Service Training

777D Off Highway Truck

BED RAISE

RIGHT

TEST/SET

LOAD INDICATORS
MODE

TOS

LEFT

PAYLOAD
MEASUREMENT

SPEED
DISTRB

CONTROL
ON/OFF

PAYLOAD MEASUREMENT SYSTEM

DIAGNOSTIC
WEIGHT
TOTAL CYCLES
TOTAL WEIGHT

POD

I/O

COMMUNICATION
PORT

STRUT
SENSORS

XII. TRUCK PAYLOAD MEASUREMENT

SYSTEM (TPMS)
1.
2.
3.
4.

Components Layout
Operation
Maintenance
Testing & Adjusting

777D Off Highway Truck

CHAPTER : TPMS

INTRODUCTION

Page:

MEASURES AND RECORDS PAYLOADS

DATE & TIME LOAD CYCLE OCCURRED

IDLE TIME

LOADING TIME

EMPTY & LOADED TRAVEL TIME

EMPTY & LOADED TRAVEL DISTANCE

DOWNLOADING CAPABILITY

XII-1

Page:
XII-2

TRUCK PAYLOAD MEASUREMENT SYSTEM

SIGNAL FLOW
BED RAISE

RIGHT

TEST/SET

LOAD INDICATORS

MEASUREMENT

SPEED
DISTRB

CONTROL
ON/OFF

PAYLOAD MEASUREMENT SYSTEM

DIAGNOSTIC
WEIGHT
TOTAL CYCLES
TOTAL WEIGHT

POD

I/O
STRUT
SENSORS

COMMUNICATION
PORT

777D Off Highway Truck

TOS

PAYLOAD

CHAPTER : TPMS

MODE

LEFT

777D Off Highway Truck

CHAPTER : TPMS

MODES OF OPERATION

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch
Switch

MODE switch located behind the POD

Page:

MODE 0

NORMAL PAYLOAD DISPLAY

MODE 1

MODEL SETTING DISPLAY

MODE 2

SYSTEM UNITS SETTING DISPLAY

MODE 3

MAXIMUM TARGET WEIGHT

MODE 4

TRUCK FLEET IDENTIFICATION

MODE 5

SYSTEM OPTIONS SETTING DISPLAY (LIGHTS ON/OFF)

MODE 6

SYSTEM CALIBRATION

MODE 7

SYSTEM STATUS DISPLAY ( FAULT CODES)

XII-3

777D Off Highway Truck

CHAPTER : TPMS

NORMAL MODE DISPLAY

MODE 0
PRESSING SET/ CLEAR SWITCH:
DISPLAY TEST SEQUENCE:
- Truck model setting
- System units setting
- Maximum trarget weight
- Truck ID code setting
- System options code setting
EXTERNAL LAMP TEST
TPMS CONTROL LED TEST
TOTAL WEIGHT
TOTAL CYCLES

Test / Set
Switch

RESTORES TO STATE WHEN TURNED OFF

DISPLAYS WEIGHT WHEN STABILIZED
FLASHING DASHES IF PAYLOAD < 60% RATED
FAULT CODE DISPLAYED IF PRESENT

TRUCK MODEL SETTING

MODE 1
MODE 1 display provides the truck model setting. MODE 1 is used to
select the truck model.

Payload Operator Display

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch
Switch

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch
Switch

785 B

777 D
R

Payload Operator Display

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch
Switch

ON / OFF Test / Set

Switch
Switch

789 B
Page:

XII-4

Diagnostic
Weight
Total cycles
Total weight

793 B

777D Off Highway Truck

CHAPTER : TPMS

SYSTEM UNITS DISPLAY

MODE 2
R
Payload Operator Display

Metric Tonnes

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

Press Test / Set Switch

to change Units while
in MODE 2
R
Payload Operator Display

Test / Set
Switch

Diagnostic
Weight
Total cycles
Total weight

U.S. Tonnes

ON / OFF Test / Set

Switch Switch

DISPLAY MAXIMUM (TARGET WEIGHT) SETTING

MODE 3
777 B

777 B

R
Payload Operator Display

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Maxinum (Target) Weight Setting Range

Truck Model
777 B (< 1991)
777D

Page:

XII-5

Rated Maximum

Minimum Setting

Maximum Setting

86 Metric tonne
(95 U.S. ton)

59 Metric tonne
(65 U.S. ton)

86 Metric tonne
(95 U.S. ton)

91 Metric tonne
(100 U.S. ton)

452Metric tonne
(500 U.S. ton)

777D Off Highway Truck

CHAPTER : TPMS

TRUCK IDENTIFICATION CODE SETTING

MODE 4
TRUCK ID SETTING (199 ID CODES).
IDENTIFIES DIFFERENT TRUCKS WITHIN ONE FLEET.

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

DISPLAY SYSTEMS OPTIONS SETTING

MODE 5
ENABLES/DISABLES:
- Payload display on POD
- External load lamps
- Last loader pass (flashing red lights)
- Automatic broadcast of payload and cycle data
- Baud rate

R
Payload Operator Display

R
Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFFTest / Set
Switch Switch

Page:

XII-6

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

777D Off Highway Truck

CHAPTER : TPMS

DISPLAY SYSTEMS OPTION SETTING

MODE 5
Systems Options Settings

Page:

External
Loader Lights
Enabled
(?)

One Pass
Indicator
Enabled
(?)

Auto
Broadcast
Enabled
(?)

Baud Rate

Option Settings

Display
Payload
Enabled (?)

o01

Yes

Yes

No

No

9600

o02

No

Yes

No

No

9600

o03

Yes

Yes

Yes

No

9600

o04

No

Yes

Yes

No

9600

o05

Yes

No

No

No

9600

o06

No

No

No

No

9600

o07

Yes

Yes

No

Yes

9600

o08

No

Yes

No

Yes

9600

o09

Yes

Yes

Yes

Yes

9600

o10

No

Yes

Yes

Yes

9600

o11

Yes

No

No

Yes

9600

o12

No

No

No

Yes

9600

o13

Yes

Yes

No

No

1200

o14

No

Yes

No

No

1200

o15

Yes

Yes

Yes

No

1200

o16

No

Yes

Yes

No

1200

o17

Yes

No

No

No

1200

o18

No

No

No

No

1200

o19

Yes

Yes

No

Yes

1200

o20

No

Yes

No

Yes

1200

o21

Yes

Yes

Yes

Yes

1200

o22

No

Yes

Yes

Yes

1200

o23

Yes

No

No

Yes

1200

o24

No

No

No

Yes

1200

XII-7

777D Off Highway Truck

CHAPTER : TPMS

SYSTEM CALIBRATION
MODE 6
This MODE is used to start the system calibration procedure.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

The message CAL starts

flashing on the POD when
MODE 6 is entered.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Depressing the Test / Set Switch for 1 Second

initiates a calibration sequence. The Payload
Monitor will store the current Suspension Cylinder
Pressures into memory.

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Calibration is complete.
(C A L no longer flashing)

Page:

XII-8

777D Off Highway Truck

CHAPTER : TPMS

SYSTEM CALIBRATION
MODE 6
CALIBRATION PROCEDURE

The system must be calibrated after system installation, suspension cylinder

recharging or after truck modifications which affect the empty weight of the truck.
Improper calibration will affect accuracy of the system.
CALIBRATION PROCEDURE:
1) Prepare the truck.
-Truck must be empty. (Remove any large accumulation of dirt and mud. The
cleaner the truck the more accurate that the calibration will be).
- All optional attachements that affect the the empty weight of the truck must be
on.
- All truck fluids should be at full capacity.
- The suspension cylinders must be properly charged.
- No TPMS system faults should be present.
2) Operate the truck at 3 to 4 km / h on a HARD LEVEL surface. Shift the
transmission to NEUTRAL. Leave the truck in NEUTRAL. Turn key switch OFF.
3) Remove the Payload Operator Display from the dash.
4) Turn the key switch and TPMS ON. Wait for the start up sequence to complete.
5) Slowly depress the mode switch 6 times to select MODE 6. The Payload
Operator DIsplay should be flashing "CAL". Depress and hold the Test / Set
switch. The POD will momentarily show dashes, followed again by "CAL".
6) Return the display mode to MODE 0 by depressing the mode switch twice, or
by turning the system power switch OFF and then back ON.
7) Turn the key switch OFF and install the POD in the dash. This completes the
calibration procedure.

Page:

XII-9

777D Off Highway Truck

CHAPTER : TPMS

SYSTEM STATUS DISPLAY MODE

MODE 7
The TPMS system has built in component status display.
It is possible to identify CRITICAL, NON-CRITICAL and INTERMITTENT faults.

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight

CRITICAL FAULTS (F01-F08) will appear

and remain ON the Payload Operator
Display any time during the loading
cycle.

ON / OFFTest / Set
Switch Switch

Payload Operator Display

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight

ON / OFF Test / Set

Switch Switch

ON / OFF Test / Set

Switch Switch

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

A FAULT that appears only at times when the display would normally
be blank indicates a NON CRITICAL FAULT (F09-F18).
If a FAULT appears and then disappears later, an INTERMITTENT
FAULT is indicated.
R

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Status Characters and Corresponding Cicuit Code

Numbers They Are Associated With
R

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Cicuit Code
Numbers

Status

A01 - A18

No Fault is detected in the Circuit

EO1 - E18

A Fault is intermittent in the Circuit

F01 - F18

A Fault is present in the Circuit

A19 - A24

No Signal is present in the Circuit

C19 - C24

A Signal is present in the Circuit

Payload Operator Display

Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch

Page: XII-10

777D Off Highway Truck

CHAPTER : TPMS

SYSTEM STATUS DISPLAY MODE

MODE 7

Circuit Description

X 00

Entry and exit point from system status

display

X 01

Left front suspension cylinder charge

X 02

Right front suspension cylinder charge

X 03

Left rear suspension cylinder charge

X 04

Right rear suspension cylinder charge

X 05

Left front suspension cylinder charge

pressure sensor circuit

X 06

Right front suspension cylinder pressure

sensor circuit

X 07

Left rear suspension cylinder pressure

sensor circuit

X 08

Right rear suspension cylinder pressure

sensor circuit

X 09

Batt backup / Real clock setting

X 10

System setting/ memory

X 11

Not used

X 12

Not used

X 13

Green Lamp open circuitor ground short

circuit

X 14

Green Lamp + battery short circuit

X 15

Page: XII-11

Red lamp open circuit or ground short circuit

X 16

Red lamp + battery short circuit

X 17

Not used

X 18

Not used

X 19

Bed raise switch status

X 20

Transmission output speed sensor status

X 21

Transmission neutral status

X 22

Not used

X23

Not used

X 24

Not used

NON CRITICAL

Cicuit Code
Numbers

CRITICAL

Circuit Code Numbers And The

Circuit They Are Associated With

777D Off Highway Truck

CHAPTER : TPMS

BASIC WEIGHING OPERATION

TRUCK STOPPED
PARKING BRAKE ON,
XMS NEUTRAL

FIRST LOAD

REPOSITIONING POSSIBLE
MAX 0.16 MILE

GREEN EXTERNAL LIGHT ON

GREEN POD LIGHT ON
POD DISPLAYS DASHES

60% LOAD

POD DISPLAYS PAYLOAD

95% PAYLOAD

RED EXTERNAL LIGHT ON

RED POD LIGHT ON

Page: XII-12

IF LAST PASS ACTIVE

EXTERNAL RED LIGHT
FLASHES WHEN ONE MORE
LOAD MAKES 95% PAYLOAD

RED EXTERNAL LIGHT ON

RED POD LIGHT ON

Page: XII-13

TPMS ACCURACY

TPMS ACCURATE TO +/- 5% 0N 95% OF PAYLOADS

IF FOLLOWING CONDITIONS ARE MET:

2)

CORRECTLY CHARGED SUSPENSION CYLINDERS

3)

NO "PUSHING" WITH BUCKET

4)

MOVING TRUCK MORE THAN 0.1 MILE (O,16 KM)

5)

ACTUATING BED RAISE LEVER WHILE LOADING

6)

INCORRECT CALIBRATION

7)

LOADING FROM CONVEYOR

8)

LEAVING LOAD SITE BEFORE PRESSURES STABILIZED

777D Off Highway Truck

GROUND SLOPE LESS THAN 5%

CHAPTER : TPMS

1)

Page: XII-14

CYCLE DATA
STORED DATA:
-LOADING TIME (MAX 7200 s)
-PAYLOAD WEIGHTS (MAX 800 US TONNES)
-LOADED STOP TIME (MAX 7200s)
-TRAVEL TIME (MAX 7200s)
-TRAVEL DISTANCE ( 50 miles)

- FLASHING RED DOT IF > 1200 CYCLES

- OLDEST 20 CYCLES DELETED
DOWNLOADED USING LAPTOP COMPUTER:
- CABLE 9X-3393
- TPMS SOFTWARE (SERD0032)
- PRINTER

777D Off Highway Truck

-1400 LOAD CYCLES

CHAPTER : TPMS

MEMORY:

Page: XII-15

TOTAL CYCLES / TOTAL WEIGHT HAULED

STORED DATA:
- TOTAL NUMBER OF CYCLES RUN (1999 CYCLES)
-TOTAL WEIGHT HAULED (MAX 199900 US TONNES)

-WAIT FOR CYCLES TO BE DISPLAYED

-WITHIN 10 SECS ACTIVATE BED RAISE LEVER
REAL TIME CLOCK
-LOGS DATE & TIME OFCOMPLETION OF EACH DATA CYCLE
-CAN ONLY BE SET WITH PC

777D Off Highway Truck

-DEPRESS TEST/SET SWITCH

CHAPTER : TPMS

CLEARING DATA:

777D Off Highway Truck

CHAPTER : TPMS

LAB EXERCISES
LAB A:
1) Using the POD on a 777D truck write down the initial TPMS configuration as shown on the
display and explain each of the numbers. Change the settins to the new values indicated in the table.
Once finished remember to leave the truck with the same initial configuration.
INITIAL SETTINGS
DISPLAY

NEW SETTINGS

EXPLANATION

DISPLAY
769D
METRIC
100
23
003

2) Use the POD to determine the total weight carried and the total cycles carried out.

TOAL WEIGHT:_____________
TOTAL CYCLES:____________
3) Scroll to mode 7 and identify any existing faults.
FAULTS

MEANING

4) Repeat LAB A using the service tool

Page: XII-16