777D Off Highway Truck: Service Training Malaga

Service Training MALAGA
777D Off Highway Truck

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

1. 2. 3. 4. Components Layout Operation Maintenance Testing & Adjusting
Adolfo August 1997

CHAPTER : Power Train
TYPICAL OFF-HIGHWAY TRUCK POWER TRAIN COMPONENT LOCATIONS

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

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

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

CLUTCH FILLING
SELECTOR PISTON SHIMS
III-5
LOAD PISTON
LOAD PISTON ORIFICE MODULATION REDUCTION VALVE LOCKUP SOLENOID ON
PRESSURE REDUCTION VALVE
SHUTTLE VALVE
TO LOCKUP CLUTCH
Page: III-6
LOCKUP CLUTCH VALVE

DIRECT DRIVE
SELECTOR PISTON
LOAD PISTON
LOAD PISTON ORIFICE MODULATION REDUCTION VALVE LOCKUP SOLENOID ON
PRESSURE REDUCTION VALVE
SHUTTLE VALVE
TO LOCKUP CLUTCH
Page: III-7
769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

NEUTRAL
INLET RELIEF VALVE LOCKUP CLUTCH PILOT OIL PRESSURE LOCKUP MODULATION PARKING BRAKE VALVE RELIEF VALVE TO BRAKE COOLING CIRCUIT BRAKE COOLING PRESSURE
OUTLET RELIEF VALVE
LOCKUP CLUTCH PRESSURE
OUTLET PRESSURE TAP
INLET PRESSURE
LOCKUP SOLENOID
LOCKUP REDUCING VALVE
TO BRAKE COOLING CIRCUIT
PARKING BRAKE RELEASE VALVE
LOCKUP CLUTCH
TORQUE CONVERTER
SHIMS
CONVERTER CHARGING PUMP
PARKING BRAKE RELEASE PRESSURE
CONVERTER SCAVENGE PUMP SCREEN
PARKING BRAKE RELEASE PUMP
Page: III-8
769D - 777D TRANSMISSION HYDRAULIC SYSTEM

NEUTRAL
DOWNSHIFT PRESSURE DOWNSHIFT UPSHIFT SOLENOID SOLENOID FILTER ON PUMP PRESSURE
UPSHIFT PRESSURE
A
ROTARY ACTUATOR
E B
NEUTRALIZER VALVE
PILOT OIL PRESSURE OIL COOLER CHARGING PUMP SCAVENGE PUMP
PRIORITY REDUCTION VALVE
F
ROTARY SELECTOR SPOOL
RELIEF VALVE TRANSMISSION CASE
D H
TANK
LUBE RELIEF VALVE
SELECTOR VALVE GROUP LUBE PRESSURE
PRESSURE CONTROL GROUP

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
NEUTRALIZER VALVE 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
G D
Page:
III-11
Page:
VALVE STATION
CLUTCH RELEASED
III-12
SELECTOR PISTON SLUG BALL CHECK VALVE LOAD PISTON
PILOT OIL PASSAGE
PLUG DECAY ORIFICE LOAD PISTON ORIFICE MODULATION REDUCTION VALVE FROM PUMP LOAD PISTON PLUG
CLUTCH PRESSURE TAP 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 PRESSURE
UPSHIFT PRESSURE
A
DOWNSHIFT UPSHIFT SOLENOID SOLENOID FILTER ROTARY ACTUATOR
E
PUMP PRESSURE
NEUTRALIZER VALVE PILOT OIL PRESSURE OIL COOLER CHARGING PUMP SCAVENGE PUMP PRIORITY REDUCTION VALVE
F
G D
RELIEF VALVE TRANSMISSION CASE
TANK
LUBE RELIEF VALVE SELECTOR VALVE GROUP LUBE PRESSURE
PRESSURE CONTROL GROUP

VALVE STATION
PRIMARY PRESSURE
LOAD PISTON PLUG (REMOVED)
Page:
III-17
Page: III-18 418 373 353 265 50 0 FILL TIME NORMAL CLUTCH SLIP
777D SHIFT MODULATION CYCLE

THIRD(3&6) TO FOURTH (1&5)
PRESSURE
NORMAL SHIFT CYCLE CLUTCH 1 CLUTCH 6 CLUTCH 5
CLUTCH 3
COMPLETE CLUTCH ENGAGEMENT
PRIMARY PRESSURE
INITIAL CLUTCH ENGAGEMENT
TIME
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
80 0
INITIAL CLUTCH ENGAGEMENT
FILL TIME NORMAL CLUTCH SLIP
TIME
Page: III-20
PRESSURE
HIGH PRIMARY PRESSURE
RESTRICTED LOAD PISTON ORIFICE SLOW MODULATION P1
COMPLETE CLUTCH ENGAGEMENT LOW PRIMARY PRESSURE INITIAL CLUTCH ENGAGEMENT
NORMAL PRIMARY PRESSURE
0
HIGH PRIMARY PRESSURE - HARSH SHIFT NORMAL CLUTCH SLIP LOW PRIMARY PRESSURE - CLUTCH SLIPPING
TIME
SHIFT MODULATION PROBLEMS

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
LAB EXERCISES
Lab B: Torque Converter Hydraulic System Component Identification

Worksheet I: (769D - 777D) Directions: Write the letter or number of the item in the correct blank on the schematic. Page: III-24
Identify Test Ports A. Inlet Pressure B. Parking Brake Release Pressure C. Lockup Clutch Pressure D. Outlet Pressure E. Pilot Pressure
Identify Components 1. Outlet Relief Valve 2. Parking Brake Release Valve 3. Converter Charging Pump 4. Torque Converter 5. Lockup Reducing Valve 6. Parking Brake Release Pump 7. Inlet Relief Valve 8. Lockup Modulation Valve 9. Scavenge Pump 10. Lockup Solenoid 11. Shuttle Valve 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______________________ Name/Code _________________________ Machine PIN (S/N)___________________ Transmission S/N ____________________ Engine S/N _________________________ S.M.H. ____________________________ Dealer ______________________________ Customer ___________________________ Job ________________________________ Application __________________________ Date _______________________________ 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 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
SPECS
ACTUAL
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.
LAB EXERCISES
769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM TORQUE CONVERTER DRIVE
Page: 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.
LAB EXERCISES
Page: III-28
769C - 777C TORQUE CONVERTER HYDRAULIC SYSTEM DIRECT DRIVE

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 following speeds: A. REVERSE and FIRST B. second half of FIRST through SEVENTH C. NEUTRAL to FIRST 5. When the lockup solenoid opens and the shuttle valve moves, the shuttle valve: A. opens a passage to drain B. closes a passage to drain 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 G D H
LAB EXERCISES
Lab F: Transmission Hydraulic System Component Identification (769D - 777D)

Page: III-30
Identify Test Ports A. Downshift Pressure B. Pump Pressure C. Lube Pressure
Identify Components 1. Charging Pump 2. Pressure Control Group 3. Rotary Selector Spool 4. Upshift Solenoid 5. Lube Relief Valve
6. Priority Reduction Valve 7. Main Relief Valve 8. Scavenge Pump 9. Downshift Solenoid 10. Rotary Actuator 11. Selector Valve Group
12. Neutralizer valve 13. Oil Cooler 14. Filter 15. Screen 16. A to C and E to H
Worksheet I
Directions: Write the letter or D. Upshift Pressure number of the item in the correct blank on the schematic. E. Pilot Pressure
Lab F: 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.
VALVE STATION
LAB EXERCISES
FROM PUMP TO CLUTCH
Identify Components Identify Test Ports 1. Ball Check Valve A. Primary and Clutch Pressures B. Pilot Pressure Page: III-31 2. Selector Piston 3. Load Piston Plug 4. Pilot Oil Passage 5. Pin 6. Pilot Oil Plug
7. Load Piston Orifice 8. Load Piston 9. Decay Orifice 10. Clutch Pressure Tap 11. Slug 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______________________ Name/Code _________________________ Machine PIN (S/N)___________________ Transmission S/N ____________________ Engine S/N _________________________ S.M.H. ____________________________ Dealer ______________________________ Customer ___________________________ Job ________________________________ Application __________________________ Date _______________________________ Serviceman __________________________
VISUAL CHECKS
______ Check 1 - Oil levels in the hydraulic tank ______ Check 5 - Transmission case oil quantity ______ Check 2 - External leakage ______ Check 3 - Oil filter examination ______ Check 4 - Magnetic screen debris DU AL S TAGE RELIEF LOCKU P CLU TCH DEACTIVATED S PECS LOW IDLE PU MP PRES S U RE DU AL S TAGE RELIEF LOCKU P CLU TCH ACTIVATED S PECS LOW IDLE PU MP PRES S U RE S PECS LOW IDLE PILOT PRES S U RE LU BE PRES S U RE HIGH IDLE NO LOW IDLE ACTU AL HIGH IDLE NO HIGH IDLE LOW IDLE ACTU AL HIGH IDLE HIGH IDLE LOW IDLE ACTU AL HIGH IDLE ______ Check 6 - Transmission oil tank debris
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 AT LOW IDLE (LOAD PIS TON PLU G REMOVED) STATION CLUTCH SPECS ACTUAL A B C D E F G H
CLU TCH CHART N R 1 2 3 4 5 6 7
PRIMARY CLU TCH PRES S U RE AT LOW IDLE (LOAD PIS TON PLU G IN S TALLED) S PECS ACTU AL S TATION A B C D E F G H CLU TCH LOW IDLE HIGH IDLE LOW IDLE HIGH IDLE
Page:
III-34

POSTTEST
As this component moves and closes a drain passage, modulation will begin Removal of this component allows the technician to check pilot pressure Allows oil from the rotary selector spool to move the selector piston Controls the rate of clutch engagement Works with the modulation reduction valve to control clutch pressure Allows clutch pressure to be directed into the center chamber of the modulation reduction valve Allows the technician to check clutch pressure Removal of this component causes the clutch pressure to remain at the primary pressure 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. 1. Load Piston 2. Pilot Oil Passage 3. Decay Orifice 4. Load Piston Plug 5. Modulation Reduction Valve 6. Load Piston Orifice 7. Ball Check Valve 8. Clutch Pressure Tap 9. Pilot Pressure Plug 10. Selector Piston 11. Slug
Page:
III-35
Directions: Match the components and test ports with the associated number or letter. (Each question is worth 1 point.)
13 1
VALVE STATION
Test Ports Primary Pressure Pilot Pressure Clutch Pressure Components Load Piston Pilot Oil Passage Decay Orifice Load Piston Plug Modulation Reduction Valve Load Piston Orifice Ball Check Valve Clutch Pressure Tap Pilot Oil Plug Selector Piston Slug Pin Page: III-36
15
14
10 11
POSTTEST
7 9 2 6 5
FROM PUMP
3 8 12
4
TO CLUTCH

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. C. 1-Modulation begins A. 1-Pilot oil moves B. 1-Selector piston closes selector piston drain 2-Load piston moves reducing valve 2-Selector piston closes 2-Pilot oil moves drain selector piston 3-Selector piston closes drain 3-Load piston moves 3-Modulation begins reducing valve 4-Pilot oil moves 4-Load piston moves selector piston 4-Modulation begins reducing valve
A. 1-Rotary selector spool opens pilot oil passage to drain 2-Load piston oil is directed through decay orifice 3-Selector piston opens drain
B. 1-Rotary selector spool opens pilot oil passage to drain 2-Selector piston opens drain 3-Load piston oil is directed through decay orifice
C. 1-Selector piston opens drain 2-Load piston oil is directed through decay orifice 3-Rotary selector spool opens pilot oil passage to drain
A. 1-Pump oil is directed through load piston orifice 2-Pump oil is directed to clutch 3-Modulation reduction valve moves
B. 1-Pump oil is directed to clutch 2-Modulation reduction valve moves 3-Pump oil is directed through load piston orifice
C. 1-Modulation reduction valve moves 2-Pump oil is directed to clutch 3-Pump oil is directed through load piston 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 Supplies oil for hydraulic energy transfer Maintains working pressure within the torque converter When energized, supplies pilot oil to initiate direct drive Relieves excess pressure to the torque converter Provides a controlled rate of engagement of the lockup clutch Transfers engine power to the transmission Reduces pump supply pressure to pilot pressure Supplies oil to the lockup clutch 1. Lockup Solenoid 2. Inlet Relief Valve 3. Torque Converter 4. Lockup Reducing Valve 5. Parking Brake Release Valve 6. Outlet Relief Valve 7. Lockup Modulation Valve 8. Converter Charging Pump 9. Diverter Valve 10. Parking Brake Release Pump 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. 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 components and test ports with the associated number or letter.
Test Ports Parking Brake Release Pressure Pilot Pressure

E
Outlet Pressure
8 C
D 1
Inlet Pressure Lockup Clutch Pressure Components Lockup Solenoid Inlet Relief Valve
TO BRAKE COOLING CIRCUIT 10 5 A
7 TO BRAKE COOLING CIRCUIT
POSTTEST
11
Torque Converter Lockup Reducing Valve Parking Brake Release Valve Outlet Relief Valve Lockup Modulation Valve Converter Charging Pump Page: III-39 Scavenge Pump Parking Brake Release Pump Shuttle Valve
6
9 12
B 3
769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

POSTTEST
Directions: Use the schematic on page 41. After each statement, circle the correct sequence of events that occurs. Example: The operator makes a shift from NEUTRAL to FIRST FORWARD and the ground speed increases. A. 1-Torque converter is in TC drive 2-Ground speed increases and the lockup clutch modulation valve is activated 3-Lockup clutch engages B. 1-Lockup clutch engages 2-Ground speed increases and the lockup clutch modulation valve is activated 3-Torque converter is in TC drive C. 1-Ground speed increases and the lockup clutch modulation valve is activated 2-Lockup clutch engages 3-Torque converter is in TC drive
A. 1-Parking brake release oil directed to lockup modulation valve spool 2-Pilot oil directed to lockup solenoid valve 3-Parking brake release pump directs oil to lockup reducing valve
B. 1-Parking brake release oil directed to lockup modulation valve spool 2-Parking brake release pump directs oil to lockup reducing valve 3-Pilot oil directed to lockup solenoid valve
C. 1-Parking brake release pump directs oil to lockup reducing valve 2-Pilot oil directed to lockup solenoid valve 3-Parking brake release oil directed to lockup modulation valve spool
A. 1-Shuttle valve moves and blocks drain 2-Load piston moves 3-Lockup solenoid valve opens
B. 1-Lockup solenoid valve opens 2-Shuttle valve moves and blocks drain 3-Load piston moves
C. 1-Load piston moves 2-Lockup solenoid valve opens 3-Shuttle valve moves and blocks drain
A. 1-Shuttle valve moves and opens drain 2-Lockup solenoid valve closes 3-Load piston moves
B. 1-Load piston moves 2-Shuttle valve moves and opens drain 3-Lockup solenoid valve closes
C. 1-Lockup solenoid valve closes 2-Shuttle valve moves and opens drain 3-Load piston moves
Page:
III-40

POSTTEST
Directions: Match the component to its primary function.
Regulates pressure inside oil cooler Reduces temperature of transmission oil Removes oil from transmission case Maintains pilot oil pressure Removes debris from transmission oil Supplies modulated pressures to clutches Directs oil to move rotary actuator vane clockwise Maintains maximum system pressure Chooses appropriate clutch combinations for each speed Six valve clutch stations Moves rotary selector spool Keeps machine from moving if transmission is started in gear Supplies oil to all clutches Directs oil to move rotary actuator vane counterclockwise Maintains and directs oil pressures to the pressure control group
1. Charging Pump 2. Pressure Control Group 3. Rotary Selector Spool 4. Upshift Solenoid 5. Oil Cooler Relief Valve 6. Priority Reduction Valve 7. Main Relief Valve 8. Scavenge Pump 9. Downshift Solenoid 10. Rotary Actuator 11. Selector Valve Group 12. Neutralizer Valve 13. Oil Cooler 14. Filter 15. Manifold 16. A through H
Page:
III-41

POSTTEST
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. 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 Pump Pressure Upshift Pressure Downshift Pressure Pilot Pressure Lube Pressure Components Scavenge Pump Priority Reduction Valve Rotary Selector Spool Neutralizer Valve Lube Relief Valve A to C and E to H Pressure Control Group Main Relief Valve Charging Pump Downshift Solenoid Filter Selector Valve Group Upshift Solenoid Oil Cooler Rotary Actuator III-43 Screen Page:
Directions: Match the components and test ports with the associated number or letter.
A 9 14 B ON 12 E 13 8 6 10 4
D A
POSTTEST
F 3 C
D H 15 16 2
5 11 C
769D- 777D TRANSMISSION HYDRAULIC SYSTEM

Directions: Use the schematic on page 45. After each statement, circle the correct sequence of events that occurs. Example: The operator has moved the shift lever from NEUTRAL to FIRST FORWARD. A. 1-Downshift solenoid is de-energized 2-Upshift solenoid is energized 3-Rotary actuator moves to FIRST SPEED FORWARD B. 1-Rotary actuator moves to FIRST SPEED FORWARD 2-Downshift solenoid is de-energized 3-Upshift solenoid is energized C. 1-Upshift solenoid is energized 2-Rotary actuator moves to FIRST SPEED FORWARD 3-Downshift solenoid is de-energized
1. The engine is started with the transmission in NEUTRAL. A. 1-Neutralizer valve moves 2-Pilot oil flows through rotary selector spool to one station 3-Downshift solenoid is energized B. 1-Pilot oil flows through rotary selector spool to one station 2-Downshift solenoid is energized 3-Neutralizer valve moves C. 1-Downshift solenoid is energized 2-Neutralizer valve moves 3-Pilot oil flows through rotary selector spool to one station
2. The engine is started with the gear shift lever in FIRST SPEED FORWARD. A. 1-Charge pump oil flows to priority reduction valve 2-Pilot oil flows to neutralizer valve 3-Rotary selector spool blocks charge pump oil to neutralizer valve 3. During an upshift, the following occurs: A. 1-Charge pump moves the upshift valve 2-Upshift solenoid is energized 3-Rotary actuator oil moves the downshift valve B. 1-Upshift solenoid is energized 2-Charge pump oil moves the rotary actuator 3-Rotary actuator moves the rotary selector spool C. 1-Rotary actuator oil moves the downshift valve 2-Upshift solenoid is energized 3-Charge pump moves the upshift valve B. 1-Rotary selector spool blocks charge pump oil to neutralizer valve 2-Pilot oil flows to neutralizer valve 3-Charge pump oil flows to priority reduction valve C. 1-Pilot oil flows to neutralizer valve 2-Rotary selector spool blocks charge pump oil to neutralizer valve 3-Charge pump oil flows to priority reduction valve
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 rotary actuator. T F
1. On some ICM transmissions, the Dual Stage Relief Valve is activated during torque converter lockup. 2. On all ICM transmission controls, REVERSE is an upshift from 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, the rotary selector spool provides a path to drain for two clutches. 4. On all ICM transmission controls, the priority reduction valve controls 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 controls the modulation of clutch engagement. 6. In an ICM transmission, the "primary pressure setting" in each station 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. 8. Final clutch pressure is adjusted with shims. 9. If the "primary pressure setting" is correct and the final clutch pressure is low, the load piston springs should be replaced. 10. When manually rotating the rotary selector spool with the engine running, power to the shift solenoids must be disconnected.
T T T
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Service Training MALAGA
777D Off Highway Truck Student book
SYSTEMS
Adolfo August 1997

777D Off Highway Truck: Service Training Malaga

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777D Off Highway Truck: Service Training Malaga

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Service Training MALAGA

777D Off Highway Truck

MODULATION REDUCTION VALVE LOCKUP SOLENOID OFF

LOAD PISTON ORIFICE PRESSURE REDUCTION VALVE

FROM PARKING BRAKE PUMP

III. POWER TRAIN

777D Off Highway Truck

TYPICAL OFF-HIGHWAY TRUCK POWER TRAIN COMPONENT LOCATIONS

TORQUE CONVERTER FILTER

TRANSMISSION OIL FILTER

TORQUE CONVERTER AND TRANSMISSION OIL

INLET AND OUTLET RELIEF VALVES

TRANSMISSION TRANSMISSION CONTROL VALVE DIFFERENTIAL AND FINAL DRIVES

LOCKUP CLUTCH TORQUE CONVERTER TORQUE TRANSFER CONVERTER GEARS PUMP

777D Off Highway Truck

TURBINE LOCKUP PISTON

STATOR ENGINE FLYWHEEL

777D Off Highway Truck

LOCKUP CLUTCH VALVE

LOAD PISTON ORIFICE MODULATION REDUCTION VALVE LOCKUP SOLENOID ON

CHAPTER : Power Train

PRESSURE REDUCTION VALVE

777D Off Highway Truck

FROM PARKING BRAKE PUMP

LOCKUP CLUTCH VALVE

LOAD PISTON ORIFICE MODULATION REDUCTION VALVE LOCKUP SOLENOID ON

CHAPTER : Power Train

PRESSURE REDUCTION VALVE

777D Off Highway Truck

FROM PARKING BRAKE PUMP

769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

OUTLET RELIEF VALVE

LOCKUP CLUTCH PRESSURE

OUTLET PRESSURE TAP

CHAPTER : Power Train

LOCKUP REDUCING VALVE

TO BRAKE COOLING CIRCUIT

777D Off Highway Truck

PARKING BRAKE RELEASE VALVE

CONVERTER CHARGING PUMP

PARKING BRAKE RELEASE PRESSURE

CONVERTER SCAVENGE PUMP SCREEN

PARKING BRAKE RELEASE PUMP

769D - 777D TRANSMISSION HYDRAULIC SYSTEM

DOWNSHIFT PRESSURE DOWNSHIFT UPSHIFT SOLENOID SOLENOID FILTER ON PUMP PRESSURE

PILOT OIL PRESSURE OIL COOLER CHARGING PUMP SCAVENGE PUMP

PRIORITY REDUCTION VALVE

CHAPTER : Power Train

777D Off Highway Truck

RELIEF VALVE TRANSMISSION CASE

LUBE RELIEF VALVE

SELECTOR VALVE GROUP LUBE PRESSURE

PRESSURE CONTROL GROUP

777D Off Highway Truck

769D - 777D TRANSMISSION SELECTOR VALVE GROUP

TRANSM. LUBE RELIEF VALVE

777D Off Highway Truck

769C - 777C TRANSMISSION SELECTOR VALVE GROUP

NEUTRALIZER VALVE PRIORITY REDUCTION VALVE

ROTARY SELECTOR SPOOL

PILOT OIL PRESSURE SCREEN RELIEF VALVE

LUBE RELIEF VALVE