777 d Test Charts

1

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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

2


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:

3


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.

1

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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 _________

2

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.

2

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.

3


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%

4


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

5


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

6


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:




Average Injection Duration

Cylinders more than 10 TO 15% from Average

7


INJECTOR CODES CALIBRATION:

Injector 1: Code: Injector 5: 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


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)

1

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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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


16880 ± 345 KPA

(2450 ± 50 PSI)

Secondary Steering Backup Relief Valve Pressure


20700 ± 400 KPA

(3000 ± 60 PSI)

2

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)

1

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.

2


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


1. ____________________

2. ____________________

3. ____________________

AVG.

FLOAT TIME @ High Idle

(With Snub) (Noise Reduction OFF)

See NOTE


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

3


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

4


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)

1

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 -

2


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)

3


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

4


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.

1

77 77 77 DD UU PP DD AA TT EEAAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT

Machine Model Date


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)

2


SETUP DESIRED ACTUAL

Control Speed Setting

Control Valve Cycles N/A

Supply Valve Cycles N/A



LOGGED DIAGNOSTIC AND EVENT CODES

Diagnostic and Event Code andDescription

Number ofOccurrences

First Occurrence Last Occurrence

3


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

1

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


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

2



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

3





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)

1

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

2

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.

1

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


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

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


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 %





Later Configurations


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%

Documents

777 d Test Charts