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793D Lab Book
1. Vital Information Management System (VIMS) p.2
2. Engine Tests p.103. Engine Power Test p.19
4. Hydraulic Fan Test p.22
5. Torque Converter Test p.266. Transmission Test p.29
7. Transmission/Chassis ECM p.32
8. Rear Axle Test p.359. Steering Test p.40
10. Hoist Test p.43
11. Air System and Brake Test p.4912. Hydraulic Auto Retarder Control (ARC) Test p.55
13. Traction Control System (TCS) Test p.59
14. Suspension Cylinder Charging p.63
15. Data View p.6516. Sensor Specifications p.68
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VVIITTAALL IINNFFOORRMMAATTIIOONN MMAANNAAGGEEMMEENNTT SSYYSSTTEEMM((VVIIMMSS))
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VVIITTAALL IINNFFOORRMMAATTIIOONN MMAANNAAGGEEMMEENNTT SSYYSSTTEEMM
((VVIIMMSS))
Machine Model______________________________ Date ______________________________
Machine Serial No.___________________________ Machine Hours _____________________
Machine Miles ______________________________ ECM Serial #______________________
VISUAL CHECKS:
Electrical Connections ________________________ Component Damage ________________
MSTAT (67828) - MACHINE STATISTICS
PARAMETER DESIRED ACTUAL
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)
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VVIIMMSS
PAYLOAD
PROGRAM CODE DESIRED ACTUAL
PAYCAL (729225) YES/NO
RAC (722) - Set Haul Road Severity0 OFF
1 high
2 medium
3 - low
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 DESIRED ACTUAL
Autolube Cycle Time
Autolube Duration
ESTAT (37828) - EVENT STATISTICS
EVENT
SYSTEM
MACHINE
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VVIIMMSS
EACK (3225) ACTIVE EVENTS
EVENT
HOUR
METER
START
LENGTH OF
TIME
CATEGORY
LEVEL LIMIT WORST
ELIST (35478) INTERMITTENT EVENTS
EVENT
HOURMETER
START
LENGTH OF
TIME
CATEGORYLEVEL LIMIT WORST
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VVIIMMSS
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 andEngine OFF.
Sensor Tests
Sensor
Supply
Voltage
(A-B)
Actual Temperature/
Pressure/ Fuel Level
(ET or VIMS)
Actual Signal
Volts/Hz/Duty Cycle/
Resistance(B-C)
Pull-up
Voltage
(B-C)
Ambient Air Temp
Aftercooler Level
Jacket Water Level
System Air Pressure
Auto Lube Pressure
Steering Oil LevelSteering Oil Temp
Steering Pressure (High) N/A N/A
Steering Pressure (Low) N/A N/A
Brake Temperature--LF
Brake Temperature--RF
Brake Temperature--LR
Brake Temperature--RR
Strut Pressure--LF
Strut Pressure--RF
Strut Pressure--LRStrut Pressure--RR
Alternator "R" Terminal N/A 12.4 to 14.75 DCV
> 95 Hz
N/A
Fuel Level Sensor
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VIMS ATTACHMENT CODES
793D ATTACHMENT CODES
Attachment Code RAC Enabled TK PH or TMPHEnabled
0 No No
4 Yes No
5 No Yes
6 Yes Yes
Road Analysis Control (RAC)
Tonne-Kilometer Per Hour (TKPH)
Ton-Mile Per Hour (TMPH)
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VIMS KEYPAD OPERATIONS
PAYCONF 7292663 Configure Payload Monitor (requires VIMS PC connection)
PAYCAL 729225 Calibrate Payload Monitor (requires VIMS PC connection)
TOT 868 Show Payload Cycle Resettable Totals
RESET 73738 Reset Displayed Payload DataESET 3738 Customize Events (requires VIMS PC connection)
SVCLIT 782548 Turn OFF Service Light
SVCSET 782738 Service Light Set (requires VIMS PC connection)
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 StatisticsELIST 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 see chart on page 5 (requires VIMS PC connection)RAC 722 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 willremove the event from the display temporarily. Severe events cannot be acknowledged.
GAUGE key--Displays parameters monitored by VIMS. Depressing the arrow keys will scroll throughthe 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).
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VIMS KEYPAD GAUGE PARAMETERS
100 ENG SPD
105 BOOST PRES
106 LT EXH TEMP
107 RT-LT EXH TEMP
108 RT EXH TEMP
111 F AFTRCLR TEMP
112 R AFTRCLR TEMP
116 COLD MODE
117 ENG DERATE %
118 AIR FLTR IN-H20
121 ENG LOAD %
122 FUEL FLTR
129 ENG FUEL RATE GAL/HR
130 ENG OIL LVL
131 ENG OIL PRES
135 ENG COOL TEMP
140 SYS VOLTAGE
197 ENG FAN SPD #1
198 ENG FAN SPD #2
199 RT-LT FAN SPD
200 ENG FAN TEMP
313 TC OUT TEMP
325 DIFF TEMP
328 DIFF LUBE PRES350 TRN LUBE TEMP
403 FAN DRIVE FLTR
416 LT PARKBK PRES
417 RT PARKBK PRES
444 STRG OIL TEMP
452 BRK/AIR PRES
460 LT F BRK TEMP
461 LT R BRK TEMP
462 RT F BRK TEMP463 RT R BRK TEMP
724 BODY ANGLE DEG
790 ATMOS PRES
791 AMB AIR TEMP
799 HOIST STATUS
NOTE: Shown are the most commonly used parameters.
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Engine Tests
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EENNGGIINNEETTEESSTTSS
Machine Model ______________________ Date ________________________________
Machine Serial No. ___________________ Machine Hours________________________
Engine Serial No. ____________________ Engine Hours _________________________
ECM Serial No. _____________________ Throttle Pedal Configuration _____________
Personality Module ___________________ Personality Module Date ________________
Performance Spec (eng plate)___________ Max Altitude _________________________
Gross Power ________________________ 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 DiagnosticCodes and the Configuration Screen, fill in the information requested.
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EENNGGIINNEETTEESSTTSS
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.
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EENNGGIINNEETTEESSTTSS
Sensor Tests
SensorSupply
Voltage
(A-B)
Desired
Signal Volts
orDuty Cycle
Actual Signal
Voltage/%
(B-C)
Actual
Temperature/
Pressure(ET or VIMS)
Pull-up
Voltage
(B-C)
Filtered Engine OilPressure
.2 to .6 0
Unfiltered Engine Oil
Pressure.2 to .6 0
Coolant Temperature.4 to 4.6
AftercoolerTemperature
.4 to 4.6
Atmospheric Pressure2.2 to 4.6
Crankcase Pressure2.2 to 4.6 0
Right Turbo Inlet
Pressure2.2 to 4.6
Left Turbo InletPressure
2.2 to 4.6
Turbo Outlet Pressure.8 to 1.5
Left ExhaustTemperature
see below
Right Exhaust
Temperaturesee below
NOTE: Analog supply voltage is 5.0 0.5Digital supply voltage is 8.0 0.5Desired 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%
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EENNGGIINNEETTEESSTTSS
T E S T S P E C S A C T U A L
ECM Supply Voltage 24
Throttle Sensor Supply Voltage (A-B) 8.0 0.5
Throttle Sensor Low Idle Duty Cycle (B-C) 16 6%
Throttle Sensor High Idle Duty Cycle (B-C)85 4%
Throttle Sensor Frequency (B-C) 150-1000 Hz
Throttle Sensor Pull-Up Voltage (B-C) 11.5 0.5
Speed Sensor Supply Voltage (A-B) 12.5 1.0
Speed Sensor Frequency (Cranking) (B-C) 23 - 40 Hz
Speed Sensor Frequency (Low Idle) (B-C) 140 Hz@700 rpm
Speed Sensor Frequency (High Idle) (B-C) 385 Hz@1960 rpm
Speed Sensor Signal Voltage (Key ON) (B-C)
less than 3.0
orgreater than 10.0
Speed Sensor Signal Voltage (Cranking) (B-C) 2.0 to 4.0
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EENNGGIINNEETTEESSTTSS
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTION
LOGGED DIAGNOSTIC CODES
DIAGNOSTIC CODE DESCRIPTIONNUMBER
OFOCCURR
FIRST
HOURMETER
LAST
HOURMETER
EVENT CODES
EVENT CODE DESCRIPTIONNUMBER
OFOCCURR
FIRST
HOURMETER
LAST
HOURMETER
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EENNGGIINNEETTEESSTTSS
INJECTOR SOLENOID TEST:
CYLINDERS OPEN
CYLINDERS SHORTED
NOTES:
OVERRIDE PARAMETERS:
ETHER INJECTION: OK NOT OK N/A
ENGINE PRELUBE: OK NOT OK N/A
OIL RENEWAL: OK NOT OK N/A
WASTEGATE: Override % Volts Current (miliamps)
0%
25%
50%
75%
100%
NOTES:
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EENNGGIINNEETTEESSTTSS
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 10 TO 15% from Average
NOTES:
CURRENT TOTALS:
FUEL TOTAL TIME
ETHER
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EENNGGIINNEETTEESSTTSS
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 CAL IBRATION: OK NOT OK
NOTES:
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Engine Power Test
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ENGINE POWER TEST
Machine Model Date
Machine Serial No. Machine Hours
Engine Serial No. Engine Hours
Performance Spec Rated Power
Throttle Pedal Config Fuel Ratio Control Offset
Flash File/Date
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
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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
S P E C S
ACTUAL
Coolant Temperature (during tests) > 71C (160F) Start:
Stop:
Low Idle RPM 700 15
High Idle RPM 1960 40
Air Filter Restriction @ TC Stall (maximum allowed) 25 in. of water
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10) DIRECT DRIVE
188 28 kPa
(27.2 4.1 psi)
Inlet Manifold Pressure (BOOST)
@ Full Load RPM (1750 10) CONV DRIVE
171 26 kPa
(24.8 3.7 psi)
*
Torque Converter Stall RPM 1672 65
Torque Converter Temperature (during stall test)> 80C (175F)
< 121C (250F)
Engine Oil Pressure @ LI207 to 600 kPa
(30 to 87 psi)
Engine Oil Pressure @ HI324 to 600 kPa
(47 to 87 psi)
Engine Oil Filter Differential Pressure @ HImaximum
70 kPa (10 psi)
Fuel Pressure @ Torque Converter Stall317 to 634 kPa
(46 to 92 psi)
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)]
OK
* Use Torque Stall for Class
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Hydraulic Fan Test
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HYDRAULIC FAN TEST
Machine Model Date
Machine Serial No. Machine Hours
Brake ECM Flash File/Date
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 theVIMS 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 thepump and motors before starting the engine.
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HYDRAULIC FAN TEST
TEST TEMPERATURESJacket 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 thehydraulic fan speed to 817 rpm, raise the engine speed to HIGH IDLE and record the pumppressure 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 solenoidunplugged. 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 TEMPERATURESJacket Water
CoolantAfter Cooler
CoolantBrake Oil Fan Drive Oil
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NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of thepump 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 Pump Pressure
Fan Speed
(Minimum 510 rpm)Engine Speed
@
High IDLE
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Torque Converter Test
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TTOORRQQUUEE CCOONNVVEERRTTEERR TTEESSTT
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:7) Using ET, choose theTransmission 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:
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TTOORRQQUUEE CCOONNVVEERRTTEERR TTEESSTT
T E S T SPECS A C T U A L
Torque Converter Oil Temperature (during tests)> 80C (175F)
< 121C (250F)
Torque Converter Inlet PressureMaximum at High Idle
with Cold Oil
930 35 kPa
(135 5 psi)
LI -
HI
STALL-
Torque Converter Outlet Pressure @ STALL rpm345 to 550 kPa
(50 to 80 psi)
LI -
HI
STALL-
Torque Converter Stall RPM1721 65
Transmission Charge Pressure (Converter Drive)LI:> 2515 kPa (365 psi)
HI:< 3065 kPa (445 psi)
LI -
HI
Transmission Charge Pressure (Direct Drive)2310 70 kPa
(335 10 psi)
@ 1300 rpm
Lockup Clutch Pilot Pressure (RV)
NEUTRAL/DIRECT DRIVE/LOW IDLE
1725 70 kPa
(250 10 psi)
Lockup Clutch Signal Pressure (from Lockup Solenoid)
NEUTRAL/DIRECT DRIVE/1300 rpm
1445 to 2240 kPa
(210 to 325 psi)
Lockup Clutch Primary Pressure
NEUTRAL/DIRECT DRIVE/LOW IDLE
1070 35 kPa
(155 5 psi)
Lockup Clutch Maximum Pressure
NEUTRAL/DIRECT DRIVE/1300 rpm
2150 to 2205 kPa
(310 to 320 psi)
NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP. ConverterStall must be ran in FIRST FORWARD with the Body DOWN.
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Transmission Test
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Transmission Test
Machine Model ____________________________ Date _______________________________
Machine Serial No.__________________________ Machine Hours_______________________
Transmission S/N___________________________ Transmission Hours ___________________
Transmission/Chassis Flash File/Release Date
CONVERTER DRIVE
PRESSURES
LOCKUP SOLENOID DE-ENERGIZED
SPECS ACTUAL
LI HI LI HI
PUMP PRESSURE
(Adjust with TransmissionRelief Valve)
2515 kPa (365 psi)
(minimum)
3065 kPa (445 psi)
(maximum)
LUBE PRESSURE80 25 kPa
(12 4 psi)
150 41 kPa
22 6 psi)
PILOT PRESSURE
(Result of setting Direct
Drive Pump Pressure)
2410 to 2755 kPa
(350 to 400 psi)xxx xxx
Transmission Oil Temperature (during tests)> 82C (180F)
< 121C (250F)
DIRECT DRIVE
PRESSURES
LOCKUP SOLENOID ENERGIZED
(plug signal line to lockup clutch valve)
SPECS ACTUAL
LI 1300 RPM LI 1300 RPM
PUMP PRESSURE
(Adjust with Priority
Reducing Valve)
xxx 2585 70 kPa
(375 10 psi)
xxx
STATION "D"
PRESSURE
xxx Adjust station "D" to
get correct rail(clutch) pressures
xxx
NEUTRAL CLUTCH
PRESSURE
STATION "C"
xxx 1724 70 kPa
(250 10 psi)
xxx
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TTRRAANNSSMMIISSSSIIOONNCCLLUUTTCCHHTTEESSTTSS
CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I.Load Piston Plug Removed
SPEEDCLUTCHESENGAGED
STATION CLUTCH SPECS ACTUAL
N 3 A 2 525 KPA(76 psi)
R 1 and 6 B 1475 KPA
(69 psi)
1 1 and 5 C 3480 KPA(70 psi)
2 2 and 5 DDUAL
RELIEFxxx xxx
3 1 and 4 E 4425 KPA
(62 psi)
4 2 and 4 F 5450 KPA
(65 psi)
5 1 and 3 G 6425 KPA
(62 psi)
6 2 and 3 H xxx xxx xxx
Primary Clutch Pressure Tolerance: +50 -35 kPa (+7 -5 psi)
MAXIMUM CLUTCH PRESSURELoad Piston Plug Installed
SPECS ACTUAL
STATION CLUTCH LI HILockUp @1300 RPM LI HI
LockUp @1300 RPM
A 2 xxx xxx1689 kPa
(245 psi)xxx xxx
B 12400 kPa
(348 psi)
2425 kPa
(352 psi)
1689 kPa
(245 psi)
C 32470 kPa
(358 psi)
2470 kPa
(358 psi)
1689 kPa
(245 psi)
DDUAL
RELIEFAdjust station "D" to get correct clutch
pressures during lockupxxx xxx
E 4 xxx xxx1689 kPa
(245 psi)
xxx xxx
F 52585 kPa(375 psi)
2720 kPa(395 psi)
1689 kPa(245 psi)
G 62585 kPa(375 psi)
2805 kPa(407 psi)
1689 kPa(245 psi)
H xxx xxx xxx 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)
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Transmission/Chassis ECM
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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 or COUNT DESIRED ACTUAL
Body Up Gear Limit Setting
Transmission Maximum Gear Setting
Lockup Clutch Count N/A
Resettable Load Count N/A
Permanent Load Count N/A
ACTIVE DIAGNOSTIC CODES
Diagnostic Code Description Cause
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TTRRAANNSSMMIISSSSIIOONN//CCHHAASSSSIISS EECCMM
LOGGED DIAGNOSTIC CODES
Diagnostic Code
andDescription
Number ofOccurrences First Occurrence Last Occurrence
LOGGED EVENTSEvent Code
andDescription
Number ofOccurrences First Occurrence Last Occurrence
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Rear Axle Test
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REAR AXLE TEST
Machine Model Date
Machine Serial No. Machine Hours
Brake ECM Software Part #/Date
VISUAL CHECKS
Oil Level Oil Viscosity
Air/Water in Oil? Oil Filter Examination
Create a Test Group on ET:
1. On the ET screen toolbar, clickFile 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:
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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 theengine 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
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REAR AXLE TEST
TEST 1:
Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass ON
TEST SPECS ACTUAL
Differential Temperature> -3 C (25 F)
< 60 C (140 F)
Engine RPM 700 10
Rear Axle Pump Drive Pressure< 22752 +/- 50 kPa(3300 +/- 70 psi)
Pressure at inlet to Differential
Filter
690 +/- 75 kPa
(100 +/- 10 psi)
Pressure at pressure tap on
manifold
0 kPa
(Less than 10 psi)
TEST 2:
Engine at High Idle, Pump Drive Diverter OFF, Final Drive Bypass ON
TEST SPECS ACTUAL
Differential Temperature> -3 C (25 F)
< 60 C (140 F)
Engine RPM 1950 20
Rear Axle Pump Drive Pressure< 22752 +/- 50 kPa(3300 +/- 70 psi)
Pressure at inlet to Differential
Filter
690 +/- 75 kPa
(100 +/- 10 psi)
Pressure at pressure tap on
manifold
0 kPa
(Less than 10 psi)
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REAR AXLE TEST
TEST 3:
Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass OFF
TEST SPECS ACTUAL
Differential Temperature> -3 C (25 F)
< 60 C (140 F)
Engine RPM 700 10
Rear Axle Pump Drive Pressure< 22752 +/- 50 kPa(3300 +/- 70 psi)
Pressure at inlet to Differential
Filter
690 +/- 75 kPa
(100 +/- 10 psi)
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 SPECS ACTUAL
Differential Temperature> -3 C (25 F)
< 60 C (140 F)
Engine RPM 700 10
Rear Axle Pump Drive PressureResidual Pressure
Only
Pressure at inlet to Differential
Filter
0 kPa
(0 psi)
Pressure at pressure tap on
manifold
0 kPa
(0 psi)
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Steering Test
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STEERING Test
Machine Model_______________________ Date ______________________________
Machine Serial No.____________________ Machine Hours _____________________
VISUAL CHECKS:
Oil level Oil Viscosity _______________________
Air/Water in Oil? Oil Filter Examination _______________
TEST SPECS ACTUAL
Steering Oil Temperature (during tests)> 60C (150F)
< 121C (250F)
Cycle Time @ High Idle
From Left to Right and Right to Left Combined
All Brakes Released
7.0 to 9.0
seconds
1. ____________________
2. ____________________
3. ____________________
AVG.
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) solenoidvalve and manifold (rear axle fan, brake cooling,
drive motor, lubrication, and steering)
18300 520 kPa(2650 75 psi)
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SSTTEEEERRIINNGGTTEESSTT
TEST SPECS ACTUAL
Pump High Pressure Cut-off @ Low Idle23100 350 kPa
(3350 50 psi)
Backup Relief Valve Pressure @ Low Idle 26000 400 kPa(3770 60 psi)
Bench Test Only
Relief/Makeup Valve Pressure (Right Turn)28500 1000 kPa
(4150 150 psi)Bench Test Only
Relief/Makeup Valve Pressure (Left Turn)28500 1000 kPa
(4150 150 psi)Bench Test Only
1. Accumulator Nitrogen Charge Pressure@ 21C (70F)
6550 350 kPa
(950 50 psi)
2. Accumulator Nitrogen Charge Pressure@ 21C (70F)
6550 350 kPa(950 50 psi)
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Hoist Test
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HHOOIISSTT TTEESSTT
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 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 changethis 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 slightadjustment 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 hoistoutput must be in HOLD whenchanging the setting.
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HHOOIISSTT TTEESSTTTEST SPECS ACTUAL
Hoist Oil Temperature(during tests)
> 65C (150F)< 121C (250F)
RAISE TIME @ High Idle
19.0 to 21.0 sec.
1. ____________________
2. ____________________
3. ____________________
AVG.
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)
4700 200 kPa
(680 30 psi)
LI -
HI -
RAISE PRESSURE @ High Idle20370 345 kPa
(2955 50 psi)
F Tap:
R Tap:
LOWER PRESSURE @ High Idle(Body Switch in RAISE Position)
3450 + 350 0 kPa
(500 + 50 0 psi)
F Tap:
R Tap:
HOLD Maximum Pressure 790 20 kPa
115 3 psi
F Tap:
R Tap
FLOAT Maximum Pressure 790 20 kPa
115 3 psi
F Tap:
R Tap
HOLD Maximum Pressure 790 20 kPa
115 3 psi
F Tap:
R Tap
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ET Setting -5 0 +5
HOIST PRESSURE IN SNUB
Maximum 1725 kPa (250 psi)
LI -
HI -
LI -
HI -
LI -
HI -
Hoist LOWER Solenoid Current %
Final Programmed Value
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HHOOIISSTT TTEESSTT
Create a Test Group on ET:
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1) On the ET screen, select theTransmission 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 %
BODY POSITION SENSOR ANGLE
TEST Hoist LOWER SolenoidCurrent %
BODY POSITIONANGLE
Body Full RAISE N/A
FLOAT to SNUB
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HHOOIISSTT TTEESSTT
HOIST
LEVERPOSITION
DUTY CYCLE
(approximate)
ACTUAL
DUTYCYCLE
SOLENOID
CURRENT %FROM ET
HOIST VALVE
SOLENOID CURRENT(mA)
(ET Solenoid % x 1900)
HOIST VALVE
SOLENOIDCURRENT (mA)
(ACTUAL)
RAISE 1 - 18%___________ mA
HOLD 24 to 48% N/A N/A N/A
FLOAT 55 to 71%___________ mA
LOWER 80 to 96%___________ mA
SNUB N/A N/A ___________ mA
NOTE: The current at the solenoids will be equal to the percentage shown on the ET screen x 1900milliamps.
DRIFT TEST: OIL TEMP MINUTES
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)
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Air System and Brakes Test
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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(CUT-OUT)
830 35 kPa
(120 5 psi)
Air Compressor Governor Setting
(CUT-IN)
655 kPa
(95 psi)
Pressure Protection Valve
(Behind Cab)
(Drain Secondary Brake Tank to See
Close Setting)
Open--
550 kPa (80 psi)
Close--
480 kPa (70 psi)
Open--
Close--
Retarder Valve--Maximum Air Pressure550 kPa
(80 psi)
Parking and Secondary Brake Control
ValveMaximum Pressure
4700200 kPa
(680 30 psi)
LI-
HI-
Parking and Secondary Brake Control
ValveMinimum Pressure
4480 200 kPa
(650 30 psi)
LI-
HI-
Towing Pump Pressure4481 kPa
(650 psi)
Towing pump pressure after:
1 minute 4 minutes -
2 minutes 5 minutes -
3 minutes -
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AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
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)
79 to 93 C(175 to 200 F)
TEST Brake Inlet Tap Brake Outlet Tap
Left Front WheelLI -
HI -
LI -
HI -
Right Front WheelLI -
HI -
LI -
HI -
Left Rear Wheel LI -
HI -
LI -
HI -
Right Rear WheelLI -
HI -
LI -
HI -
Brake Cooling Oil Pressure (Body Down in SNUB)
Brake Cooling Oil Temperature(during brake cooling pressure test) 79 to 93 C(175 to 200 F)
TEST RETARDER ENGAGED RETARDER RELEASED
Hoist Pump Front (front brake oil cooling)LI -
HI -
LI -
HI -
Hoist Pump Rear (front brake oil cooling)LI -
HI -
LI -
HI -
Rear Brake Oil CoolerLI -
HI -
LI -
HI -
NOTE: 793D Hoist and Rear Oil Cooler Relief Valve settings are
790 kPa (115 psi) or less
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AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
BRAKE CYLINDER OPERATION
(Apply Service Brake Pedal)
TEST
AIR PRESSURE
@ Brake Cylinder
OIL PRESSURE
@ 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
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.
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AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
SLACK ADJUSTER OPERATION
SLACK ADJUSTER TAP WHEEL PORT TAP
Engaged Released EngagedReleased
Residual Pressure
Left Front
WheelFront
Right Front
Wheel
Left Rear
WheelRear
Right Rear
Wheel
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 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.
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AAIIRR SSYYSSTTEEMM AANNDD BBRRAAKKEE TTEESSTT
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 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
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Hydraulic Auto Retarder Control (ARC) Test
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HHYYDDRRAAUULL IICC AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT
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 Adjusters2) On the ET screen toolbar, select Diagnostics Diagnostics Tests Auto Retarder Test3) Switch ON the ARC ON/OFF switch4) Click the Start button and the Auto Retarder Test will be turned ON5) 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
Functional Test Maximum Air Pressure(Brake Cylinder)Maximum Brake Oil
Pressure (Slack Adjuster)
Front Brake Cylinder Air/Oil Ratio
(6.6 to 1)
Rear Brake Cylinder Air/Oil Ratio
(6.6 to 1)
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HHYYDDRRAAUULL IICC AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT
SETUP DESIRED ACTUAL
Control Speed Setting
Control Valve Cycles N/A
Supply Valve Cycles N/A
ACTIVE DIAGNOSTIC CODES and DESCRIPTION
Diagnostic Code Description Cause
LOGGED DIAGNOSTIC AND EVENT CODES
Diagnostic and Event Code andDescription
Number ofOccurrences
First Occurrence Last Occurrence
NOTE: On machines equipped with the Extended Life Power Train, the brake cylinder air to oilratio is 5.1:1 (Only on the Front Master Cylinders).
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HHYYDDRRAAUULL IICC AAUUTTOO RREETTAARRDDEERR CCOONNTTRROOLL ((AARRCC)) TTEESSTT
ARC OVERSPEED PROTECTION
Horn and Light Activate *
Activat ion Speed(supply solenoid ON)
ARC Shutoff
Auto Upshift **
2100 rpm
2125 rpm
2100 rpm
2075 rpm
2300 rpm
ARC Control Speed
ARC NORMAL OPERATION
FUNCTION ENGINE SPEED
Activat ion Speed(supply solenoid ON)
1850 rpm
ARC Contro l Range
Factory Setting
1850 to 1950 rpm
1950 rpm
* The Horn and Light are contro lled by the Engine ECM
** The Auto Upshift is controlled by the Transmission ECM
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Traction Control System (TCS) Test
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TTRRAACCTTIIOONN CCOONNTTRROOLL SSYYSSTTEEMM ((TTCCSS)) TTEESSTT
Machine Model Date
Machine Serial No. Machine Hours
Brake ECM Flash File/Date
TEST 1: Perform TCS test using the TCS TEST SWITCH:1) Using ET, choose the Brake ECM2) 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 ON6) 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
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TRACTION CONTROL SYSTEM (TCS) TEST
TEST SPECS ACTUAL
Brake Oil Temperature (during tests) > 65C (150F)
Parking Brake Release Pressure4700 200 kPa
(680 30 psi)
LI-
HI-
Left Brake Pressure (Released)
Left Brake Pressure (Engaged)< 300 kPa(44 psi)
Right Brake Pressure (Released)
Right Brake Pressure (Engaged) < 300 kPa(44 psi)
ET Proportional Solenoid Percentage 44%
Proportional Solenoid
Resistance/Voltage
12 to 22 ohms
0 to 12 Volts
Left Selector Solenoid
Resistance/Voltage
18 to 45 ohms
24 Volts
Right Selector Solenoid
Resistance/Voltage
18 to 45 ohms24 Volts
NOTE: When the brakes are ENGAGED, gauge pressure will drop quickly to approximately1380 kPa (200 psi), and then gradually decrease. This is the function of the proportional solenoidand orifices.
TEST 2: FUNCTIONAL TEST
Run the engine at Low Idle. Engage FIRST GEAR and release the brakes. With the TCS TestSwitch Depressed, do the brakes ENGAGE and RELEASE intermittently?
Wheels Turned to the RIGHT: YES NO
Wheels Turned to the LEFT: YES NO
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TTRRAACCTTIIOONN CCOONNTTRROOLL SSYYSSTTEEMM ((TTCCSS)) TTEESSTT
ACTIVE DIAGNOSTIC CODES and DESCRIPTION
Fault Code Description Cause
LOGGED DIAGNOSTIC CODES
Diagnostic Code andDescription
Number ofOccurrences
First Occurrence Last Occurrence
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Suspension Cylinder Charging
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FFRROONNTT SSUUSSPPEENNSSIIOONN CCYYLL IINNDDEERR CCHHAARRGGIINNGG
Refer to: Special Instruction SEHS9411 Servicing the Suspension Cylinders for Off-Highway Trucks
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Data View
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DataView Users Guide
1. Install DataView Software in Laptop (NEHS0662) or STW NETG5030
2. Connect DataView Box to Laptop printer port with cable provided3. 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 sensor8. 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 sensors10. 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 Manual15. 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 manually19. Click on 4
thIcon 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. SelectAdd 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.)
DDAATTAAVVIIEEWW TTOOOOLLSS
NEHS0662 Software and Instruction ManualJERD2163 Software Updates
131-5051 DataView Portable Tech Station Group
153-9630 PWM-Analog Test Group Sensor Adapter Kit
213-3274 100 psi sensor
213-3275 1000 psi sensor213-3276 7500 psi sensor
6V4144 Internal 1/4 nptf Valved Coupler (for each sensor)6V2198 18 ft. sensor extension cable
137-0168 Machine battery power cable
137-0170 12V Cigarette Lighter power cable4C4463 Yellow case for small parts
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C-SERIES SENSORS IN DATAVIEW SENSOR TABLE
100-3055 - Temperature: Brake, Differential, Torque Converter, Transmission (digital)163-7882 - Temperature: Engine Exhaust (digital)
102-2240 - Temperature: Engine Coolant, Rear Aftercooler Coolant (analog)
118-7226 - Temperature: Front Aftercooler Coolant (VIMS), Steering (digital)
118-3909 - Temperature: 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: Throttle (digital)141-5746 - PWM Pressure: Air System (digital)
157-8394 - PWM Pressure: Rear Parking Brakes (digital)
160-1582 - PWM Pressure: Rear Axle Oil (digital)
Speed Sensor Teeth (PPR)
SSEENNSSOORRNumber of Teeth
Engine Output Speed (EOS)Sensor
151
Fan Motor Output Speed
Sensor67
Transmission Output Speed
(TOS) Sensor120
Traction Control System
(TCS)Wheel Speed Sensors
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 madefrom 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.
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Sensor Specifications
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ANALOG TEMPERATURE SENSOR CHARTS
SENSOR VOLTAGE SPECIFICATION
ENGINE JACKET WATER, REAR AFTERCOOLER and FUEL
102-2240 Analog Temperature Sensors
TEMPERATURE SIGNAL VOLTAGE-40 to -20 C (-40 to -4 F) .5 to .57 DCV
-20 to 0 C (-4 to 32 F) .57 to .75 DCV
0 to 20 C (32 to 68 F) .75 to 1.16 DCV
20 to 40 C (68 to 104 F) 1.16 to 1.86 DCV
40 to 60 C (104 to 140 F) 1.86 to 2.74 DCV
60 to 80 C (140 to 176 F) 2.74 to 3.53 DCV
80 to 100 C (176 to 212 F) 3.53 to 4.1 DCV
100 to 120 C (212 to 248 F) 4.1 to 4.46 DCV
Tolerance is 10 %
SENSOR VOLTAGE SPECIFICATION
ENGINE OIL
106-0735 Analog Temperature Sensor
TEMPERATURE SIGNAL VOLTAGE
-40 to -20 C (-40 to -4 F) .2 to .57 DCV-20 to 0 C (-4 to 32 F) .57 to 1.12 DCV
0 to 20 C (32 to 68 F) 1.12 to 1.71 DCV
20 to 40 C (68 to 104 F) 1.71 to 2.31 DCV
40 to 60 C (104 to 140 F) 2.31 to 2.94 DCV
60 to 80 C (140 to 176 F) 2.94 to 3.55 DCV
80 to 100 C (176 to 212 F) 3.55 to 4.0 DCV
100 to 120 C (212 to 248 F) 4.0 to 4.37 DCV
Tolerance is 10 %
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ANALOG PRESSURE SENSOR CHARTS
SENSOR VOLTAGE SPECIFICATION
ATMOSPHERIC, CRANKCASE and TURBO INLET
PRESSURE
161-9926 Analog Pressure Sensor
ABSOLUTE PRESSURE SIGNAL VOLTAGE
0 to 20.7 kPa (0 to 3 psi) 0 to .89 DCV
20.7 to 41.3 kPa (3 to 6 psi) .89 to 1.78 DCV
41.3 to 62 kPa (6 to 9 psi) 1.78 to 2.67 DCV
62 to 82.7 kPa (9 to 12 psi) 2.67 to 3.56 DCV
82.7 to 103 kPa (12 to 15 psi) 3.56 to 4.44 DCV
Tolerance is 3 %
SENSOR VOLTAGE SPECIFICATION
TURBO OULET PRESSURE
194-6724 Analog Pressure Sensor
ABSOLUTE PRESSURE SIGNAL VOLTAGE
0 to 34.5 kPa (0 to 5 psi) 0 to .33 DCV
34.5 to 68.9 kPa (5 to 10 psi) .33 to .66 DCV
68.9 to 103.4 kPa (10 to 15 psi) .66 to .99 DCV
103.4 to 137.8 kPa (15 to 20 psi) .99 to 1.32 DCV
137.8 to 172.3 kPa (20 to 25 psi) 1.32 to 1.65 DCV
172.3 to 206.7 kPa (25 to 30 psi) 1.65 to 1.98 DCV
206.7 to 241.2 kPa (30 to 35 psi) 1.98 to 2.31 DCV
241.2 to 275.6 kPa (35 to 40 psi) 2.31 to 2.64 DCV
Tolerance is 3 %
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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 DUTY CYCLE
-40 to -20 C (-40 to -4 F) 10 to 11.3 %
-20 to 0 C (-4 to 32 F) 11.3 to 15 %
0 to 20 C (32 to 68 F) 15 to 23.2 %
20 to 40 C (68 to 104 F) 23.2 to 37.2 %
40 to 60 C (104 to 140 F) 37.2 to 54.7 %
60 to 80 C (140 to 176 F) 54.7 to 70.6 %
80 to 100 C (176 to 212 F) 70.6 to 82 %
100 to 120 C (212 to 248 F) 82 to 89.3 %
Tolerance is 10 %
SENSOR DUTY CYCLE SPECIFICATION
AMBIENT TEMPERATURE
118-3909 Digital Temperature Sensor
TEMPERATURE DUTY CYCLE
-60 to -40 C (-76 to -40 F) 1 to 4 %
-40 to -20 C (-40 to -4 F) 4 to 11.3 %
-20 to 0 C (-4 to 32 F) 11.3 to 22.3 %
0 to 20 C (32 to 68 F) 22.3 to 34.2 %
20 to 40 C (68 to 104 F) 34.2 to 46.2 %
40 to 60 C (104 to 140 F) 46.2 to 58.8 %
60 to 80 C (140 to 176 F) 58.8 to 70.9 %
80 to 100 C (176 to 212 F) 70.9 to 80.6 %
100 to 120 C (212 to 248 F) 80.6 to 87.4 %
Tolerance is 10 %
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EXHAUST TEMPERATURE SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
163-7882 Digital Temperature Sensor (Exhaust)
TEMPERATURE DUTY CYCLE
50 to 200 C (122 to 392 F) 22 to 33.2 %
200 to 400 C (392 to 725 F) 33.2 to 50 %
400 to 600 C (725 to 1112 F) 50 to 67 %
600 to 850 C (1112 to 1562 F) 67 to 88.4 %
Tolerance is 10 %
DIFFERENTIAL PRESSURE SENSOR CHART
SENSOR DUTY CYCLE SPECIFICATION
160-1582 Digital Pressure Sensor on Rear Axle Valve
ABSOLUTE PRESSURE DUTY CYCLE
0 to 137.8 kPa (0 to 20 psi) 0 to 13.6 %
137.8 to 275.6 kPa (20 to 40 psi) 13.6 to 29.6 %
275.6 to 413.4 kPa (40 to 60 psi) 29.6 to 45.6 %
413.4 to 551.2 kPa (60 to 80 psi) 45.6 to 61.6 %
551.2 to 689 kPa (80 to 100 psi) 61.6 to 77.6 %
689 to 826.8 kPa (100 to 120 psi) 77.6 to 93.6 %
Tolerance is 3 %
ULTRASONIC FUEL LEVEL SENSOR CHART
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
124-9325 Ultrasonic Fuel Level Sensor
Depth of Fuel (Shallow Tank) DUTY CYCLE
0 to 250 mm (0 to 9.9 inch) 6 to 25 %
250 to 500 mm (9.9 to 19.7 inch) 25 to 45 %
500 to 750 mm (19.7 to 29.6 inch) 45 to 64 %
750 to 1000 mm (29.6 to 39.4 inch) 64 to 84 %
Tolerance is 10 %
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AIR PRESSURE SENSOR CHARTS:
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
141-5746, 185-0600 Pressure Sensor (AIR)
Air Pressure DUTY CYCLE0 to 140 kPa (20 psi) 1.2 to 13.2 %
140 kPa (20 psi) to 275 kPa (40 psi) 13.2 to 25.2 %
275 kPa (40 psi) to 415 kPa (60 psi) 25.2 to 37.2 %
415 kPa (60 psi) to 550 kPa (80 psi) 37.2 to 49.2 %
550 kPa (80 psi) to 690 kPa (100 psi) 49.2 to 61.1 %
690 kPa (100 psi) to 825 kPa (120 psi) 61.1 to 73.1 %
825 kPa (120 psi) to 965 kPa (140 psi) 73.1 to 85.1 %
Tolerance is 3 %