Individual Clutch Modulation (ICM) Control Valves (3065, 3139)

4/3/2020 793C Off-Highway Truck 4GZ00001-UP (MACHINE) POWERED BY 3516B Engine(SEBP2791 - 150) - Systems & Components
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Product: TRUCK
Model: 793C TRUCK 4GZ
Configuration: 793C Off-Highway Truck 4GZ00001-UP (MACHINE)
POWERED BY 3516B Engine
Reuse And Salvage Guidelines

Individual Clutch Modulation (ICM) Control Valves{3065, 3139}
Media Number -SEBF8134-09 Publication Date -30/08/2012 Date Updated -30/08/2012
Caterpillar: Confidential Yellow
i05042692
Individual Clutch Modulation (ICM) Control Valves{3065, 3139}

SMCS - 3065; 3139
Articulated Truck:
735B (S/N: L4D1-UP; T4P1-UP)
740 (S/N: AXM1-UP; B1P1-UP)
740 EJECTOR (S/N: B1R1-UP)
740B (S/N: L4E1-UP; T4R1-UP)
740B EJECTOR (S/N: L4F1-UP; T4S1-UP)
D400 PS (S/N: 1MD1-UP)
D400D PS (S/N: 8TF1-UP)
D400E Series 2 (S/N: APF1-UP; 8PS1-UP)
D400E (S/N: 2YR1-UP)
Off-Highway Truck/Tractor:
69D (S/N: 9SS1-UP; 9XS1-UP)
73D (S/N: 9YS1-UP)
768B (S/N: 79S1-UP)
768C (S/N: 02X1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769B (S/N: 99F1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
772 (S/N: 10S1-UP; 11S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 63W1-UP)
773D (S/N: 7ER1-UP; 7CS1-UP)
776 (S/N: 14H1-UP; 14W1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP)
777D HAA (S/N: AGY1-UP)
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777G (S/N: TNM1-UP; RDR1-UP)
784B (S/N: 5RK1-UP)
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784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
Quarry Truck:
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: MWH1-UP; JWS1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: RFM1-UP; MJS1-UP)
Petroleum Transmission:
TH48-E80 (S/N: FRT1-UP)
Underground Articulated Truck:
AD55 (S/N: ANW1-UP; DNW1-UP)
Wheel Tractor-Scraper:
621E (S/N: 6AB1-UP; 6BB1-UP; 2PD1-UP; 2TF1-UP)
621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)
621G (S/N: DBB1-UP; ANG1-UP; KLK1-UP; CEN1-UP; ALP1-UP; CEP1-UP; KJW1-UP;
DBX1-UP)
621R (S/N: 12Y1-UP)
621S (S/N: 8KD1-UP)
623E (S/N: 6CB1-UP; 6DB1-UP; 6YF1-UP; 5SG1-UP)
623F (S/N: 5SG1-UP; 6BK1-UP; 3XW1-UP; 5EW1-UP)
623G (S/N: AWB1-UP; DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)
627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 7CG1-UP; 3WJ1-UP)
627F (S/N: 4YK1-UP; 1DL1-UP)
627G (S/N: DBD1-UP; AXF1-UP; AYK1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)
631E Series 2 (S/N: 1AB1-UP; 1BB1-UP; 1NB1-UP; 6PC1-UP; 3ND1-UP)
631E (S/N: 4LD1-UP)
631G (S/N: DFA1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; AXZ1-UP)
633D (S/N: 19W1-UP; 25W1-UP)
633E Series 2 (S/N: 1EB1-UP; 2PS1-UP)
637E Series 2 (S/N: 1FB1-UP; 1HB1-UP; 7CB1-UP)
637E (S/N: 1JB1-UP; 1LB1-UP)
637G (S/N: AWE1-UP; CEH1-UP; CEJ1-UP; DFJ1-UP; CEM1-UP; AYN1-UP; AXT1-UP;
DEX1-UP; DEY1-UP)
651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)
657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-
UP; 91Z1-UP)
657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP)
Introduction
Table 1
Revision Summary of Changes in SEBF8134 r080jh14
09 Updated effectivity.
08 Update Effectivity
© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be violation
of intellectual property law.
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to
benefit from cost reductions. Every effort has been made in order to provide the most current information
that is known to Caterpillar. Continuing improvement and advancement of product design might have caused
changes to your product which are not included in this publication. This Reuse and Salvage Guideline must
be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the Service
Information System. In order to address an urgent issue, use the following resources in order to communicate
your request to Caterpillar Repair Process Engineering:
Caterpillar Dealer Technical Communicator
Dealer Solution Network
Caterpillar Technical Representative
Knowledge Network
Summary
The reusability information contained in this guideline was developed for control valves used in the
Individual Clutch Modulation (ICM) transmissions. Although there are similarities among all hydraulic
valves, do not apply the ICM reusability guidelines to other applications due to different operating
environments.
Glossary
Anodized Layer - Anodizing is a chemical hardening process for aluminum. The anodized layer is the
hardened surface, and is darker than plain aluminum.
Balance Groove - Balance Grooves are shallow, circumferential grooves machined into a valve spool that:
provide lubrication to sides of spool, act as a labyrinth type pressure seal, and center spool in bore.
Frosting - Frosting is a gray, satiny appearance, usually the result of fine abrasive.
Metering - Metering is a theoretical line-to-line condition of a metering spool and of a valve body where the
flow and pressure regulation occurs.
Metering Edge - The metering edge is the edge of a spool or body land where metering occurs.
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Illustration 1 g02155886
(1) Metering edges
Use again minimum length. Clearance from the plane of the pressure control valve body to the spool is not
sliding (right) past the metering edges.
Do not use again. Internal leakage occurs from the spool sliding (right) past the two metering edges. The
metering edges are not horizontal across the surface. There are filed down or beveled edges.
Pressure Control Valve Group

Nomenclature
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(2) Gallery clean out holes
(3) Station housing
(4) Shims
(5) Pin
(6) Modulating orifice
(7) Load piston
(8) Selector piston
(9) Modulation reduction valve
(10) Reaction slug
Note: Pressure control valve groups typically consist of six to eight stations. Components and configurations
may vary.
Modulating Orifice (6)

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The modulating orifices are generally trouble free items and should be replaced only if large pieces of debris
are found in the control valve.
Modulation Reduction Valve (9)

Both metering edges must be sharp (0.25 mm (0.010 inch) maximum radius). Nicks or scratches are
permitted on metering edges if the scratches do not catch a seal pick pushed across the metering edges.
Frosted surfaces are acceptable.
Modulation reduction valve
(1) Metering edges
(11) Hole
(12) Orifice hole
(13) Valve ball
Check valve ball (13) must seal against the seat. Use the following procedure to check the ball seal and refer
to Illustration 3:
1. Insert a (oiled) reaction slug into the valve spool.
2. Close off orifice hole (12) .
3. Put a drop of oil in hole (11) .
4. Push reaction slug into the bore, the slug should resist movement.
Use again. If the check valve ball seals against the seat, the valve may be used again.
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(14) Scratches near metering edges
(15) Scratches away from metering edges
Use again. If longitudinal scratches on the metering edges are not deep enough to catch a seal pick, the
modulation reduction valve may be used again.
Note: Scratches on the modulation reduction valve away from the metering edges generally do not cause
operational problems.
(16) Frosted surfaces
Use again. Valves with frosted surface are reusable.
Reaction Slug (10)
Reaction slug wear does not generally have an adverse effect on transmission operation.
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Reaction slug
Use again. Frosting will not cause functional problems.
Selector Piston (8) and Load Piston (7)
Selector piston
(17) Scratched through anodized layer
Do not use again. If the selector or load piston has scratches that have gone through the anodized layer, the
piston should not be used again. Refer to Illustration 7.
Illustration 8 g02156284 r080jh14

Load piston Caterpillar: Confidential Yellow
(18) Location of the part number
Use again. A depressed area, surrounded by a raised ridge near the part number is a result of the
manufacturing process. The depressed area is not an indication of a defective part. Refer to Illustration 8.
Selector piston
Do not use again. If there are any deep scratches that have broken through the anodized layer, the piston
should not be used again. Refer to Illustration 9.
Valve Body
Check the bores for excessive wear, such as spalling, pitting, and cracking.
Valve body bore
Do not use again. If any in-line scratches are seen in the bores, the valve body should not be used again.
Refer to Illustration 10.
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Valve body bore
Do not use again. If any scratches catch a seal pick that is pushed across the bore, the valve body should not
be used again. Refer to Illustration 11.
Measuring tool
If no excessive wear is found, use a suitable measuring device to measure the lands of the bores.
The preferred method of measurement is to use an air gauge in order to measure the lands in each bore at
three locations. The measurements should be taken 120 degrees apart.
Use the dimension listed in Table 2 to determine if the part can be reused.
Table 2
Bore Dimension
Bore Diameter r080jh14
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Modulating relief
22.225 ± 0.015 mm (0.8750 ± 0.0006 inch)
Valve body
Note: Measure the valve body bore with a measuring device.
Station Housing (3)
Selector valve bore
(19) Porosity
(20) Wear steps r080jh14

(21) Band not worn
Do not use again. If any scratches catch a seal pick, the valve should not be used again. If any wear steps
can be felt in selector valve bore, the valve should not be used again.
Selector valve bore has wear steps that can be felt. The small holes near the bottom of the bore are casting
porosity that are not reason to replace the housing. Refer to Illustration 14.
Selector valve bore
(22) Visible wear pattern
Use again. The area at the mouth of the selector bore is made slightly larger than the rest of the bore, and is
not a wear step. A wear pattern can be seen in the bore, but no wear steps can be felt. Refer to Illustration 15.
Pins (5)
Remove any burrs before using the pin again.
Note: In order to maintain the correct pressure rise characteristics, Ensure that the pins are installed into the
same stations from which the pins were removed.
Pins
Use again. After the removal of burrs, the pin may be used again. r080jh14
Do not use again. If the pins are mushroomed or peened, the pins should not be used again.`
Shims (4)
Shims
Do not use again. If the shims are not flat or are deformed in any way, the shims should not be used again.
Selector and Pressure Control Valve Group

Nomenclature
Typical example
(23) Relief valve
(24) Filter
(25) Rotary selector pool
(26) Drive pin
(27) Neutralizer valve
(28) Priority reduction valve
Selector Body
Check the bores for excessive wear, such as spalling, pitting, and cracking. If excessive wear is present, do
not use the valve body again. No scratches are acceptable in the bores. r080jh14
Selector and pressure control valve
Rotary selector spool bore
Do not use again. This spool bore was damaged by a loose pin on the rotary selector spool shaft. Refer to
Illustration 20.
If there are any damaged areas in the bore that can stop a seal pick, the valve body should not be used again.
Control valve bore
Do not use again. If any scratches on the control valve bore catch a seal pick that is pushed across the
surface, the valve body should not be reused. Refer to Illustration 21.
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Caterpillar: Confidential
If no excessive wear is found, use a suitable measuring device to measure the lands of the bores. Yellow
Measuring tool
The preferred method of measurement is to use an air gauge in order to measure the lands in each bore at
three locations. The measurements should be taken 120 degrees apart.
Use the dimensions listed in Table 3 to determine if the part can be reused.
Table 3
Bore Dimensions
Bore Diameter
Rotary selector spool

34.930 ± 0.015 mm (1.3752 ± 0.0006 inch)
Relief / neutralizer valve

28.580 ± 0.015 mm (1.1252 ± 0.0006 inch)
Priority reduction valve

25.400 ± 0.015 mm (1.0000 ± 0.0006 inch)
Rotary Selector Spool (25)
An earlier version is pictured. Later spools have balance grooves between each row of holes. Both versions
can be used again.
The grinding method used can cause the spool to appear to have been cam ground. Spools with this type of
appearance can be used again.
Note: Be sure to clean the filter inside the selector spool (refer to Illustration 18) before assembling the valve
group.
Rotary selector spool
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(29) Cam-ground appearance Caterpillar: Confidential Yellow
(A) Charge end of spool
Use again. If there are no scratches that catch a seal pick, the spool may be used again.
Do not use again. If scratches on charge end of spool catch a seal pick that is pushed across the surface, the
spool should not be used again.
Drive Pin (26)

Notches or grooves, on the pin head and shank (near the end) usually appear early in pin life. This condition
will stop as the pieces "wear in", providing a larger contact area.
The pin must fit tightly into the bore of the rotary selector spool. If loose, the pin can move out of place and
drag on the bore of valve body causing a shifting problem.
Push against the drive pin, if drive pin is fits tight in the bore of the spool, use spool assembly again. (Do not
press the pin out of the bore.) If drive pin is loose in the bore, a new pin should be installed. Use a new spool
assembly, if the bore in the spool assembly has been damaged and a new pin does not fit tightly.
Drive pin
(30) Acceptable groove
(31) Acceptable notch
(32) Not acceptable notch
Do not use again. If, the notch in central part of body could cause the pin to break.
Rotary Actuator Group
Rotary actuator group
(33) Actuator vane
(34) Shuttle valve
Rotary Actuator Vane
Notches or grooves in the drive pin slot for the rotary actuator vane usually appear early in the service life of
the part life. As the pieces "wear in", the notches do not increase and provide a larger contact area.
Rotary actuator vane
(35) Wear notches
Use again. Notches in the rotary actuator valve are acceptable. r080jh14
Inspect the shaft at the end of the drive slot for cracks.
Do not use again. If any rotary actuator vanes have cracks, the rotary actuator should not be used again.
Rotary actuator vane
(36) Crack
Do not use again. Cracks at the drive slots are not permitted.
Shuttle Valve
Shake the valve assembly. The check ball must be heard.
Shuttle valve
(37) Check ball
Use again. If the check ball can be heard when the valve assembly is shaken, the valve may be used again.
Shuttle valve
(38) Frosted surface
(39) Pin
Use again. A frosted surface is acceptable.
Do not use again. If the pin moves when pushed, the valve should not be used again.
Copyright 1993 - 2020 Caterpillar Inc. Wed Mar 04 2020 22:31:42 GMT-0500 (hora de verano de la isla de Pascua)
All Rights Reserved.
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Individual Clutch Modulation (ICM) Control Valves (3065, 3139)

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4/3/2020 793C Off-Highway Truck 4GZ00001-UP (MACHINE) POWERED BY 3516B Engine(SEBP2791 - 150) - Systems & Components

Reuse And Salvage Guidelines

Individual Clutch Modulation (ICM) Control Valves{3065, 3139}

784C (S/N: 2PZ1-UP)

Caterpillar Dealer Technical Communicator

Dealer Solution Network

Caterpillar Technical Representative

Pressure Control Valve Group

(3) Station housing

(6) Modulating orifice

(7) Load piston

(8) Selector piston

(9) Modulation reduction valve

(10) Reaction slug

Modulating Orifice (6)

Modulation Reduction Valve (9)

Frosted surfaces are acceptable.

(1) Metering edges

(12) Orifice hole

(13) Valve ball

1. Insert a (oiled) reaction slug into the valve spool.

2. Close off orifice hole (12) .

3. Put a drop of oil in hole (11) .

(14) Scratches near metering edges

(15) Scratches away from metering edges

(16) Frosted surfaces

Use again. Valves with frosted surface are reusable.

Reaction Slug (10)

Use again. Frosting will not cause functional problems.

Selector Piston (8) and Load Piston (7)

(17) Scratched through anodized layer

Illustration 8 g02156284 r080jh14

(18) Location of the part number

Note: Measure the valve body bore with a measuring device.

Station Housing (3)

(20) Wear steps r080jh14

(22) Visible wear pattern

Selector and Pressure Control Valve Group

(23) Relief valve

(25) Rotary selector pool

(26) Drive pin

(27) Neutralizer valve

(28) Priority reduction valve

Rotary selector spool

Relief / neutralizer valve

Priority reduction valve

Rotary Selector Spool (25)

(A) Charge end of spool

Drive Pin (26)

(30) Acceptable groove

(31) Acceptable notch

(32) Not acceptable notch

Rotary Actuator Group

(33) Actuator vane

(34) Shuttle valve

Rotary Actuator Vane

(35) Wear notches

(37) Check ball

(38) Frosted surface

Use again. A frosted surface is acceptable.

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