777D Off Highway Truck: Service Training Malaga

Service Training
MALAGA
777D Off Highway Truck
LOCKUP CLUTCH VALVE

TORQUE CONVERTER DRIVE
LOAD SELECTOR
PISTON PISTON
LOAD PISTON
ORIFICE
MODULATION
REDUCTION PRESSURE
VALVE REDUCTION
VALVE
LOCKUP
SOLENOID
OFF
SHUTTLE
VALVE TO
LOCKUP
CLUTCH FROM
PARKING BRAKE
PUMP
III. POWER TRAIN

1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
CHAPTER : Power Train
TYPICAL OFF-HIGHWAY TRUCK

POWER TRAIN
COMPONENT LOCATIONS
LOCKUP LOCKUP
SOLENOID MODULATION
VALVE
TRANSMISSION
PUMP
TORQUE
CONVERTER
SOLENOIDS
UPSHIFT
DOWNSHIFT
TRANSMISSION
TORQUE TRANSMISSION TORQUE CONVERTER

CONVERTER FILTER OIL FILTER AND TRANSMISSION OIL
INLET AND
OUTLET RELIEF VALVES
DRIVE TRANSMISSION
SHAFT
TRANSMISSION
CONTROL VALVE
DIFFERENTIAL AND
FINAL DRIVES
LOCKUP
CLUTCH
TORQUE TRANSFER
CONVERTER GEARS
TORQUE PUMP
CONVERTER
Page: III-2
TORQUE CONVERTER
CONVERTER DRIVE
TURBINE TORQUE CONVERTER

INLET OIL
LOCKUP PISTON IMPELLER
TORQUE CONVERTER
LOCKUP OIL PASSAGE
STATOR
ENGINE FLYWHEEL
FREEWHEEL
ASSEMBLY TO TRANSFER
GEARS
Page: III-3
TORQUE CONVERTER
DIRECT DRIVE
TURBINE
LOCKUP IMPELLER TORQUE

PISTON CONVERTER
INLET OIL
STATOR TORQUE
CONVERTER
LOCKUP OIL
PASSAGE
ENGINE FLYWHEEL
TOTRANSFER
GEARS
FREEWHEEL
ASSEMBLY
Page: III-4
Page:
LOCKUP CLUTCH VALVE

III-5
CLUTCH FILLING
LOAD SELECTOR
PISTON PISTON
SHIMS
LOAD PISTON
ORIFICE
MODULATION

REDUCTION
VALVE PRESSURE
REDUCTION

VALVE
LOCKUP
SOLENOID
ON
SHUTTLE
VALVE TO
LOCKUP FROM
CLUTCH PARKING BRAKE
PUMP
Page:
III-6
LOCKUP CLUTCH VALVE

DIRECT DRIVE
SELECTOR
LOAD PISTON
PISTON
LOAD PISTON
ORIFICE
MODULATION

REDUCTION PRESSURE
VALVE REDUCTION

VALVE
LOCKUP
SOLENOID
ON
SHUTTLE TO
VALVE LOCKUP
CLUTCH
FROM
PARKING BRAKE
PUMP
Page:
III-7
769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

NEUTRAL
INLET
RELIEF VALVE OUTLET
BRAKE COOLING RELIEF VALVE
LOCKUP CLUTCH
PILOT OIL PRESSURE PRESSURE
LOCKUP LOCKUP CLUTCH OUTLET

MODULATION PRESSURE PRESSURE
PARKING BRAKE VALVE
RELIEF VALVE TAP
TO BRAKE
COOLING CIRCUIT
INLET
PRESSURE

LOCKUP
SOLENOID LOCKUP
REDUCING
VALVE
TO BRAKE

COOLING
CIRCUIT
PARKING BRAKE
RELEASE VALVE TORQUE SHIMS
LOCKUP
CLUTCH CONVERTER
CONVERTER PARKING BRAKE

CHARGING RELEASE PRESSURE CONVERTER
PUMP SCAVENGE
PUMP
PARKING SCREEN
BRAKE
RELEASE
PUMP
Page:
III-8
769D - 777D TRANSMISSION

HYDRAULIC SYSTEM
NEUTRAL
UPSHIFT
DOWNSHIFT PRESSURE
PRESSURE
A
DOWNSHIFT UPSHIFT
SOLENOID SOLENOID
ROTARY
FILTER ACTUATOR
ON E
PUMP
PRESSURE
B
NEUTRALIZER
VALVE
F

PILOT OIL PRIORITY
PRESSURE REDUCTION
ROTARY
SELECTOR
C
VALVE SPOOL
OIL COOLER

CHARGING
PUMP SCAVENGE
PUMP
RELIEF
D
VALVE
TRANSMISSION H
CASE
TANK
LUBE
RELIEF VALVE SELECTOR VALVE
PRESSURE CONTROL
GROUP GROUP
LUBE
PRESSURE
769D - 777D TRANSMISSION SELECTOR VALVE

GROUP
NEUTRAL
NEUTRALIZER
VALVE
ROTARY
SELECTOR
SPOOL
PRIORITY
REDUCTION
VALVE
PILOT
OIL
PRESSURE
SCREEN
RELIEF
VALVE
TRANSM.
LUBE
RELIEF
VALVE
LUBRICATION
PRESSURE
Page: III-9
769C - 777C TRANSMISSION SELECTOR VALVE

GROUP
STARTING IN FIRST SPEED FORWARD
ROTARY
NEUTRALIZER SELECTOR
VALVE SPOOL
PRIORITY
REDUCTION
VALVE
PILOT OIL
PRESSURE
SCREEN
RELIEF
VALVE
LUBE
RELIEF
VALVE
LUBRICATION
PRESSURE
Page: III-10
769D - 777D PRESSURE

CONTROL GROUP
NEUTRAL
E
B
F
C
G
D
Page: III-11
Page:
VALVE STATION
III-12
CLUTCH RELEASED
SELECTOR PISTON
SLUG BALL CHECK VALVE
LOAD PISTON
PILOT OIL
PASSAGE

PLUG
DECAY ORIFICE
LOAD PISTON
ORIFICE LOAD PISTON PLUG
MODULATION
REDUCTION CLUTCH PRESSURE TAP
VALVE FROM PUMP
TO CLUTCH
VALVE STATION
CLUTCH ENGAGED
Page: III-13
VALVE STATION
CLUTCH ENGAGED/WITH PIN
Page: III-14
VALVE STATION
CLUTCH DECAY
DECAY
ORIFICE
Page: III-15
Page:
III-16
769C - 777C TRANSMISSION

HYDRAULIC SYSTEM
THIRD SPEED FORWARD
DOWNSHIFT UPSHIFT
PRESSURE PRESSURE
A
DOWNSHIFT UPSHIFT
SOLENOID SOLENOID
ROTARY
FILTER ACTUATOR
E
PUMP
PRESSURE
B

NEUTRALIZER
VALVE
PILOT OIL PRIORITY

F
PRESSURE REDUCTION ROTARY

VALVE SELECTOR
OIL COOLER SPOOL C
CHARGING
PUMP SCAVENGE
PUMP
D
RELIEF
VALVE
TRANSMISSION H
CASE
LUBE
TANK
RELIEF VALVE PRESSURE CONTROL
SELECTOR VALVE GROUP
GROUP
LUBE
PRESSURE
VALVE STATION
PRIMARY PRESSURE
LOAD PISTON
PLUG (REMOVED)
Page: III-17
Page:
III-18
777D SHIFT MODULATION CYCLE

THIRD(3&6) TO FOURTH (1&5)
PRESSURE
NORMAL SHIFT CYCLE
CLUTCH 1
418
CLUTCH 6
373 CLUTCH 5

353

CLUTCH 3
265
COMPLETE CLUTCH ENGAGEMENT
PRIMARY
PRESSURE INITIAL CLUTCH ENGAGEMENT
50
0
TIME
FILL TIME
NORMAL CLUTCH SLIP
Page:
III-19
777C SHIFT MODULATION CYCLE

SECOND TO THIRD
PRESSURE
NORMAL SHIFT CYCLE
CLUTCH 3
418
373
CLUTCH 6

CLUTCH 1

265
COMPLETE CLUTCH ENGAGEMENT
PRIMARY
PRESSURE INITIAL CLUTCH ENGAGEMENT
80
TIME
FILL TIME
NORMAL CLUTCH SLIP
Page:
III-20
PRESSURE RESTRICTED LOAD PISTON

ORIFICE
SLOW MODULATION
HIGH
PRIMARY
PRESSURE P1
COMPLETE CLUTCH
ENGAGEMENT
LOW
PRIMARY

PRESSURE
INITIAL CLUTCH
NORMAL ENGAGEMENT

PRIMARY
PRESSURE
0 TIME
HIGH PRIMARY PRESSURE - HARSH
SHIFT
NORMAL CLUTCH SHIFT MODULATION
SLIP PROBLEMS
LOW PRIMARY PRESSURE - CLUTCH
SLIPPING RESTRICTED LOAD PISTON
ORIFICE
CLUTCH SLIPPING
LAB EXERCISES
Lab A: Component Location and Identification Worksheet I
769D - 777D Off-highway Trucks
Torque Converter Hydraulic System
Directions: Refer to the Lab A Handout Illustration Worksheet V. Place the correct letter or number
next to the component. During the slide presentation, use this sheet to take notes on the function of each
component.
______ Torque Converter - example: Located on the rear of the engine. Provides a fluid coupling
between the engine and the transmission and multiplies torque. Contains a lockup clutch for
more efficient operation.
______ Torque Converter Pump (1. Scavenge, 2. Charging, and 3. Park Brake Release) -
______ Torque Converter Scavenge Screen -
______ Torque Converter Charging Filter -
______ Torque Converter Inlet Relief Valve -
______ Torque Converter Outlet Relief Valve -
______ Torque Converter Lockup Clutch Valve -
______ Parking Brake Release Valve -
______ Parking Brake Release Filter -
______ Lockup Clutch Solenoid Valve -
Page: III-21
LAB EXERCISES
Lab A: Component Location and Identification Worksheet ID
769D - 777D Off-highway Trucks
Transmission Hydraulic System
Directions: Refer to the Lab A Handout Illustration Worksheet V. Place the correct letter or number
next to the component. During the slide presentation, use this sheet to take notes on the function of each
component.
______ Transmission Tank - example: Located on the left side of the truck. Contains a sight gauge for
checking power train hydraulic level.
______ Transmission Pump -
______ Transmission Filter -
______ Transmission Magnetic Suction Screen -
______ Transmission Oil Cooler -
______ Transmission Control Valve -
______ Upshift Solenoid Valve -
______ Downshift Solenoid Valve -
Page: III-22
LAB EXERCISES
Lab A: Component Location and Identification Worksheet V
Torque Converter and Transmission Hydraulic Systems Component Identification
TYPICAL OFF-HIGHWAY TRUCK

POWER TRAIN
COMPONENT LOCATIONS
Page: III-23
TO BRAKE
COOLING
CIRCUIT
TO
BRAKE
COOLING
CIRCUIT

LAB EXERCISES

Lab B: Torque Converter
Identify Test Ports
Hydraulic System Identify Components
Component Identification A. Inlet Pressure 7. Inlet Relief Valve
1. Outlet Relief Valve
B. Parking Brake Release Pressure 8. Lockup Modulation Valve
Worksheet I: (769D - 777D) 2. Parking Brake Release Valve
C. Lockup Clutch Pressure 9. Scavenge Pump
Directions: Write the letter 3. Converter Charging Pump
Page:
or number of the item in the D. Outlet Pressure 10. Lockup Solenoid

4. Torque Converter
correct blank on the E. Pilot Pressure
5. Lockup Reducing Valve 11. Shuttle Valve
schematic.
III-24
6. Parking Brake Release Pump 12. Lockup Clutch

LAB EXERCISES
Lab C: Torque Converter Hydraulic System Testing
Shop Lab Exercise
Procedure:
Perform the following tests listed in the Power Train Testing and
Adjusting Service Manual Module for the lab machine used:
• Visual Checks (8) for the hydraulic system which include Brake
Cooling, Torque Converter, and Hoist Hydraulic Systems
• Torque Converter Outlet Pressure
• Torque Converter Inlet Pressure
• Parking Brake Release Pressure
• Lockup Clutch Pilot Pressure
• Lockup Clutch Leakage
• Lockup Clutch Signal Pressure (785B - 793B)
• Lockup Clutch Maximum Pressure
• Lockup Clutch Primary Pressure
Class notes
Lab D Worksheets (I and II)
Off-highway Truck
Mechanic's tools
The following test equipment:
1 - 8T0854 Gauge 1000 kPa (145 psi)

1 - 8T0850 Gauge 4000 kPa (580 psi)
1 - 8T0851 Gauge 16000 kPa (2300 psi)
1 - 6V3965 Nipple
1 - 6V4143 Valved Coupler
1 - 6V3079 Diagnostic Hose
1 - 6V3121 Multitach Group
1 - Oil container [approximately 19 l (5 gal.) capacity]
1 - Special Instruction "6V3121 Multitach Group" (Form
SEHS7807)
Page: III-25
LAB EXERCISES
Lab C: Torque Converter Hydraulic System Testing
769C - 777C Off-highway Trucks - Worksheet I
Directions: Use this sheet to check off each of the steps listed in the Power Train Testing and
Adjusting Service Manual Module.
Machine Model______________________ Dealer ______________________________

Name/Code _________________________ Customer ___________________________
Machine PIN (S/N)___________________ Job ________________________________
Transmission S/N ____________________ Application __________________________
Engine S/N _________________________ Date _______________________________
S.M.H. ____________________________ Serviceman __________________________
VISUAL CHECKS
______ Check 1 - Oil levels in the hydraulic tank ______ Check 5 - Torque converter scavenge screen
______ Check 2 - External Leakage ______ Check 6 - Oil cooler screens
______ Check 3 - Parking brake release oil filter ______ Check 7 - Components inside hydraulic tank
______ Check 4 - Torque converter oil filter ______ Check 8 - Inspect return oil screen
TEST SPECS ACTUAL
Torque Converter Outlet Pressure at Stall
Torque Converter Stall Speed
Torque Converter Inlet Pressure
Lockup Clutch Pilot Pressure
Parking Brake Release Pressure
Lockup Clutch Leakage
Lockup Clutch Maximum Pressure
Lockup Clutch Primary Pressure
Page: III-26
Lab D: Tracing Torque Converter Oil System Flow (769D - 777D)
Worksheet I
Directions: Trace the flow of oil during the condition listed below using different colored pencils to show each path.
TO BRAKE
COOLING
CIRCUIT

LAB EXERCISES

TO BRAKE
COOLING
CIRCUIT
769D - 777D TORQUE

CONVERTER
Page:
HYDRAULIC SYSTEM
TORQUE CONVERTER
DRIVE
III-27
Lab D: Tracing Torque Converter Oil System Flow (769D - 777D)
Worksheet II
Directions: Trace the flow of oil during the condition listed below using different colored pencils to show each path.
TO BRAKE
COOLING
CIRCUIT TO
BRAKE
COOLING
CIRCUIT

LAB EXERCISES

Page:
769C - 777C TORQUE CONVERTER

HYDRAULIC SYSTEM
DIRECT DRIVE
III-28
LAB EXERCISES
Lab E: Torque Converter Hydraulic System Operation (769D - 777D)
Worksheet I
Directions: Circle the letter of the correct statement that completes the sentence.
Example: Torque converter leakage oil is removed from the torque converter by the:
A. Parking brake release pump
B. Scavenge pump
C. Charging pump
1. The torque converter is in direct drive in the 5. When the lockup solenoid opens and the shuttle
following speeds: valve moves, the shuttle valve:
A. REVERSE and FIRST A. opens a passage to drain
B. second half of FIRST through SEVENTH B. closes a passage to drain
C. NEUTRAL to FIRST C. directs lockup clutch oil to the lockup clutch
2. If the torque converter lockup solenoid does not 6. Torque converter operating pressure is
receive an electrical signal in SECOND SPEED maintained by the:
FORWARD, the torque converter will:
A. inlet relief valve
A. stay in DIRECT DRIVE
B. outlet relief valve
B. go to DIRECT DRIVE
C. parking brake release valve
C. go to TORQUE CONVERTER DRIVE
7. Modulation of the lockup clutch is determined
3. The source of torque converter lockup oil is by the:
from the:
A. load piston
A. transmission charging pump
B. modulation reducing valve
B. torque converter charging pump
C. load piston orifice
C. parking brake release pump
4. Excess oil pressure to the torque converter

during a cold start-up is prevented by the
_______.
A. inlet relief valve
B. outlet relief valve
C. parking brake release valve
Page: III-29
A
ON E
B
F
C

LAB EXERCISES
H

Lab F: Transmission
Hydraulic System
Component
Identification
(769D - 777D) Identify Test Ports Identify Components 6. Priority Reduction Valve 12. Neutralizer valve
A. Downshift Pressure 1. Charging Pump 7. Main Relief Valve 13. Oil Cooler
Page:
Worksheet I B. Pump Pressure 2. Pressure Control Group 14. Filter

8. Scavenge Pump
C. Lube Pressure 3. Rotary Selector Spool 9. Downshift Solenoid 15. Screen
Directions: Write the letter or
III-30
number of the item in the D. Upshift Pressure 4. Upshift Solenoid 10. Rotary Actuator 16. A to C and E to H
correct blank on the schematic. E. Pilot Pressure 5. Lube Relief Valve 11. Selector Valve Group
Lab F: VALVE STATION
Transmission
Hydraulic System
Component
Identification
Pressure Control
Group Valve Station
Worksheet III
Directions: Write the
letter or number of the
item in the correct
blank on the schematic.

LAB EXERCISES

FROM PUMP
TO CLUTCH
Identify Test Ports Identify Components

A. Primary and Clutch Pressures 1. Ball Check Valve 7. Load Piston Orifice
B. Pilot Pressure 2. Selector Piston 8. Load Piston
3. Load Piston Plug 9. Decay Orifice
Page:
4. Pilot Oil Passage 10. Clutch Pressure Tap

5. Pin 11. Slug
III-31
6. Pilot Oil Plug 12. Modulation Reduction Valve

LAB EXERCISES
Lab G: Transmission Hydraulic System Testing
Shop Lab Exercise
Procedures:
Perform the following tests listed in the Power Train Testing and
Adjusting Service Manual Module for the lab machine used:
• Visual Checks (6)

• Transmission Pump Pressure
• Transmission Lubrication Pressure
• Pilot Pressure
• Pressure Control Group Clutch Pressures
• Primary Clutch Pressures
• Dual Stage Relief Valve Pressure
Class notes
Lab G Worksheets (I and II)
Off-highway Truck
Mechanic's tools
The following test equipment:
1 - 1U5481 Pressure Gauge Group

1 - 1U5482 Pressure Adaptor Group
1 - 3B7282 Nipple
1 - 3B6552 Nipple
1 - 6V4142 Unvalved Nipple
1 - 6V6064 or FT1775 Transmission Test Cover
Page: III-32
LAB EXERCISES
769D - 793C Off-highway Trucks - Worksheet I
Directions: Use this sheet to check off each of the steps listed in the Power Train Testing and Adjusting
Service Manual Module. All tests should be run with the transmission in NEUTRAL.
Machine Model______________________ Dealer ______________________________
Name/Code _________________________ Customer ___________________________
Machine PIN (S/N)___________________ Job ________________________________
Transmission S/N ____________________ Application __________________________
Engine S/N _________________________ Date _______________________________
S.M.H. ____________________________ Serviceman __________________________
VISUAL CHECKS
______ Check 1 - Oil levels in the hydraulic tank ______ Check 5 - Transmission case oil quantity
______ Check 2 - External leakage ______ Check 6 - Transmission oil tank debris
______ Check 3 - Oil filter examination
______ Check 4 - Magnetic screen debris
DU AL S TAGE RELIEF LOCKU P CLU TCH DEACTIVATED
S PECS ACTU AL
LOW HIGH LOW HIGH

IDLE IDLE IDLE IDLE
PU MP PRES S U RE
DU AL S TAGE RELIEF LOCKU P CLU TCH ACTIVATED
S PECS ACTU AL
LOW HIGH LOW HIGH

IDLE IDLE IDLE IDLE
PU MP PRES S U RE
S PECS ACTU AL
LOW HIGH LOW HIGH

IDLE IDLE IDLE IDLE
PILOT PRES S U RE NO NO
LU BE PRES S U RE
Page: III-33
LAB EXERCISES
769D - 793C Off-highway Trucks - Worksheet II
Directions: Use this sheet to check off each of the steps listed in the Power Train Testing and Adjusting
Service Manual Module.
PRIMARY CLU TCH PRES S U RE

CLU TCH CHART AT LOW IDLE
(LOAD PIS TON PLU G REMOVED)
N STATION CLUTCH SPECS ACTUAL
R A
1 B
2 C
3 D
4 E
5 F
6 G
7 H
PRIMARY CLU TCH PRES S U RE AT LOW IDLE

(LOAD PIS TON PLU G IN S TALLED)
S PECS ACTU AL
S TATION CLU TCH LOW HIGH LOW HIGH
IDLE IDLE IDLE IDLE
A
B
C
D
E
F
G
H
Page: III-34
POSTTEST
As this component moves and closes a drain passage, 1. Load Piston

modulation will begin
2. Pilot Oil Passage
Removal of this component allows the technician to
check pilot pressure 3. Decay Orifice
Allows oil from the rotary selector spool to move the 4. Load Piston Plug
selector piston
5. Modulation Reduction
Controls the rate of clutch engagement Valve
Works with the modulation reduction valve to control 6. Load Piston Orifice
clutch pressure
7. Ball Check Valve
Allows clutch pressure to be directed into the center
chamber of the modulation reduction valve 8. Clutch Pressure Tap
Allows the technician to check clutch pressure 9. Pilot Pressure Plug
Removal of this component causes the clutch pressure to 10. Selector Piston
remain at the primary pressure
11. Slug
Controls the rate of clutch release
Works with load piston to control clutch pressure
Directions: Modified True/False. If a statement is false, underline or circle the word or words that
make the statement incorrect and replace with word(s) to make the statement correct. (Each question is
worth 2 points.)
a transmission
Example: F 1. This is an engine class.
1. To initiate clutch filling, pilot oil moves the selector piston.
2. The size of the modulation reducing valve determines the rate of clutch modulation.
3. To check the primary clutch pressure, remove the load piston plug.
4. Pins in a clutch station increase the modulation time.
5. Clutch release time is determined by the decay orifice.
Page: III-35
Directions: Match the
components and test ports with
the associated number or letter.
(Each question is worth 1 point.)
13
Test Ports VALVE STATION

1
Primary Pressure 15 14
Pilot Pressure
10
Clutch Pressure
Components 11
Load Piston

POSTTEST
Pilot Oil Passage 7

Decay Orifice
Load Piston Plug
Modulation Reduction 9
Valve
Load Piston Orifice
6 3
Ball Check Valve
2 8 12
Clutch Pressure Tap 5
Pilot Oil Plug FROM PUMP
4
Page:
Selector Piston TO CLUTCH

Slug
III-36
Pin
POSTTEST
Directions: Use the schematic on page 38. After each statement, circle the correct sequence of events
that occurs.
Example: The operator makes a shift from NEUTRAL to FIRST FORWARD.

A. 1-Pilot oil moves B. 1-Selector piston closes C. 1-Modulation begins
selector piston drain
2-Load piston moves
2-Selector piston closes 2-Pilot oil moves reducing valve
drain selector piston
3-Selector piston closes
3-Load piston moves 3-Modulation begins drain
reducing valve
4-Load piston moves 4-Pilot oil moves
4-Modulation begins reducing valve selector piston
A. 1-Rotary selector spool B. 1-Rotary selector spool C. 1-Selector piston opens

opens pilot oil passage opens pilot oil passage drain
to drain to drain
2-Load piston oil is
2-Load piston oil is 2-Selector piston opens directed through
directed through drain decay orifice
decay orifice
3-Load piston oil is 3-Rotary selector spool
3-Selector piston opens directed through opens pilot oil passage
drain decay orifice to drain
A. 1-Pump oil is directed B. 1-Pump oil is directed to C. 1-Modulation reduction

through load piston clutch valve moves
orifice 2-Modulation reduction 2-Pump oil is directed to
2-Pump oil is directed to valve moves clutch
clutch 3-Pump oil is directed 3-Pump oil is directed
3-Modulation reduction through load piston through load piston
valve moves orifice orifice
Page: III-37
POSTTEST
Torque Converter Hydraulic System Posttest
(769D - 777D)
Directions: Match the component to its primary function.
Maintains high oil pressure to the lockup reducing valve 1. Lockup Solenoid
Supplies oil for hydraulic energy transfer 2. Inlet Relief Valve
Maintains working pressure within the torque converter 3. Torque Converter
When energized, supplies pilot oil to initiate direct drive 4. Lockup Reducing Valve
Relieves excess pressure to the torque converter 5. Parking Brake Release

Valve
Provides a controlled rate of engagement of the
lockup clutch 6. Outlet Relief Valve
Transfers engine power to the transmission 7. Lockup Modulation Valve
Reduces pump supply pressure to pilot pressure 8. Converter Charging Pump
Supplies oil to the lockup clutch 9. Diverter Valve
10. Parking Brake Release

Pump
make the statement incorrect and replace with word(s) to make the statement correct.
a power train
Example: F 1. This is an engine class.
1. The inlet relief valve controls the maximum pressure in the torque converter.
2. The parking brake release pump supplies oil to the lockup modulation valve.
3. Lockup clutch oil pressure is controlled by the parking brake release valve.
4. Transmission oil pressure is used to pressurize the torque converter lockup clutch when the
torque converter is in direct drive.
5. When the transmission is in REVERSE, the torque converter is in direct drive.
6. Direct drive is in gears FIRST through SEVENTH.
Page: III-38
Directions: Match the
Test Ports
Parking Brake Release
Pressure
Pilot Pressure
E
Outlet Pressure D
C
8
1
Inlet Pressure TO BRAKE
COOLING CIRCUIT
7
Lockup Clutch Pressure 10
A TO BRAKE
COOLING
5
Components CIRCUIT

POSTTEST
4
Lockup Solenoid
Inlet Relief Valve

11
Torque Converter 2
9
12
Lockup Reducing Valve
6
B
Parking Brake Release 3
Valve
Outlet Relief Valve
769D - 777D TORQUE CONVERTER
Lockup Modulation Valve HYDRAULIC SYSTEM
Converter Charging Pump
Page:
Scavenge Pump
Parking Brake Release
Pump
III-39
Shuttle Valve
POSTTEST
that occurs.
Example: The operator makes a shift from NEUTRAL to FIRST FORWARD and the ground speed
increases.
A. 1-Torque converter is in B. 1-Lockup clutch engages C. 1-Ground speed

TC drive increases and the
2-Ground speed
lockup clutch
2-Ground speed increases and the
modulation valve is
increases and the lockup clutch
activated
lockup clutch modulation valve is
modulation valve is activated 2-Lockup clutch engages
activated
3-Torque converter is in 3-Torque converter is in
3-Lockup clutch engages TC drive TC drive
A. 1-Parking brake release B. 1-Parking brake release C. 1-Parking brake release

oil directed to lockup oil directed to lockup pump directs oil to
modulation valve spool modulation valve spool lockup reducing valve
2-Pilot oil directed to 2-Parking brake release 2-Pilot oil directed to
lockup solenoid valve pump directs oil to lockup solenoid valve
lockup reducing valve
3-Parking brake release 3-Parking brake release
pump directs oil to 3-Pilot oil directed to oil directed to lockup
lockup reducing valve lockup solenoid valve modulation valve spool
A. 1-Shuttle valve moves B. 1-Lockup solenoid valve C. 1-Load piston moves

and blocks drain opens
2-Lockup solenoid valve
2-Load piston moves 2-Shuttle valve moves opens
and blocks drain
3-Lockup solenoid valve 3-Shuttle valve moves
opens 3-Load piston moves and blocks drain
A. 1-Shuttle valve moves B. 1-Load piston moves C. 1-Lockup solenoid valve

and opens drain closes
2-Shuttle valve moves
2-Lockup solenoid valve and opens drain 2-Shuttle valve moves
closes and opens drain
3-Lockup solenoid valve
3-Load piston moves closes 3-Load piston moves
Page: III-40
POSTTEST
Directions: Match the component to its primary function.
Regulates pressure inside oil cooler

1. Charging Pump
Reduces temperature of transmission oil 2. Pressure Control Group
3. Rotary Selector Spool
Removes oil from transmission case
4. Upshift Solenoid
Maintains pilot oil pressure
5. Oil Cooler Relief Valve
Removes debris from transmission oil 6. Priority Reduction Valve
7. Main Relief Valve
Supplies modulated pressures to clutches
8. Scavenge Pump
Directs oil to move rotary actuator vane clockwise
9. Downshift Solenoid
Maintains maximum system pressure 10. Rotary Actuator
11. Selector Valve Group
Chooses appropriate clutch combinations for each speed
12. Neutralizer Valve
Six valve clutch stations
13. Oil Cooler
Moves rotary selector spool 14. Filter
15. Manifold
Keeps machine from moving if transmission is started in
gear 16. A through H
Supplies oil to all clutches
Directs oil to move rotary actuator vane

counterclockwise
Maintains and directs oil pressures to the pressure

control group
Page: III-41
POSTTEST
make the statement incorrect and replace with word(s) to make the statement correct.
a transmission
Example: F 1. This is an electrical test.
1. In NEUTRAL, no clutches are engaged.
2. If the machine is started IN GEAR, the neutralizer valve stops the flow of pilot oil.
3. Clutch pressure is maintained by the relief valve.
4. Reverse is an upshift.
5. During a shift, clutches are always drained and then refilled.
6. REVERSE and the first half of FIRST are torque converter drive.
Page: III-42
Test Ports Directions: Match the
Pump Pressure
Upshift Pressure
Downshift Pressure
Pilot Pressure
Lube Pressure
Components
Scavenge Pump
Priority Reduction Valve A
D
A
Rotary Selector Spool 9 4
14
Neutralizer Valve 10 E
ON

POSTTEST
B B
Lube Relief Valve
12
A to C and E to H

F
E 6
1 3 C
Pressure Control Group 13
8
Main Relief Valve
G
Charging Pump
7 D
Downshift Solenoid
H
Filter 16
15
Selector Valve Group 5
11 2
Upshift Solenoid C
Page:
Oil Cooler
Rotary Actuator 769D- 777D TRANSMISSION
HYDRAULIC SYSTEM
III-43
Screen
that occurs.
Example: The operator has moved the shift lever from NEUTRAL to FIRST FORWARD.
A. 1-Downshift solenoid is B. 1-Rotary actuator moves C. 1-Upshift solenoid is

de-energized to FIRST SPEED energized
FORWARD
2-Upshift solenoid is 2-Rotary actuator moves
energized 2-Downshift solenoid is to FIRST SPEED
de-energized FORWARD
3-Rotary actuator moves
to FIRST SPEED 3-Upshift solenoid is 3-Downshift solenoid is
FORWARD energized de-energized
1. The engine is started with the transmission in NEUTRAL.

A. 1-Neutralizer valve B. 1-Pilot oil flows through C. 1-Downshift solenoid is
moves rotary selector spool to energized
one station
2-Pilot oil flows through 2-Neutralizer valve
rotary selector spool to 2-Downshift solenoid is moves
one station energized
3-Pilot oil flows through
3-Downshift solenoid is 3-Neutralizer valve rotary selector spool to
energized moves one station
2. The engine is started with the gear shift lever in FIRST SPEED FORWARD.
A. 1-Charge pump oil flows B. 1-Rotary selector spool C. 1-Pilot oil flows to
to priority reduction blocks charge pump oil neutralizer valve
valve to neutralizer valve
2-Rotary selector spool
2-Pilot oil flows to 2-Pilot oil flows to blocks charge pump oil
neutralizer valve neutralizer valve to neutralizer valve
3-Rotary selector spool 3-Charge pump oil flows 3-Charge pump oil flows
blocks charge pump oil to priority reduction to priority reduction
to neutralizer valve valve valve
3. During an upshift, the following occurs:
A. 1-Charge pump moves B. 1-Upshift solenoid is C. 1-Rotary actuator oil

the upshift valve energized moves the downshift
valve
2-Upshift solenoid is 2-Charge pump oil
energized moves the rotary 2-Upshift solenoid is
actuator energized
3-Rotary actuator oil
moves the downshift 3-Rotary actuator moves 3-Charge pump moves
valve the rotary selector the upshift valve
spool
Page: III-44
Directions: After each statement, circle T if the statement is TRUE, and F if the statement is FALSE.
Example: When activated, the shift solenoids allow oil to flow to the T F
rotary actuator.
1. On some ICM transmissions, the Dual Stage Relief Valve is activated T F

during torque converter lockup.
2. On all ICM transmission controls, REVERSE is an upshift from T F

NEUTRAL and the downshift solenoid is activated whenever the
shift lever is in NEUTRAL.
3. When the transmission shift lever is in a speed other than NEUTRAL, T F

the rotary selector spool provides a path to drain for two clutches.
4. On all ICM transmission controls, the priority reduction valve controls T F

the pressure of the "pilot oil" that is used to shift the selector piston
in each station.
5. The load piston orifice in an ICM transmission is a "cascade-type" and T F

controls the modulation of clutch engagement.
6. In an ICM transmission, the "primary pressure setting" in each station T F

can cause harsh shifts when too low and clutch slipping when too high.
7. The "primary pressure settings" are the same for all ICM clutch stations. T F
8. Final clutch pressure is adjusted with shims. T F
9. If the "primary pressure setting" is correct and the final clutch pressure T F
is low, the load piston springs should be replaced.
10. When manually rotating the rotary selector spool with the engine T F
running, power to the shift solenoids must be disconnected.
Page: III-45
Service Training
MALAGA

Student book
SYSTEMS
Adolfo
August 1997

777D Off Highway Truck: Service Training Malaga

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Service Training

777D Off Highway Truck

LOCKUP CLUTCH VALVE

III. POWER TRAIN

TYPICAL OFF-HIGHWAY TRUCK

TORQUE TRANSMISSION TORQUE CONVERTER

TURBINE TORQUE CONVERTER

LOCKUP IMPELLER TORQUE

LOCKUP CLUTCH VALVE

CHAPTER : Power Train

777D Off Highway Truck

LOCKUP CLUTCH VALVE

CHAPTER : Power Train

777D Off Highway Truck

769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

LOCKUP LOCKUP CLUTCH OUTLET

CHAPTER : Power Train

777D Off Highway Truck

CONVERTER PARKING BRAKE

769D - 777D TRANSMISSION

CHAPTER : Power Train

777D Off Highway Truck

769D - 777D TRANSMISSION SELECTOR VALVE

769C - 777C TRANSMISSION SELECTOR VALVE

769D - 777D PRESSURE

CHAPTER : Power Train

769C - 777C TRANSMISSION

CHAPTER : Power Train

PILOT OIL PRIORITY

777D Off Highway Truck

777D SHIFT MODULATION CYCLE

CHAPTER : Power Train

777D Off Highway Truck

COMPLETE CLUTCH ENGAGEMENT

777C SHIFT MODULATION CYCLE

CHAPTER : Power Train

777D Off Highway Truck

COMPLETE CLUTCH ENGAGEMENT

PRESSURE RESTRICTED LOAD PISTON

CHAPTER : Power Train

777D Off Highway Truck

769D - 777D Off-highway Trucks

Torque Converter Hydraulic System

______ Torque Converter Scavenge Screen -

______ Torque Converter Charging Filter -

______ Torque Converter Inlet Relief Valve -

______ Torque Converter Outlet Relief Valve -

______ Torque Converter Lockup Clutch Valve -

______ Parking Brake Release Valve -

______ Parking Brake Release Filter -

______ Lockup Clutch Solenoid Valve -

Transmission Hydraulic System

______ Transmission Pump -

______ Transmission Filter -

______ Transmission Magnetic Suction Screen -

______ Transmission Oil Cooler -

______ Transmission Control Valve -

______ Upshift Solenoid Valve -

______ Downshift Solenoid Valve -

TYPICAL OFF-HIGHWAY TRUCK

CHAPTER : Power Train

777D Off Highway Truck

or number of the item in the D. Outlet Pressure 10. Lockup Solenoid

Machine Model Dealer ________