Professional Documents
Culture Documents
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
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
VIMS
EACK (3225) ACTIVE EVENTS EVENT
HOUR METER START LENGTH OF CATEGORY LEVEL TIME
LIMIT
WORST
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
N/A
Road Analysis Control (RAC) Tonne-Kilometer Per Hour (TKPH) Ton-Mile Per Hour (TMPH)
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
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
14
ENGINE TESTS
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTION
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:
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:
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:
OK
NOT OK
OK
NOT OK
18
19
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
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 *
21
22
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
TEST TEMPERATURES
Jacket Water Coolant After Cooler Coolant Brake Oil Steering Drive Oil
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.
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
26
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
SPECS
> 80C (175F) < 121C (250F)
ACTUAL
LI Maximum at High Idle HI with Cold Oil 930 35 kPa (135 5 psi) STALL-
345 to 550 kPa (50 to 80 psi) 1721 65 LI: > 2515 kPa (365 psi) HI: < 3065 kPa (445 psi)
LI HI STALL-
LI HI
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 ___________________
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
xxx
xxx
xxx
30
A B C
2 1 3
DUAL RELIEF
D
E F G H
4 5 6
xxx
xxx
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
First Occurrence
Last Occurrence
34
35
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
37
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
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
Pressure setting for the (priority valve) solenoid valve and manifold (rear axle fan, brake cooling, drive motor, lubrication, and steering)
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
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
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:
SPECS
+ Battery (24 Volts) Approx 5 Volts Full Raise to Full Lower 5 to 95 %
ACTUAL
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.
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
49
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
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
OIL PRESSURE
@ Slack Adjuster
XXXX
XXXX
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
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 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
54
55
Functional Test Front Brake Cylinder Air/Oil Ratio (6.6 to 1) Rear Brake Cylinder Air/Oil Ratio (6.6 to 1)
56
N/A N/A
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
ENGINE SPEED
1850 rpm 1850 to 1950 rpm 1950 rpm
* The Horn and Light are controlled by the Engine ECM ** The Auto Upshift is controlled by the Transmission ECM
58
59
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
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) 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
LOGGED DIAGNOSTIC CODES Diagnostic Code and Description Number of Occurrences First Occurrence Last Occurrence
62
63
64
Data View
65
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)
Number of Teeth
151 67 120 48
Sensor Specifications
68
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
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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 %
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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 %
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