You are on page 1of 73

793D Lab Book

1. Vital Information Management System (VIMS) 2. Engine Tests 3. Engine Power Test 4. Hydraulic Fan Test 5. Torque Converter Test 6. Transmission Test 7. Transmission/Chassis ECM 8. Rear Axle Test 9. Steering Test 10. Hoist Test 11. Air System and Brake Test 12. Hydraulic Auto Retarder Control (ARC) Test 13. Traction Control System (TCS) Test 14. Suspension Cylinder Charging 15. Data View 16. Sensor Specifications p.2 p.10 p.19 p.22 p.26 p.29 p.32 p.35 p.40 p.43 p.49 p.55 p.59 p.63 p.65 p.68

VITAL INFORMATION MANAGEMENT SYSTEM (VIMS)

VITAL INFORMATION MANAGEMENT SYSTEM (VIMS)


Machine Model______________________________ Machine Serial No.___________________________ Machine Miles ______________________________ Date ______________________________ Machine Hours _____________________ ECM Serial #______________________

VISUAL CHECKS: Electrical Connections ________________________ Component Damage ________________

MSTAT (67828) - MACHINE STATISTICS PARAMETER Source Code S: Configuration Code C: (flash file) Hardware H: Model Number Serial Number Equipment Number Attachment Code (see chart on page 5) Languages PRI: SEC: Configuration Type Operator ID Source Ver: ATTACH (288224) (see chart on page 5) DESIRED ACTUAL

VIMS
PAYLOAD PROGRAM CODE PAYCAL (729225) RAC (722) - Set Haul Road Severity DESIRED YES/NO 0 OFF 1 high 2 medium 3 - low ACTUAL

PAYCONF (7292663) Max Payload Weight: Last Pass Indicator: Overload Limit % (105 to 120): Enhanced Scrbrd MSG: - Disabled - Reweigh Only - Count Up - Count Down Second Gear Reweigh Option: TOT (868) Load Count: Total Payload: Travel Distance: Travel Time: RESET (73738) YES/NO LUBSET (582738) - AUTO LUBE SETTINGS PARAMETER Autolube Cycle Time Autolube Duration DESIRED ACTUAL

ESTAT (37828) - EVENT STATISTICS EVENT SYSTEM MACHINE 4

VIMS
EACK (3225) ACTIVE EVENTS EVENT
HOUR METER START LENGTH OF CATEGORY LEVEL TIME

LIMIT

WORST

ELIST (35478) INTERMITTENT EVENTS EVENT


HOUR METER START LENGTH OF CATEGORY LEVEL TIME

LIMIT

WORST

VIMS
Use a Multimeter and check the Supply Voltage, Signal Output, and Pull-Up Voltages. Use the test group below to record the actual values of the sensor outputs. All measurements are taken with Key On and Engine OFF.

Sensor Tests
Supply Voltage Sensor Ambient Air Temp Aftercooler Level Jacket Water Level System Air Pressure Auto Lube Pressure Steering Oil Level Steering Oil Temp Steering Pressure (High) Steering Pressure (Low) Brake Temperature--LF Brake Temperature--RF Brake Temperature--LR Brake Temperature--RR Strut Pressure--LF Strut Pressure--RF Strut Pressure--LR Strut Pressure--RR Alternator "R" Terminal Fuel Level Sensor (A-B) Actual Temperature/ Pressure/ Fuel Level (ET or VIMS) Actual Signal Volts/Hz/Duty Cycle/ Resistance (B-C) Pull-up Voltage (B-C)

N/A N/A

N/A N/A

N/A

12.4 to 14.75 DCV > 95 Hz

N/A

VIMS ATTACHMENT CODES


793D ATTACHMENT CODES Attachment Code 0 4 5 6 RAC Enabled No Yes No Yes TKPH or TMPH Enabled No No Yes Yes

Road Analysis Control (RAC) Tonne-Kilometer Per Hour (TKPH) Ton-Mile Per Hour (TMPH)

VIMS KEYPAD OPERATIONS


PAYCONF PAYCAL TOT RESET ESET SVCLIT SVCSET TEST MSTAT LUBSET LUBMAN EACK ESTAT ELIST EREC ERSET DLOG DLRES LA UN ODO BLT CON ATTACH RAC 7292663 729225 868 73738 3738 782548 782738 8378 67828 582738 582626 3225 37828 35478 3732 37738 3564 35737 52 86 636 258 266 288224 722 Configure Payload Monitor (requires VIMS PC connection) Calibrate Payload Monitor (requires VIMS PC connection) Show Payload Cycle Resettable Totals Reset Displayed Payload Data Customize Events (requires VIMS PC connection) Turn OFF Service Light Service Light Set (requires VIMS PC connection) Self-Test Instrumentation Show Machine Statistics (source and config codes) Set Lube Cycle Times Manual Lube Show Acknowledged Events (Active) Show Event Statistics Show Event List (Intermittent) Start Event Recorder Configure 1 Event Recorder (requires VIMS PC connection) Start/Stop Data Logger Reset Data Logger Change Language Change Units Odometer Set/Reset (requires VIMS PC connection) Change Backlight Change Display Contrast see chart on page 5 (requires VIMS PC connection) Set Haul Road Severity (0 - OFF, 1 - high, 2 - medium, 3 low) (requires VIMS PC connection)

OK Key--Used to complete keypad entries and to acknowledge events. Acknowledging an event will remove the event from the display temporarily. Severe events cannot be acknowledged. GAUGE key--Displays parameters monitored by VIMS. Depressing the arrow keys will scroll through the parameters. Entering the parameter number and the GAUGE key selects that parameter. F1 Key--Provides additional information on the current event being displayed. For MAINTENANCE (SYSTEM) events, the MID, CID, FMI is displayed. For DATA (MACHINE) events, the current parameter value is displayed (temperature, pressure, rpm). 8

VIMS KEYPAD GAUGE PARAMETERS


100 105 106 107 108 111 112 116 117 118 121 122 129 130 131 135 140 197 198 199 200 313 325 328 350 403 416 417 444 452 460 461 462 463 724 790 791 799 ENG SPD BOOST PRES LT EXH TEMP RT-LT EXH TEMP RT EXH TEMP F AFTRCLR TEMP R AFTRCLR TEMP COLD MODE ENG DERATE % AIR FLTR IN-H20 ENG LOAD % FUEL FLTR ENG FUEL RATE GAL/HR ENG OIL LVL ENG OIL PRES ENG COOL TEMP SYS VOLTAGE ENG FAN SPD #1 ENG FAN SPD #2 RT-LT FAN SPD ENG FAN TEMP TC OUT TEMP DIFF TEMP DIFF LUBE PRES TRN LUBE TEMP FAN DRIVE FLTR LT PARKBK PRES RT PARKBK PRES STRG OIL TEMP BRK/AIR PRES LT F BRK TEMP LT R BRK TEMP RT F BRK TEMP RT R BRK TEMP BODY ANGLE DEG ATMOS PRES AMB AIR TEMP HOIST STATUS

NOTE: Shown are the most commonly used parameters. 9

Engine Tests

10

ENGINE TESTS
Machine Model ______________________ Machine Serial No. ___________________ Engine Serial No. ____________________ ECM Serial No. _____________________ Personality Module ___________________ Performance Spec (eng plate) ___________ Gross Power ________________________ Date ________________________________ Machine Hours ________________________ Engine Hours _________________________ Throttle Pedal Configuration _____________ Personality Module Date ________________ Max Altitude _________________________ Full Load RPM________________________

Fuel Ratio Control Offset (-25 to 0) _______________________________________________ Dual Horsepower (2160 hp only) Multi-Torque (2160/2300 hp)

Using the Engine Information Plate and the ET Screens, ECM Summary, Logged Diagnostic Codes and the Configuration Screen, fill in the information requested.

11

ENGINE TESTS
Create a Test Group on ET: 1) Using ET, choose the 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.

12

ENGINE TESTS
Supply Voltage (A-B)
Filtered Engine Oil Pressure Unfiltered Engine Oil Pressure Coolant Temperature Aftercooler Temperature Atmospheric Pressure Crankcase Pressure Right Turbo Inlet Pressure Left Turbo Inlet Pressure Turbo Outlet Pressure Left Exhaust Temperature Right Exhaust Temperature NOTE:

Sensor

Sensor Tests Desired Actual Signal Actual Pull-up Signal Volts Voltage/% Temperature/ Voltage or Pressure Duty Cycle (B-C) (ET or VIMS) (B-C) .2 to .6 .2 to .6 .4 to 4.6 .4 to 4.6 2.2 to 4.6 2.2 to 4.6 2.2 to 4.6 2.2 to 4.6 .8 to 1.5 see below see below
0 0 0

Analog supply voltage is 5.0 0.5 Digital supply voltage is 8.0 0.5 Desired signal voltages are at Key ON. Exhaust Temperature Sensor Duty Cycles: below 49C (120F) 10% to 21% 49 to 851C (120 to 1564F) - 22% to 88% above 851C (1564F) 88% to 90%

13

ENGINE TESTS
TEST ECM Supply Voltage Throttle Sensor Supply Voltage (A-B) Throttle Sensor Low Idle Duty Cycle (B-C) Throttle Sensor High Idle Duty Cycle (B-C) Throttle Sensor Frequency (B-C) Throttle Sensor Pull-Up Voltage (B-C) Speed Sensor Supply Voltage (A-B) Speed Sensor Frequency (Cranking) (B-C) Speed Sensor Frequency (Low Idle) (B-C) Speed Sensor Frequency (High Idle) (B-C) Speed Sensor Signal Voltage (Key ON) (B-C) SPECS ACTUAL

24 8.0 0.5 16 6% 85 4% 150-1000 Hz 11.5 0.5 12.5 1.0 23 - 40 Hz 140 Hz@700 rpm 385 Hz@1960 rpm less than 3.0 or greater than 10.0 2.0 to 4.0

Speed Sensor Signal Voltage (Cranking) (B-C)

14

ENGINE TESTS
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTION

LOGGED DIAGNOSTIC CODES


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

EVENT CODES
EVENT CODE DESCRIPTION NUMBER OF OCCURR FIRST HOUR METER LAST HOUR METER

15

ENGINE TESTS
INJECTOR SOLENOID TEST: CYLINDERS OPEN CYLINDERS SHORTED NOTES:

OVERRIDE PARAMETERS: ETHER INJECTION: ENGINE PRELUBE: OIL RENEWAL: OK OK OK NOT OK NOT OK NOT OK N/A N/A N/A

WASTEGATE:

Override % 0% 25% 50% 75% 100%

Volts

Current (miliamps)

NOTES:

16

ENGINE TESTS
CYLINDER CUTOUT TEST: Injector 1: Injector 2: Injector 3: Injector 4: Injector 5: Injector 6: Injector 7: Injector 8: Duration: Duration: Duration: Duration: Duration: Duration: Duration: Duration: Injector 9: Duration:

Injector 10: Duration: Injector 11: Duration: Injector 12: Duration: Injector 13: Duration: Injector 14: Duration: Injector 15: Duration: Injector 16: Duration:

Average Injection Duration Cylinders more than 10 TO 15% from Average NOTES:

CURRENT TOTALS: FUEL ETHER TOTAL TIME

17

ENGINE TESTS
INJECTOR CODES CALIBRATION: Injector 1: Injector 2: Injector 3: Injector 4: Injector 5: Injector 6: Injector 7: Injector 8: Code: Code: Code: Code: Code: Code: Code: Code: Injector 9: Injector 10: Injector 11: Injector 12: Injector 13: Injector 14: Injector 15: Injector 16: Code: Code: Code: Code: Code: Code: Code: Code:

NOTE: Default is 1100 NOTES:

PRESSURE SENSOR CALIBRATION: NOTES:

OK

NOT OK

TIMING CALIBRATION: NOTES:

OK

NOT OK

18

Engine Power Test

19

ENGINE POWER TEST


Machine Model Machine Serial No. Engine Serial No. Performance Spec Throttle Pedal Config Flash File/Date Date Machine Hours Engine Hours Rated Power Fuel Ratio Control Offset

Horsepower Configuration (Rating Selection): Dual Horsepower (2160 hp only) Multi-Torque (2160/2300 hp)

VISUAL CHECKS
Oil Level Oil Filter Examination

Create a Test Group on ET: 1) Using ET, choose the Engine ECM 2) In the Status Group, create a new group name "Engine Power Test" 3) Select the items as shown on the ET screen below:

NOTE: 151 flywheel gear teeth for magnetic pickup engine speed

20

ENGINE POWER TEST (8WM HD - No Wastegate)


Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on the chart provided. TEST Coolant Temperature (during tests) SPECS > 71C (160F) ACTUAL Start: Stop:

Low Idle RPM


High Idle RPM Air Filter Restriction @ TC Stall (maximum allowed) Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 10) DIRECT DRIVE Inlet Manifold Pressure (BOOST) @ Full Load RPM (1750 10) CONV DRIVE

700 15 1960 40 25 in. of water 188 28 kPa (27.2 4.1 psi) 171 26 kPa (24.8 3.7 psi) 1672 65 > 80C (175F) < 121C (250F) 207 to 600 kPa (30 to 87 psi) 324 to 600 kPa (47 to 87 psi) maximum 70 kPa (10 psi) 317 to 634 kPa (46 to 92 psi) OK *

Torque Converter Stall RPM


Torque Converter Temperature (during stall test) Engine Oil Pressure @ LI Engine Oil Pressure @ HI Engine Oil Filter Differential Pressure @ HI Fuel Pressure @ Torque Converter Stall Fuel Filter Status [maximum restriction 140 kPa (20 psi)] * Use Torque Stall for Class

21

Hydraulic Fan Test

22

HYDRAULIC FAN TEST


Machine Model Machine Serial No. Brake ECM Flash File/Date Date Machine Hours

Create a Test Group on ET: 4) On the ET screen, choose the Brake ECM 5) In the Status Group, create a new group named "793D Fan Test" 6) Select the items as shown on the ET screen below from the Brake ECM, the Engine ECM and the VIMS ECM:

NOTE: The Air Conditioner must be OFF during all tests except the A/C Test. Use the VIMS Data Logger to capture additional information during the fan tests. NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of the pump and motors before starting the engine.

23

HYDRAULIC FAN TEST

TEST TEMPERATURES
Jacket Water Coolant After Cooler Coolant Brake Oil Steering Drive Oil

TEST: HYDRAULIC FAN HIGH PRESSURE CUT-OFF

Tools
1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView 2) Fan Pump Port Cover Plate (5P0048) 3) Cover Plate Seal (1P3704) High Pressure Cut-Off Test Procedure: To determine the high pressure cut-off setting at the current altitude, use ET to override the hydraulic fan speed to 817 rpm, raise the engine speed to HIGH IDLE and record the pump pressure and fan speeds. Pump cut-off pressure should be set a minimum of 2070 kPa (300 psi) above the pressure required to maintain maximum fan speed (817 rpm) with the solenoid unplugged. This will vary with the elevation above sea level. 1) Install a blocker plate in the line from the makeup valve to the fan motor. 2) Disconnect the pump control solenoid. 3) Operate the truck at LOW IDLE. The pump should be at the cut-off pressure. 4) At sea level, adjust the cut-off pressure to 27000 345 kPa (3920 50 psi). At higher altitudes a lower cut-off pressure may be desired. HYDRAULIC FAN HIGH PRESSURE CUT-OFF Engine Speed @ HIGH IDLE PUMP PRESSURE

TEST TEMPERATURES
Jacket Water Coolant After Cooler Coolant Brake Oil Fan Drive Oil

24

NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of the pump and motors before starting the engine.

TEST 3: HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY

Tools
1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView 2) Laptop with ET Pump and Motor Efficiency Test Procedure: 1) Unplug the pump solenoid and operate the truck at LOW IDLE. If the pump and motor both have acceptable volumetric efficiencies, the fan speed should be a minimum of 817 rpm. HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY Fan Speed Pump Pressure (Minimum 510 rpm) Engine Speed @ High IDLE

25

Torque Converter Test

26

TORQUE CONVERTER TEST


Machine Model Machine Serial No. Converter Serial No. Transmission/Chassis ECM Flash File/Date Date Machine Hours Converter Hours

VISUAL CHECKS
Oil Level Oil Filter Examination

Create a Test Group on ET: 7) Using ET, choose the Transmission ECM 8) In the Status Group, create a new group name "Torque Converter Test" 9) Select the items as shown on the ET screen below:

27

TORQUE CONVERTER TEST


TEST Torque Converter Oil Temperature (during tests)

SPECS
> 80C (175F) < 121C (250F)

ACTUAL

Torque Converter Inlet Pressure

LI Maximum at High Idle HI with Cold Oil 930 35 kPa (135 5 psi) STALL-

Torque Converter Outlet Pressure @ STALL rpm

345 to 550 kPa (50 to 80 psi) 1721 65 LI: > 2515 kPa (365 psi) HI: < 3065 kPa (445 psi)

LI HI STALL-

Torque Converter Stall RPM

Transmission Charge Pressure (Converter Drive)

LI HI

Transmission Charge Pressure (Direct Drive)

2310 70 kPa (335 10 psi) @ 1300 rpm 1725 70 kPa (250 10 psi) 1445 to 2240 kPa (210 to 325 psi) 1070 35 kPa (155 5 psi) 2150 to 2205 kPa (310 to 320 psi)

Lockup Clutch Pilot Pressure (RV) NEUTRAL/DIRECT DRIVE/LOW IDLE Lockup Clutch Signal Pressure (from Lockup Solenoid) NEUTRAL/DIRECT DRIVE/1300 rpm Lockup Clutch Primary Pressure NEUTRAL/DIRECT DRIVE/LOW IDLE Lockup Clutch Maximum Pressure NEUTRAL/DIRECT DRIVE/1300 rpm

NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP. Converter Stall must be ran in FIRST FORWARD with the Body DOWN.

28

Transmission Test

29

Transmission Test
Machine Model ____________________________ Machine Serial No.__________________________ Transmission S/N ___________________________ Transmission/Chassis Flash File/Release Date Date _______________________________ Machine Hours _______________________ Transmission Hours ___________________

CONVERTER DRIVE PRESSURES

LOCKUP SOLENOID DE-ENERGIZED


SPECS LI HI 3065 kPa (445 psi) (maximum) 150 41 kPa 22 6 psi) LI

ACTUAL
HI

PUMP PRESSURE (Adjust with Transmission Relief Valve) LUBE PRESSURE PILOT PRESSURE (Result of setting Direct Drive Pump Pressure)

2515 kPa (365 psi) (minimum) 80 25 kPa (12 4 psi) 2410 to 2755 kPa (350 to 400 psi)

xxx > 82C (180F) < 121C (250F)

xxx

Transmission Oil Temperature (during tests)

DIRECT DRIVE PRESSURES


LI PUMP PRESSURE (Adjust with Priority Reducing Valve) STATION "D" PRESSURE NEUTRAL CLUTCH PRESSURE STATION "C" xxx xxx

LOCKUP SOLENOID ENERGIZED (plug signal line to lockup clutch valve)


SPECS 1300 RPM 2585 70 kPa (375 10 psi) Adjust station "D" to get correct rail (clutch) pressures 1724 70 kPa (250 10 psi) LI xxx ACTUAL 1300 RPM

xxx

xxx

xxx

30

TRANSMISSION CLUTCH TESTS


CLUTCH CHART
SPEED N R 1 2 3 4 5 6
CLUTCHES ENGAGED

PRIMARY CLUTCH PRESSURE @ L.I.

Load Piston Plug Removed


STATION CLUTCH SPECS 525 KPA (76 psi) 475 KPA (69 psi) 480 KPA (70 psi) xxx 425 KPA (62 psi) 450 KPA (65 psi) 425 KPA (62 psi) xxx xxx ACTUAL

3 1 and 6 1 and 5 2 and 5 1 and 4 2 and 4 1 and 3 2 and 3

A B C

2 1 3
DUAL RELIEF

D
E F G H

4 5 6
xxx

xxx

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

MAXIMUM CLUTCH PRESSURE Load Piston Plug Installed


SPECS STATION CLUTCH LockUp @ 1300 RPM 1689 kPa xxx xxx (245 psi) 2400 kPa 2425 kPa 1689 kPa (348 psi) (352 psi) (245 psi) 2470 kPa 2470 kPa 1689 kPa (358 psi) (358 psi) (245 psi) Adjust station "D" to get correct clutch pressures during lockup 1689 kPa xxx xxx (245 psi) 2585 kPa 2720 kPa 1689 kPa (375 psi) (395 psi) (245 psi) 2585 kPa 2805 kPa 1689 kPa (375 psi) (407 psi) (245 psi) xxx xxx xxx LI HI LI xxx ACTUAL HI xxx LockUp @ 1300 RPM

A
B C

2 1 3
DUAL RELIEF

D
E F G H

xxx xxx

xxx xxx

4 5 6
xxx

xxx

xxx

xxx

Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi) NOTE: During LockUp test, plug lockup signal hose to lockup valve "D" station pressure will be approximately 965 kPa (140 psi)

31

Transmission/Chassis ECM

32

TRANSMISSION/CHASSIS ECM
Machine Model ___________________________ Machine Serial No. ________________________ Transmission Serial No. ____________________ Flash File________________________________ ECM Location Code ______________________ Date _________________________________ Machine Hours _________________________ Transmission Hours _____________________ Flash File Release Date __________________ ECM Serial No. ________________________

VISUAL CHECKS: Electrical Connections SETUP or COUNT Body Up Gear Limit Setting Transmission Maximum Gear Setting Lockup Clutch Count Resettable Load Count Permanent Load Count N/A N/A N/A ACTIVE DIAGNOSTIC CODES Diagnostic Code Description Cause Component Damage ___________________ DESIRED ACTUAL

33

TRANSMISSION/CHASSIS ECM
LOGGED DIAGNOSTIC CODES Diagnostic Code and Description Number of Occurrences

First Occurrence

Last Occurrence

LOGGED EVENTS Event Code and Description Number of Occurrences

First Occurrence

Last Occurrence

34

Rear Axle Test

35

REAR AXLE TEST


Machine Model Machine Serial No. Brake ECM Software Part #/Date Date Machine Hours

VISUAL CHECKS
Oil Level Air/Water in Oil? Oil Viscosity Oil Filter Examination

Create a Test Group on ET: 1. On the ET screen toolbar, click File Select ECM and choose Brake ECM 2. In the Status Group, create a new group name "793 Rear Axle Test" 3. Select the items as shown on the ET screen below:

36

REAR AXLE TEST


During the Rear Axle test, the Rear Axle Pump Drive Oil Diverter Solenoid and the Final Drive Oil Bypass Solenoid must be turned ON or OFF with ET as directed in order to perform the tests. Run the engine at LOW IDLE and HIGH IDLE accordingly and record the data into the charts.

Pressure Tap Points:


1) Rear Axle Pump Drive --- 0 27560 kPa (0-4000 psi) gauge 2) Final Drive Filter --- 0 689 kPa (0-100 psi) gauge 3) Differential Filter--- 0 1378 kPa (0-200 psi) gauge

37

REAR AXLE TEST


TEST 1: Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass ON TEST Differential Temperature Engine RPM Rear Axle Pump Drive Pressure Pressure at inlet to Differential Filter Pressure at pressure tap on manifold SPECS > -3 C (25 F) < 60 C (140 F) 700 10 < 22752 +/- 50 kPa (3300 +/- 70 psi) 690 +/- 75 kPa (100 +/- 10 psi) 0 kPa (Less than 10 psi) ACTUAL

TEST 2: Engine at High Idle, Pump Drive Diverter OFF, Final Drive Bypass ON TEST Differential Temperature Engine RPM Rear Axle Pump Drive Pressure Pressure at inlet to Differential Filter Pressure at pressure tap on manifold SPECS > -3 C (25 F) < 60 C (140 F) 1950 20 < 22752 +/- 50 kPa (3300 +/- 70 psi) 690 +/- 75 kPa (100 +/- 10 psi) 0 kPa (Less than 10 psi) ACTUAL

38

REAR AXLE TEST


TEST 3: Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass OFF TEST Differential Temperature Engine RPM Rear Axle Pump Drive Pressure Pressure at inlet to Differential Filter SPECS > -3 C (25 F) < 60 C (140 F) 700 10 < 22752 +/- 50 kPa (3300 +/- 70 psi) 690 +/- 75 kPa (100 +/- 10 psi) ACTUAL

Pressure at pressure tap on manifold

570 +/- 75 kPa (80 +/- 10 psi)

TEST 4: Engine at Low Idle, Pump Drive Diverter ON, Final Drive Bypass ON TEST Differential Temperature Engine RPM Rear Axle Pump Drive Pressure Pressure at inlet to Differential Filter Pressure at pressure tap on manifold SPECS > -3 C (25 F) < 60 C (140 F) 700 10 Residual Pressure Only 0 kPa (0 psi) 0 kPa (0 psi) 39 ACTUAL

Steering Test

40

STEERING Test
Machine Model_______________________ Machine Serial No.____________________ Date ______________________________ Machine Hours _____________________

VISUAL CHECKS: Oil level Air/Water in Oil? TEST Steering Oil Temperature (during tests) Oil Viscosity _______________________ Oil Filter Examination _______________ SPECS > 60C (150F) < 121C (250F) 7.0 to 9.0 seconds
1. ____________________ 2. ____________________ 3. ____________________ AVG.

ACTUAL

Cycle Time @ High Idle From Left to Right and Right to Left Combined All Brakes Released

Steering wheel turns from stop to stop @ High Idle All Brakes Released (turn at one revolution per second) 793D: 4.0 to 5.0 turns

Left to Right 1. ____________________ 2. ____________________ 3. ____________________ AVG.

Right to Left 1. ____________________ 2. ____________________ 3. ____________________ AVG.

Pressure setting for the (priority valve) solenoid valve and manifold (rear axle fan, brake cooling, drive motor, lubrication, and steering)

18300 520 kPa (2650 75 psi)

41

STEERING TEST
TEST Pump High Pressure Cut-off @ Low Idle Backup Relief Valve Pressure @ Low Idle Relief/Makeup Valve Pressure (Right Turn) Relief/Makeup Valve Pressure (Left Turn) 1. Accumulator Nitrogen Charge Pressure @ 21C (70F) 2. Accumulator Nitrogen Charge Pressure @ 21C (70F) SPECS 23100 350 kPa (3350 50 psi) 26000 400 kPa (3770 60 psi) 28500 1000 kPa (4150 150 psi) 28500 1000 kPa (4150 150 psi) 6550 350 kPa (950 50 psi) 6550 350 kPa (950 50 psi)
Bench Test Only

ACTUAL

Bench Test Only

Bench Test Only

42

Hoist Test

43

HOIST TEST
Machine Model ____________________________ Machine Serial No.__________________________ Hoist System Enable Status ___________________ Date _____________________________________ Machine Hours _____________________________ Hoist LOWER Adjustment Setting _____________

Transmission/Chassis ECM Flash File/Date __________________________________________________ VISUAL CHECKS: Oil level __________________________________ Air/Water in Oil? ___________________________ Oil Viscosity ______________________________ 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 Disabled Status. The Hoist Disabled Status is a test mode only and will prevent the hoist cylinders from accidentally being moved. After the body is installed, enable the Hoist Status for the hoist system to function properly. Shown below are the three Hoist Statuses. Hoist System Enable Status: - hoist system is not installed - hoist system is installed and enabled (normal operation) - hoist system is installed but disabled Make sure the engine is not running and the truck is not moving. Transmission Output Speed (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 output in SNUB, pump output pressure must be less than 1725 kPa (250 psi). The hoist output must be in HOLD when changing the setting.

44

HOIST TEST
TEST Hoist Oil Temperature (during tests) RAISE TIME @ High Idle 19.0 to 21.0 sec. SPECS > 65C (150F) < 121C (250F)
1. ____________________ 2. ____________________ 3. ____________________ AVG.

ACTUAL

LOWER TIME @ High Idle (including snub) 17.0 to 19.0 sec.

1. ____________________ 2. ____________________ 3. ____________________ AVG.

FLOAT TIME @ High Idle (including snub) 17.0 to 19.0 sec.

1. ____________________ 2. ____________________ 3. ____________________ AVG.

PILOT PRESSURE (Parking Brake Retraction) RAISE PRESSURE @ High Idle

4700 200 kPa (680 30 psi) 20370 345 kPa (2955 50 psi)

LI HI F Tap: R Tap:

LOWER PRESSURE @ High Idle (Body Switch in RAISE Position) HOLD Maximum Pressure FLOAT Maximum Pressure HOLD Maximum Pressure

3450 + 350 0 kPa F Tap: (500 + 50 0 psi) R Tap: 790 20 kPa 115 3 psi 790 20 kPa 115 3 psi 790 20 kPa 115 3 psi F Tap: R Tap F Tap: R Tap F Tap: R Tap

45

ET Setting HOIST PRESSURE IN SNUB Maximum 1725 kPa (250 psi) Hoist LOWER Solenoid Current % Final Programmed Value LI HI -

-5 LI HI -

0 LI HI -

+5

46

HOIST TEST
Create a Test Group on ET: 1) On the ET screen, select the 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


Supply Voltage Pull-Up Voltage Signal Duty Cycle %

SPECS
+ Battery (24 Volts) Approx 5 Volts Full Raise to Full Lower 5 to 95 %

ACTUAL

BODY POSITION SENSOR ANGLE TEST


Body Full RAISE FLOAT to SNUB 47

Hoist LOWER Solenoid Current %


N/A

BODY POSITION ANGLE

HOIST TEST
HOIST LEVER POSITION HOIST VALVE DUTY CYCLE ACTUAL SOLENOID CURRENT % SOLENOID CURRENT (approximate) DUTY (mA) FROM ET CYCLE (ET Solenoid % x 1900) RAISE HOLD FLOAT LOWER SNUB 1 - 18% 24 to 48% 55 to 71% 80 to 96% N/A N/A N/A ___________ mA N/A ___________ mA ___________ mA ___________ mA N/A HOIST VALVE SOLENOID CURRENT (mA) (ACTUAL)

NOTE: The current at the solenoids will be equal to the percentage shown on the ET screen x 1900 milliamps.

DRIFT TEST: OIL TEMP

MINUTES ACCEPTABLE CYLINDER DRIFT

MINUTES 12.4 9.6 7.8 6.4 5.3 4.4 3.8 3.2 2.8

OIL TEMPERATURE 38 C (100 F) 43 C (110 F) 49 C (120 F) 54 C (130 F) 60 C (140 F) 66 C (150 F) 71 C (160 F) 77 C (170 F) 82 C (180 F)

CYLINDER DRIFT 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in) 6.40 mm (0.25 in)

48

Air System and Brakes Test

49

AIR SYSTEM AND BRAKE TEST


Machine Model ______________________ Machine Serial No.____________________ Date ______________________________ Machine Hours _____________________

VISUAL CHECKS: Hose Connections Air Leaks Component Damage ________________ Oil Leaks _________________________

TEST Air Compressor Governor Setting (CUT-OUT) Air Compressor Governor Setting (CUT-IN) Pressure Protection Valve (Behind Cab) (Drain Secondary Brake Tank to See Close Setting) Retarder Valve--Maximum Air Pressure Parking and Secondary Brake Control ValveMaximum Pressure Parking and Secondary Brake Control ValveMinimum Pressure Towing Pump Pressure

SPECS 830 35 kPa (120 5 psi) 655 kPa (95 psi) Open-550 kPa (80 psi) Close-480 kPa (70 psi) 550 kPa (80 psi) 4700200 kPa (680 30 psi) 4480 200 kPa (650 30 psi) 4481 kPa (650 psi) LIHILIHIOpen-Close--

ACTUAL

Towing pump pressure after: 1 minute 2 minutes 3 minutes 50 4 minutes 5 minutes -

AIR SYSTEM AND BRAKE TEST


Brake Cooling Oil Pressure At Wheels (Body Down in SNUB)
AT WHEEL INLET: Low Idle Minimum 14 kPa (2 psi) High Idle Maximum 450 35 kPa (65 5 psi) Brake Cooling Oil Temperature (during brake cooling pressure test) TEST Left Front Wheel Right Front Wheel Left Rear Wheel Right Rear Wheel LI HI LI HI LI HI LI HI 79 to 93 C (175 to 200 F) Brake Inlet Tap LI HI LI HI LI HI LI HI Brake Outlet Tap

Brake Cooling Oil Pressure (Body Down in SNUB)


Brake Cooling Oil Temperature (during brake cooling pressure test) TEST 79 to 93 C (175 to 200 F) RETARDER ENGAGED RETARDER RELEASED LI HI LI HI LI HI -

Hoist Pump Front (front brake oil cooling) LI HI Hoist Pump Rear (front brake oil cooling) Rear Brake Oil Cooler LI HI LI HI -

NOTE: 793D Hoist and Rear Oil Cooler Relief Valve settings are 790 kPa (115 psi) or less

51

AIR SYSTEM AND BRAKE TEST


BRAKE CYLINDER OPERATION (Apply Service Brake Pedal) AIR PRESSURE TEST
Brake Cylinder Air/Oil Ratio Front Brake Cylinders: Brake Cylinder #1 Brake Cylinder #2 @ Brake Cylinder 6.6 to 1

OIL PRESSURE
@ Slack Adjuster

XXXX

XXXX

Rear Brake Cylinders: Brake Cylinder #3 Brake Cylinder #4

XXXX

XXXX

NOTE: On machines equipped with the Extended Life Power Train, the brake cylinder air to oil ratio is 5.1:1 (Only on the Front Master Cylinders.

52

AIR SYSTEM AND BRAKE TEST


SLACK ADJUSTER OPERATION SLACK ADJUSTER TAP WHEEL PORT TAP
Released Residual Pressure Left Front Wheel Right Front Wheel Left Rear Wheel Right Rear Wheel

Engaged

Released

Engaged

Front

Rear

Released (residual) pressure at "S" port after releasing parking brakes: 793 front - 59 kPa (8.6 psi) 793 rear - 68 kPa (9.9 psi) NOTE: Low residual pressure MAY indicate a failed Slack Adjuster. High residual pressure MAY indicate warped brake discs. Rotate wheel to see if pressure fluctuates.

Brake Assembly Leakage


TEST 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. 53 Start Pressure Pressure after 5 minutes

AIR SYSTEM AND BRAKE TEST

BRAKE OIL MAKEUP TANK REFILL OPERATION Flow into the makeup tank is acceptable: YES ________ NO _________

BRAKE HOLDING CAPACITY Service Brake Engaged Parking Brake Engaged rpm rpm Manual Retarder Engaged Secondary Brake Engaged rpm rpm

NOTE: Minimum 1400 rpm

AIR COMPRESSOR TEST


To test the air compressor efficiency, lower the air system pressure to 480 kPa (70 psi). Start the engine and 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). The time to raise the pressure should be 50 seconds or less. If the time recorded is greater than 50 seconds, check for leaks or a restriction in the system. If no leaks or restrictions are found, the air compressor may have a problem. Time to charge system: seconds

54

Hydraulic Auto Retarder Control (ARC) Test

55

HYDRAULIC AUTO RETARDER CONTROL (ARC) TEST


Machine Model Machine Serial No. 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 Date Machine Hours

Functional Test Front Brake Cylinder Air/Oil Ratio (6.6 to 1) Rear Brake Cylinder Air/Oil Ratio (6.6 to 1)

Maximum Air Pressure (Brake Cylinder)

Maximum Brake Oil Pressure (Slack Adjuster)

56

HYDRAULIC AUTO RETARDER CONTROL (ARC) TEST


SETUP Control Speed Setting Control Valve Cycles Supply Valve Cycles DESIRED ACTUAL

N/A N/A

ACTIVE DIAGNOSTIC CODES and DESCRIPTION


Diagnostic Code Description Cause

LOGGED DIAGNOSTIC AND EVENT CODES Diagnostic and Event Code and Description Number of Occurrences First Occurrence Last Occurrence

NOTE: On machines equipped with the Extended Life Power Train, the brake cylinder air to oil ratio is 5.1:1 (Only on the Front Master Cylinders).

57

HYDRAULIC AUTO RETARDER CONTROL (ARC) TEST

ARC NORMAL OPERATION FUNCTION


Activation Speed (supply solenoid ON) ARC Control Range Factory Setting

ENGINE SPEED
1850 rpm 1850 to 1950 rpm 1950 rpm

ARC OVERSPEED PROTECTION


Horn and Light Activate * Activation Speed (supply solenoid ON) ARC Control Speed ARC Shutoff Auto Upshift ** 2100 rpm 2100 rpm 2125 rpm 2075 rpm 2300 rpm

* The Horn and Light are controlled by the Engine ECM ** The Auto Upshift is controlled by the Transmission ECM

58

Traction Control System (TCS) Test

59

TRACTION CONTROL SYSTEM (TCS) TEST


Machine Model Machine Serial No. Brake ECM Flash File/Date TEST 1: Perform TCS test using the TCS TEST SWITCH: 1) Using ET, choose the Brake ECM 2) In the Status Group, create a new group name "TCS Test" 3) Select the items as shown on the ET screen below: Date Machine Hours

4) 5) 6) 7)

Run the engine at LOW IDLE Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED Depress the TCS Test Switch and observe the TCS Proportional Solenoid signal sweep between 044% 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 60

TRACTION CONTROL SYSTEM (TCS) TEST


TEST Brake Oil Temperature (during tests)

SPECS
> 65C (150F) 4700 200 kPa (680 30 psi) LIHI-

ACTUAL

Parking Brake Release Pressure Left Brake Pressure (Released) Left Brake Pressure (Engaged) Right Brake Pressure (Released) Right Brake Pressure (Engaged) ET Proportional Solenoid Percentage Proportional Solenoid Resistance/Voltage Left Selector Solenoid Resistance/Voltage Right Selector Solenoid Resistance/Voltage

< 300 kPa (44 psi)

< 300 kPa (44 psi) 44% 12 to 22 ohms 0 to 12 Volts 18 to 45 ohms 24 Volts 18 to 45 ohms 24 Volts

NOTE: When the brakes are ENGAGED, gauge pressure will drop quickly to approximately 1380 kPa (200 psi), and then gradually decrease. This is the function of the proportional solenoid and orifices.

TEST 2: FUNCTIONAL TEST Run the engine at Low Idle. Engage FIRST GEAR and release the brakes. With the TCS Test Switch Depressed, do the brakes ENGAGE and RELEASE intermittently? Wheels Turned to the RIGHT: Wheels Turned to the LEFT: YES YES NO NO

61

TRACTION CONTROL SYSTEM (TCS) TEST


ACTIVE DIAGNOSTIC CODES and DESCRIPTION Fault Code Description Cause

LOGGED DIAGNOSTIC CODES Diagnostic Code and Description Number of Occurrences First Occurrence Last Occurrence

62

Suspension Cylinder Charging

63

FRONT SUSPENSION CYLINDER CHARGING


Refer to: Special Instruction SEHS9411 Servicing the Suspension Cylinders for Off-Highway Trucks

64

Data View

65

DataView Users Guide


1. Install DataView Software in Laptop (NEHS0662) or STW NETG5030 2. Connect DataView Box to Laptop printer port with cable provided 3. Connect sensors and cables to Machine and DataView Box. (Max possible is 9, 6 analog and 3 frequency). 4. Power On DataView Box 5. 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 sensor 8. 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 sensors 10. Click on Clock Icon (Setup Logger Tool) (third icon from left) 11. Select all channels 12. 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 Manual 15. Send Configuration 16. 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 logging 18. Raise Trigger Switch again to Stop Logging manually 19. Click on 4th Icon from left (Graph Viewer Tool) and select one of the data sources 20. 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 menu Open a New File and Name it the Machine Serial Number (789C 2BW00201) Enter a new document name and description (Brake cooling test with sensors at xx, xx, xxx, etc.)

DATAVIEW TOOLS
NEHS0662 JERD2163 131-5051 153-9630 213-3274 213-3275 213-3276 6V4144 6V2198 137-0168 137-0170 4C4463 Software and Instruction Manual Software Updates DataView Portable Tech Station Group PWM-Analog Test Group Sensor Adapter Kit 100 psi sensor 1000 psi sensor 7500 psi sensor Internal 1/4 nptf Valved Coupler (for each sensor) 18 ft. sensor extension cable Machine battery power cable 12V Cigarette Lighter power cable Yellow case for small parts

66

C-SERIES SENSORS IN DATAVIEW SENSOR TABLE 100-3055 - Temperature: 163-7882 - Temperature: 102-2240 - Temperature: 118-7226 - Temperature: 118-3909 - Temperature: Brake, Differential, Torque Converter, Transmission (digital) Engine Exhaust (digital) Engine Coolant, Rear Aftercooler Coolant (analog) Front Aftercooler Coolant (VIMS), Steering (digital) 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: 141-5746 - PWM Pressure: 157-8394 - PWM Pressure: 160-1582 - PWM Pressure: Throttle (digital) Air System (digital) Rear Parking Brakes (digital) Rear Axle Oil (digital)

Speed Sensor Teeth (PPR)


SENSOR Engine Output Speed (EOS) Sensor Fan Motor Output Speed Sensor Transmission Output Speed (TOS) Sensor Traction Control System (TCS) Wheel Speed Sensors

Number of Teeth
151 67 120 48

Engine and Fan Speed Adapter Cable


To measure the Engine and Fan Speeds with DataView, a two-pin adapter T-cable will need to be made from either a 153-9626 3-pin HD-10 Adapter cable or a 153-9627 3-pin DT Adapter cable. Remove the 3-pin plug and receptacle from the T-cable. Cut the red wire. The red wire is not needed with the 2-pin passive speed sensors. Using a 102-8802 2-pin DT receptacle kit and a 155-2270 2-pin DT plug kit, install the white wires in pin location 1 and install the black wires in pin location 2. Shown is a DataView screen while running the hydraulic fan override test. 67

Sensor Specifications

68

ANALOG TEMPERATURE SENSOR CHARTS

SENSOR VOLTAGE SPECIFICATION ENGINE JACKET WATER, REAR AFTERCOOLER and FUEL 102-2240 Analog Temperature Sensors TEMPERATURE -40 to -20 C (-40 to -4 F) -20 to 0 C (-4 to 32 F) 0 to 20 C (32 to 68 F) 20 to 40 C (68 to 104 F) 40 to 60 C (104 to 140 F) 60 to 80 C (140 to 176 F) 80 to 100 C (176 to 212 F) 100 to 120 C (212 to 248 F) Tolerance is 10 % SIGNAL VOLTAGE .5 to .57 DCV .57 to .75 DCV .75 to 1.16 DCV 1.16 to 1.86 DCV 1.86 to 2.74 DCV 2.74 to 3.53 DCV 3.53 to 4.1 DCV 4.1 to 4.46 DCV

SENSOR VOLTAGE SPECIFICATION ENGINE OIL 106-0735 Analog Temperature Sensor TEMPERATURE -40 to -20 C (-40 to -4 F) -20 to 0 C (-4 to 32 F) 0 to 20 C (32 to 68 F) 20 to 40 C (68 to 104 F) 40 to 60 C (104 to 140 F) 60 to 80 C (140 to 176 F) 80 to 100 C (176 to 212 F) 100 to 120 C (212 to 248 F) Tolerance is 10 % SIGNAL VOLTAGE .2 to .57 DCV .57 to 1.12 DCV 1.12 to 1.71 DCV 1.71 to 2.31 DCV 2.31 to 2.94 DCV 2.94 to 3.55 DCV 3.55 to 4.0 DCV 4.0 to 4.37 DCV

69

ANALOG PRESSURE SENSOR CHARTS SENSOR VOLTAGE SPECIFICATION ATMOSPHERIC, CRANKCASE and TURBO INLET PRESSURE 161-9926 Analog Pressure Sensor ABSOLUTE PRESSURE 0 to 20.7 kPa (0 to 3 psi) 20.7 to 41.3 kPa (3 to 6 psi) 41.3 to 62 kPa (6 to 9 psi) 62 to 82.7 kPa (9 to 12 psi) 82.7 to 103 kPa (12 to 15 psi) Tolerance is 3 % SIGNAL VOLTAGE 0 to .89 DCV .89 to 1.78 DCV 1.78 to 2.67 DCV 2.67 to 3.56 DCV 3.56 to 4.44 DCV

SENSOR VOLTAGE SPECIFICATION TURBO OULET PRESSURE 194-6724 Analog Pressure Sensor ABSOLUTE PRESSURE 0 to 34.5 kPa (0 to 5 psi) 34.5 to 68.9 kPa (5 to 10 psi) 68.9 to 103.4 kPa (10 to 15 psi) 103.4 to 137.8 kPa (15 to 20 psi) 137.8 to 172.3 kPa (20 to 25 psi) 172.3 to 206.7 kPa (25 to 30 psi) 206.7 to 241.2 kPa (30 to 35 psi) 241.2 to 275.6 kPa (35 to 40 psi) Tolerance is 3 % SIGNAL VOLTAGE 0 to .33 DCV .33 to .66 DCV .66 to .99 DCV .99 to 1.32 DCV 1.32 to 1.65 DCV 1.65 to 1.98 DCV 1.98 to 2.31 DCV 2.31 to 2.64 DCV

70

DIGITAL TEMPERATURE SENSOR CHARTS

SENSOR DUTY CYCLE SPECIFICATION BRAKE, DIFFERENTIAL, CONVERTER, TRANSMISSION, STEERING, FRONT AFTERCOOLER and FAN DRIVE 100-3055, 118-7226 Digital Temperature Sensors TEMPERATURE -40 to -20 C (-40 to -4 F) -20 to 0 C (-4 to 32 F) 0 to 20 C (32 to 68 F) 20 to 40 C (68 to 104 F) 40 to 60 C (104 to 140 F) 60 to 80 C (140 to 176 F) 80 to 100 C (176 to 212 F) 100 to 120 C (212 to 248 F) Tolerance is 10 % DUTY CYCLE 10 to 11.3 % 11.3 to 15 % 15 to 23.2 % 23.2 to 37.2 % 37.2 to 54.7 % 54.7 to 70.6 % 70.6 to 82 % 82 to 89.3 %

SENSOR DUTY CYCLE SPECIFICATION AMBIENT TEMPERATURE 118-3909 Digital Temperature Sensor TEMPERATURE -60 to -40 C (-76 to -40 F) -40 to -20 C (-40 to -4 F) -20 to 0 C (-4 to 32 F) 0 to 20 C (32 to 68 F) 20 to 40 C (68 to 104 F) 40 to 60 C (104 to 140 F) 60 to 80 C (140 to 176 F) 80 to 100 C (176 to 212 F) 100 to 120 C (212 to 248 F) Tolerance is 10 % DUTY CYCLE 1 to 4 % 4 to 11.3 % 11.3 to 22.3 % 22.3 to 34.2 % 34.2 to 46.2 % 46.2 to 58.8 % 58.8 to 70.9 % 70.9 to 80.6 % 80.6 to 87.4 %

71

EXHAUST TEMPERATURE SENSOR CHART SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION 163-7882 Digital Temperature Sensor (Exhaust) TEMPERATURE 50 to 200 C (122 to 392 F) 200 to 400 C (392 to 725 F) 400 to 600 C (725 to 1112 F) 600 to 850 C (1112 to 1562 F) Tolerance is 10 % DUTY CYCLE 22 to 33.2 % 33.2 to 50 % 50 to 67 % 67 to 88.4 %

DIFFERENTIAL PRESSURE SENSOR CHART SENSOR DUTY CYCLE SPECIFICATION 160-1582 Digital Pressure Sensor on Rear Axle Valve ABSOLUTE PRESSURE 0 to 137.8 kPa (0 to 20 psi) 137.8 to 275.6 kPa (20 to 40 psi) 275.6 to 413.4 kPa (40 to 60 psi) 413.4 to 551.2 kPa (60 to 80 psi) 551.2 to 689 kPa (80 to 100 psi) 689 to 826.8 kPa (100 to 120 psi) Tolerance is 3 % ULTRASONIC FUEL LEVEL SENSOR CHART SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION 124-9325 Ultrasonic Fuel Level Sensor Depth of Fuel (Shallow Tank) 0 to 250 mm (0 to 9.9 inch) 250 to 500 mm (9.9 to 19.7 inch) 500 to 750 mm (19.7 to 29.6 inch) 750 to 1000 mm (29.6 to 39.4 inch) Tolerance is 10 % 72 DUTY CYCLE 6 to 25 % 25 to 45 % 45 to 64 % 64 to 84 % DUTY CYCLE 0 to 13.6 % 13.6 to 29.6 % 29.6 to 45.6 % 45.6 to 61.6 % 61.6 to 77.6 % 77.6 to 93.6 %

AIR PRESSURE SENSOR CHARTS:


SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION 141-5746, 185-0600 Pressure Sensor (AIR) Air Pressure 0 to 140 kPa (20 psi) 140 kPa (20 psi) to 275 kPa (40 psi) 275 kPa (40 psi) to 415 kPa (60 psi) 415 kPa (60 psi) to 550 kPa (80 psi) 550 kPa (80 psi) to 690 kPa (100 psi) 690 kPa (100 psi) to 825 kPa (120 psi) 825 kPa (120 psi) to 965 kPa (140 psi) Tolerance is 3 % DUTY CYCLE 1.2 to 13.2 % 13.2 to 25.2 % 25.2 to 37.2 % 37.2 to 49.2 % 49.2 to 61.1 % 61.1 to 73.1 % 73.1 to 85.1 %

73

You might also like