VITAL INFORMATION MANAGEMENT SYSTEM

(VIMS)

Machine Model______________________________ Date ______________________________

Machine Serial No.___________________________ Machine Hours _____________________

VISUAL CHECKS:

Electrical Connections ________________________ Component Damage _________________

MSTAT (67828) - MACHINE STATISTICS

PARAMETER DESIRED ACTUAL

Source Code S:

Configuration Code C:

Hardware H:

Model Number

Serial Number

Equipment Number

Attachment Code (ATTACH) – Used to 0 – NO

recognize if RAC module is present
4 - YES
Languages
PRI:
SEC:

Configuration Type

Operator ID

1
 VIMS

PAYLOAD

PROGRAM CODE DESIRED ACTUAL

PAYCAL (729225) YES/NO

0 – OFF
1 – low
RAC (722) Set Haul Road Severity 2 – medium
3 - high
ESET (3738) Customize Payload Overload
Events

PAYCONF (7292663)
Max Payload Weight:
Last Pass Indicator:
TOT (868)
Load Count:
Total Payload:
Travel Distance:
Travel Time:
RESET (73738) YES/NO

LUBSET (582738) - AUTO LUBE SETTINGS

PARAMETER DESIRED ACTUAL

Autolube Cycle Time

Autolube Duration

ESTAT (37828) - EVENT STATISTICS

EVENT

SYSTEM

MACHINE

2
 VIMS

EACK (3225): ACTIVE EVENTS

HOUR METER CATEGORY

EVENT LENGTH OF TIME
START LEVEL

ELIST (35478): INTERMITTENT EVENTS

HOUR METER LENGTH OF TIME CATEGORY

EVENT
START LEVEL

3
 VIMS

Sensor Tests
Supply Actual Temperature/ Actual Signal Pull-up
Sensor Voltage Pressure/ Fuel Level Volts/Hz/Duty Cycle/ Voltage
Resistance

Ambient Air Temp

Aftercooler Level

Jacket Water Level

System Air Pressure

Auto Lube Pressure

Steering Oil Level

Steering Oil Temp

Steering Pressure (High) N/A N/A

Steering Pressure (Low) N/A N/A

Strut Pressure--LF

Strut Pressure--RF

Strut Pressure--LR

Strut Pressure--RR
12.4 to 14.75 DCV
Alternator "R" Terminal N/A N/A
> 95 Hz

Fuel Level Sender

NOTE: Sensor supply voltage is 8.0 ± 0.5 or 24.8 to 29.5

4
 VIMS KEYPAD OPERATIONS
PAYCONF 7292663 Configure Payload Monitor
(requires VIMS PC connection)
PAYCAL 729225 Calibrate Payload Monitor
TOT 868 Show Payload Cycle Resettable Totals
RESET 73738 Reset Displayed Data
ESET 3738 Customize Payload Overload Events
(requires VIMS PC connection)
SVCLIT 782548 Reset Service Light
SVCSET 782738 Service Light Set
TEST 8378 Self-Test Instrumentation
MSTAT 67828 Show Machine Statistics (source and config codes)

LUBSET 582738 Set Lube Cycle Times

LUBMAN 582626 Manual Lube
EACK 3225 Show Acknowledged Events (Active)
ESTAT 37828 Show Event Statistics
ELIST 35478 Show Event List (Intermittent)

EREC 3732 Start Event Recorder

ERSET 37738 Configure 1 Event Recorder
(requires VIMS PC connection)

DLOG 3564 Start/Stop Data Logger

DLRES 35737 Reset Data Logger
LA 52 Change Language
UN 86 Change Units
ODO 636 Odometer Set/Reset
(requires VIMS PC connection)
BLT 258 Change Backlight
CON 266 Change Display Contrast

ATTACH 288224 RAC module is present (0 – NO, 4 – YES)

RAC 722 Set Haul Road Severity
(0 - OFF, 1 - low, 2 - medium, 3 – high)
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).
5
 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

WASTEGATE: Override % Volts Current (miliamps)

0%

25%

50%

75%

100%

NOTES:

5
CYLINDER CUTOUT TEST:

Injector 1: Duration: Injector 9: Duration:

Injector 2: Duration: Injector 10: Duration:

Injector 3: Duration: Injector 11: Duration:

Injector 4: Duration: Injector 12: Duration:

Injector 5: Duration: Injector 13: Duration:

Injector 6: Duration: Injector 14: Duration:

Injector 7: Duration: Injector 15: Duration:

Injector 8: Duration: Injector 16: Duration:

Average Injection Duration

Cylinders more than 100 from Average

NOTES:

CURRENT TOTALS:

FUEL TOTAL TIME

ETHER

6
 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:

NOTE: Default is 1100

NOTES:

PRESSURE SENSOR CALIBRATION: OK NOT OK

NOTES:

TIMING CALIBRATION: OK NOT OK

NOTES:

7
 785C 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 – Select ECM and choose 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

1
785C Eng Power Test.doc
 785C 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) 182 ± 30 kPa
@ Full Load RPM (1750 ± 10) (26 ± 5 psi)
Inlet Manifold Pressure (BOOST) 178 ± 30 kPa
@ TC Stall RPM (1640 ± 65 rpm) (26 ± 5 psi)
Torque Converter Stall RPM 1640 ± 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
785C Eng Power Test.doc
 789C 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 – Select ECM and choose 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

1
789C Eng Power Test.doc
 789C 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) 178 ± 30 kPa
@ Full Load RPM (1750 ± 10) (26 ± 5 psi)
Inlet Manifold Pressure (BOOST) 178 ± 30 kPa
@ TC Stall RPM (1715 ± 65 rpm) (26 ± 5 psi)
Torque Converter Stall RPM 1715 ± 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
789C Eng Power Test.doc
 793C 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

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) On the ET screen toolbar, click Datalink – Select ECM and choose 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

1
793C EngPowerTest.doc
793C ENGINE POWER TEST (7TR wastegate)
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 1965 ± 10

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

6.2 kPa
Inlet Manifold Pressure (BOOST) 207 ± 35 kPa
@ Full Load RPM (1750 ± 10) (30 ± 5 psi)

Inlet Manifold Pressure (BOOST) _______ ± 30 kPa

@ TC Stall RPM (1672 ± 65 rpm) (_______ ± 5 psi)

Torque Converter Stall RPM 1672 ± 65

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

< 121°C (250°F)

Engine Oil Pressure @ LI 193 to 600 kPa

(28 to 87 psi)

Engine Oil Pressure @ HI 324 to 600 kPa

(47 to 87 psi)

Engine Oil Filter Differential Pressure @ HI maximum

70 kPa (10 psi)

Fuel Pressure @ Torque Converter Stall 303 to 600 kPa

(44 to 87 psi)
Fuel Filter Status
OK
[maximum restriction 140 kPa (20 psi)]

LI -
Wastegate % < 60 % HI -

Stall -

2
793C EngPowerTest.doc
 793C 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 SPECS ACTUAL

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

Low Idle RPM 700 ± 10

High Idle RPM 1965 ± 20

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

6.2 kPa
Inlet Manifold Pressure (BOOST) 191 ± 35 kPa
@ Full Load RPM (1750 ± 10) (28 ± 5 psi)

Inlet Manifold Pressure (BOOST) _______ ± 30 kPa

@ TC Stall RPM (1672 ± 65 rpm) (_______ ± 5 psi)

Torque Converter Stall RPM 1672 ± 65

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

< 121°C (250°F)

Engine Oil Pressure @ LI 220 to 600 kPa

(32 to 87 psi)

Engine Oil Pressure @ HI 324 to 600 kPa

(47 to 87 psi)

Engine Oil Filter Differential Pressure @ HI maximum

70 kPa (10 psi)

Fuel Pressure @ Torque Converter Stall 317 to 634 kPa

(46 to 92 psi)
Fuel Filter Status
OK
[maximum restriction 140 kPa (20 psi)]

3
793C EngPowerTest.doc
 785C/789C/793C TORQUE CONVERTER TEST

Machine Model Date

Machine Serial No. Machine Hours

Converter Serial No. Converter Hours

Transmission/Chassis ECM Flash File/Date

VISUAL CHECKS

Oil Level Oil Filter Examination

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 ‘Torque Converter Test’
3) Select the items as shown on the ET screen below:

Converter Clutch Slip Engine Speed TC Out Speed

Torque Converter Output RPM vs Engine RPM 700 rpm
CONVERTER DRIVE 1300 rpm
1950 rpm
Torque Converter Output RPM vs Engine RPM 700 rpm
DIRECT DRIVE 1300 rpm
1950 rpm

1
785C-793C Conv Test.doc
 785C/789C TORQUE CONVERTER TEST

TEST SPECS ACTUAL

> 80°C (175°F)

Torque Converter Oil Temperature (during tests)
< 121°C (250°F)
Max Restriction LI -
Torque Converter Charge Filter Restriction 140 ± 15 kPa
(20 ± 2 psi) HI -
Maximum at High Idle LI -
with Cold Oil
Torque Converter Inlet Pressure
930 ± 35 kPa HI –
(135 ± 5 psi)
STALL-

LI -
345 to 550 kPa
Torque Converter Outlet Pressure @ STALL rpm HI –
(50 to 80 psi)

STALL-

Torque Converter Stall RPM

785C--1640 ± 65 rpm
789C--1715 ± 65 rpm

4700 ± 200 kPa LI-

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

Lockup Clutch Pilot Pressure (RV) 1725 ± 70 kPa

NEUTRAL/Low Idle (250 ± 10 psi)

Lockup Clutch Signal Pressure (from Lockup Solenoid) 1445 to 2240 kPa
NEUTRAL/Direct Drive/1300 rpm (210 to 325 psi)

Lockup Clutch Primary Pressure 1030 ± 35 kPa

NEUTRAL/Direct Drive/Low Idle (150 ± 5 psi)

Lockup Clutch Maximum Pressure 2135 ± 70 kPa

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

2
785C-793C Conv Test.doc
 793C TORQUE CONVERTER TEST

TEST SPECS ACTUAL

> 80°C (175°F)

Torque Converter Oil Temperature (during tests)
< 121°C (250°F)
Max Restriction LI -
Torque Converter Charge Filter Restriction 140 ± 15 kPa
(20 ± 2 psi) HI -
Maximum at High Idle LI -
with Cold Oil
Torque Converter Inlet Pressure
930 ± 35 kPa HI –
(135 ± 5 psi)
STALL-

LI -
345 to 550 kPa
Torque Converter Outlet Pressure @ STALL rpm HI –
(50 to 80 psi)

STALL-

Torque Converter Stall RPM 1672 ± 65 rpm

LI– > 2515 kPa LI -

(365 psi)
Transmission Charge Pressure
1750 rpm –
1750 rpm– < 3065 kPa
(445 psi) 1300 -
Dir Drv

Lockup Clutch Pilot Pressure (RV) 1725 ± 70 kPa

NEUTRAL/Direct Drive/Low Idle (250 ± 10 psi)

Lockup Clutch Signal Pressure (from Lockup Solenoid) 1445 to 2240 kPa
NEUTRAL/Direct Drive/1300 rpm (210 to 325 psi)

Lockup Clutch Primary Pressure 1030 ± 35 kPa

NEUTRAL/Direct Drive/Low Idle (150 ± 5 psi)

Lockup Clutch Maximum Pressure 2150 to 2350 kPa

NEUTRAL/DIRECT DRIVE/1300 rpm (310 to 340 psi)

3
785C-793C Conv Test.doc
 7 8 5 C/ 7 8 9 C TRA N S MIS S ION TES T
Machine Model _____________________________ Date ________________________________

Machine Serial No. __________________________ Machine Hours _______________________

Transmission S/N ___________________________ Transmission Hours ___________________

Transmission/Chassis Flash File/Release Date

VISUAL CHECKS:

Oil level Oil Viscosity _______________________

Air/Water in Oil? Oil Filter Examination ________________

DUAL STAGE LOCKUP SOLENOID DE-ENERGIZED

RELIEF
SPECS ACTUAL
LI HI LI HI

PUMP PRESSURE 2515 kPa (365 psi) 3175 kPa (460 psi)
(minimum) (maximum)

LUBE PRESSURE 4 kPa (.6 psi) 140 to 205 kPa

(minimum) 20 to 30 psi)

PILOT PRESSURE 1755 ± 35 kPa xxx xxx

(255 ± 5 psi)

> 82°C (180°F)

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

DUAL STAGE LOCKUP SOLENOID ENERGIZED

RELIEF (plug signal line to lockup clutch valve)
SPECS ACTUAL
LI 1300 RPM LI 1300 RPM

PUMP PRESSURE xxx 2100 ± 100 kPa xxx

(305 ± 15 psi)
Adjust station "D" to
xxx xxx
STATION "D" PRESSURE get correct pump and
clutch pressures

xxx 2020 + 240 - 100 kPa xxx

ALL CLUTCH PRESSURES
(293 + 35 - 15 psi)

1
 7 8 5 C/ 7 8 9 C 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
2 525 KPA
N 3 A (76 psi)
1 475 KPA
R 1 and 6 B (69 psi)
3 480 KPA
1 1 and 5 C (70 psi)
DUAL
2 2 and 5 D RELIEF xxx xxx

4 425 KPA
3 1 and 4 E (62 psi)
5 450 KPA
4 2 and 4 F (65 psi)
6 425 KPA
5 1 and 3 G (62 psi)

6 2 and 3 H xxx 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 LockUp @ LI HI LockUp @
1300 RPM 1300 RPM
2 xxx xxx 2020 kPa xxx xxx
A (293 psi)
1 2760 kPa 2890 kPa 2020 kPa
B (400 psi) (419 psi) (293 psi)
3 2470 kPa 2470 kPa 2020 kPa
C (358 psi) (358 psi) (293 psi)
DUAL Adjust station "D" to get correct clutch xxx xxx
D RELIEF pressures during lockup
4 xxx xxx 2020 kPa xxx xxx
E (293 psi)
5 2705 kPa 2705 kPa 2020 kPa
F (392 psi) (392 psi) (293 psi)
6 2760 kPa 2805 kPa 2020 kPa
G (400 psi) (407 psi) (293 psi)

H xxx xxx xxx xxx xxx xxx xxx

Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi)
"D" station pressure will be approximatley 1380 kPa (200 psi)

2
 7 9 3 C TRA N S MIS S ION TES T
Machine Model ___________________________ Date _______________________________

Machine Serial No. ________________________ Machine Hours_______________________

Transmission S/N _________________________ Transmission Hours___________________

Transmission/Chassis Flash File/Release Date

VISUAL CHECKS:
Oil level Oil Viscosity _______________________

Air/Water in Oil? Oil Filter Examination ________________

CONVERTER LOCKUP SOLENOID DE-ENERGIZED

DRIVE PRESSURES
SPECS ACTUAL
LI HI LI HI
PUMP PRESSURE 2515 kPa (365 psi) 3065 kPa (445 psi)
(Adjust with Transmission (minimum) (maximum)
Relief Valve)

LUBE PRESSURE 5 to 65 kPa 160 ± 50 kPa

(.5 to 10 psi) 23 ± 7 psi)

PILOT PRESSURE 2410 to 2755 kPa

(Result of setting Direct xxx xxx
Drive Pump Pressure) (350 to 400 psi)

Transmission Oil Temperature (during tests) > 82°C (180°F)

< 121°C (250°F)

DIRECT DRIVE LOCKUP SOLENOID ENERGIZED

PRESSURES (plug signal line to lockup clutch valve)
SPECS ACTUAL
LI 1300 RPM LI 1300 RPM
PUMP PRESSURE
xxx 2310 ± 70 kPa
(Adjust with Priority
Reducing Valve) (335 ± 10 psi)

Adjust station "D" to

xxx
STATION "D" PRESSURE get correct rail
(clutch) pressures

ALL CLUTCH PRESSURES xxx 1620 ± 70 kPa

(235 ± 10 psi)

1
 7 9 3 C 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
2 525 KPA
N 3 A (76 psi)
1 475 KPA
R 1 and 6 B (69 psi)
3 480 KPA
1 1 and 5 C (70 psi)
DUAL
2 2 and 5 D RELIEF xxx xxx

4 425 KPA
3 1 and 4 E (62 psi)
5 450 KPA
4 2 and 4 F (65 psi)
6 425 KPA
5 1 and 3 G (62 psi)

6 2 and 3 H xxx 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 LockUp @ LI HI LockUp @

1300 RPM 1300 RPM
2 xxx xxx 1620 kPa xxx xxx
A (235 psi)
1 2400 kPa 2425 kPa 1620 kPa
B (348 psi) (352 psi) (235 psi)
3 2470 kPa 2470 kPa 1620 kPa
C (358 psi) (358 psi) (235 psi)
DUAL Adjust station "D" to get correct clutch xxx xxx
D RELIEF pressures during lockup
4 xxx xxx 1620 kPa xxx xxx
E (235 psi)
5 2585 kPa 2720 kPa 1620 kPa
F (375 psi) (395 psi) (235 psi)
6 2585 kPa 2805 kPa 1620 kPa
G (375 psi) (407 psi) (235 psi)
xxx xxx xxx xxx xxx xxx xxx
H
Maximum Clutch Pressure Tolerance: +240 -100 kPa (+35 -15 psi)
NOTE: During LockUp test, plug lockup signal hose to lockup valve

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
 785C/789C/793C OFF-HIGHWAY TRUCK
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

> 60°C (150°F)
Steering Oil Temperature (during tests)
< 121°C (250°F)

1. ____________________
Cycle Time @ High Idle 7.0 to 9.0
2. ____________________
(steer at one revolution per second) seconds
From Left to Right and Right to Left Combined 3. ____________________

AVG.
Left to Right Right to Left
Steering wheel turns from stop to stop
1. ____________________ 1. ____________________
785C: ________ turns
2. ____________________ 2. ____________________
789C: 3.0 to 4.0 turns
793C: ________ turns 3. ____________________ 3. ____________________

AVG. AVG.
785C Pump Compensator Valve Pressure
Cut-out -
Cut-out - 17580 ± 345 kPa (2550 ± 50 psi)
Cut-in - 13950 kPa (2025 psi) Cut-in -

Accumulator Charge Valve Pressure @ Low Idle

Cut-out
789C: 18300 ± 345 kPa (2655 ± 50 psi)
793C: 21400 ± 345 kPa (3100 ± 50 psi)
Accumulator Charge Valve Pressure @ Low Idle
Cut-in
789C: 16470 ± 345 kPa (2390 ± 50 psi)
793C: 19200 ± 315 kPa (2785 ± 45 psi)

1
 7 8 5 C / 7 8 9 C / 7 9 3 C S T E E RING T E S T

TEST SPECS ACTUAL

Pump Low Pressure Standby Pressure @ Low Idle 2067 to 3617 kPa
(789C/793C only) (300 to 525 psi)

1. ____________________
Cycle time from Cut-out to Cut-in greater than
2. ____________________
15 seconds
3. ____________________

AVG.

Pump High Pressure Cut-off @ Low Idle

789C: 20000 ± 345 kPa (2900 ± 50 psi)
793C: 23100 ± 345 kPa (3350 ± 50 psi)

Backup Relief Valve Pressure @ Low Idle

785C: 20670 ± 400 kPa (3000 ± 60 psi)
789C: 22740 ± 345 kPa (3300 ± 50 psi)
793C: 26000 ± 400 kPa (3775 ± 60 psi)

Relief/Makeup Valve Pressure (Right Turn)

785C: 18270 ± 345 kPa (2650 ± 50 psi)
789C: 28000 ± 1000 kPa (4065 ± 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)

Relief/Makeup Valve Pressure (Left Turn)

785C: 18270 ± 345 kPa (2650 ± 50 psi)
789C: 28000 ± 1000 kPa (4065 ± 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)

1. Accumulator Nitrogen Charge Pressure

@ 21°C (70°F)
785C: 8270 ± 0 kPa (1200 ± 0 psi)
789C: 5512 ± 345 kPa (800 ± 50 psi)
793C: 6545 ± 345 kPa (950 ± 50 psi)

2. Accumulator Nitrogen Charge Pressure

@ 21°C (70°F)
785C: 8270 ± 0 kPa (1200 ± 0 psi)
789C: 5512 ± 345 kPa (800 ± 50 psi)
793C: 6545 ± 345 kPa (950 ± 50 psi)

2
 7 8 5 C / 7 8 9 C / 7 9 3 C 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 8 5 C / 7 8 9 C / 7 9 3 C 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)

RAISE TIME @ High Idle 1. ____________________

785C: 17.0 to 19.0 seconds
2. ____________________
789C: 18.0 to 20.0 seconds
3. ____________________
793C: 18.0 to 20.0 seconds
AVG.

LOWER TIME @ High Idle ________ seconds 1. ____________________

(not including snub)
785C: ________ to ________ seconds 2. ____________________
789C: 16.0 to 17.0 seconds ________ seconds
(including snub) 3. ____________________
793C: ________ to ________ seconds
AVG.

FLOAT TIME @ High Idle ________ seconds 1. ____________________

(not including snub)
785C: ________ to ________ seconds 2. ____________________
________ seconds
789C: 16.0 to 18.0 seconds (including snub) 3. ____________________
793C: ________ to ________ seconds
AVG.

PILOT PRESSURE 4700 ± 200 kPa LI -

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

RAISE PRESSURE @ High Idle F Tap:

785C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)
789C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)
793C: 20370 + 700 - 0 kPa (2955 + 100 - 0 psi) R Tap:

LOWER PRESSURE @ High Idle 3450 + 350 – 0 kPa F Tap:

(Body Switch in RAISE Position) (500 + 50 – 0 psi) R Tap:

ET Setting -5 0 +5

HOIST PRESSURE IN FLOAT LI - LI - LI -

Maximum 1725 kPa (250 psi) HI - HI - HI -

Final Programmed Value

2
 7 8 5 C / 7 8 9 C / 7 9 3 C 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 8 5 C / 7 8 9 C / 7 9 3 C HOIS T T E S T

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

RAISE 5 - 20%
___________ mA
HOLD 25 to 35% N/A 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
 785C/789C/793C 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-
4481 kPa
Towing Pump Pressure
(650 psi)

Towing pump pressure after:

1 minute – 4 minutes -

2 minutes – 5 minutes -

3 minutes -

1
 785C/789C/793C AIR SYSTEM AND BRAKE TEST

Brake Cooling Oil Pressure (Body Down in Float)

Inlet: Low Idle Minimum – 14 kPa (2 psi) High Idle Maximum - 172 kPa (25 psi)

Brake Cooling Oil Temperature 79 to 93 °C

(during brake cooling pressure test) (175 to 200 °F)

TEST Brake Inlet Tap Brake Outlet Tap

LI - LI -
Left Front Wheel (793C Hoist Front)
HI - HI -
LI - LI -
Right Front Wheel (793C Hoist Rear)
HI - HI -

(793C Rear Oil Cooler) LI - LI -

Left Rear Wheel
HI - HI -
LI - LI -
Right Rear Wheel
HI - HI -

BRAKE CYLINDER OPERATION

(Apply Service Brake Pedal)
TEST AIR PRESSURE OIL PRESSURE
@ Brake Cylinder @ Slack Adjuster
Brake Cylinder Air/Oil Ratio 6.6 to 1

Front Brake Cylinders: XXXX XXXX

Brake Cylinder #1

Brake Cylinder #2

Rear Brake Cylinders: XXXX XXXX

Brake Cylinder #3

Brake Cylinder #4

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

SLACK ADJUSTER OPERATION

SLACK ADJUSTER TAP WHEEL PORT TAP

Released
Engaged Released Engaged
Residual Pressure

Left Front
Wheel
Front
Right Front
Wheel

Left Rear
Wheel
Rear
Right Rear
Wheel

Released (residual) pressure at "S" port after releasing parking brakes:

785 front - 103 kPa (14.9 psi) 785 rear - 59 kPa (8.6 psi)
789 front - 106 kPa (15.3 psi) 789 rear - 65 kPa (9.5 psi)
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 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
 785C/789C/793C 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 rpm Manual Retarder Engaged rpm

Parking Brake Engaged rpm Secondary Brake Engaged rpm

NOTE: Minimum 1200 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 40 seconds or less. If the time recorded is greater than 40 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

4
 785C/789C/793C
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
C-Series ARC Test.doc
 785C/789C/793C
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
C-Series ARC Test.doc
 785C/789C/793C
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
C-Series ARC Test.doc
 785C/789C/793C
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 – Select ECM and choose 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:

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
785C-793C TCS Test.doc
 785C/789C/793C
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
785C-793C TCS Test.doc
 785C/789C/793C
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
785C-793C 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 Sensor Specs.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 CHARTS:

Early Configurations

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 %

Later Configurations

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION

Pressure Sensor (AIR)
Air Pressure DUTY CYCLE
117 kPa (17 psi) 10.7 %
140 kPa (20 psi) 13.3 %
275 kPa (40 psi) 26.4 %
415 kPa (60 psi) 39.7 %
550 kPa (80 psi) 53.0 %
690 kPa (100 psi) 66.4 %
825 kPa (120 psi) 79.7 %

Tolerance is ± 10%
2 Sensor Specs.doc
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%

3 Sensor Specs.doc