Service Training
777D Off Highway Truck
BED RAISE RIGHT
TEST/SET
LOAD INDICATORS
LEFT
MODE
PAYLOAD
MEASUREMENT
TOS SPEED
DISTRB
CONTROL
ON/OFF PAYLOAD MEASUREMENT SYSTEM
DIAGNOSTIC
WEIGHT
POD TOTAL CYCLES
TOTAL WEIGHT
I/O COMMUNICATION
PORT
STRUT
SENSORS
XII. TRUCK PAYLOAD MEASUREMENT
SYSTEM (TPMS)
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
777D Off Highway Truck
CHAPTER : TPMS
INTRODUCTION
- MEASURES AND RECORDS PAYLOADS
- DATE & TIME LOAD CYCLE OCCURRED
- IDLE TIME
- LOADING TIME
- EMPTY & LOADED TRAVEL TIME
- EMPTY & LOADED TRAVEL DISTANCE
- DOWNLOADING CAPABILITY
Page: XII-1
Page:
TRUCK PAYLOAD MEASUREMENT SYSTEM
XII-2
SIGNAL FLOW
BED RAISE RIGHT
TEST/SET
LOAD INDICATORS
LEFT
CHAPTER : TPMS
MODE
PAYLOAD
777D Off Highway Truck
MEASUREMENT
TOS SPEED
DISTRB
CONTROL
ON/OFF PAYLOAD MEASUREMENT SYSTEM
DIAGNOSTIC
WEIGHT
POD TOTAL CYCLES
TOTAL WEIGHT
I/O COMMUNICATION
PORT
STRUT
SENSORS
777D Off Highway Truck
CHAPTER : TPMS
MODES OF OPERATION
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
MODE switch located behind the POD
MODE 0 NORMAL PAYLOAD DISPLAY
MODE 1 MODEL SETTING DISPLAY
MODE 2 SYSTEM UNITS SETTING DISPLAY
MODE 3 MAXIMUM TARGET WEIGHT
MODE 4 TRUCK FLEET IDENTIFICATION
MODE 5 SYSTEM OPTIONS SETTING DISPLAY (LIGHTS ON/OFF)
MODE 6 SYSTEM CALIBRATION
MODE 7 SYSTEM STATUS DISPLAY ( FAULT CODES)
Page: XII-3
777D Off Highway Truck
CHAPTER : TPMS
NORMAL MODE DISPLAY
MODE 0
PRESSING SET/ CLEAR SWITCH:
DISPLAY TEST SEQUENCE:
- Truck model setting
- System units setting
- Maximum trarget weight
- Truck ID code setting Test / Set
- System options code setting Switch
EXTERNAL LAMP TEST
TPMS CONTROL LED TEST
TOTAL WEIGHT
TOTAL CYCLES
RESTORES TO STATE WHEN TURNED OFF
DISPLAYS WEIGHT WHEN STABILIZED
FLASHING DASHES IF PAYLOAD < 60% RATED
FAULT CODE DISPLAYED IF PRESENT
TRUCK MODEL SETTING
MODE 1
MODE 1 display provides the truck model setting. MODE 1 is used to
select the truck model.
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch
777 D 785 B
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch
789 B 793 B
Page: XII-4
777D Off Highway Truck
CHAPTER : TPMS
SYSTEM UNITS DISPLAY
MODE 2
R
Payload Operator Display
Metric Tonnes
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
Press Test / Set Switch
to change Units while
in MODE 2
R Test / Set
Payload Operator Display Switch
Diagnostic
Weight
Total cycles
Total weight U.S. Tonnes
ON / OFF Test / Set
Switch Switch
DISPLAY MAXIMUM (TARGET WEIGHT) SETTING
MODE 3
777 B 777 B
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch
Maxinum (Target) Weight Setting Range
Truck Model Rated Maximum Minimum Setting Maximum Setting
86 Metric tonne 59 Metric tonne 86 Metric tonne
777 B (< 1991) (95 U.S. ton) (65 U.S. ton) (95 U.S. ton)
91 Metric tonne 452Metric tonne
777D (100 U.S. ton) 0 (500 U.S. ton)
Page: XII-5
777D Off Highway Truck
CHAPTER : TPMS
TRUCK IDENTIFICATION CODE SETTING
MODE 4
TRUCK ID SETTING (199 ID CODES).
IDENTIFIES DIFFERENT TRUCKS WITHIN ONE FLEET.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
DISPLAY SYSTEMS OPTIONS SETTING
MODE 5
ENABLES/DISABLES:
- Payload display on POD
- External load lamps
- Last loader pass (flashing red lights)
- Automatic broadcast of payload and cycle data
- Baud rate
R R
Payload Operator Display Payload Operator Display
Diagnostic Diagnostic
Weight Weight
Total cycles Total cycles
Total weight Total weight
ON / OFFTest / Set ON / OFF Test / Set
Switch Switch Switch Switch
Page: XII-6
777D Off Highway Truck
CHAPTER : TPMS
DISPLAY SYSTEMS OPTION SETTING
MODE 5
Systems Options Settings
External One Pass Auto
Display Loader Lights Indicator Broadcast
Payload Baud Rate
Option Settings Enabled Enabled Enabled
Enabled (?) (?) (?) (?)
o01 Yes Yes No No 9600
o02 No Yes No No 9600
o03 Yes Yes Yes No 9600
o04 No Yes Yes No 9600
o05 Yes No No No 9600
o06 No No No No 9600
o07 Yes Yes No Yes 9600
o08 No Yes No Yes 9600
o09 Yes Yes Yes Yes 9600
o10 No Yes Yes Yes 9600
o11 Yes No No Yes 9600
o12 No No No Yes 9600
o13 Yes Yes No No 1200
o14 No Yes No No 1200
o15 Yes Yes Yes No 1200
o16 No Yes Yes No 1200
o17 Yes No No No 1200
o18 No No No No 1200
o19 Yes Yes No Yes 1200
o20 No Yes No Yes 1200
o21 Yes Yes Yes Yes 1200
o22 No Yes Yes Yes 1200
o23 Yes No No Yes 1200
o24 No No No Yes 1200
Page: XII-7
777D Off Highway Truck
CHAPTER : TPMS
SYSTEM CALIBRATION
MODE 6
This MODE is used to start the system calibration procedure.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
The message CAL starts
flashing on the POD when
MODE 6 is entered.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
Depressing the Test / Set Switch for 1 Second
initiates a calibration sequence. The Payload
Monitor will store the current Suspension Cylinder
Pressures into memory.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
Calibration is complete.
(C A L no longer flashing)
Page: XII-8
777D Off Highway Truck
CHAPTER : TPMS
SYSTEM CALIBRATION
MODE 6
CALIBRATION PROCEDURE
The system must be calibrated after system installation, suspension cylinder
recharging or after truck modifications which affect the empty weight of the truck.
Improper calibration will affect accuracy of the system.
CALIBRATION PROCEDURE:
1) Prepare the truck.
-Truck must be empty. (Remove any large accumulation of dirt and mud. The
cleaner the truck the more accurate that the calibration will be).
- All optional attachements that affect the the empty weight of the truck must be
on.
- All truck fluids should be at full capacity.
- The suspension cylinders must be properly charged.
- No TPMS system faults should be present.
2) Operate the truck at 3 to 4 km / h on a HARD LEVEL surface. Shift the
transmission to NEUTRAL. Leave the truck in NEUTRAL. Turn key switch OFF.
3) Remove the Payload Operator Display from the dash.
4) Turn the key switch and TPMS ON. Wait for the start up sequence to complete.
5) Slowly depress the mode switch 6 times to select MODE 6. The Payload
Operator DIsplay should be flashing "CAL". Depress and hold the Test / Set
switch. The POD will momentarily show dashes, followed again by "CAL".
6) Return the display mode to MODE 0 by depressing the mode switch twice, or
by turning the system power switch OFF and then back ON.
7) Turn the key switch OFF and install the POD in the dash. This completes the
calibration procedure.
Page: XII-9
777D Off Highway Truck
CHAPTER : TPMS
SYSTEM STATUS DISPLAY MODE
MODE 7
The TPMS system has built in component status display.
It is possible to identify CRITICAL, NON-CRITICAL and INTERMITTENT faults.
R
Payload Operator Display CRITICAL FAULTS (F01-F08) will appear
Diagnostic
Weight
and remain ON the Payload Operator
Total cycles
Total weight
Display any time during the loading
cycle.
ON / OFFTest / Set
Switch Switch
R
Payload Operator Display
R
Payload Operator Display
R
Payload Operator Display
Diagnostic Diagnostic Diagnostic
Weight Weight Weight
Total cycles Total cycles Total cycles
Total weight Total weight Total weight
ON / OFF Test / Set ON / OFF Test / Set ON / OFF Test / Set
Switch Switch Switch Switch Switch Switch
A FAULT that appears only at times when the display would normally
be blank indicates a NON CRITICAL FAULT (F09-F18).
If a FAULT appears and then disappears later, an INTERMITTENT
FAULT is indicated.
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
Status Characters and Corresponding Cicuit Code
Numbers They Are Associated With
R
Payload Operator Display
Cicuit Code
Diagnostic
Weight Numbers Status
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
A01 - A18 No Fault is detected in the Circuit
R EO1 - E18 A Fault is intermittent in the Circuit
Payload Operator Display
Diagnostic
Weight
Total cycles
F01 - F18 A Fault is present in the Circuit
Total weight
ON / OFF Test / Set
Switch Switch A19 - A24 No Signal is present in the Circuit
C19 - C24 A Signal is present in the Circuit
R
Payload Operator Display
Diagnostic
Weight
Total cycles
Total weight
ON / OFF Test / Set
Switch Switch
Page: XII-10
777D Off Highway Truck
CHAPTER : TPMS
SYSTEM STATUS DISPLAY MODE
MODE 7
Circuit Code Numbers And The
Circuit They Are Associated With
Cicuit Code
Numbers Circuit Description
Entry and exit point from system status
X 00 display
X 01 Left front suspension cylinder charge
X 02 Right front suspension cylinder charge
X 03 Left rear suspension cylinder charge
CRITICAL
X 04 Right rear suspension cylinder charge
X 05 Left front suspension cylinder charge
pressure sensor circuit
Right front suspension cylinder pressure
X 06 sensor circuit
Left rear suspension cylinder pressure
X 07 sensor circuit
Right rear suspension cylinder pressure
X 08 sensor circuit
X 09 Batt backup / Real clock setting
X 10 System setting/ memory
NON CRITICAL
X 11 Not used
X 12 Not used
Green Lamp open circuitor ground short
X 13 circuit
X 14 Green Lamp + battery short circuit
X 15 Red lamp open circuit or ground short circuit
X 16 Red lamp + battery short circuit
X 17 Not used
X 18 Not used
X 19 Bed raise switch status
X 20 Transmission output speed sensor status
X 21 Transmission neutral status
X 22 Not used
X23 Not used
X 24 Not used
Page: XII-11
777D Off Highway Truck
CHAPTER : TPMS
BASIC WEIGHING OPERATION
TRUCK STOPPED
PARKING BRAKE ON,
XMS NEUTRAL
REPOSITIONING POSSIBLE
FIRST LOAD MAX 0.16 MILE
GREEN EXTERNAL LIGHT ON
GREEN POD LIGHT ON
POD DISPLAYS DASHES
60% LOAD
POD DISPLAYS PAYLOAD
IF LAST PASS ACTIVE
95% PAYLOAD EXTERNAL RED LIGHT
FLASHES WHEN ONE MORE
LOAD MAKES 95% PAYLOAD
RED EXTERNAL LIGHT ON RED EXTERNAL LIGHT ON
RED POD LIGHT ON RED POD LIGHT ON
Page: XII-12
Page: XII-13
TPMS ACCURACY
TPMS ACCURATE TO +/- 5% 0N 95% OF PAYLOADS
IF FOLLOWING CONDITIONS ARE MET:
1) GROUND SLOPE LESS THAN 5%
2) CORRECTLY CHARGED SUSPENSION CYLINDERS
CHAPTER : TPMS
3) NO "PUSHING" WITH BUCKET
777D Off Highway Truck
4) MOVING TRUCK MORE THAN 0.1 MILE (O,16 KM)
5) ACTUATING BED RAISE LEVER WHILE LOADING
6) INCORRECT CALIBRATION
7) LOADING FROM CONVEYOR
8) LEAVING LOAD SITE BEFORE PRESSURES STABILIZED
Page: XII-14
CYCLE DATA
STORED DATA:
-LOADING TIME (MAX 7200 s)
-PAYLOAD WEIGHTS (MAX 800 US TONNES)
-LOADED STOP TIME (MAX 7200s)
-TRAVEL TIME (MAX 7200s)
-TRAVEL DISTANCE ( 50 miles)
CHAPTER : TPMS
MEMORY:
777D Off Highway Truck
-1400 LOAD CYCLES
- FLASHING RED DOT IF > 1200 CYCLES
- OLDEST 20 CYCLES DELETED
DOWNLOADED USING LAPTOP COMPUTER:
- CABLE 9X-3393
- TPMS SOFTWARE (SERD0032)
- PRINTER
Page: XII-15
TOTAL CYCLES / TOTAL WEIGHT HAULED
STORED DATA:
- TOTAL NUMBER OF CYCLES RUN (1999 CYCLES)
-TOTAL WEIGHT HAULED (MAX 199900 US TONNES)
CHAPTER : TPMS
CLEARING DATA:
777D Off Highway Truck
-DEPRESS TEST/SET SWITCH
-WAIT FOR CYCLES TO BE DISPLAYED
-WITHIN 10 SECS ACTIVATE BED RAISE LEVER
REAL TIME CLOCK
-LOGS DATE & TIME OFCOMPLETION OF EACH DATA CYCLE
-CAN ONLY BE SET WITH PC
777D Off Highway Truck
CHAPTER : TPMS
LAB EXERCISES
LAB A:
1) Using the POD on a 777D truck write down the initial TPMS configuration as shown on the
display and explain each of the numbers. Change the settins to the new values indicated in the table.
Once finished remember to leave the truck with the same initial configuration.
INITIAL SETTINGS NEW SETTINGS
DISPLAY EXPLANATION DISPLAY
769D
METRIC
100
23
003
2) Use the POD to determine the total weight carried and the total cycles carried out.
TOAL WEIGHT:_____________
TOTAL CYCLES:____________
3) Scroll to mode 7 and identify any existing faults.
FAULTS MEANING
4) Repeat LAB A using the service tool
Page: XII-16
