Service Training

MALAGA

777D Off Highway Truck

BED RAISE RIGHT

TEST/SET

LOAD INDICATORS
LEFT

MODE
PAYLOAD

MEASUREMENT
TOS SPEED
DISTRB
CONTROL
ON/OFF PAYLOAD MEASUREMENT SYSTEM
DIAGNOSTIC
WEIGHT

POD TOTAL CYCLES

TOTAL WEIGHT

I/O COMMUNICATION
PORT
STRUT
SENSORS

XII. TRUCK PAYLOAD MEASUREMENT

SYSTEM (TPMS)
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
 777D Off Highway Truck
CHAPTER : TPMS

INTRODUCTION

- MEASURES AND RECORDS PAYLOADS

- DATE & TIME LOAD CYCLE OCCURRED

- IDLE TIME

- LOADING TIME

- EMPTY & LOADED TRAVEL TIME

- EMPTY & LOADED TRAVEL DISTANCE

- DOWNLOADING CAPABILITY

Page: XII-1
Page:

TRUCK PAYLOAD MEASUREMENT SYSTEM

XII-2

SIGNAL FLOW

BED RAISE RIGHT

TEST/SET

LOAD INDICATORS
LEFT

CHAPTER : TPMS
MODE
PAYLOAD

777D Off Highway Truck

MEASUREMENT
TOS SPEED
DISTRB
CONTROL
ON/OFF PAYLOAD MEASUREMENT SYSTEM
DIAGNOSTIC
WEIGHT

POD TOTAL CYCLES

TOTAL WEIGHT

I/O COMMUNICATION
PORT
STRUT
SENSORS
 777D Off Highway Truck
CHAPTER : TPMS

MODES OF OPERATION

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

MODE switch located behind the POD

MODE 0 NORMAL PAYLOAD DISPLAY

MODE 1 MODEL SETTING DISPLAY

MODE 2 SYSTEM UNITS SETTING DISPLAY

MODE 3 MAXIMUM TARGET WEIGHT

MODE 4 TRUCK FLEET IDENTIFICATION

MODE 5 SYSTEM OPTIONS SETTING DISPLAY (LIGHTS ON/OFF)

MODE 6 SYSTEM CALIBRATION

MODE 7 SYSTEM STATUS DISPLAY ( FAULT CODES)

Page: XII-3
 777D Off Highway Truck
CHAPTER : TPMS

NORMAL MODE DISPLAY

MODE 0
PRESSING SET/ CLEAR SWITCH:

DISPLAY TEST SEQUENCE:

- Truck model setting
- System units setting
- Maximum trarget weight
- Truck ID code setting Test / Set
- System options code setting Switch
EXTERNAL LAMP TEST
TPMS CONTROL LED TEST
TOTAL WEIGHT
TOTAL CYCLES

RESTORES TO STATE WHEN TURNED OFF

DISPLAYS WEIGHT WHEN STABILIZED

FLASHING DASHES IF PAYLOAD < 60% RATED

FAULT CODE DISPLAYED IF PRESENT

TRUCK MODEL SETTING

MODE 1

MODE 1 display provides the truck model setting. MODE 1 is used to

select the truck model.

R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch

777 D 785 B
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch

789 B 793 B

Page: XII-4
 777D Off Highway Truck
CHAPTER : TPMS

SYSTEM UNITS DISPLAY

MODE 2

R
Payload Operator Display

Metric Tonnes
Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch
Press Test / Set Switch
to change Units while
in MODE 2

R Test / Set
Payload Operator Display Switch

Diagnostic
Weight
Total cycles
Total weight U.S. Tonnes
ON / OFF Test / Set
Switch Switch

DISPLAY MAXIMUM (TARGET WEIGHT) SETTING

MODE 3

777 B 777 B
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight

ON / OFF Test / Set ON / OFF Test / Set

Switch Switch Switch Switch

Maxinum (Target) Weight Setting Range

Truck Model Rated Maximum Minimum Setting Maximum Setting
86 Metric tonne 59 Metric tonne 86 Metric tonne
777 B (< 1991) (95 U.S. ton) (65 U.S. ton) (95 U.S. ton)
91 Metric tonne 452Metric tonne
777D (100 U.S. ton) 0 (500 U.S. ton)

Page: XII-5
 777D Off Highway Truck
CHAPTER : TPMS

TRUCK IDENTIFICATION CODE SETTING

MODE 4
TRUCK ID SETTING (199 ID CODES).
IDENTIFIES DIFFERENT TRUCKS WITHIN ONE FLEET.

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

DISPLAY SYSTEMS OPTIONS SETTING

MODE 5
ENABLES/DISABLES:
- Payload display on POD
- External load lamps
- Last loader pass (flashing red lights)
- Automatic broadcast of payload and cycle data
- Baud rate

R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight

ON / OFFTest / Set ON / OFF Test / Set

Switch Switch Switch Switch

Page: XII-6
 777D Off Highway Truck
CHAPTER : TPMS

DISPLAY SYSTEMS OPTION SETTING

MODE 5

Systems Options Settings

External One Pass Auto
Display Loader Lights Indicator Broadcast
Payload Baud Rate
Option Settings Enabled Enabled Enabled
Enabled (?) (?) (?) (?)

o01 Yes Yes No No 9600

o02 No Yes No No 9600

o03 Yes Yes Yes No 9600

o04 No Yes Yes No 9600

o05 Yes No No No 9600

o06 No No No No 9600

o07 Yes Yes No Yes 9600

o08 No Yes No Yes 9600

o09 Yes Yes Yes Yes 9600

o10 No Yes Yes Yes 9600

o11 Yes No No Yes 9600

o12 No No No Yes 9600

o13 Yes Yes No No 1200

o14 No Yes No No 1200

o15 Yes Yes Yes No 1200

o16 No Yes Yes No 1200

o17 Yes No No No 1200

o18 No No No No 1200

o19 Yes Yes No Yes 1200

o20 No Yes No Yes 1200

o21 Yes Yes Yes Yes 1200

o22 No Yes Yes Yes 1200

o23 Yes No No Yes 1200

o24 No No No Yes 1200

Page: XII-7
 777D Off Highway Truck
CHAPTER : TPMS

SYSTEM CALIBRATION
MODE 6
This MODE is used to start the system calibration procedure.

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

The message CAL starts

flashing on the POD when
MODE 6 is entered.

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

Depressing the Test / Set Switch for 1 Second

initiates a calibration sequence. The Payload
Monitor will store the current Suspension Cylinder
Pressures into memory.

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

Calibration is complete.
(C A L no longer flashing)

Page: XII-8
 777D Off Highway Truck
CHAPTER : TPMS

SYSTEM CALIBRATION
MODE 6

CALIBRATION PROCEDURE

The system must be calibrated after system installation, suspension cylinder

recharging or after truck modifications which affect the empty weight of the truck.
Improper calibration will affect accuracy of the system.

CALIBRATION PROCEDURE:

1) Prepare the truck.

-Truck must be empty. (Remove any large accumulation of dirt and mud. The
cleaner the truck the more accurate that the calibration will be).
- All optional attachements that affect the the empty weight of the truck must be
on.
- All truck fluids should be at full capacity.
- The suspension cylinders must be properly charged.
- No TPMS system faults should be present.

2) Operate the truck at 3 to 4 km / h on a HARD LEVEL surface. Shift the

transmission to NEUTRAL. Leave the truck in NEUTRAL. Turn key switch OFF.

3) Remove the Payload Operator Display from the dash.

4) Turn the key switch and TPMS ON. Wait for the start up sequence to complete.

5) Slowly depress the mode switch 6 times to select MODE 6. The Payload
Operator DIsplay should be flashing "CAL". Depress and hold the Test / Set
switch. The POD will momentarily show dashes, followed again by "CAL".

6) Return the display mode to MODE 0 by depressing the mode switch twice, or
by turning the system power switch OFF and then back ON.

7) Turn the key switch OFF and install the POD in the dash. This completes the
calibration procedure.

Page: XII-9
 777D Off Highway Truck
CHAPTER : TPMS

SYSTEM STATUS DISPLAY MODE

MODE 7
The TPMS system has built in component status display.
It is possible to identify CRITICAL, NON-CRITICAL and INTERMITTENT faults.

R
Payload Operator Display CRITICAL FAULTS (F01-F08) will appear
Diagnostic
Weight
and remain ON the Payload Operator
Total cycles
Total weight
Display any time during the loading
cycle.
ON / OFFTest / Set
Switch Switch

R
Payload Operator Display
R
Payload Operator Display
R
Payload Operator Display

Diagnostic Diagnostic Diagnostic

Weight Weight Weight
Total cycles Total cycles Total cycles
Total weight Total weight Total weight

ON / OFF Test / Set ON / OFF Test / Set ON / OFF Test / Set

Switch Switch Switch Switch Switch Switch

A FAULT that appears only at times when the display would normally
be blank indicates a NON CRITICAL FAULT (F09-F18).
If a FAULT appears and then disappears later, an INTERMITTENT
FAULT is indicated.

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch
Status Characters and Corresponding Cicuit Code
Numbers They Are Associated With
R
Payload Operator Display
Cicuit Code
Diagnostic
Weight Numbers Status
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

A01 - A18 No Fault is detected in the Circuit

R EO1 - E18 A Fault is intermittent in the Circuit

Payload Operator Display

Diagnostic
Weight
Total cycles
F01 - F18 A Fault is present in the Circuit
Total weight

ON / OFF Test / Set

Switch Switch A19 - A24 No Signal is present in the Circuit

C19 - C24 A Signal is present in the Circuit

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

Page: XII-10
 777D Off Highway Truck
CHAPTER : TPMS

SYSTEM STATUS DISPLAY MODE

MODE 7
Circuit Code Numbers And The
Circuit They Are Associated With

Cicuit Code
Numbers Circuit Description

Entry and exit point from system status

X 00 display

X 01 Left front suspension cylinder charge

X 02 Right front suspension cylinder charge

X 03 Left rear suspension cylinder charge

CRITICAL
X 04 Right rear suspension cylinder charge

X 05 Left front suspension cylinder charge

pressure sensor circuit
Right front suspension cylinder pressure
X 06 sensor circuit
Left rear suspension cylinder pressure
X 07 sensor circuit
Right rear suspension cylinder pressure
X 08 sensor circuit
X 09 Batt backup / Real clock setting

X 10 System setting/ memory

NON CRITICAL

X 11 Not used

X 12 Not used
Green Lamp open circuitor ground short
X 13 circuit

X 14 Green Lamp + battery short circuit

X 15 Red lamp open circuit or ground short circuit

X 16 Red lamp + battery short circuit

X 17 Not used

X 18 Not used

X 19 Bed raise switch status

X 20 Transmission output speed sensor status

X 21 Transmission neutral status

X 22 Not used

X23 Not used

X 24 Not used

Page: XII-11
 777D Off Highway Truck
CHAPTER : TPMS

BASIC WEIGHING OPERATION

TRUCK STOPPED
PARKING BRAKE ON,
XMS NEUTRAL

REPOSITIONING POSSIBLE
FIRST LOAD MAX 0.16 MILE

GREEN EXTERNAL LIGHT ON

GREEN POD LIGHT ON
POD DISPLAYS DASHES

60% LOAD

POD DISPLAYS PAYLOAD

IF LAST PASS ACTIVE

95% PAYLOAD EXTERNAL RED LIGHT
FLASHES WHEN ONE MORE
LOAD MAKES 95% PAYLOAD

RED EXTERNAL LIGHT ON RED EXTERNAL LIGHT ON

RED POD LIGHT ON RED POD LIGHT ON

Page: XII-12
Page: XII-13

TPMS ACCURACY

TPMS ACCURATE TO +/- 5% 0N 95% OF PAYLOADS

IF FOLLOWING CONDITIONS ARE MET:

1) GROUND SLOPE LESS THAN 5%

2) CORRECTLY CHARGED SUSPENSION CYLINDERS

CHAPTER : TPMS
3) NO "PUSHING" WITH BUCKET

777D Off Highway Truck

4) MOVING TRUCK MORE THAN 0.1 MILE (O,16 KM)

5) ACTUATING BED RAISE LEVER WHILE LOADING

6) INCORRECT CALIBRATION

7) LOADING FROM CONVEYOR

8) LEAVING LOAD SITE BEFORE PRESSURES STABILIZED

Page: XII-14

CYCLE DATA

STORED DATA:
-LOADING TIME (MAX 7200 s)

-PAYLOAD WEIGHTS (MAX 800 US TONNES)

-LOADED STOP TIME (MAX 7200s)

-TRAVEL TIME (MAX 7200s)

-TRAVEL DISTANCE ( 50 miles)

CHAPTER : TPMS
MEMORY:

777D Off Highway Truck

-1400 LOAD CYCLES

- FLASHING RED DOT IF > 1200 CYCLES

- OLDEST 20 CYCLES DELETED

DOWNLOADED USING LAPTOP COMPUTER:

- CABLE 9X-3393

- TPMS SOFTWARE (SERD0032)

- PRINTER
Page: XII-15

TOTAL CYCLES / TOTAL WEIGHT HAULED

STORED DATA:

- TOTAL NUMBER OF CYCLES RUN (1999 CYCLES)

-TOTAL WEIGHT HAULED (MAX 199900 US TONNES)

CHAPTER : TPMS
CLEARING DATA:

777D Off Highway Truck

-DEPRESS TEST/SET SWITCH

-WAIT FOR CYCLES TO BE DISPLAYED

-WITHIN 10 SECS ACTIVATE BED RAISE LEVER

REAL TIME CLOCK

-LOGS DATE & TIME OFCOMPLETION OF EACH DATA CYCLE

-CAN ONLY BE SET WITH PC

 777D Off Highway Truck
CHAPTER : TPMS

LAB EXERCISES
LAB A:

1) Using the POD on a 777D truck write down the initial TPMS configuration as shown on the
display and explain each of the numbers. Change the settins to the new values indicated in the table.

Once finished remember to leave the truck with the same initial configuration.

INITIAL SETTINGS NEW SETTINGS

DISPLAY EXPLANATION DISPLAY

769D

METRIC

100

23

003

2) Use the POD to determine the total weight carried and the total cycles carried out.

TOAL WEIGHT:_____________

TOTAL CYCLES:____________

3) Scroll to mode 7 and identify any existing faults.

FAULTS MEANING

4) Repeat LAB A using the service tool

Page: XII-16