA(55 psi)
R 1 and 7 B 2 275 KPA(40 psi)
1 2 and 6 C 1 345 KPA(50 psi)
2 1 and 6 D xxx xxx
3 3 and 6 E 5 345 KPA(50 psi)
4 1 and 5 F 6 415 KPA(60 psi)
5 3 and 5 G 7 415 KPA(60 psi)
6 1 and 4 H 3 550 KPA(80 psi)
7 3 and 4 xxx xxx
Primary Clutch Pressure Tolerance: +50 -35 kPa (+7 -5 psi)
MAXIMUM CLUTCH PRESSURE
Load Piston Plug InstalledSPECS ACTUAL
STATION CLUTCH LI HI LI HI
A 4 xxx 1425 kPa(207 psi) xxx
B 2 2365 kPa(343 psi)
2365 kPa(343 psi)
C 1 2780 kPa(403 psi)
2880 kPa(418 psi)
D xxx xxx xxx xxx xxx
E 5 xxx 2435 kPa(373 psi) xxx
F 6 2515 kPa(365 psi)
2515 kPa(365 psi)
G 7 2760 kPa(400 psi)
2760 kPa(400 psi)
H 3 xxx 1825 kPa(265 psi) xxx
Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi)
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TT RR AA NN SS MM II SS SS II OO NN // CC HH AA SS SS II SS EE CC MM
Machine Model ___________________________ Date _________________________________
Machine Serial No. ________________________ Machine Hours _________________________
Transmission Serial No. ____________________ Transmission Hours _____________________
Flash File (Software Part #)__________________ Flash File Release Date __________________
ECM Location Code _______________________ ECM Serial No. ________________________
VISUAL CHECKS:
Electrical Connections Component Damage ____________________
SETUP DESIRED ACTUAL
Economy Mode (ON or OFF) Not Used on 777D Not Used on 777D
Body Up Gear Limit Setting (1 to 3)
Transmission Maximum Gear Setting
(3 to 7)
Lockup Clutch Count N/A
Permanent Load Count N/A
ACTIVE DIAGNOSTIC CODES and DESCRIPTION
Diagnostic Code Description Cause
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TT RR AA NN SS MM II SS SS II OO NN // CC HH AA SS SS II SS EE CC MM
INTERMITTENT DIAGNOSTIC CODES
Diagnostic Codeand
DescriptionNumber of
Occurrences First Occurrence Last Occurrence
LOGGED EVENTS
Event Codeand
DescriptionNumber of
Occurrences First Occurrence Last Occurrence
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777777DD UUPPDDAATTEE 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) > 38°C (100°F)
< 121°C (250°F)
Cycle Time @ High Idle
From Left to Right and Right to Left Combined
All Brakes Released5.5 to 7.5 seconds
1. ____________________
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
Left to Right
1. ____________________
2. ____________________
3. ____________________
AVG.
Right to Left
1. ____________________
2. ____________________
3. ____________________
AVG.
Primary Steering Pressure @ High Idle
(Steer hard against stops)
23425 ± 345 KPA
(3400 ± 50 PSI)
Primary Steering Backup Relief Valve Pressure @High Idle(Steer hard against stops)
26000 ± 400 KPA
(3775 ± 60 PSI)
Low Pressure Standby @ Low Idle
(Do Not Steer)
2070 to 2950 KPA
(300 to 430 PSI)
Secondary Steering Pressure
(Steer hard against stops)
16880 ± 345 KPA
(2450 ± 50 PSI)
Secondary Steering Backup Relief Valve Pressure
(Steer hard against stops)
20700 ± 400 KPA
(3000 ± 60 PSI)
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777777DD UUPPDDAATTEE SSTTEEEERRIINNGG TTEESSTT
TEST SPECS ACTUAL
Steering Pressure Switch
Pressure Reducing Valve
2600 + 500 - 200 KPA
(375 + 70 - 30 PSI)
Crossover Relief Valve (Left) 27200 ± 690 KPA
(3950 ± 100 PSI)
Crossover Relief Valve (Right) 27200 ± 690 KPA
(3950 ± 100 PSI)
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77 77 77 DD UU PP DD AA TT EE HHOOIISSTT TTEESSTT
Machine Model ____________________________ Date _____________________________________
Machine Serial No. _________________________ Machine Hours_____________________________
Hoist System Enable Status___________________ Hoist LOWER Adjustment Setting _____________
Transmission ECM Flash File (Software Grp Part #) /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 thefactory without bodies installed are set at the Hoist Enable Status 2. The Hoist Enable Status 2 is a test mode only andwill prevent the hoist cylinders from accidentally being activated. After the body is installed, change the Hoist EnableStatus 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 installed1 - 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 fromchanging.
The hoist valve LOWER position is an adjustable parameter in the Transmission/Chassis ECM using ET. The slightadjustment provides a means to compensate for valve differences. The adjustment range is from -5 to +5 with zero asthe 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 than1725 kPa (250 psi). The hoist lever must be in HOLD when changing the setting.
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77 77 77 DD UU PP DD AA TT EE HHOOIISSTT TTEESSTT
TEST SPECS ACTUAL
Hoist Oil Temperature(during tests)
> 65°C (150°F)
< 121°C (250°F)
RAISE TIME @ High Idle
(Noise Reduction OFF)
14.0 to 16.0 seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
LOWER (POWER DOWN) TIME
@ High Idle
(With Snub) (Noise Reduction OFF)
See NOTE
10.5 to 12.5 seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
FLOAT TIME @ High Idle
(With Snub) (Noise Reduction OFF)
See NOTE
10.5 to 12.5 seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
PILOT PRESSURE
(Parking Brake Retraction)
4700 ± 200 kPa
(680 ± 30 psi)
LI -
HI -
RAISE PRESSURE @ High Idle 18950 + 520 - 0 kPa
(2750 + 75 - 0 psi)
LOWER PRESSURE @ High Idle
(Body Switch in RAISE Position)
3450 ± 350 kPa
(500 ± 50 psi)
NOTE: The FLOAT and LOWER time can be changed with the Hoist Adjustment Setting in the ETConfiguration Screen
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77 77 77 DD UU PP DD AA TT EE HHOOIISSTT TTEESSTT
Create a Test Group on ET:1) Using ET, choose the Transmission ECM2) In the Status Group, create a new group name "Hoist Test"3) Select the items as shown on the ET screen below:
ET Setting -5 0 +5
HOIST PRESSURE IN SNUB
(At Pump Tap)
Maximum 1725 kPa (250 psi)
LI -
HI -
LI -
HI -
LI -
HI -
Hoist Lower Solenoid Current(Hoist Output in SNUB)
Final Programmed Value
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77 77 77 DD UU PP DD AA TT EE HHOOIISSTT TTEESSTT
HOIST LEVER SENSOR
TEST SPECS ACTUAL
Supply Voltage + Battery (24 Volts)
Pull-Up Voltage Approx 5 Volts
HOISTLEVER
POSITION
DUTY CYCLE(approximate)
ACTUALDUTYCYCLE
SOLENOIDCURRENT %
FROM ET
HOIST VALVESOLENOID CURRENT
(mA)(ET Solenoid % x 1900)
HOIST VALVESOLENOID
CURRENT (mA)(ACTUAL)
RAISE 5 - 20%___________ mA
HOLD 25 to 35% 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.
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)
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777777DD UUPPDDAATTEE AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
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 CloseSetting)
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--
Front Brake Ratio Valve (50/50 operation) (below 65 psi only)
Retarder Valve--Maximum Air Pressure 550 ± 35 kPa
(80 ± 5 psi)
Parking Brake Release Valve 4700 ± 200 kPa
(680 ± 30 psi)
LI-
HI-
Brake Cooling Oil Temperature
(during brake cooling pressure test)
79 to 93 °C
175 to 200 °F
Brake Cooling Oil Pressure (SNUB Only)
Relief Valve Setting: 585 ± 15 kPa (85 ± 2 psi)
LI - min 14 kPa (2 psi)
HI - max 172 kPa (25 psi)
LI -
HI -
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777777DD UUPPDDAATTEE AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
AIR COMPRESSOR TEST
To test the air compressor efficiency, lower the air system pressure to 480 kPa (70 psi). Start the engineand 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). Thetime 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 compressormay have a problem.
Time to charge system: seconds
TEST SPECS ACTUAL
Towing Pump Pressure (minimum) 3790 kPa (550 psi)
Towing pump pressure after:
1 minute: 4 minutes:
2 minutes: 5 minutes:
3 minutes:
BRAKE CYLINDER OPERATION
TEST BRAKE AIR PRESSURE
@ Brake Cylinder
BRAKE OIL PRESSURE
@ Slack Adjuster or BrakeCaliper
Front Brake Cylinders
Air/Oil Ratio (11.8 to 1)
Rear Brake Cylinders
Air/Oil Ratio (6.6 to 1)
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777777DD UUPPDDAATTEE AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
SLACK ADJUSTER OPERATION
SLACK ADJUSTER TAP WHEEL PORT TAP
Engaged Released Engaged Released
Residual Pressure
Left FrontWheel
FrontRight FrontWheel
Left RearWheel
RearRight RearWheel
NOTE: Low residual pressure MAY indicate a failed Slack Adjuster. High residual pressure may alsoindicate 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 rpm Manual Retarder Engaged rpm
Parking Brake Engaged rpm Secondary Brake Engaged rpm
NOTE: Minimum 1200 rpm
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777777DD UUPPDDAATTEE AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
BRAKE OIL MAKEUP TANK REFILL OPERATION
Flow into the makeup tank is acceptable: YES ________ NO _________
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.
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77 77 77 DD UU PP DD AA TT EEAAUUTTOO 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 Adjusters2) On the ET screen toolbar, select Diagnostics – Diagnostics Tests – Auto Retarder Test3) Switch ON the ARC ON/OFF switch4) Click the Start button and the Auto Retarder Test will be turned ON5) 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 TestMaximum 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)
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77 77 77 DD UU PP DD AA TT EEAAUUTTOO 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 andDescription
Number ofOccurrences
First Occurrence Last Occurrence
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77 77 77 DD UU PP DD AA TT EEAAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT
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 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
** Auto Upshifts are controlled by the Transmission/Chassis ECM
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77 77 77 DD UU PP DD AA TT EE
TT RR AA CC TT II OO NN CC OO NN TT RR OO LL SS YY SS TT EE MM (( TT CC SS )) TT EE SS TT
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 ECM2) 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 IDLE5) Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON6) Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED7) 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 accordingly9) Record the data into the chart
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77 77 77 DD UU PP DD AA TT EE
TT RR AA CC TT II OO NN CC OO NN TT RR OO LL SS YY SS TT EE MM (( TT CC SS )) TT EE SS TT
TEST SPECS ACTUAL
Brake Oil Temperature (during tests) > 65°C (150°F)
Parking Brake Release Pressure4700 ± 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 SolenoidResistance/Voltage
12 to 22 ohms0 to 12 Volts
Left Selector SolenoidResistance/Voltage
18 to 45 ohms24 Volts
Right Selector SolenoidResistance/Voltage
18 to 45 ohms24 Volts
NOTE: When the brakes are ENGAGED, gauge pressure will drop quickly to approximately1380 kPa (200 psi), then gradually decrease. This is the function of the proportional solenoidand 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; BrakesENGAGE and RELEASE intermittently?
Wheels Turned to the RIGHT: YES NO
Wheels Turned to the LEFT: YES NO
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77 77 77 DD UU PP DD AA TT EE
TT RR AA CC TT II OO NN CC OO NN TT RR OO LL SS YY SS TT EE MM (( TT CC SS )) TT EE SS TT
ACTIVE DIAGNOSTIC CODES and DESCRIPTION
Diagnostic Code Description Cause
LOGGED DIAGNOSTIC CODES
Diagnostic Code andDescription
Number ofOccurrences
First Occurrence Last Occurrence
FFRROONNTT SSUUSSPPEENNSSII OONN CCYY LL II NNDDEERR CCHH AA RRGGII NNGG
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 MeasurementAfter 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 ModelShim 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)
RREEAA RR SSUUSSPPEENNSSII OONN CCYY LL II NNDDEERR CCHH AA RRGGII NNGG
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 DIMENSIONSDistance Below Top Of
Suspension Cylinder Housing
Truck ModelFirst 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)
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DataView Users Guide
1. Install DataView Software in Laptop (NEHS0662) or STW – NETG50302. Connect DataView Box to Laptop printer port with cable provided3. Connect sensors and cables to Machine and DataView Box. (Max possible is 9, 6 analog and 3
frequency).4. Power On DataView Box5. 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
sensor8. 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 sensors10. Click on Clock Icon (Setup Logger Tool) (third icon from left)11. Select all channels12. 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 Manual15. Send Configuration16. 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 logging18. Raise Trigger Switch again to Stop Logging manually19. Click on 4th Icon from left (Graph Viewer Tool) and select one of the data sources20. 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 menuOpen 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 Software and Instruction Manual131-5051 DataView Portable Tech Station Group153-9630 PWM-Analog Test Group Sensor Adapter Kit143-4062 100 psi sensor143-4065 1000 psi sensor143-4066 7500 psi sensor6V4144 Internal 1/4 nptf Valved Coupler (for each sensor)6V2198 18 ft. sensor extension cable137-0168 Machine battery power cable137-0170 12V Cigarette Lighter power cable4C6824 Carrying case for Sensors and Cables4C4463 Yellow case for small parts
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777D SENSORS IN DATAVIEW SENSOR TABLE
102-2240 - Temperature: Engine Coolant, Rear Aftercooler Coolant (analog)118-7226 - Temperature: Brake, Torque Converter (digital)163-7882 - Temperature: Engine Exhaust (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)185-0600 - PWM Pressure: Air System (digital)157-8394 - PWM Pressure: Rear Parking Brakes (digital)
Speed Sensor Teeth (PPR)
Sensor Number of Teeth
Engine Output Speed (EOS)Sensor
151
Transmission Output Speed(TOS) Sensor
120
Traction Control System(TCS)Wheel Speed Sensors
48
Engine Speed Adapter Cable
To measure the Engine Speed with DataView, a 2-pin adapter T-cable will need to be made from eithera 153-9626 3-pin HD-10 Adapter cable or a 153-9627 3-pin DT Adapter cable. Remove the 3-pin plugand receptacle from the T-cable. Cut the red wire. The red wire is not needed with the 2-pin passivespeed sensors. Using a 102-8802 2-pin DT receptacle kit and a 155-2270 2-pin DT plug kit, install thewhite wires in pin location 1 and install the black wires in pin location 2.
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DIGITAL TEMPERATURE SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
Digital 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%
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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
9X5272, 161-9931, 100-4311 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
153-3962, 185-0600 Pressure Sensor (AIR)
Air Pressure DUTY CYCLE
0 kPa (0 psi) 9.6 %
140 kPa (20 psi) 19.6 %
275 kPa (40 psi) 31.3 %
415 kPa (60 psi) 41.2 %
550 kPa (80 psi) 50.2 %
690 kPa (100 psi) 62 %
825 kPa (120 psi) 83 %
Tolerance is ± 10%