777d Update Test Charts

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CATERPILLAR MONITORING SYSTEM

Machine Model ___________________ Date _____________________________

Machine Serial No._________________ Machine Hours _____________________

ECM Part No. ____________________ Software Part No./Date _______________

VISUAL CHECKS:

Electrical Connections Component Damage ____________

SETUP SPECS ACTUAL

MODE 1: Harness Code Setting

MODE 6: Permanent Load Count N/A

MODE 7.7: Economy Shift Setting

MODE 4: LOGGED RECORDS

GAUGES MAX/MIN ALLOWABLE ACTUAL

Engine Coolant Temperature 107°C (225°F)

Brake Oil Temperature 121°C (250°F)

System Air Pressure 483 kPa (70 psi)

Fuel Level 10%

3400 - 2475 rpm


Tachometer
3500 - 2100 rpm
769D-75.2 km/h (46.7 mph)
Ground Speed 771D-56.3 km/h (35.0 mph)
773D-65.8 km/h (41.1 mph)
775D-65.8 km/h (41.1 mph)
777D-60.4 km/h (37.5 mph)

ALERT INDICATORS ON IN MODE 4

1
CATERPILLAR MONITORING SYSTEM

MODE 3: ACTIVE FAULT CODES and DESCRIPTION

FAULT CODE DESCRIPTION CAUSE

MODE 3: INTERMITTENT FAULT CODES and DESCRIPTION

FAULT 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:

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

Brake Oil Temperature

Torque Converter Oil


Temperature

Brake Air Pressure

Fuel Level Sender N/A

Alternator "R" N/A 12.4 to 14.75 DCV


Terminal > 95 Hz
Brake Overstroke N/A
Switch

Transmission Filter N/A


Switch

NOTE: Most sensor supply voltage is 8.0 ± 0.5

Brake Air Pressure supply voltage is + Battery

Fuel level resistance: Empty--92 ohm's Full--3.5 ohm's

3
TRUCK PRODUCTION MANAGEMENT SYSTEM
(TPMS)
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 Code


Setting

MODE 5: System Options Setting

YES
MODE 6: System Calibration
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 _________

1
TPMS

MODE 7: ACTIVE FAULTS

Description Cause

MODE 7: INTERMITTENT FAULTS

Description Cause

2
777D-793C OFF-HIGHWAY T RUCK
E NGINE T E S T S

Machine Model ______________________ Date _________________________________


Machine Serial No. ___________________ Machine Hours ________________________
Engine Serial No. _____________________ Engine Hours__________________________

ECM Serial No. ______________________ ECM Location Code ___________________

Personality Module ___________________ Personality Module Date_________________

Performance Spec ____________________ Max Altitude __________________________

Gross Power _________________________ Full Load RPM ________________________

TEST SPECS ACTUAL

ECM Supply Voltage 24

Throttle Sensor Supply Voltage 8.0 ± 0.5

Throttle Sensor Low Idle Duty Cycle 16 ± 6%


Early - 48 ± 4%
Throttle Sensor High Idle Duty Cycle Later - 85 ± 4%
Throttle Sensor Frequency 150-1000 Hz

Throttle Sensor Pull-Up Voltage 11.5 ± 0.5

Speed Sensor Supply Voltage 12.5 ± 1.0

Speed Sensor Frequency (Cranking) ≈ 23 - 40 Hz

Speed Sensor Frequency (Low Idle) 140 Hz@700 rpm

Speed Sensor Frequency (High Idle) 385 Hz@1960 rpm


less than 3.0
Speed Sensor Signal Voltage (Key ON) or
greater than 10.0
Speed Sensor Signal Voltage (Cranking) 2.0 to 4.0

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

Sensor Supply Desired Actual Signal Actual Pull-up


Voltage Signal Volts Voltage Temperature/ Voltage
Pressure
Filtered Engine Oil .2 to .6
Pressure

Unfiltered Engine Oil .2 to .6


Pressure

Coolant Temperature .4 to 4.6

Aftercooler .4 to 4.6
Temperature

Atmospheric Pressure 2.2 to 4.6

Crankcase Pressure 2.2 to 4.6

Right Turbo Inlet 2.2 to 4.6


Pressure

Left Turbo Inlet 2.2 to 4.6


Pressure

Turbo Outlet Pressure .8 to 1.5

Left Exhaust see below


Temperature

Right Exhaust see below


Temperature

NOTE: Analog supply voltage is 5.0±0.5


Desired 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%

3
E NGINE T E S T S

ACTIVE FAULT CODES


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

LOGGED FAULT CODES


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

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:

ETHER INJECTION: OK NOT OK

ENGINE PRELUBE: OK NOT OK

: OK NOT OK

: OK NOT OK

: OK NOT OK

NOTES:

CYLINDER CUTOUT TEST:

Average Injection Duration

Cylinders more than 300 from Average

5
E NGINE T E S T S
INJECTOR CODES CALIBRATION:

Injector 1: Code: Injector 9: Code:

Injector 2: Code: Injector 10: Code:

Injector 3: Code: Injector 11: Code:

Injector 4: Code: Injector 12: Code:

Injector 5: Code: Injector 13: Code:

Injector 6: Code: Injector 14: Code:

Injector 7: Code: Injector 15: Code:

Injector 8: Code: Injector 16: Code:

NOTES:

PRESSURE SENSOR CALIBRATION: OK NOT OK

NOTES:

TIMING CALIBRATION: OK NOT OK

NOTES:

6
777D UPDATE ENGINE POWER TEST
Machine Model Date

Machine Serial No. Machine Hours

Engine Serial No. Engine Hours

Rating No. Rated Power

Flash File/Date

Throttle Pedal Configuration

VISUAL CHECKS

Oil Level Oil Filter Examination

Create a Test Group on ET:


1) On the ET screen toolbar, click Datalink Ð Select ECM and choose Engine ECM
2) In the Configuration Screen, make sure the engine is set to 746 kW (1000 hp)
3) In the Status Group, create a new group name ÔEngine Power TestÕ
4) Select the items as shown on the ET screen below:
• Note: Torque Converter Outlet Temp has to be selected from the Cat Monitoring
System Module

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.

TEST SPECS ACTUAL

Coolant Temperature (during tests) > 71°C (160°F)

Low Idle RPM 700 ± 10

High Idle RPM 1935 ± 30

Air Filter Restriction @ TC Stall (maximum allowed) 25 in. of water


6.2 kPa
Inlet Manifold Pressure (BOOST) 221 ± 35 kPa
@ Full Load RPM (1750 ± 10) (32 ± 5 psi)
Inlet Manifold Pressure (BOOST) 210 ± 35 kPa
@ TC Stall RPM (1605 ± 65 rpm) (30 ± 5 psi)
Torque Converter Stall RPM 1605 ± 65

Torque Converter Temperature (during stall test) > 80°C (175°F)


< 121°C (250°F)
Engine Oil Pressure @ LI 170 to 600 kPa
(25 to 87 psi)
Engine Oil Pressure @ HI 365 to 600 kPa
(53 to 87 psi)
Engine Oil Filter Differential Pressure @ HI maximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall 360 to 725 kPa
(52 to 105 psi)
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)] OK

Coolant Conditioner Concentration (% or PPM) 3 - 6 % or 1200 ppm

Coolant Minimum Temperature Protection

*1 Radiator Top Tank Temperature @ TC Stall

*2 Water Pump Outlet Temperature @ TC Stall

*1 Should be less than 110°F over ambient


*2 Should be 8° to 20°F less than Top Tank Temp/thermostat open (> 88°C/190°F)

2
777D UD Eng Power Test.doc
777D UPDATE TORQUE CONVERTER TEST
Machine Model Date

Machine Serial No. Machine Hours

Converter Serial No. Converter Hours

Transmission ECM Flash File/Date

VISUAL CHECKS

Oil Level Oil Viscosity

Air/Water in Oil? Oil Filter Examination

TEST SPECS ACTUAL

80 ± 3°C
Torque Converter Oil Temperature (during tests)
(160 ± 5°F)

930 ± 35 kPa
Torque Converter Inlet Pressure @ High Idle
(135 ± 5 psi)

380 to 520 kPa


Torque Converter Outlet Pressure @ Stall RPM
(55 to 75 psi)

Torque Converter Stall RPM 1540 to 1670 rpm

LI -
4700 ± 200 kPa
Parking Brake Release Pressure
(680 ± 30 psi)
HI -

Lockup Clutch Pressure 0 to 35 kPa


NEUTRAL/CONVERTER DRIVE/HIGH IDLE (0 to 5 psi)

Lockup Clutch Pressure 2135 ± 70 kPa


NEUTRAL/DIRECT DRIVE/1300 rpm (310 ± 10 psi)

Lockup Clutch Pilot Pressure (RV) 1725 ± 70 kPa


NEUTRAL/DIRECT DRIVE/LOW IDLE (250 ± 10 psi)

Lockup Clutch Primary Pressure (LP plug removed) 1030 ± 35 kPa


NEUTRAL/DIRECT DRIVE/LOW IDLE (150 ± 5 psi)

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

Machine Model ________________________ Date __________________________

Machine Serial Number __________________ Machine Hours __________________

Transmission Serial Number ______________ Transmission Hours ______________

Transmission/Chassis Flash File/Release 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
TRANSMISSION minimum maximum
PUMP PRESSURE 2480 kPa 3200 kPa
(360 psi) (465 psi)

4 to 41 kPa 83 to 138 kPa


LUBE PRESSURE (.5 to 6 psi) (12 to 20 psi)

PILOT PRESSURE 1725±70 kPa


@ Low Idle
N/A N/A
(250±10 psi)

Transmission Oil Temperature (during tests) 80 ± 3°C


(160 ± 5 ° F)

1
777D UPDATE TRA N S MIS S ION CLU TCH TES TS

CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I.


Load Piston Plug Removed
SPEED CLUTCHES STATION CLUTCH SPECS ACTUAL
ENGAGED
4 380 KPA
N 1 A (55 psi)
2 275 KPA
R 1 and 7 B (40 psi)
1 345 KPA
1 2 and 6 C (50 psi)
xxx xxx
2 1 and 6 D
5 345 KPA
3 3 and 6 E (50 psi)
6 415 KPA
4 1 and 5 F (60 psi)
7 415 KPA
5 3 and 5 G (60 psi)
3 550 KPA
6 1 and 4 H (80 psi)

7 3 and 4 xxx xxx

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

MAXIMUM CLUTCH PRESSURE


Load Piston Plug Installed
SPECS ACTUAL

STATION CLUTCH LI HI LI HI
4 1425 kPa
A xxx (207 psi) xxx

2 2365 kPa 2365 kPa


B (343 psi) (343 psi)
1 2780 kPa 2880 kPa
C (403 psi) (418 psi)

D xxx xxx xxx xxx 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 _________________________________

Machine Serial No. ________________________ Machine Hours _________________________

Transmission Serial No. ____________________ Transmission Hours _____________________

Flash File ________________________________ Flash File Release Date __________________

ECM Location Code _______________________ ECM Serial No. ________________________

VISUAL CHECKS:

Electrical Connections Component Damage ____________________

SETUP DESIRED ACTUAL


Body Up Gear Limit Setting

Transmission Maximum Gear Setting

Lockup Clutch Count N/A

Permanent Load Count N/A

ACTIVE FAULT CODES and DESCRIPTION

Fault Code Description Cause

1
TRANSMISSION/CHASSIS ECM

INTERMITTENT FAULT CODES


Fault Code
and Number of
Description Occurrences First Occurrence Last Occurrence

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

Machine Model_______________________ Date ______________________________

Machine Serial No.____________________ Machine Hours _____________________

VISUAL CHECKS:
Oil level Oil Viscosity _______________________
Air/Water in Oil? Oil Filter Examination _______________

TEST SPECS ACTUAL

> 38°C (100°F)


Steering Oil Temperature (during tests)
< 121°C (250°F)

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. ____________________

3.3 turns 3. ____________________ 3. ____________________

AVG. AVG.

Primary Steering Pressure @ High Idle 23425 ± 345 KPA


(Steer hard against stops) (3400 ± 50 PSI)

Primary Steering Backup Relief Valve Pressure @ 26000 ± 400 KPA


High Idle
(Steer hard against stops) (3775 ± 60 PSI)

Low Pressure Standby @ Low Idle 2070 to 2950 KPA


(Do Not Steer) (300 to 430 PSI)

Secondary Steering Pressure 16880 ± 345 KPA


(Steer hard against stops) (2450 ± 50 PSI)

Secondary Steering Backup Relief Valve Pressure 20700 ± 400 KPA


(Steer hard against stops) (3000 ± 60 PSI)

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

TEST SPECS ACTUAL

Steering Pressure Switch 2600 + 500 - 200 KPA


Pressure Reducing Valve (375 + 70 - 30 PSI)

27200 ± 690 KPA


Crossover Relief Valve (Left)
(3950 ± 100 PSI)

27200 ± 690 KPA


Crossover Relief Valve (Right)
(3950 ± 100 PSI)

2
777D UD Steer Test.doc
7 7 7 D U P D A T E HOIS T T E S T

Machine Model ____________________________ Date _____________________________________

Machine Serial No. _________________________ Machine Hours_____________________________

Hoist System Enable Status___________________ Hoist LOWER Adjustment Setting _____________

Transmission/Chassis ECM Flash File/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 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 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

TEST SPECS ACTUAL

Hoist Oil Temperature > 65°C (150°F)


(during tests) < 121°C (250°F)

DRIFT
(See Chart on Page 4)

Without Noise Reduction 1. ____________________


14.8 ± 1 seconds
RAISE TIME @ High Idle 2. ____________________
With Noise Reduction
18.2 ± 1 seconds 3. ____________________

AVG.

9.8 ± 1 seconds 1. ____________________


(not including snub)
2. ____________________
LOWER (POWER DOWN) TIME 11.4 ± 1 seconds
@ High Idle (including snub) 3. ____________________

AVG.

9.8 ± 1 seconds 1. ____________________


(not including snub)
2. ____________________
FLOAT TIME @ High Idle 11.4 ± 1 seconds
(including snub) 3. ____________________

AVG.

PILOT PRESSURE 4700 ± 200 kPa LI -


(Parking Brake Retraction) (680 ± 30 psi)
HI -

RAISE PRESSURE @ High Idle 18950 + 520 - 0 kPa


(2750 + 75 - 0 psi)

LOWER PRESSURE @ High Idle 3450 ± 350 kPa


(Body Switch in RAISE Position) (500 ± 50 psi)

ET Setting -5 0 +5

HOIST PRESSURE IN FLOAT LI - LI - LI -


(At Pump Tap)
Maximum 1725 kPa (250 psi) HI - HI - HI -

Final Programmed Value

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:

HOIST LEVER SENSOR

TEST SPECS ACTUAL

Supply Voltage + Battery (24 Volts)

Pull-Up Voltage Approx 5 Volts

Signal Duty Cycle % Full Raise to Full Lower


5 to 95 %

3
7 7 7 D U P D A T E HOIS T T E S T

HOIST VALVE HOIST VALVE


HOIST LEVER DUTY CYCLE ACTUAL SOLENOID SOLENOID
POSITION (approximate) DUTY CYCLE CURRENT (mA) CURRENT (mA)
(Solenoid% x 1900) (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.

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)

4
777D UPDATE AIR SYSTEM AND BRAKE TEST

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 830 ± 35 kPa
(CUT-OUT) (120 ± 5 psi)
Air Compressor Governor Setting 655 ± 35 kPa
(CUT-IN) (95 ± 5 psi)
Open--
#1 Pressure Protection Valve Open--
550 kPa (80 psi)
(Behind Cab)
(Drain Secondary Brake Tank to See Close-- Close--
Close Setting) 480 kPa (70 psi)
Open-- Open--
#2 Pressure Protection Valve 380 kPa (55 psi)

(ARC Relay Valve) Close-- Close--


310 kPa (45 psi)
550 ± 35 kPa
Retarder Valve--Maximum Air Pressure
(80 ± 5 psi)

4700 ± 200 kPa LI-


Parking Brake Retraction Valve
(680 ± 30 psi) HI-
Brake Cooling Oil Temperature 79 to 93 °C
(during brake cooling pressure test) 175 to 200 °F
LI - min 14 kPa (2 psi) LI -
Brake Cooling Oil Pressure
HI - max 172 kPa (25 psi) HI -
4481 kPa
Towing Pump Pressure
(650 psi)

1
777D UPDATE AIR SYSTEM AND BRAKE TEST

BRAKE CYLINDER OPERATION

AIR PRESSURE OIL PRESSURE


TEST
@ Brake Cylinder @ Slack Adjuster

Front Brake Cylinders


11.8 to 1

Rear Brake Cylinders


6.6 to 1

BRAKE OIL MAKEUP TANK REFILL OPERATION

Flow into the makeup tank is acceptable: YES ________ NO _________

BRAKE HOLDING CAPACITY

Service Brake Engaged rpm Manual Retarder Engaged rpm

Parking Brake Engaged rpm Secondary Brake Engaged rpm

2
785C/789C/793C AIR SYSTEM AND BRAKE TEST

SLACK ADJUSTER OPERATION

SLACK ADJUSTER TAP WHEEL PORT TAP


Engaged Engaged Released
Released Residual
Retarder Service Retarder Service 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 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.

3
777D UPDATE
AUTO RETARDER CONTROL (ARC) TEST
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 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

Maximum Air Pressure Maximum Brake Oil


Functional Test (Brake Cylinder) Pressure (Slack Adjuster)

Front Brake Cylinder Air/Oil Ratio


(6.6 to 1)

Rear Brake Cylinder Air/Oil Ratio


(6.6 to 1)
1
777D UD ARC Test.doc
777D UPDATE
AUTO RETARDER CONTROL (ARC) TEST

SETUP DESIRED ACTUAL

Control Speed Setting

Control Valve Cycles

Supply Valve Cycles

ACTIVE FAULT CODES and DESCRIPTION

Fault Code Description Cause

LOGGED FAULT AND EVENT CODES


Fault Code and Number of
First Occurrence Last Occurrence
Description Occurrences

2
777D UD ARC Test.doc
777D UPDATE
AUTO RETARDER CONTROL (ARC) TEST

ARC NORMAL OPERATION

FUNCTION ENGINE SPEED


Activation Speed
(supply solenoid ON) 1850 rpm

ARC Control Range 1850 to 1950 rpm

Factory Setting 1950 rpm

ARC OVERSPEED PROTECTION

Horn and Light Activate * 2100 rpm


Activation Speed 2100 rpm
(supply solenoid ON)
ARC Control Speed 2180 rpm

ARC Shutoff 2075 rpm

Auto Upshift ** 2300 rpm

* The Horn and Light are controlled by the Engine ECM


** Auto Upshifts are controlled by the Transmission/Chassis ECM

3
777D UD ARC Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST
Machine Model Date

Machine Serial No. Machine Hours

Brake ECM Flash File/Date

TEST 1 : Perform TCS test using the TCS TEST SWITCH:


1) On the ET screen toolbar, select Datalink Ð Select ECM and choose Brake ECM
2) In the Status Group, create a new group name ÔTCS TestÕ
3) Select the items as shown on the ET screen below:

4) Run the engine at LOW IDLE


5) Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON
6) Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED
7) 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

1
777D UD TCS Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST

TEST SPECS ACTUAL

Brake Oil Temperature (during tests) > 65°C (150°F)

4700 ± 200 kPa LI-


Parking Brake Release Pressure
(680 ± 30 psi) HI-

Left Brake Pressure (Released)

Left Brake Pressure (Engaged) < 300 kPa


(44 psi)

Right Brake Pressure (Released)

< 300 kPa


Right Brake Pressure (Engaged)
(44 psi)

ET Proportional Solenoid Percentage 44%

Proportional Solenoid 12 to 22 ohms


Resistance/Voltage 0 to 12 Volts
Left Selector Solenoid 18 to 45 ohms
Resistance/Voltage 24 Volts
Right Selector Solenoid 18 to 45 ohms
Resistance/Voltage 24 Volts

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: YES NO

Wheels Turned to the LEFT: YES NO

2
777D UD TCS Test.doc
777D UPDATE
TRACTION CONTROL SYSTEM (TCS) TEST

ACTIVE FAULT CODES and DESCRIPTION

Fault Code Description Cause

LOGGED FAULT CODES

Fault Code and Number of


First Occurrence Last Occurrence
Description Occurrences

3
777D UD TCS Test.doc
FRONT SUSPENSION CYLINDER CHARGING

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 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

Shim Thickness
Truck Model 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)
REAR SUSPENSION CYLINDER CHARGING

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 DIMENSIONS


Distance Below Top Of
Suspension Cylinder Housing
First Charge Line Second Charge Line
Truck Model mm (in.) 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)
TEMPERATURE SENSOR CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION


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%

1 777D UD Sensors Spec Chart.doc


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 CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION

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 %

Tolerance is ± 10%

ULTRASONIC FUEL LEVEL SENSOR CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION

Ultrasonic Fuel Level Sensor


SIGNAL
Depth of Fuel (Shallow Tank) DUTY CYCLE
VOLTAGE
0 to 250 mm (0 to 9.9 inch) 0.6 to 1.9 DCV 6 to 25 %
250 to 500 mm (9.9 to 19.7 inch) 1.9 to 3.2 DCV 25 to 45 %
500 to 750 mm (19.7 to 29.6 inch) 3.2 to 4.5 DCV 45 to 64 %
750 to 1000 mm (29.6 to 39.4 inch) 4.5 to 5.7 DCV 64 to 84 %

Tolerance is ± 10%

2 777D UD Sensors Spec Chart.doc


777D UPDATE OFF-HIGHWAY TRUCK
SPEED SENSOR GEAR TEETH

Pulses Per Revolution (PPR)

Speed Sensor Teeth (PPR)


Sensor Number of Teeth

Transmission Output Speed 120


(TOS) Sensor

Engine Output Speed (EOS) 151


Sensor

TCS Wheel Speed Sensor 48

1
777D UD Speed Sensor Teeth.doc

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