VITAL INFORMATION MANAGEMENT SYSTEM

(VIMS)
Machine Model______________________________

Date ______________________________

Machine Serial No.___________________________

Machine Hours _____________________

Machine Miles ______________________________

VISUAL CHECKS:

Electrical Connections ________________________

Component Damage ________________

MSTAT (67828) - MACHINE STATISTICS

PARAMETER

DESIRED

Source Code S:
Configuration Code C:
Hardware H:
Model Number
Serial Number
Equipment Number
Attachment Code (see chart on page 5)
Languages
PRI:
SEC:
Configuration Type
Operator ID
ATTACH (288224) (see chart on page 5)

ACTUAL

VIMS
PAYLOAD
PROGRAM CODE

DESIRED

ACTUAL

YES/NO

PAYCAL (729225)
RAC (722) - Set Haul Road Severity

0 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

Autolube Cycle Time

Autolube Duration

ESTAT (37828) - EVENT STATISTICS

EVENT
SYSTEM
MACHINE
2

ACTUAL

VIMS
EACK (3225) ACTIVE EVENTS
EVENT

HOUR
METER
START

LENGTH OF CATEGORY
LEVEL
TIME

LIMIT

WORST

LIMIT

WORST

ELIST (35478) INTERMITTENT EVENTS

EVENT

HOUR
METER
START

LENGTH OF CATEGORY
LEVEL
TIME

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

Sensor Tests
Sensor

Supply
Voltage

Actual Temperature/
Pressure/ Fuel Level

(A-B)

(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 Level
Steering 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--LR
Strut Pressure--RR
Alternator "R" Terminal

N/A

12.4 to 14.75 DCV

> 95 Hz

Fuel Level Sensor

N/A

VIMS ATTACHMENT CODES

785C/789C/793C ATTACHMENT CODES
Attachment Code

RAC Enabled

TKPH or TMPH
Enabled

No

No

Yes

No

No

Yes

Yes

Yes

Road Analysis Control (RAC)

Tonne-Kilometer Per Hour (TKPH)
Ton-Mile Per Hour (TMPH)

VIMS KEYPAD OPERATIONS

PAYCONF
PAYCAL
TOT
RESET
ESET
SVCLIT

7292663
729225
868
73738
3738
782548

Configure Payload Monitor (requires VIMS PC connection)

Calibrate Payload Monitor (requires VIMS PC connection)
Show Payload Cycle Resettable Totals
Reset Displayed Payload Data
Customize Events (requires VIMS PC connection)
Turn OFF Service Light

SVCSET
TEST
MSTAT

782738
8378
67828

Service Light Set (requires VIMS PC connection)

Self-Test Instrumentation
Show Machine Statistics (source and config codes)

LUBSET
LUBMAN

582738
582626

Set Lube Cycle Times

Manual Lube

EACK
ESTAT
ELIST

3225
37828
35478

Show Acknowledged Events (Active)

Show Event Statistics
Show Event List (Intermittent)

EREC
ERSET

3732
37738

Start Event Recorder

Configure 1 Event Recorder (requires VIMS PC connection)

DLOG
DLRES

3564
35737

Start/Stop Data Logger

Reset Data Logger

LA
UN

52
86

Change Language
Change Units

ODO

636

Odometer Set/Reset (requires VIMS PC connection)

BLT
CON

258
266

Change Backlight
Change Display Contrast

ATTACH
RAC

288224
722

see chart on page 5 (requires VIMS PC connection)

Set Haul Road Severity
(0 - OFF, 1 - high, 2 - medium, 3 low)
(requires VIMS PC connection)

OK Key--Used to complete keypad entries and to acknowledge events. Acknowledging an event will
remove the event from the display temporarily. Severe events cannot be acknowledged.
GAUGE key--Displays parameters monitored by VIMS. Depressing the arrow keys will scroll through
the parameters. Entering the parameter number and the GAUGE key selects that parameter.
F1 Key--Provides additional information on the current event being displayed. For MAINTENANCE
(SYSTEM) events, the MID, CID, FMI is displayed. For DATA (MACHINE) events, the current
parameter value is displayed (temperature, pressure, rpm).
6

VIMS KEYPAD GAUGE PARAMETERS

100
105
106
107
108
111
112
116
117
118
121
122
129
130
131
135
140
197
198
199
200
313
325
328
350
403
416
417
444
452
460
461
462
463
724
790
791
799

ENG SPD
BOOST PRES
LT EXH TEMP
RT-LT EXH TEMP
RT EXH TEMP
F AFTRCLR TEMP
R AFTRCLR TEMP
COLD MODE
ENG DERATE %
AIR FLTR IN-H20
ENG LOAD %
FUEL FLTR
ENG FUEL RATE GAL/HR
ENG OIL LVL
ENG OIL PRES
ENG COOL TEMP
SYS VOLTAGE
ENG FAN SPD #1
ENG FAN SPD #2
RT-LT FAN SPD
ENG FAN TEMP
TC OUT TEMP
DIFF TEMP
DIFF LUBE PRES
TRN LUBE TEMP
FAN DRIVE FLTR
LT PARKBK PRES
RT PARKBK PRES
STRG OIL TEMP
BRK/AIR PRES
LT F BRK TEMP
LT R BRK TEMP
RT F BRK TEMP
RT R BRK TEMP
BODY ANGLE DEG
ATMOS PRES
AMB AIR TEMP
HOIST STATUS

NOTE: Shown are the most commonly used parameters.

7

785C-793C OFF-HIGHWAY TRUCK

ENGINE TESTS
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 Diagnostic
Codes and the Configuration Screen, fill in the information requested.

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

With the engine NOT running, record the information on the chart provided.

ENGINE TESTS
Sensor Tests
Sensor

Supply
Voltage
(A-B)

Desired
Signal Volts
or
Duty Cycle

Actual Signal
Voltage/%
(B-C)

Actual
Pull-up
Temperature/ Voltage
Pressure
(ET or VIMS) (B-C)

Filtered Engine Oil

Pressure

.2 to .6

Unfiltered Engine Oil

Pressure

.2 to .6

Coolant Temperature

.4 to 4.6

Aftercooler
Temperature

.4 to 4.6

Atmospheric Pressure

2.2 to 4.6

Crankcase Pressure

2.2 to 4.6

Right Turbo Inlet

Pressure

2.2 to 4.6

Left Turbo Inlet

Pressure

2.2 to 4.6

Turbo Outlet Pressure

.8 to 1.5

Left Exhaust
Temperature

see below

Right Exhaust
Temperature

see below

NOTE:

Analog supply voltage is 5.0 0.5

Digital supply voltage is 8.0 0.5
Desired signal voltages are at Key ON.
Exhaust Temperature Sensor Duty Cycles: below 49C (120F) 10% to 21%
49 to 851C (120 to 1564F) - 22% to 88%
above 851C (1564F) 88% to 90%
3

ENGINE TESTS
TEST

SPECS

24

ECM Supply Voltage

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)

Early - 48 4%
Later - 85 4%
150-1000 Hz

Throttle Sensor Frequency (B-C)

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

or
greater than 10.0

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

2.0 to 4.0

ACTUAL

ENGINE TESTS
ACTIVE DIAGNOSTIC CODES
DIAGNOSTIC CODE

DESCRIPTION

LOGGED DIAGNOSTIC CODES

DIAGNOSTIC CODE

DESCRIPTION

NUMBER
OF
OCCURR

FIRST
HOUR
METER

LAST
HOUR
METER

NUMBER
OF
OCCURR

FIRST
HOUR
METER

LAST
HOUR
METER

EVENT CODES
EVENT CODE

DESCRIPTION

ENGINE TESTS
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:
(793 only)

Override %

Volts

0%
25%
50%
75%
100%

NOTES:

Current (miliamps)

ENGINE TESTS
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

ENGINE TESTS
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

OK

NOT OK

NOTES:

TIMING CALIBRATION:
NOTES:

785C 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
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
1

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
> 71C (160F)

Coolant Temperature (during tests)

ACTUAL
Start:
Stop:

Low Idle RPM

700 10

High Idle RPM

1937 10

Air Filter Restriction @ TC Stall (maximum allowed)

25 in. of water

Inlet Manifold Pressure (BOOST)

@ Full Load RPM (1750 10)

194 30 kPa
(28.2 4.3 psi)

Inlet Manifold Pressure (BOOST)

@ TC Stall RPM (1642 65 rpm)

206 30 kPa
(29.8 4.3 psi)
1642 65

Torque Converter Stall RPM

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

> 80C (175F)

< 121C (250F)
200 to 600 kPa
(29 to 87 psi)
345 to 600 kPa
(50 to 87 psi)
maximum
70 kPa (10 psi)
338 to 682 kPa
(49 to 99 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 110F over ambient
*2 Should be 8 to 20F less than Top Tank Temp/thermostat open (> 88C/190F)

789C 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
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

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
> 71C (160F)

Coolant Temperature (during tests)

ACTUAL
Start:
Stop:

Low Idle RPM

700 10

High Idle RPM

1937 10

Air Filter Restriction @ TC Stall (maximum allowed)

25 in. of water

Inlet Manifold Pressure (BOOST)

@ Full Load RPM (1750 10)

198 30 kPa
(28.8 4.3 psi)

Inlet Manifold Pressure (BOOST)

@ TC Stall RPM (1718 65 rpm)

194 30 kPa
(28.2 4.3 psi)

Torque Converter Stall RPM

1718 65

Torque Converter Temperature (during stall test)

Engine Oil Pressure @ LI
Engine Oil Pressure @ HI
Engine Oil Filter Differential Pressure @ HI
Fuel Pressure @ Torque Converter Stall
Fuel Filter Status
[maximum restriction 140 kPa (20 psi)]

> 80C (175F)

< 121C (250F)
207 to 600 kPa
(30 to 87 psi)
338 to 600 kPa
(49 to 87 psi)
maximum
70 kPa (10 psi)
317 to 634 kPa
(46 to 92 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 110F over ambient
*2 Should be 8 to 20F less than Top Tank Temp/thermostat open (> 88C/190F)
2

793C 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
1

793C (4AR, 4GZ, ATY) ENGINE POWER TEST

(7TR with Wastegate)
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on
the chart provided.
TEST

SPECS
> 71C (160F)

Coolant Temperature (during tests)

ACTUAL
Start:
Stop:

Low Idle RPM

700 10

High Idle RPM

1965 10

Air Filter Restriction @ TC Stall (maximum allowed)

25 in. of water

Inlet Manifold Pressure (BOOST)

@ Full Load RPM (1750 10) DIRECT DRIVE

207 31 kPa
(30.1 4.5 psi)

Inlet Manifold Pressure (BOOST)

@ Full Load RPM (1750 10) CONV DRIVE
Torque Converter Stall RPM

181 27 kPa
(26.3 4 psi)

1672 65

Torque Converter Temperature (during stall test)

> 80C (175F)

< 121C (250F)

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 [max restriction 140 kPa (20 psi)]

OK
LI -

Wastegate %

< 60 %

HI Stall -

* Use Torque Stall for Class

2

793C (4AR, 4GZ, ATY) 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
> 71C (160F)

Coolant Temperature (during tests)

ACTUAL
Start:
Stop:

Low Idle RPM

700 10

High Idle RPM

1965 20

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 @ LI

207 to 600 kPa

(30 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

[maximum restriction 140 kPa (20 psi)]

OK

* Use Torque Stall for Class

793C (CBR) ENGINE POWER TEST

(SOUND TRUCK)
Run the engine at Low Idle, High Idle and TC Stall accordingly and record the information on
the chart provided.
TEST

SPECS
> 71C (160F)

Coolant Temperature (during tests)

ACTUAL
Start:
Stop:

Low Idle RPM

700 10

High Idle RPM

1965 20

Air Filter Restriction @ TC Stall (maximum allowed)

25 in. of water

Inlet Manifold Pressure (BOOST)

@ Full Load RPM (1600 10) DIRECT DRIVE

189 28 kPa
(27.4 4 psi)

Inlet Manifold Pressure (BOOST)

184 28 kPa
(26.7 4 psi)

@ Full Load RPM (1600 10) CONV DRIVE

Torque Converter Stall RPM

1640 65

Torque Converter Temperature (during stall test)

> 80C (175F)

< 121C (250F)

Engine Oil Pressure @ LI

207 to 600 kPa

(30 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

[maximum restriction 140 kPa (20 psi)]

OK

* Use Torque Stall for Class

NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP.
Converter Stall must be ran in FIRST FORWARD with the Body DOWN.
4

793C HYDRAULIC FAN TEST

Machine Model

Date

Machine Serial No.

Machine Hours

Brake ECM Flash File/Date

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

NOTE: The Air Conditioner must be OFF during all tests except the A/C Test.
Use the VIMS Data Logger to capture additional information during the fan tests.
NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of
the pump and motors before starting the engine.
1

793C HYDRAULIC FAN TEST

With COLD temperatures and LOW IDLE, the fan drive pump should be turned OFF. Fan speed
will be approximately 100 rpm.
Using the "Fan Speed Override" function of ET, perform the following Fan Test:
TEST 1: HYDRAULIC FAN OVERRIDE
Tools
1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView
2) Laptop with ET
During the test, fan speed will be overridden to 200, 300, 400, 500, 625, 700 rpm and the
solenoid disconnected.
Fan Speed Override Procedure:
1) On the ET screen toolbar, click on Diagnostics Override Parameters
2) Select "Desired Engine Cooling Fan Speed Override" and change the value to the
required rpm (see ET screens below)
3) Using DataView, VIMS or ET, observe the Fan Speeds

793C HYDRAULIC FAN TEST

Run the engine at LOW IDLE and HIGH IDLE. Using DataView, VIMS or the ET "793C Fan
Test" group and a pressure gauge, record the data into the chart.
NOTE: When accelerating from LOW IDLE to HIGH IDLE, the fan drive pressure will
spike to start the fan rotation. The spike pressure may be the pump High Pressure Cut-off
setting of 27000 345 kPa (3920 50 psi) at sea level. The high pressure cut-off valve
setting must be set lower at higher altitudes. If the fan drive pump solenoid is disconnected
and the engine is run at high idle, the fan would overspeed if the high pressure cut-off valve
setting is too high.

TEST TEMPERATURES
Jacket Water
Coolant

After Cooler
Coolant

Brake Oil

Fan Drive Oil

HYDRAULIC FAN OVERRIDE

Engine
Speed

Fan Override
Speed

Left
Fan Speed

Right
Fan Speed

Desired
Pump
Pressure

Actual Pump
Pressure

200 rpm
300 rpm
400 rpm
Low Idle
Neutral

500 rpm
625 rpm
700 rpm
DISCONNECT
SOLENOID

HYDRAULIC FAN OVERRIDE

Engine
Speed

Fan Override
Speed

Left
Fan Speed

Right
Fan Speed

200 rpm
300 rpm
400 rpm
High Idle
Neutral

500 rpm
625 rpm
700 rpm
DISCONNECT
SOLENOID

Desired
Pump
Pressure

Actual Pump
Pressure

TEST 2: HYDRAULIC FAN HIGH PRESSURE CUT-OFF

Tools
1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView
2) Fan Pump Port Cover Plate (5P0048)
3) Cover Plate Seal (1P3704)
High Pressure Cut-Off Test Procedure:
To determine the high pressure cut-off setting at the current altitude, use ET to override the
hydraulic fan speed to 625 rpm, raise the engine speed to HIGH IDLE and record the pump
pressure and fan speeds. We now know what pressure is required to rotate the fans at
625 rpm at the current altitude. For example, at our current altitude it required approximately
16675 kPa (2420 psi) to rotate the fans at 625 rpm. Pump cut-off pressure should be set a
minimum of 2070 kPa (300 psi) above the pressure required to maintain maximum fan speed
(625 rpm) with the solenoid unplugged. This will vary with the elevation above sea level. So, at
this altitude we should set the pump cut-off pressure to a minimum of
18740 kPa (2720 psi).
1) Install the 5P0048 cover plate at the pump discharge port.
2) Operate the truck at LOW IDLE. The pump should be at the cut-off pressure.
3) 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
@
LOW IDLE

PUMP PRESSURE

TEST TEMPERATURES
Jacket Water
Coolant

After Cooler
Coolant

Brake Oil

Fan Drive Oil

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

TEST 3: HYDRAULIC FAN PUMP AND MOTOR EFFICIENCY

Tools
1) Fan Pump Pressure -- 34450 kPa (5000 psi) gauge or DataView
2) Laptop with ET
3) Fan Motor Port Cover Plate (5P0048) x 2
4) Cover Plate Seal (1P3704) x 2
optional
1) Bolt (8T4910) x 8 -- M12 x 1.75 x 60mm
2) Washer (8T4223) x 8
3) Cover (7I7133) x 2
Pump and Motor Efficiency Test Procedure:
1) Install two 5P0048 port cover plates in the Left Fan Motor supply and return ports to
completely block the Left Fan Motor (or at the manifold block between the two fan motors).
Blocking the flow of oil to one of the motors will isolate all of the pump flow to one motor.
2) Unplug the pump solenoid and operate the truck at LOW IDLE.
3) Remove the cover plates from the Left Fan Motor and install them in the Right Fan Motor.
Repeat the above low idle check.
If the pump and motor both have acceptable volumetric efficiencies, the fan speed should be a
minimum of 510 rpm.
If both fan speeds are about the same, but the fan speeds are too low, then the pump may have a
problem supplying the required flow. If only one fan speed is too low, then the slow fan motor
may be failing.

HYDRAULIC FAN PUMP AND

MOTOR EFFICIENCY
LEFT Motor
Right Motor
Pump Pressure
Fan Speed
Blocked
(Minimum
510 rpm)
Engine Speed
@
LOW IDLE

HYDRAULIC FAN PUMP AND

MOTOR EFFICIENCY
RIGHT Motor
Left Motor
Pump Pressure
Fan Speed
Blocked
(Minimum
510 rpm)
Engine Speed
@
LOW IDLE
6

793C HYDRAULIC FAN TEST

TEST 4: AIR CONDITIONING TEST
Air Conditioning Test Procedure:
1) Turn the Air Conditioner Switch ON. When the Compressor turns ON, the Fan Speed is set
to Maximum. Record the Fan Speed at Low and High Idle.
AIR CONDITIONING TEST
Compressor OFF
Fan Speed

Engine Speed

Left

Compressor ON
Fan Speed

Right

Left

Right

LOW IDLE:
HIGH IDLE:

FAN SPEED VERSUS PUMP SOLENOID CURRENT

FAN SPEED (RPM)

800
700
600
500
400
300
200
100
0
0

100

200

300

400

500

600

700

PUMP SOLENOID CURRENT (mA)

LOW IDLE FAN SPEED

HIGH IDLE FAN SPEED

800

793C HYDRAULIC FAN TEST

ENGINE FAN CONTROL C (F)
JACKET WATER
TEMPERATURE

AFTERCOOLER
TEMPERATURE

BRAKE
TEMPERATURE

FAN
CONTROL

< 88 (190)

< 78 (172)

< 102 (215)

BASE TEMP
OFF

> 88 (190)
< 98 (208)

> 78 (172)
< 88 (190)

> 102 (215)

< 107 (225)

MODULATE TO
TEMP CHART

> 98 (208)

> 88 (190)

> 107 (225)

MAXIMUM

ENGINE RPM

COOLANT
TEMPERATURE
ABOVE
BASE TEMP

700

1C (1.8F)

.5C (1F)

2C (3.6F)

150

150

1C (2F)

3C (5.4F)

150

186

208

1.5C (3F)

4C (7.2F)

171

249

277

2C (4F)

5C (9F)

192

280

312

2.5C (5F)

6C (10.8F)

150

235

342

381

3C (6F)

7C (12.6F)

162

277

405

451

3.5C (7F)

8C (14.4F)

186

320

466

520

4C (8F)

9C (16.2F)

208

363

529

589

4.5C (9F)

10C (18F)

224

384

560

624

5C (10F)

1200

1750

1950

DESIRED ENGINE FAN SPEEDS

BRAKE
TEMPERATURE
ABOVE
BASE TEMP

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) Using ET, choose the 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:

785C/789C TORQUE CONVERTER TEST

TEST

SPECS

ACTUAL

> 80C (175F)

< 121C (250F)

Torque Converter Oil Temperature (during tests)

Maximum at High Idle

with Cold Oil

Torque Converter Inlet Pressure

930 35 kPa
(135 5 psi)

LI HI
STALLLI -

Torque Converter Outlet Pressure @ STALL rpm

345 to 550 kPa

(50 to 80 psi)

HI
STALL-

Torque Converter Stall RPM

785C--1642 65 rpm
789C--1718 65 rpm
4700 200 kPa
(680 30 psi)

Parking Brake Release Pressure

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

1030 35 kPa
(150 5 psi)

Lockup Clutch Maximum Pressure

NEUTRAL/DIRECT DRIVE/1300 rpm

2135 70 kPa
(310 10 psi)

LIHI-

793C TORQUE CONVERTER TEST

TEST

SPECS

ACTUAL

> 80C (175F)

< 121C (250F)

Torque Converter Oil Temperature (during tests)

Maximum at High Idle

with Cold Oil

Torque Converter Inlet Pressure

930 35 kPa
(135 5 psi)

LI HI
STALLLI -

Torque Converter Outlet Pressure @ STALL rpm

345 to 550 kPa

(50 to 80 psi)

HI
STALL-

Torque Converter Stall RPM

4AR, 4GZ, ATY 1672 65 rpm
CBR
1640 65 rpm

Transmission Charge Pressure (Converter Drive)

LI:
> 2515 kPa (365 psi)

LI -

HI:
< 3065 kPa (445 psi)

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
Lockup Clutch Primary Pressure
NEUTRAL/DIRECT DRIVE/LOW IDLE

1445 to 2240 kPa

(210 to 325 psi)
1030 35 kPa
(150 5 psi)

Lockup Clutch Maximum Pressure

NEUTRAL/DIRECT DRIVE/1300 rpm

2150 to 2350 kPa

(310 to 340 psi)

NOTE: Engine Speed is reduced to 1600 rpm in REVERSE and when the Body is UP.
Converter Stall must be ran in FIRST FORWARD with the Body DOWN.
3

785C/789C 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

PUMP PRESSURE

2515 kPa (365 psi)

(minimum)

3175 kPa (460 psi)

(maximum)

LUBE PRESSURE

4 kPa (.6 psi)

(minimum)

140 to 205 kPa

20 to 30 psi)

PILOT PRESSURE

1755 35 kPa
(255 5 psi)

xxx

xxx

LOCKUP SOLENOID ENERGIZED

(plug signal line to lockup clutch valve)
SPECS

ACTUAL

LI

1300 RPM

LI

PUMP PRESSURE

xxx

2100 100 kPa

(305 15 psi)

xxx

STATION "D"

xxx

Adjust station "D" to

get correct pump and
clutch pressures

xxx

2020 + 240 - 100 kPa

(293 + 35 - 15 psi)

xxx

PRESSURE
NEUTRAL CLUTCH
PRESSURE
STATION "C"

HI

> 82C (180F)

< 121C (250F)

Transmission Oil Temperature (during tests)

DIRECT DRIVE
PRESSURES

LI

xxx

1300 RPM

785C/789C TRANSMISSION CLUTCH TESTS

PRIMARY CLUTCH PRESSURE @ L.I.
Load Piston Plug Removed

CLUTCH CHART
SPEED

CLUTCHES
ENGAGED

STATION

CLUTCH

SPECS

1 and 6

1 and 5

525 KPA
(76 psi)
475 KPA
(69 psi)
480 KPA
(70 psi)

2 and 5

DUAL
RELIEF

xxx

xxx

1 and 4

2 and 4

1 and 3

2 and 3

xxx

425 KPA
(62 psi)
450 KPA
(65 psi)
425 KPA
(62 psi)
xxx

xxx

ACTUAL

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

MAXIMUM CLUTCH PRESSURE

Load Piston Plug Installed
SPECS
STATION

CLUTCH

DUAL
RELIEF

xxx

ACTUAL

LockUp @
1300 RPM
2020 kPa
xxx
xxx
(293 psi)
2760 kPa
2890 kPa
2020 kPa
(400 psi)
(419 psi)
(293 psi)
2470 kPa
2470 kPa
2020 kPa
(358 psi)
(358 psi)
(293 psi)
Adjust station "D" to get correct clutch
pressures during lockup
2020 kPa
xxx
xxx
(293 psi)
2705 kPa
2705 kPa
2020 kPa
(392 psi)
(392 psi)
(293 psi)
2760 kPa
2805 kPa
2020 kPa
(400 psi)
(407 psi)
(293 psi)
xxx
xxx
xxx
LI

HI

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

LI

HI

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

LockUp @
1300 RPM

xxx

793C 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

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

ACTUAL

LI

HI

2515 kPa (365 psi)

(minimum)

3065 kPa (445 psi)

(maximum)

5 to 65 kPa
(.5 to 10 psi)

160 50 kPa
23 7 psi)

2410 to 2755 kPa

xxx

> 82C (180F)

< 121C (250F)

Transmission Oil Temperature (during tests)

LOCKUP SOLENOID ENERGIZED

(plug signal line to lockup clutch valve)
SPECS

ACTUAL

LI

1300 RPM

LI

PUMP PRESSURE
(Adjust with Priority
Reducing Valve)

xxx

2310 70 kPa
(335 10 psi)

xxx

STATION "D"

xxx

Adjust station "D" to

get correct rail
(clutch) pressures

xxx

xxx

1620 70 kPa
(235 10 psi)

xxx

PRESSURE
NEUTRAL CLUTCH
PRESSURE
STATION "C"

HI

xxx

(350 to 400 psi)

DIRECT DRIVE
PRESSURES

LI

1300 RPM

793C TRANSMISSION CLUTCH TESTS

CLUTCH CHART

PRIMARY CLUTCH PRESSURE @ L.I.

Load Piston Plug Removed

SPEED

CLUTCHES
ENGAGED

STATION

CLUTCH

SPECS

1 and 6

1 and 5

525 KPA
(76 psi)
475 KPA
(69 psi)
480 KPA
(70 psi)

2 and 5

DUAL
RELIEF

xxx

xxx

1 and 4

2 and 4

1 and 3

2 and 3

xxx

425 KPA
(62 psi)
450 KPA
(65 psi)
425 KPA
(62 psi)
xxx

xxx

ACTUAL

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

MAXIMUM CLUTCH PRESSURE

Load Piston Plug Installed
SPECS
STATION CLUTCH

DUAL
RELIEF

xxx

ACTUAL

LockUp @
1300 RPM
1620 kPa
xxx
xxx
(235 psi)
2400 kPa
2425 kPa
1620 kPa
(348 psi)
(352 psi)
(235 psi)
2470 kPa
2470 kPa
1620 kPa
(358 psi)
(358 psi)
(235 psi)
Adjust station "D" to get correct clutch
pressures during lockup
1620 kPa
xxx
xxx
(235 psi)
2585 kPa
2720 kPa
1620 kPa
(375 psi)
(395 psi)
(235 psi)
2585 kPa
2805 kPa
1620 kPa
(375 psi)
(407 psi)
(235 psi)
xxx
xxx
xxx
LI

HI

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)

LI

HI

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

LockUp @
1300 RPM

xxx

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:
Component Damage ____________________

Electrical Connections
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

TRANSMISSION/CHASSIS ECM
LOGGED DIAGNOSTIC CODES
Diagnostic Code
and
Description

Number of
Occurrences

First Occurrence

Last Occurrence

First Occurrence

Last Occurrence

LOGGED EVENTS
Event Code
and
Description

Number of
Occurrences

785C OFF-HIGHWAY TRUCK

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

> 60C (150F)

< 121C (250F)

Steering Oil Temperature (during tests)

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.

Left to Right

Steering wheel turns from stop to stop @ High Idle

Right to Left

All Brakes Released

1. ____________________

1. ____________________

(steer at one revolution per second)

2. ____________________

2. ____________________

3. ____________________

3. ____________________

AVG.

AVG.

3.0 to 4.0 turns

Pump Compensator Valve Pressure

17580 345 kPa

(2550 50 psi)

Backup Relief Valve Pressure @ Low Idle

20670 400 kPa

(3000 60 psi)

Crossover Relief Valve Pressure (Right Turn)

18270 345 kPa

(2650 50 psi)

Crossover Relief Valve Pressure (Left Turn)

18270 345 kPa

(2650 50 psi)

RH Accumulator Nitrogen Charge Pressure

@ 21C (70F)

8270 0 kPa
(1200 0 psi)

LH Accumulator Nitrogen Charge Pressure

@ 21C (70F)

8270 0 kPa
(1200 0 psi)

785C OFF-HIGHWAY TRUCK

STEERING TEST
Pump Compensator Valve Pressure Test:
Put a 34450 kPa (5000 psi) gauge on the pressure tap at the bottom of the left steering accumulator
In order to use the 785C pump controller as a pressure compensator, the low-pressure standby
adjustment screw (screw furthest from pump body) must be turned all the way in. This will block the
margin spool from moving and allow the high-pressure cutoff spool to control the pump outlet pressure.
Pump low-pressure standby is not used on the 785C Trucks.
Start the engine and leave it at Low Idle. As the accumulators fill, the pressure of the oil through the
pump outlet increases. The pump supply pressure will increase until the pressure of the oil in the pump
compensator valve is high enough to overcome the spring force on the compensator (high pressure
cutoff) spool. The spool then moves and opens the passage to the minimum angle actuator piston. This
movement occurs when the outlet oil pressure is approximately 17580 345 kPa (2550 50 psi). The
pressure setting can be adjusted with the high-pressure cutoff adjustment screw (screw closest to pump
body).
Backup Relief Valve Pressure Test:
The back-up relief valve must be adjusted only on a test bench. The pressure setting of the back-up
relief valve can be changed by adjusting the spring force that keeps the relief valve seated (closed). To
change the relief valve setting, remove the protective cap and turn the adjustment screw clockwise to
increase or counterclockwise to decrease the pressure setting. One revolution of the setscrew will
change the pressure setting 3800 kPa (550 psi).
A functional test of the back-up relief valve can be performed on the machine by installing a manual
hydraulic pump at the location of the Auxiliary Power Unit (APU) connector and installing blocker
plates to prevent oil from flowing to the accumulators. See the service manual for more detailed
information.
Crossover Relief Valve Pressure Test:
Put two 34450 kPa (5000 psi) gauges on the pressure taps on the crossover relief valve housing on the
left frame rail in the engine compartment.
The crossover relief valve housing contains two pressure taps where steering system pressure can be
measured. One tap shows pressure during a left turn and the other tap shows pressure during a right
turn.
To check the steering system pressure, turn the steering wheel completely in either direction. Operate
the engine at LOW IDLE. Continue to turn the steering wheel after the wheels have stopped and the
pressure will increase to the pump compensator valve setting. Check the steering pressure while turning
in both directions. The pump compensator valve setting should be observed on the gauge in both
directions. If the pressure readings are different, one of the crossover relief valve settings is probably
incorrect. A misadjusted valve must be removed and readjusted on a test bench.
2

789C/793C OFF-HIGHWAY TRUCK

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

> 60C (150F)

< 121C (250F)

Steering Oil Temperature (during tests)

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.

Left to Right

Steering wheel turns from stop to stop @ High Idle

All Brakes Released
(steer at one revolution per second)
789C: 3.0 to 4.0 turns
793C: 4.0 to 5.0 turns

Right to Left

1. ____________________

1. ____________________

2. ____________________

2. ____________________

3. ____________________

3. ____________________

AVG.

AVG.

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)
Cycle time from Cut-out to Cut-in

greater than
15 seconds

1. ____________________
2. ____________________
3. ____________________
AVG.

789C/793C STEERING TEST

TEST

SPECS

Pump Low Pressure Standby Pressure @ Low Idle

2067 to 3617 kPa

(300 to 525 psi)

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
789C: 22740 345 kPa (3300 50 psi)
793C: 26000 400 kPa (3775 60 psi)
Relief/Makeup Valve Pressure (Right Turn)
789C: 28000 1000 kPa (4065 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)
Relief/Makeup Valve Pressure (Left Turn)
789C: 28000 1000 kPa (4065 150 psi)
793C: 27000 to 29000 kPa (3920 to 4210 psi)
1. Accumulator Nitrogen Charge Pressure
@ 21C (70F)
789C: 5512 345 kPa (800 50 psi)
793C: 6545 345 kPa (950 50 psi)
2. Accumulator Nitrogen Charge Pressure
@ 21C (70F)
789C: 5512 345 kPa (800 50 psi)
793C: 6545 345 kPa (950 50 psi)

ACTUAL

785C/789C/793C HOIST TEST

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
change this parameter. When the engine is running there is sometimes some jitter on the TOS signal, which could keep the
parameter from changing.
The hoist valve LOWER position is an adjustable parameter in the Transmission/Chassis ECM using ET. The slight
adjustment provides a means to compensate for valve differences. The adjustment range is from -5 to +5 with zero as the
default. A negative number will decrease the lower speed and a positive number will increase the lower speed. With the
engine at HIGH IDLE and the hoist output in SNUB, pump output pressure must be less than
1725 kPa (250 psi). The hoist output must be in HOLD when changing the setting.

785C/789C/793C HOIST TEST

TEST

SPECS

Hoist Oil Temperature

(during tests)

ACTUAL

> 65C (150F)

< 121C (250F)

RAISE TIME @ High Idle

785C: 14.0 to 16.0 seconds
789C: 17.0 to 19.0 seconds
793C: 19.0 to 21.0 seconds

1. ____________________
2. ____________________
3. ____________________
AVG.

LOWER TIME @ High Idle (including snub)

1. ____________________

785C: 15 to 17 seconds
789C: 14.0 to 16.0 seconds
793C: 17.0 to 19.0 seconds

2. ____________________
3. ____________________
AVG.

FLOAT TIME @ High Idle (including snub)

1. ____________________

785C: 15 to 17 seconds
789C: 14.0 to 16.0 seconds
793C: 17.0 to 19.0 seconds

2. ____________________
3. ____________________
AVG.

PILOT PRESSURE
(Parking Brake Retraction)

4700 200 kPa

(680 30 psi)

RAISE PRESSURE @ High Idle

HI F Tap:

785C: 17225 345 kPa (2500 50 psi)

789C: 17225 345 kPa (2500 50 psi)
789C: 18950 345 kPa (2750 50 psi) (cast pump)
793C: 20370 345 kPa (2955 50 psi)
LOWER PRESSURE @ High Idle
(Body Switch in RAISE Position)

LI -

R Tap:

3450 + 350 0 kPa F Tap:

(500 + 50 0 psi) R Tap:

ET Setting

-5

+5

HOIST PRESSURE IN SNUB

LI -

LI -

LI -

Maximum 1725 kPa (250 psi)

HI -

HI -

HI -

Hoist LOWER Solenoid Current %

Final Programmed Value
2

785C/789C/793C HOIST TEST

Create a Test Group on ET:
1) On the ET screen, select the Transmission ECM
2) In the Status Group, create a new group name "Hoist Test"
3) Select the items as shown on the ET screen below:

HOIST LEVER SENSOR

TEST

SPECS

Supply Voltage

+ Battery (24 Volts)

Pull-Up Voltage

Approx 5 Volts

Signal Duty Cycle %

ACTUAL

Full Raise to Full Lower

5 to 95 %

BODY POSITION SENSOR ANGLE

TEST
Body Full RAISE

Hoist LOWER Solenoid

Current %
N/A

FLOAT to SNUB

BODY POSITION
ANGLE

785C/789C/793C HOIST TEST

HOIST
LEVER
POSITION

DUTY CYCLE ACTUAL SOLENOID

HOIST VALVE
(approximate)
DUTY
CURRENT % SOLENOID CURRENT
CYCLE
FROM ET
(mA)

HOIST VALVE
SOLENOID
CURRENT (mA)

(ET Solenoid % x 1900)

RAISE

1 - 18%

HOLD

24 to 48%

FLOAT

55 to 71%

___________ mA

LOWER

80 to 96%

___________ mA

SNUB

N/A

(ACTUAL)

___________ mA
N/A

N/A

N/A

N/A

___________ mA

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

DRIFT TEST: OIL TEMP

MINUTES
ACCEPTABLE CYLINDER DRIFT

MINUTES

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)

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

Air Compressor Governor Setting

(CUT-OUT)

830 35 kPa
(120 5 psi)

Air Compressor Governor Setting

(CUT-IN)

655 35 kPa
(95 5 psi)

ACTUAL

#1 Pressure Protection Valve

(Behind Cab)

Open-550 kPa (80 psi)

Open--

(Drain Secondary Brake Tank to See

Close Setting)

Close-480 kPa (70 psi)

Close--

#2 Pressure Protection Valve

Open-380 kPa (55 psi)

Open--

Close-310 kPa (45 psi)

Close--

(ARC Relay Valve)

Retarder Valve--Maximum Air Pressure

Parking Brake Retraction Valve

Towing Pump Pressure

55035 kPa
(80 5 psi)
4700200 kPa
(680 30 psi)
4481 kPa
(650 psi)

Towing pump pressure after:

1 minute

4 minutes -

2 minutes

5 minutes -

3 minutes 1

LIHI-

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

Brake Cooling Oil Pressure At Wheels (Body Down in SNUB)
AT WHEEL INLET: Low Idle Minimum 14 kPa (2 psi) High Idle Maximum - 172 kPa (25 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 Wheel

LI HI -

LI HI -

Right Front Wheel

LI HI -

LI HI -

Left Rear Wheel

LI HI -

LI HI -

Right Rear Wheel

LI HI -

LI HI -

793C Brake Cooling Oil Pressure (Body Down in SNUB)

Brake Cooling Oil Temperature
(during brake cooling pressure test)
TEST

79 to 93 C
(175 to 200 F)
RETARDER ENGAGED

RETARDER RELEASED

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 Cooler

LI HI -

LI HI -

NOTE: 793C Hoist Pump (front oil cooling) and Rear Oil Cooler Relief Valve settings are
790 kPa (115 psi)

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

BRAKE CYLINDER OPERATION
(Apply Service Brake Pedal)
TEST
Brake Cylinder Air/Oil Ratio
Front Brake Cylinders:

AIR PRESSURE

OIL PRESSURE

@ Brake Cylinder

@ Slack Adjuster

6.6 to 1

XXXX

XXXX

XXXX

XXXX

Brake Cylinder #1
Brake Cylinder #2
Rear Brake Cylinders:
Brake Cylinder #3
Brake Cylinder #4

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

SLACK ADJUSTER OPERATION
SLACK ADJUSTER TAP
Engaged

WHEEL PORT TAP

Released

Engaged

Released
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.
4

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: 785C/789C Minimum 1200 rpm

793C Minimum 1300 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

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

Functional Test

Maximum Air Pressure

(Brake Cylinder)

Front Brake Cylinder Air/Oil Ratio

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

Maximum Brake Oil

Pressure (Slack Adjuster)

AUTO RETARDER CONTROL (ARC) TEST

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 and
Description

Number of
Occurrences

First Occurrence

Last Occurrence

AUTO RETARDER CONTROL (ARC) TEST

ARCNORMALOPERATION
FUNCTION

ENGINESPEED

ActivationSpeed
(supplysolenoidON)

1850rpm
1850to1950rpm

ARCControlRange
FactorySetting

1950rpm

ARCOVERSPEEDPROTECTION
HornandLightActivate*

2100rpm

ActivationSpeed
(supplysolenoidON)

2100rpm

ARCControlSpeed

2125rpm

ARCShutoff

2075rpm

AutoUpshift**

2300rpm

*TheHornandLightarecontrolledbytheEngineECM
**TheAutoUpshiftiscontrolledbytheTransmissionECM

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

4)
5)
6)
7)

Run the engine at LOW IDLE

Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON
Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED
Depress the TCS Test Switch and observe the TCS Proportional Solenoid signal sweep
between 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

TRACTION CONTROL SYSTEM (TCS) TEST

TEST

SPECS

Brake Oil Temperature (during tests)

> 65C (150F)

Parking Brake Release Pressure

4700 200 kPa

(680 30 psi)

ACTUAL

LIHI-

Left Brake Pressure (Released)

< 300 kPa
(44 psi)

Left Brake Pressure (Engaged)

Right Brake Pressure (Released)

< 300 kPa

(44 psi)

Right Brake Pressure (Engaged)

44%

ET Proportional Solenoid Percentage

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 ohms
24 Volts

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

TEST 2: FUNCTIONAL TEST

Run the engine at Low Idle. Engage FIRST GEAR and release the brakes. With the TCS Test
Switch Depressed, do the brakes ENGAGE and RELEASE intermittently?
Wheels Turned to the RIGHT:

YES

NO

Wheels Turned to the LEFT:

YES

NO

TRACTION CONTROL SYSTEM (TCS) TEST

ACTIVE DIAGNOSTIC CODES and DESCRIPTION
Fault Code

Description

Cause

LOGGED DIAGNOSTIC CODES

Diagnostic Code and
Description

Number of
Occurrences

First Occurrence Last Occurrence

FRONT SUSPENSION CYLINDER CHARGING

Machine Model __________________________

Date_____________________________________

Serial Number ___________________________

Machine Hours_____________________________

Oil Charge Dimension: _________________________

769-773:
777-793:

25 mm (1.0 in.)
13 mm (0.5 in.)

Nitrogen Charge Dimension: ____________________

769-773:
777:
785-793:

170 mm (6.7 in.)

216 mm (8.5 in.)
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: _______________________

Chrome Length Measurement

After Gauge Block is Removed: *

769-777:
785-789:
793:

2400 kPa (350 psi)

2200 kPa (320 psi)
2300 kPa (335 psi)

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

Truck Model

Shim Thickness
mm/5.5 C
(in./10 F)

768D/769D/771D773E/775E

3.2 (0.125)

776D/777D

5.1 (0.20)

784C/785C/789C/793C

6.4 (0.25)

REAR SUSPENSION CYLINDER CHARGING

Machine Model __________________________

Date_____________________________________

Serial Number ___________________________

Service Meter Hours________________________

Oil Charge Dimension: ___________________

769-773:
777-793:

25 mm (1.0 in.)
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: *
(After Charging is Complete
for future inspection)

Left Rear _____________ Right Rear ____________

Wiped Chrome Dimension After Operation: Left Rear _____________ Right Rear ____________
* dimension between the center line of the top mounting pin and the bottom mounting pin

Truck Model

NITROGEN CHARGE DIMENSIONS

Distance Below Top Of
Suspension Cylinder Housing
First Charge Line
Second Charge Line
mm (in.)
mm (in.)

769D/771D

128 (5.0)

140 (5.5)

773E/775E

124 (4.9)

137 (5.4)

776D/777D

102 (4.0)

114 (4.5)

784C/785C

104 (4.1)

117 (4.6)

789C

108 (4.25)

121 (4.75)

793C

121 (4.75)

133 (5.25)

DataView Users Guide

1. Install DataView Software in Laptop (NEHS0662) or STW NETG5030
2. Connect DataView Box to Laptop printer port with cable provided
3. Connect sensors and cables to Machine and DataView Box. (Max possible is 9, 6 analog and
3 frequency).
4. Power On DataView Box
5. Start DataView Application on Laptop (Setup screen will pop up with channels displayed)
6. Select each channel and Double Click the channel to define it (put in a long name and short name).
When done select OK.
7. Select each Pressure Channel and click on the 0.0 Icon (second icon from right) to Zero each
sensor
8. For speed sensors, enter the number of teeth or Pulses Per Revolution (PPR)
9. When using PWM/Analog Sensor adapter kit (153-9630) make sure NOT to use small black PWM
sensor adapter box with analog sensors
10. Click on Clock Icon (Setup Logger Tool) (third icon from left)
11. Select all channels
12. Click on 5th Icon from the right (Setup Logger) (looks like a cassette tape)
13. Set Sample Rate (usually leave alone) and Log Time Before and After Trigger (make sure time
After is longer than test will take i.e. 10 min)
14. Set a Trigger pressure or No Trigger Channel for Manual
15. Send Configuration
16. Raise Trigger Switch for Manual Logging. Lower Trigger Switch for Auto Logging.
17. Click on 2nd Icon from left (graph) to view Sensor Status Real Time while logging
18. Raise Trigger Switch again to Stop Logging manually
19. Click on 4th Icon from left (Graph Viewer Tool) and select one of the data sources
20. Move four sensors from Available to Selected and select next to set ranges and select Finish.
Select Add Graph to see a second graph at same time with more sensors. Select OK to see graphs.
Use mouse to select area of graph.
After Data Logging is complete, Select File and Download Data Log from pull-down menu
Open a New File and Name it the Machine Serial Number (789C 2BW00201)
Enter a new document name and description (Brake cooling test with sensors at xx, xx, xxx, etc.)

DATAVIEW TOOLS
NEHS0662
JERD2163
131-5051
153-9630
213-3274
213-3275
213-3276
6V4144
6V2198
137-0168
137-0170
4C4463

Software and Instruction Manual

Software Updates
DataView Portable Tech Station Group
PWM-Analog Test Group Sensor Adapter Kit
100 psi sensor
1000 psi sensor
7500 psi sensor
Internal 1/4 nptf Valved Coupler (for each sensor)
18 ft. sensor extension cable
Machine battery power cable
12V Cigarette Lighter power cable
Yellow case for small parts
1

C-SERIES SENSORS IN DATAVIEW SENSOR TABLE

100-3055 - Temperature:
163-7882 - Temperature:
102-2240 - Temperature:
118-7226 - Temperature:
118-3909 - Temperature:

Brake, Differential, Torque Converter, Transmission (digital)

Engine Exhaust (digital)
Engine Coolant, Rear Aftercooler Coolant (analog)
Front Aftercooler Coolant (VIMS), Steering (digital)
Ambient (digital)

161-9926 - Pressure: Atmospheric, Turbo Inlet, Crankcase (analog)

194-6724 - Pressure: Turbo Out (Boost) (analog) (was 161-9929)
194-6725 - Pressure: Engine Oil (analog) (was 161-9931)
176-1602 - PWM Position:
141-5746 - PWM Pressure:
157-8394 - PWM Pressure:
160-1582 - PWM Pressure:

Throttle (digital)
Air System (digital)
Rear Parking Brakes (digital)
Rear Axle Oil (digital)

Speed Sensor Teeth (PPR)

Number of Teeth

Sensor
Engine Output Speed (EOS)
Sensor

151

Fan Motor Output Speed

Sensor

67

Transmission Output Speed

(TOS) Sensor

120

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
made from either a 153-9626 3-pin HD-10 Adapter cable or a 153-9627 3-pin DT Adapter cable.
Remove the 3-pin plug and receptacle from the T-cable. Cut the red wire. The red wire is not needed
with the 2-pin passive speed sensors. Using a 102-8802 2-pin DT receptacle kit and a 155-2270 2-pin
DT plug kit, install the white wires in pin location 1 and install the black wires in pin location 2.

Shown is a DataView screen while running the hydraulic fan override test.

ANALOG TEMPERATURE SENSOR CHARTS

SENSOR VOLTAGE SPECIFICATION
ENGINE JACKET WATER, REAR AFTERCOOLER and FUEL
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
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%

ANALOG PRESSURE SENSOR CHARTS

SENSOR VOLTAGE SPECIFICATION
ATMOSPHERIC and TURBO INLET PRESSURE
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
Analog Pressure Sensor
ABSOLUTE PRESSURE
0 to 34.5 kPa (0 to 5 psi)

SIGNAL VOLTAGE
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%

SENSOR VOLTAGE SPECIFICATION

ENGINE OIL PRESSURE
Analog Pressure Sensor
ABSOLUTE PRESSURE
0 to 137.8 kPa (0 to 20 psi)

SIGNAL VOLTAGE
0 to .6 DCV

137.8 to 275.6 kPa (20 to 40 psi)

.6 to 1.2 DCV

275.6 to 413.4 kPa (40 to 60 psi)

1.2 to 1.8 DCV

413.4 to 551.2 kPa (60 to 80 psi)

1.8 to 2.4 DCV

551.2 to 689 kPa (80 to 100 psi)

2.4 to 3.0 DCV

689 to 826.8 kPa (100 to 120 psi)

3.0 to 3.6 DCV

826.8 to 964.6 kPa (120 to 140 psi)

3.6 to 4.2 DCV

Tolerance is 3%

DIGITAL TEMPERATURE SENSOR CHARTS

SENSOR DUTY CYCLE SPECIFICATION
BRAKE, DIFFERENTIAL, CONVERTER, TRANSMISSION,
STEERING, FRONT AFTERCOOLER and FAN DRIVE
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
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%

EXHAUST TEMPERATURE SENSOR CHART

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
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%
REAR PARKING BRAKE RELEASE PRESSURE SENSOR CHART
SENSOR DUTY CYCLE SPECIFICATION
Digital Pressure Sensor on TCS Valve
ABSOLUTE PRESSURE
0 to 1378 kPa (0 to 200 psi)

DUTY CYCLE
0 to 22.3 %

1378 to 2756 kPa (200 to 400 psi)

22.3 to 46.1 %

2756 to 4134 kPa (400 to 600 psi)

46.1 to 70.0 %

4134 to 5512 kPa (600 to 800 psi)

70.0 to 93.8 %

Tolerance is 3%

DIFFERENTIAL PRESSURE SENSOR CHART

SENSOR DUTY CYCLE SPECIFICATION
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
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%

AIR PRESSURE SENSOR CHARTS:

Early Configurations
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
9X5272, 100-4311 Pressure Sensor (AIR)
Air Pressure

DUTY CYCLE

0 to 200 kPa (0 to 29 psi)

8 to 13 %

200 to 400 kPa (29 to 58 psi)

13 to 19 %

400 to 600 kPa (58 to 88 psi)

19 to 25 %

600 to 800 kPa (88 to 115 psi)

25 to 30 %

800 to 1000 kPa (115 to 145 psi)

30 to 36 %

Later Configurations
SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION
141-5746, 185-0600 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%