777d Update Test Charts
777d Update Test Charts
777d Update Test Charts
VISUAL CHECKS:
1
CATERPILLAR MONITORING SYSTEM
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:
2
CATERPILLAR MONITORING SYSTEM
Sensor Tests
Actual Temperature/ Actual Signal Pull-Up
Sensor Supply Voltage Air Pressure/ Volts/Hz/Duty Cycle/ Voltage
Fuel Level Resistance
3
TRUCK PRODUCTION MANAGEMENT SYSTEM
(TPMS)
Machine Model ___________________ Date _________________________
VISUAL CHECKS:
YES
MODE 6: System Calibration
NO
1
TPMS
Description Cause
Description Cause
2
777D-793C OFF-HIGHWAY T RUCK
E NGINE T E S T S
1
E NGINE T E S T S
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink – Select ECM and choose Engine ECM
2) In the Status Group, create a new group name ‘Engine Test’
3) Select the items as shown on the ET screen below:
With the engine NOT running, record the information on the chart provided.
2
E NGINE T E S T S
Sensor Tests
Aftercooler .4 to 4.6
Temperature
3
E NGINE T E S T S
EVENT CODES
NUMBER FIRST LAST
FAULT CODE DESCRIPTION OF HOUR HOUR
OCCURR METER METER
4
E NGINE T E S T S
INJECTOR SOLENOID TEST:
CYLINDERS OPEN
CYLINDERS SHORTED
NOTES:
OVERRIDE PARAMETERS:
: OK NOT OK
: OK NOT OK
: OK NOT OK
NOTES:
5
E NGINE T E S T S
INJECTOR CODES CALIBRATION:
NOTES:
NOTES:
NOTES:
6
777D UPDATE ENGINE POWER TEST
Machine Model Date
Flash File/Date
VISUAL CHECKS
1
777D UD Eng Power Test.doc
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.
2
777D UD Eng Power Test.doc
777D UPDATE TORQUE CONVERTER TEST
Machine Model Date
VISUAL CHECKS
80 ± 3°C
Torque Converter Oil Temperature (during tests)
(160 ± 5°F)
930 ± 35 kPa
Torque Converter Inlet Pressure @ High Idle
(135 ± 5 psi)
LI -
4700 ± 200 kPa
Parking Brake Release Pressure
(680 ± 30 psi)
HI -
1
777D UD Converter Test.doc
7 7 7 D U PD A TE OFF- HIGHWA Y TRU CK
TRA N S MIS S ION TES T
VISUAL CHECKS:
SPECS ACTUAL
LI HI LI HI
TRANSMISSION minimum maximum
PUMP PRESSURE 2480 kPa 3200 kPa
(360 psi) (465 psi)
1
777D UPDATE TRA N S MIS S ION CLU TCH TES TS
STATION CLUTCH LI HI LI HI
4 1425 kPa
A xxx (207 psi) xxx
5 2435 kPa
xxx xxx
E (373 psi)
6 2515 kPa 2515 kPa
F (365 psi) (365 psi)
7 2760 kPa 2760 kPa
G (400 psi) (400 psi)
1825 kPa
H 3 xxx (265 psi) xxx
Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi)
2
TRANSMISSION/CHASSIS ECM
Machine Model ___________________________ Date _________________________________
VISUAL CHECKS:
1
TRANSMISSION/CHASSIS ECM
LOGGED EVENTS
Event Code
and Number of
Description Occurrences First Occurrence Last Occurrence
2
7 7 7 D U P D A T E S T E E RING T E S T
VISUAL CHECKS:
Oil level Oil Viscosity _______________________
Air/Water in Oil? Oil Filter Examination _______________
1. ____________________
Cycle Time @ High Idle 7.3 ± 1
2. ____________________
(steer at one revolution per second) seconds
From Left to Right and Right to Left Combined 3. ____________________
All Brakes Released
AVG.
Left to Right Right to Left
Steering wheel turns from stop to stop @ High Idle
1. ____________________ 1. ____________________
All Brakes Released
2. ____________________ 2. ____________________
AVG. AVG.
1
777D UD Steer Test.doc
7 7 7 D U P D A T E S T E E RING T E S T
2
777D UD Steer Test.doc
7 7 7 D U P D A T E HOIS T T E S T
VISUAL CHECKS:
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.
The hoist valve LOWER position is an adjustable parameter in the Transmission/Chassis ECM using ET. The slight
adjustment provides a means to compensate for valve differences. The adjustment range is from -5 to +5 with zero as
the default. A negative number will decrease the lower speed and a positive number will increase the lower speed.
With the engine at HIGH IDLE and the hoist lever in FLOAT, pump output pressure must be less than
1725 kPa (250 psi). The hoist lever must be in HOLD when changing the setting.
1
7 7 7 D U P D A T E HOIS T T E S T
DRIFT
(See Chart on Page 4)
AVG.
AVG.
AVG.
ET Setting -5 0 +5
2
7 7 7 D U P D A T E HOIS T T E S T
Create a Test Group on ET:
1) On the ET screen toolbar, click Datalink – Select ECM and choose Transmission ECM
2) In the Status Group, create a new group name “Hoist Test”
3) Select the items as shown on the ET screen below:
3
7 7 7 D U P D A T E HOIS T T E S T
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.
4
777D UPDATE AIR SYSTEM AND BRAKE TEST
VISUAL CHECKS:
1
777D UPDATE AIR SYSTEM AND BRAKE TEST
2
785C/789C/793C AIR SYSTEM AND BRAKE TEST
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.
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.
3
777D UPDATE
AUTO RETARDER CONTROL (ARC) TEST
Machine Model Date
2
777D UD ARC Test.doc
777D UPDATE
AUTO RETARDER CONTROL (ARC) TEST
3
777D UD ARC Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST
Machine Model Date
1
777D UD TCS Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST
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.
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?
2
777D UD TCS Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST
3
777D UD TCS Test.doc
FRONT SUSPENSION CYLINDER CHARGING
Wiped Chrome Dimension After Operation: Left Front _____________ Right Front ____________
Shim Thickness
Truck Model mm/5.5 °C
(in./10 °F)
Wiped Chrome Dimension After Operation: Left Rear _____________ Right Rear ____________
* dimension between the center line of the top mounting pin and the bottom mounting pin
Tolerance is ± 10%
Tolerance is ± 10%
Tolerance is ± 3%
Tolerance is ± 10%
Tolerance is ± 10%
1
777D UD Speed Sensor Teeth.doc