793D Lab Book

1. Vital Information Management System (VIMS) p.2

2. Engine Tests p.10
3. Engine Power Test p.19
4. Hydraulic Fan Test p.22
5. Torque Converter Test p.26
6. Transmission Test p.29
7. Transmission/Chassis ECM p.32
8. Rear Axle Test p.35
9. Steering Test p.40
10. Hoist Test p.43
11. Air System and Brake Test p.49
12. 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.65
16. Sensor Specifications p.68

1
VITAL INFORMATION MANAGEMENT SYSTEM
(VIMS)

2
 VITAL INFORMATION MANAGEMENT SYSTEM
(VIMS)
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)

3
 VIMS

PAYLOAD

PROGRAM CODE DESIRED ACTUAL

PAYCAL (729225) YES/NO

0 – OFF
RAC (722) - Set Haul Road Severity 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

4
 VIMS

EACK (3225) ACTIVE EVENTS

HOUR LENGTH OF CATEGORY

EVENT METER TIME LEVEL LIMIT WORST
START

ELIST (35478) INTERMITTENT EVENTS

HOUR LENGTH OF CATEGORY

EVENT METER TIME LEVEL LIMIT WORST
START

5
 VIMS
Use a Multimeter and check the Supply Voltage, Signal Output, and Pull-Up Voltages. Use the test group
below to record the actual values of the sensor outputs. All measurements are taken with Key On and
Engine OFF.

Sensor Tests
Supply Actual Temperature/ Actual Signal Pull-up
Voltage Pressure/ Fuel Level Volts/Hz/Duty Cycle/ Voltage
Sensor Resistance
(A-B) (ET or VIMS) (B-C) (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 N/A

> 95 Hz
Fuel Level Sensor

6
 VIMS ATTACHMENT CODES

793D ATTACHMENT CODES

Attachment Code RAC Enabled TKPH or TMPH
Enabled
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)

7
 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 Data
ESET 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 Statistics
ELIST 35478 Show Event List (Intermittent)

EREC 3732 Start Event Recorder

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

DLOG 3564 Start/Stop Data Logger

DLRES 35737 Reset Data Logger

LA 52 Change Language
UN 86 Change Units

ODO 636 Odometer Set/Reset (requires VIMS PC connection)

BLT 258 Change Backlight

CON 266 Change Display Contrast

ATTACH 288224 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 will
remove the event from the display temporarily. Severe events cannot be acknowledged.

GAUGE key--Displays parameters monitored by VIMS. Depressing the arrow keys will scroll through
the parameters. Entering the parameter number and the GAUGE key selects that parameter.

F1 Key--Provides additional information on the current event being displayed. For MAINTENANCE
(SYSTEM) events, the MID, CID, FMI is displayed. For DATA (MACHINE) events, the current
parameter value is displayed (temperature, pressure, rpm).
8
 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 PRES
350 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 TEMP
463 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.

9
Engine Tests

10
 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.

11
 ENGINE TESTS

Create a Test Group on ET:

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

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

12
 ENGINE TESTS

Sensor Tests
Supply Desired Actual Signal Actual Pull-up
Sensor Voltage Signal Volts Voltage/% Temperature/ Voltage
or Pressure
(A-B) Duty Cycle (B-C) (ET or VIMS) (B-C)
Filtered Engine Oil
Pressure .2 to .6 0

Unfiltered Engine Oil

Pressure .2 to .6 0

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 0

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 49°C (120°F) - 10% to 21%
49 to 851°C (120 to 1564°F) - 22% to 88%
above 851°C (1564°F) - 88% to 90%

13
 ENGINE TESTS

TEST SPECS ACTUAL

ECM Supply Voltage 24

Throttle Sensor Supply Voltage (A-B) 8.0 ± 0.5

Throttle Sensor Low Idle Duty Cycle (B-C) 16 ± 6%

85 ± 4%
Throttle Sensor High Idle Duty Cycle (B-C)

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

less than 3.0
Speed Sensor Signal Voltage (Key ON) (B-C) or
greater than 10.0
Speed Sensor Signal Voltage (Cranking) (B-C) 2.0 to 4.0

14
 ENGINE TESTS
ACTIVE DIAGNOSTIC CODES

DIAGNOSTIC CODE DESCRIPTION

LOGGED DIAGNOSTIC CODES

NUMBER FIRST LAST
DIAGNOSTIC CODE DESCRIPTION OF HOUR HOUR
OCCURR METER METER

EVENT CODES
NUMBER FIRST LAST
EVENT CODE DESCRIPTION OF HOUR HOUR
OCCURR METER METER

15
 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: Override % Volts Current (miliamps)

0%

25%

50%

75%

100%

NOTES:

16
 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

17
 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

NOTES:

TIMING CALIBRATION: OK NOT OK

NOTES:

18
Engine Power Test

19
 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

20
 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 ACTUAL
SPECS

Coolant Temperature (during tests) > 71°C (160°F) 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) 188 ± 28 kPa

@ Full Load RPM (1750 ± 10) – DIRECT DRIVE (27.2 ± 4.1 psi)

Inlet Manifold Pressure (BOOST) 171 ± 26 kPa *

@ Full Load RPM (1750 ± 10) – CONV DRIVE (24.8 ± 3.7 psi)

Torque Converter Stall RPM 1672 ± 65

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

< 121°C (250°F)

Engine Oil Pressure @ LI 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 OK
[maximum restriction 140 kPa (20 psi)]

* Use Torque Stall for Class

21
Hydraulic Fan Test

22
 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 the
VIMS ECM:

NOTE: The Air Conditioner must be OFF during all tests except the A/C Test.
Use the VIMS Data Logger to capture additional information during the fan tests.

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

23
 HYDRAULIC FAN TEST

TEST TEMPERATURES
Jacket Water After Cooler Brake Oil Steering Drive
Coolant Coolant 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 the
hydraulic fan speed to 817 rpm, raise the engine speed to HIGH IDLE and record the pump
pressure and fan speeds. Pump cut-off pressure should be set a minimum of 2070 kPa (300 psi)
above the pressure required to maintain maximum fan speed (817 rpm) with the solenoid
unplugged. This will vary with the elevation above sea level.
1) Install a blocker plate in the line from the makeup valve to the fan motor.
2) Disconnect the pump control solenoid.
3) Operate the truck at LOW IDLE. The pump should be at the cut-off pressure.
4) At sea level, adjust the cut-off pressure to 27000 ± 345 kPa (3920 ± 50 psi). At higher altitudes a
lower cut-off pressure may be desired.

HYDRAULIC FAN HIGH PRESSURE CUT-OFF

Engine Speed
@ PUMP PRESSURE
HIGH IDLE

TEST TEMPERATURES
Jacket Water After Cooler Brake Oil Fan Drive Oil
Coolant Coolant

24
NOTICE: Ensure that the pump and motor cases are filled with oil and bleed the air out of the
pump and motors before starting the engine.

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
Fan Speed
Pump Pressure
Engine Speed (Minimum 510 rpm)
@
High IDLE

25
Torque Converter Test

26
 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:

7) Using ET, choose the Transmission ECM
8) In the Status Group, create a new group name "Torque Converter Test"
9) Select the items as shown on the ET screen below:

27
 TORQUE CONVERTER TEST

TEST SPECS ACTUAL

> 80°C (175°F)

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

LI -
Maximum at High Idle
Torque Converter Inlet Pressure with Cold Oil HI –
930 ± 35 kPa STALL-
(135 ± 5 psi)

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

Torque Converter Stall RPM

1721 ± 65

LI: LI -
Transmission Charge Pressure (Converter Drive) > 2515 kPa (365 psi)

HI: HI –
< 3065 kPa (445 psi)
2310 ± 70 kPa
Transmission Charge Pressure (Direct Drive) (335 ± 10 psi)
@ 1300 rpm

Lockup Clutch Pilot Pressure (RV) 1725 ± 70 kPa

NEUTRAL/DIRECT DRIVE/LOW IDLE (250 ± 10 psi)

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

Lockup Clutch Primary Pressure 1070 ± 35 kPa

NEUTRAL/DIRECT DRIVE/LOW IDLE (155 ± 5 psi)

Lockup Clutch Maximum Pressure 2150 to 2205 kPa

NEUTRAL/DIRECT DRIVE/1300 rpm (310 to 320 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.

28
Transmission Test

29
 Transmission Test
Machine Model ____________________________ Date _______________________________

Machine Serial No.__________________________ Machine Hours _______________________

Transmission S/N ___________________________ Transmission Hours ___________________

Transmission/Chassis Flash File/Release Date

CONVERTER DRIVE LOCKUP SOLENOID DE-ENERGIZED

PRESSURES
SPECS ACTUAL
LI HI LI HI
PUMP PRESSURE 2515 kPa (365 psi) 3065 kPa (445 psi)
(Adjust with Transmission (minimum) (maximum)
Relief Valve)
80 ± 25 kPa 150 ± 41 kPa
LUBE PRESSURE
(12 ± 4 psi) 22 ± 6 psi)

PILOT PRESSURE 2410 to 2755 kPa

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

> 82°C (180°F)

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

DIRECT DRIVE LOCKUP SOLENOID ENERGIZED

PRESSURES (plug signal line to lockup clutch valve)
SPECS ACTUAL
LI 1300 RPM LI 1300 RPM
PUMP PRESSURE xxx 2585 ± 70 kPa xxx
(Adjust with Priority (375 ± 10 psi)
Reducing Valve)

xxx Adjust station "D" to xxx

STATION "D" get correct rail
(clutch) pressures
PRESSURE
NEUTRAL CLUTCH xxx 1724 ± 70 kPa xxx
PRESSURE
(250 ± 10 psi)
STATION "C"
30
 TRANSMISSION CLUTCH TESTS

CLUTCH CHART PRIMARY CLUTCH PRESSURE @ L.I.

Load Piston Plug Removed
CLUTCHES
SPEED STATION CLUTCH SPECS ACTUAL
ENGAGED
525 KPA
N 3 A 2 (76 psi)
475 KPA
R 1 and 6 B 1 (69 psi)
480 KPA
1 1 and 5 C 3 (70 psi)
DUAL
2 2 and 5 D xxx xxx
RELIEF
425 KPA
3 1 and 4 E 4 (62 psi)
450 KPA
4 2 and 4 F 5 (65 psi)
425 KPA
5 1 and 3 G 6 (62 psi)
6 2 and 3 H xxx xxx xxx
Primary Clutch Pressure Tolerance: +50 -35 kPa (+7 -5 psi)

MAXIMUM CLUTCH PRESSURE

Load Piston Plug Installed
SPECS ACTUAL
LockUp @ LockUp @
STATION CLUTCH LI HI LI HI
1300 RPM 1300 RPM
1689 kPa
A 2 xxx xxx xxx xxx
(245 psi)
2400 kPa 2425 kPa 1689 kPa
B 1 (348 psi) (352 psi) (245 psi)
2470 kPa 2470 kPa 1689 kPa
C 3 (358 psi) (358 psi) (245 psi)
DUAL Adjust station "D" to get correct clutch
D xxx xxx
RELIEF pressures during lockup
1689 kPa
E 4 xxx xxx xxx xxx
(245 psi)
2585 kPa 2720 kPa 1689 kPa
F 5 (375 psi) (395 psi) (245 psi)
2585 kPa 2805 kPa 1689 kPa
G 6 (375 psi) (407 psi) (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)
31
Transmission/Chassis ECM

32
 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

33
 TRANSMISSION/CHASSIS ECM

LOGGED DIAGNOSTIC CODES

Diagnostic Code
and Number of
Description Occurrences First Occurrence Last Occurrence

LOGGED EVENTS
Event Code
and Number of
Description Occurrences First Occurrence Last Occurrence

34
Rear Axle Test

35
 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, click File – Select ECM and choose Brake ECM
2. In the Status Group, create a new group name "793 Rear Axle Test"
3. Select the items as shown on the ET screen below:

36
 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 the
engine 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

37
 REAR AXLE TEST

TEST 1:

Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass ON

TEST SPECS ACTUAL

> -3 °C (25 °F)

Differential Temperature
< 60 °C (140 °F)

Engine RPM 700 ± 10

< 22752 +/- 50 kPa

Rear Axle Pump Drive Pressure
(3300 +/- 70 psi)

Pressure at inlet to Differential 690 +/- 75 kPa

Filter (100 +/- 10 psi)

Pressure at pressure tap on 0 kPa

manifold
(Less than 10 psi)

TEST 2:

Engine at High Idle, Pump Drive Diverter OFF, Final Drive Bypass ON

TEST SPECS ACTUAL

> -3 °C (25 °F)

Differential Temperature
< 60 °C (140 °F)

Engine RPM 1950 ± 20

< 22752 +/- 50 kPa

Rear Axle Pump Drive Pressure
(3300 +/- 70 psi)

Pressure at inlet to Differential 690 +/- 75 kPa

Filter (100 +/- 10 psi)

Pressure at pressure tap on 0 kPa

manifold
(Less than 10 psi)

38
 REAR AXLE TEST

TEST 3:

Engine at Low Idle, Pump Drive Diverter OFF, Final Drive Bypass OFF

TEST SPECS ACTUAL

> -3 °C (25 °F)

Differential Temperature
< 60 °C (140 °F)

Engine RPM 700 ± 10

< 22752 +/- 50 kPa

Rear Axle Pump Drive Pressure
(3300 +/- 70 psi)

Pressure at inlet to Differential 690 +/- 75 kPa

Filter (100 +/- 10 psi)

Pressure at pressure tap on 570 +/- 75 kPa

manifold (80 +/- 10 psi)

TEST 4:

Engine at Low Idle, Pump Drive Diverter ON, Final Drive Bypass ON

TEST SPECS ACTUAL

> -3 °C (25 °F)

Differential Temperature
< 60 °C (140 °F)

Engine RPM 700 ± 10

Residual Pressure
Rear Axle Pump Drive Pressure
Only

Pressure at inlet to Differential 0 kPa

Filter (0 psi)

Pressure at pressure tap on 0 kPa

manifold (0 psi)

39
Steering Test

40
 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

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

1. ____________________
Cycle Time @ High Idle 7.0 to 9.0
2. ____________________
From Left to Right and Right to Left Combined seconds
All Brakes Released 3. ____________________

AVG.
Left to Right Right to Left
Steering wheel turns from stop to stop @ High Idle
All Brakes Released 1. ____________________ 1. ____________________
(turn at one revolution per second)
2. ____________________ 2. ____________________
793D: 4.0 to 5.0 turns
3. ____________________ 3. ____________________

AVG. AVG.

Pressure setting for the (priority valve) solenoid

18300 ± 520 kPa
valve and manifold (rear axle fan, brake cooling,
(2650 ± 75 psi)
drive motor, lubrication, and steering)

41
 STEERING TEST

TEST SPECS ACTUAL

23100 ± 350 kPa
Pump High Pressure Cut-off @ Low Idle (3350 ± 50 psi)
26000 ± 400 kPa
Backup Relief Valve Pressure @ Low Idle Bench Test Only
(3770 ± 60 psi)
28500 ± 1000 kPa
Relief/Makeup Valve Pressure (Right Turn) Bench Test Only
(4150 ± 150 psi)
28500 ± 1000 kPa
Relief/Makeup Valve Pressure (Left Turn) Bench Test Only
(4150 ± 150 psi)
6550 ± 350 kPa
1. Accumulator Nitrogen Charge Pressure
@ 21°C (70°F) (950 ± 50 psi)
6550 ± 350 kPa
2. Accumulator Nitrogen Charge Pressure
@ 21°C (70°F) (950 ± 50 psi)

42
Hoist Test

43
 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.

44
 HOIST TEST
TEST SPECS ACTUAL
Hoist Oil Temperature > 65°C (150°F)
(during tests) < 121°C (250°F)

RAISE TIME @ High Idle 1. ____________________

2. ____________________
19.0 to 21.0 sec.
3. ____________________

AVG.

LOWER TIME @ High Idle (including snub) 1. ____________________

2. ____________________
17.0 to 19.0 sec.
3. ____________________

AVG.

FLOAT TIME @ High Idle (including snub) 1. ____________________

2. ____________________
17.0 to 19.0 sec.
3. ____________________

AVG.

PILOT PRESSURE 4700 ± 200 kPa LI -

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

RAISE PRESSURE @ High Idle

20370 ± 345 kPa F Tap:
(2955 ± 50 psi)
R Tap:
LOWER PRESSURE @ High Idle 3450 + 350 – 0 kPa F Tap:
(Body Switch in RAISE Position) (500 + 50 – 0 psi) R Tap:

HOLD Maximum Pressure 790 ± 20 kPa F Tap:

115 ± 3 psi R Tap
FLOAT Maximum Pressure 790 ± 20 kPa F Tap:
115 ± 3 psi R Tap
HOLD Maximum Pressure 790 ± 20 kPa F Tap:
115 ± 3 psi R Tap

45
 ET Setting -5 0 +5
HOIST PRESSURE IN SNUB LI - LI - LI -
Maximum 1725 kPa (250 psi) HI - HI - HI -

Hoist LOWER Solenoid Current %

Final Programmed Value

46
 HOIST TEST
Create a Test Group on ET:
1) On the ET screen, select the Transmission ECM
2) In the Status Group, create a new group name "Hoist Test"
3) Select the items as shown on the ET screen below:

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 Solenoid BODY POSITION
Current % ANGLE
Body Full RAISE N/A

FLOAT to SNUB
47
 HOIST TEST

HOIST DUTY CYCLE ACTUAL SOLENOID HOIST VALVE HOIST VALVE

LEVER (approximate) DUTY CURRENT % SOLENOID CURRENT SOLENOID
POSITION CYCLE FROM ET (mA) CURRENT (mA)
(ET Solenoid % x 1900) (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 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)

48
Air System and Brakes Test

49
 AIR SYSTEM AND BRAKE TEST

Machine Model ______________________ Date ______________________________

Machine Serial No.____________________ Machine Hours _____________________

VISUAL CHECKS:

Hose Connections Component Damage ________________

Air Leaks Oil Leaks _________________________

TEST SPECS ACTUAL

Air Compressor Governor Setting 830 ± 35 kPa
(CUT-OUT) (120 ± 5 psi)

Air Compressor Governor Setting 655 kPa

(CUT-IN) (95 psi)
Open--
Pressure Protection Valve Open--
550 kPa (80 psi)
(Behind Cab)
(Drain Secondary Brake Tank to See Close-- Close--
Close Setting) 480 kPa (70 psi)
550 kPa
Retarder Valve--Maximum Air Pressure
(80 psi)

Parking and Secondary Brake Control 4700±200 kPa LI-

(680 ± 30 psi) HI-
Valve—Maximum Pressure

4480 ± 200 kPa LI-

Parking and Secondary Brake Control
(650 ± 30 psi) HI-
Valve—Minimum Pressure
4481 kPa
Towing Pump Pressure
(650 psi)

Towing pump pressure after:

1 minute – 4 minutes -

2 minutes – 5 minutes -

3 minutes -

50
 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 – 450 ± 35 kPa (65 ± 5
psi)

Brake Cooling Oil Temperature 79 to 93 °C

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

TEST Brake Inlet Tap Brake Outlet Tap

Left Front Wheel LI - LI -

HI - HI -

Right Front Wheel LI - LI -

HI - HI -

Left Rear Wheel LI - LI -

HI - HI -

Right Rear Wheel LI - LI -

HI - HI -

Brake Cooling Oil Pressure (Body Down in SNUB)

Brake Cooling Oil Temperature 79 to 93 °C

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

TEST RETARDER ENGAGED RETARDER RELEASED

Hoist Pump Front (front brake oil cooling) LI - LI -

HI - HI -

Hoist Pump Rear (front brake oil cooling) LI - LI -

HI - HI -

Rear Brake Oil Cooler LI - LI -

HI - HI -

NOTE: 793D Hoist and Rear Oil Cooler Relief Valve settings are
790 kPa (115 psi) or less

51
 AIR SYSTEM AND BRAKE TEST

BRAKE CYLINDER OPERATION

(Apply Service Brake Pedal)
AIR PRESSURE OIL PRESSURE
TEST @ Brake Cylinder @ Slack Adjuster

Brake Cylinder Air/Oil Ratio 6.6 to 1

Front Brake Cylinders: XXXX XXXX

Brake Cylinder #1

Brake Cylinder #2

Rear Brake Cylinders: XXXX XXXX

Brake Cylinder #3

Brake Cylinder #4

NOTE: On machines equipped with the Extended Life Power Train, the brake cylinder air to oil
ratio is 5.1:1 (Only on the Front Master Cylinders.

52
AIR SYSTEM AND BRAKE TEST

SLACK ADJUSTER OPERATION

SLACK ADJUSTER TAP WHEEL PORT TAP

Released
Engaged Released Engaged
Residual Pressure

Left Front
Wheel
Front
Right Front
Wheel

Left Rear
Wheel
Rear
Right Rear
Wheel

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

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.

53
 AIR SYSTEM AND BRAKE TEST

BRAKE OIL MAKEUP TANK REFILL OPERATION

Flow into the makeup tank is acceptable: YES ________ NO _________

BRAKE HOLDING CAPACITY

Service Brake Engaged rpm Manual Retarder Engaged rpm

Parking Brake Engaged rpm Secondary Brake Engaged rpm

NOTE: Minimum 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

54
Hydraulic Auto Retarder Control (ARC) Test

55
 HYDRAULIC AUTO RETARDER CONTROL (ARC) TEST

Machine Model Date

Machine Serial No. Machine Hours

Brake ECM Flash File/Date

Perform ARC test using ET diagnostics:

1) Connect 0-1000 psi gauges to the Front and Rear Slack Adjusters
2) On the ET screen toolbar, select Diagnostics – Diagnostics Tests – Auto Retarder Test
3) Switch ON the ARC ON/OFF switch
4) Click the Start button and the Auto Retarder Test will be turned ON
5) The ARC Control Solenoid Current will sweep from 0 –100%
6) The ARC Pressure Switch Status will toggle between ‘Low’ and ‘High’
7) Observe the Front & Rear Slack Adjusters pressure increase and decrease accordingly

Maximum Air Pressure Maximum Brake Oil

Functional Test (Brake Cylinder) Pressure (Slack Adjuster)

Front Brake Cylinder Air/Oil Ratio

(6.6 to 1)

Rear Brake Cylinder Air/Oil Ratio

(6.6 to 1)

56
 HYDRAULIC 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 Number of
Description First Occurrence Last Occurrence
Occurrences

NOTE: On machines equipped with the Extended Life Power Train, the brake cylinder air to oil
ratio is 5.1:1 (Only on the Front Master Cylinders).

57
 HYDRAULIC AUTO RETARDER CONTROL (ARC) TEST

ARC NORMAL OPERATION

FUNCTION ENGINE SPEED
Activation Speed
1850 rpm
(supply solenoid ON)
ARC Control Range 1850 to 1950 rpm

Factory Setting 1950 rpm

ARC OVERSPEED PROTECTION

Horn and Light Activate * 2100 rpm

Activation Speed
2100 rpm
(supply solenoid ON)

ARC Control Speed 2125 rpm

ARC Shutoff 2075 rpm

Auto Upshift ** 2300 rpm

* The Horn and Light are controlled by the Engine ECM

** The Auto Upshift is controlled by the Transmission ECM

58
Traction Control System (TCS) Test

59
 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) Run the engine at LOW IDLE

5) Pull down the Manual Retarder fully and observe the ET screen to show Retarder ON
6) Release the parking brake and observe the ET screen to show Parking Brake DISENGAGED
7) Depress the TCS Test Switch and observe the TCS Proportional Solenoid signal sweep between 0-
44%
8) At the same time, the Left & Right Rear Brake Solenoid will toggle between On & Off and the Left &
Right Parking Brake Oil Pressure will increase and decrease accordingly
9) Record the data into the chart

60
 TRACTION CONTROL SYSTEM (TCS) TEST

TEST SPECS ACTUAL

Brake Oil Temperature (during tests) > 65°C (150°F)

4700 ± 200 kPa LI-

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

Left Brake Pressure (Released)

< 300 kPa

Left Brake Pressure (Engaged)
(44 psi)

Right Brake Pressure (Released)

< 300 kPa

Right Brake Pressure (Engaged)
(44 psi)

ET Proportional Solenoid Percentage 44%

Proportional Solenoid 12 to 22 ohms

Resistance/Voltage 0 to 12 Volts
Left Selector Solenoid 18 to 45 ohms
Resistance/Voltage 24 Volts
Right Selector Solenoid 18 to 45 ohms
Resistance/Voltage 24 Volts

NOTE: When the brakes are ENGAGED, gauge pressure will drop quickly to approximately
1380 kPa (200 psi), 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

61
 TRACTION CONTROL SYSTEM (TCS) TEST

ACTIVE DIAGNOSTIC CODES and DESCRIPTION

Fault Code Description Cause

LOGGED DIAGNOSTIC CODES

Diagnostic Code and Number of

First Occurrence Last Occurrence
Description Occurrences

62
Suspension Cylinder Charging

63
 FRONT SUSPENSION CYLINDER CHARGING

Refer to: Special Instruction SEHS9411 “Servicing the Suspension Cylinders for Off-Highway Trucks”

64
Data View

65
 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 Software and Instruction Manual

JERD2163 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 sensor
213-3276 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 cable
4C4463 Yellow case for small parts

66
 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)

SENSOR
Number of Teeth
Engine Output Speed (EOS)
151
Sensor

Fan Motor Output Speed

67
Sensor

Transmission Output Speed

120
(TOS) Sensor

Traction Control System

48
(TCS)
Wheel Speed Sensors

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.

67
Sensor Specifications

68
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 %

69
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 %

70
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 %

71
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 %
72
AIR PRESSURE SENSOR CHARTS:

SENSOR VOLTAGE/DUTY CYCLE SPECIFICATION

141-5746, 185-0600 Pressure Sensor (AIR)
Air Pressure DUTY CYCLE
0 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 %

73