Manual Power Train Caterpillar 777d Off Highway Truck Components

Service Training
MALAGA
777D Off Highway Truck

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

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

TORQUE CONVERTER
DIRECT DRIVE
TURBINE
LOCKUP
PISTON
TORQUE
CONVERTER
INLET OIL
IMPELLER
TORQUE
CONVERTER
LOCKUP OIL
PASSAGE
ENGINE FLYWHEEL
STATOR
FREEWHEEL
ASSEMBLY
Page:
III-4
TOTRANSFER
GEARS
Page:
III-5
LOCKUP CLUTCH VALVE

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

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

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

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

TO CLUTCH
DECAY ORIFICE
LOAD PISTON
ORIFICE
PLUG

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
ROTARY
ACTUATOR
FILTER
E
PUMP
PRESSURE
OIL COOLER
CHARGING
PUMP
PRIORITY
REDUCTION
VALVE
F
ROTARY
SELECTOR
SPOOL
SCAVENGE
PUMP
G
D
RELIEF
VALVE
TRANSMISSION
CASE
TANK
LUBE
RELIEF VALVE
SELECTOR VALVE
GROUP
LUBE
PRESSURE
PRESSURE CONTROL
GROUP
PILOT OIL
PRESSURE
NEUTRALIZER
VALVE

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 5
CLUTCH 3
COMPLETE CLUTCH ENGAGEMENT
PRIMARY
PRESSURE
50
INITIAL CLUTCH ENGAGEMENT
0
FILL TIME
NORMAL CLUTCH SLIP
TIME
265
CLUTCH 6
373
353
Page:
III-19
777C SHIFT MODULATION CYCLE

SECOND TO THIRD
PRESSURE
NORMAL SHIFT CYCLE
418
373
CLUTCH 3
COMPLETE CLUTCH ENGAGEMENT
80
PRIMARY
PRESSURE
INITIAL CLUTCH ENGAGEMENT
0
FILL TIME
NORMAL CLUTCH SLIP
TIME
CLUTCH 1
265
CLUTCH 6
Page:
III-20
PRESSURE
HIGH
PRIMARY
PRESSURE
RESTRICTED LOAD PISTON

ORIFICE
SLOW MODULATION
P1
COMPLETE CLUTCH
ENGAGEMENT
TIME
HIGH PRIMARY PRESSURE - HARSH

SHIFT
NORMAL CLUTCH
SLIP
LOW PRIMARY PRESSURE - CLUTCH
SLIPPING
SHIFT MODULATION
PROBLEMS
RESTRICTED LOAD PISTON
ORIFICE
CLUTCH SLIPPING
NORMAL
PRIMARY
PRESSURE
LOW
PRIMARY
PRESSURE
INITIAL CLUTCH
ENGAGEMENT

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
B. Parking Brake Release Pressure

C. Lockup Clutch Pressure
D. Outlet Pressure
E. Pilot Pressure
Identify Components
1. Outlet Relief Valve
7. Inlet Relief Valve
2. Parking Brake Release Valve
8. Lockup Modulation Valve
3. Converter Charging Pump
9. Scavenge Pump
III-24
4. Torque Converter
10. Lockup Solenoid
5. Lockup Reducing Valve
11. Shuttle Valve
6. Parking Brake Release Pump
12. Lockup Clutch
Page:
Directions: Write the letter

or number of the item in the
correct blank on the
schematic.
A. Inlet Pressure
Worksheet I: (769D - 777D)
Identify Test Ports
LAB EXERCISES
Lab B: Torque Converter

Hydraulic System
Component Identification

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
TEST
______ Check 8 - Inspect return oil screen
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
III-27
Page:
769D - 777D TORQUE

CONVERTER
HYDRAULIC SYSTEM
TORQUE CONVERTER
DRIVE
LAB EXERCISES
TO BRAKE
COOLING
CIRCUIT
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
III-28
LAB EXERCISES
Page:
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:
5. When the lockup solenoid opens and the shuttle

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
E
ON
B
F
C
G
Identify Test Ports
Identify Components
6. Priority Reduction Valve
12. Neutralizer valve
7. Main Relief Valve
13. Oil Cooler
B. Pump Pressure
2. Pressure Control Group
8. Scavenge Pump
14. Filter
C. Lube Pressure
3. Rotary Selector Spool
9. Downshift Solenoid
15. Screen
III-30
1. Charging Pump
Page:
A. Downshift Pressure
Worksheet I
Directions: Write the letter or

D. Upshift Pressure
number of the item in the
correct blank on the schematic. E. Pilot Pressure
4. Upshift Solenoid
10. Rotary Actuator
5. Lube Relief Valve
11. Selector Valve Group
16. A to C and E to H
Lab F: Transmission
Hydraulic System
Component
Identification
(769D - 777D)
LAB EXERCISES
VALVE STATION
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.
B. Pilot Pressure
7. Load Piston Orifice
9. Decay Orifice
3. Load Piston Plug

4. Pilot Oil Passage
10. Clutch Pressure Tap
III-31
8. Load Piston
Page:
2. Selector Piston
5. Pin
11. Slug
6. Pilot Oil Plug
12. Modulation Reduction Valve
Identify Components
Identify Test Ports
1. Ball Check Valve
A. Primary and Clutch Pressures
TO CLUTCH
LAB EXERCISES
FROM PUMP

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

S PECS
LOW
IDLE
HIGH
IDLE
ACTU AL
LOW
IDLE
HIGH
IDLE
PU MP PRES S U RE
S PECS
LOW
IDLE
PILOT PRES S U RE
HIGH
IDLE
NO
ACTU AL
LOW
IDLE
HIGH
IDLE
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.
CLU TCH CHART

N
PRIMARY CLU TCH PRES S U RE

AT LOW IDLE
(LOAD PIS TON PLU G REMOVED)
STATION
CLUTCH
SPECS
ACTUAL
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
IDLE
HIGH
IDLE
LOW
IDLE
HIGH
IDLE
A
B
C
D
E
F
G
H
Page:
III-34

POSTTEST
As this component moves and closes a drain passage,
modulation will begin
1. Load Piston
2. Pilot Oil Passage
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
3. Decay Orifice
4. Load Piston Plug
5. Modulation Reduction
Valve
6. Load Piston Orifice
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

remain at the primary pressure
10. Selector Piston

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
Primary Pressure
VALVE STATION
15
14
Pilot Pressure
10
Clutch Pressure
11
Components
Load Piston Plug
Modulation Reduction
Valve
Load Piston Orifice
Ball Check Valve
Clutch Pressure Tap
Page:
Pilot Oil Plug

Selector Piston
III-36
Slug
Pin
6
5
FROM PUMP
4
TO CLUTCH
3
8
12
Decay Orifice
Pilot Oil Passage
POSTTEST
Load Piston

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
A. 1-Pump oil is directed

through load piston
orifice
2-Pump oil is directed to
clutch
3-Modulation reduction
valve moves
B. 1-Rotary selector spool

to drain
C. 1-Selector piston opens

drain
2-Selector piston opens

drain

directed through
decay orifice

directed through
decay orifice
3-Rotary selector spool

to drain
B. 1-Pump oil is directed to

clutch
C. 1-Modulation reduction
valve moves
2-Modulation reduction
valve moves
2-Pump oil is directed to

clutch
3-Pump oil is directed

through load piston
orifice
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
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

Test Ports
Parking Brake Release
Pressure
Pilot Pressure
E
Outlet Pressure
Inlet Pressure
TO BRAKE
COOLING CIRCUIT
Lockup Clutch Pressure
7
10
TO BRAKE
COOLING
CIRCUIT
A
5
Components

Valve
12
6
B
3
Outlet Relief Valve

Lockup Modulation Valve
Converter Charging Pump
Page:
Scavenge Pump
III-39

Pump
Shuttle Valve
769D - 777D TORQUE CONVERTER

HYDRAULIC SYSTEM
11
Torque Converter
Inlet Relief Valve
POSTTEST
Lockup Solenoid
Lockup Reducing 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
TC drive
2-Ground speed
increases and the
lockup clutch
modulation valve is
activated
3-Lockup clutch engages
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
A. 1-Shuttle valve moves

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

and opens drain
closes
3-Load piston moves
B. 1-Lockup clutch engages

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

pump directs oil to
B. 1-Lockup solenoid valve

opens
2-Shuttle valve moves
and blocks drain
3-Load piston moves
B. 1-Load piston moves

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

pump directs oil to
C. 1-Load piston moves

opens
and blocks drain
C. 1-Lockup solenoid valve

closes
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
1. Charging Pump
2. Pressure Control Group
3. Rotary Selector Spool
4. Upshift Solenoid
Maintains pilot oil pressure

Removes debris from transmission oil
Supplies modulated pressures to clutches
5. Oil Cooler Relief Valve

6. Priority Reduction Valve
7. Main Relief Valve
8. Scavenge Pump
Directs oil to move rotary actuator vane clockwise

Maintains maximum system pressure
Chooses appropriate clutch combinations for each speed
9. Downshift Solenoid
10. Rotary Actuator
11. Selector Valve Group
12. Neutralizer Valve
Six valve clutch stations

Moves rotary selector spool
Keeps machine from moving if transmission is started in
gear
13. Oil Cooler

14. Filter
15. Manifold
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
Pump Pressure

Upshift Pressure
Downshift Pressure
Pilot Pressure
Lube Pressure
Components
Scavenge Pump
Priority Reduction Valve
Rotary Selector Spool
14
Neutralizer Valve
12
Pressure Control Group

Main Relief Valve
E
13
F
3
8
G
Charging Pump
D
Downshift Solenoid
Filter
Selector Valve Group
Page:
Upshift Solenoid
15
16
5
11
C
Oil Cooler
Rotary Actuator
III-43
Screen
769D- 777D TRANSMISSION

HYDRAULIC SYSTEM
A to C and E to H
POSTTEST
Lube Relief Valve
10
ON

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
B. 1-Rotary actuator moves

to FIRST SPEED
FORWARD
3-Rotary actuator moves

to FIRST SPEED
FORWARD
C. 1-Upshift solenoid is
energized
2-Downshift solenoid is
de-energized

to FIRST SPEED
FORWARD
energized
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
B. 1-Pilot oil flows through

one station
energized
energized
3-Neutralizer valve
moves
C. 1-Downshift solenoid is
energized
2-Neutralizer valve
moves
3-Pilot oil flows through
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
B. 1-Rotary selector spool

blocks charge pump oil
to neutralizer valve
C. 1-Pilot oil flows to

neutralizer valve
2-Pilot oil flows to

neutralizer valve
2-Pilot oil flows to

neutralizer valve


3-Charge pump oil flows

valve
3-Charge pump oil flows

valve
3. During an upshift, the following occurs:

A. 1-Charge pump moves
the upshift valve
energized
3-Rotary actuator oil
moves the downshift
valve
B. 1-Upshift solenoid is
energized
2-Charge pump oil
moves the rotary
actuator
the rotary selector
spool
C. 1-Rotary actuator oil

moves the downshift
valve
energized
3-Charge pump moves
the upshift 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.
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.
Page:
III-45
Service Training
MALAGA

Student book
SYSTEMS
Adolfo
August 1997

Manual Power Train Caterpillar 777d Off Highway Truck Components

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Service Training

777D Off Highway Truck

III. POWER TRAIN

777D Off Highway Truck

TYPICAL OFF-HIGHWAY TRUCK

777D Off Highway Truck

777D Off Highway Truck

LOCKUP CLUTCH VALVE

777D Off Highway Truck

CHAPTER : Power Train

LOCKUP CLUTCH VALVE

777D Off Highway Truck

CHAPTER : Power Train

769D - 777D TORQUE CONVERTER HYDRAULIC SYSTEM

777D Off Highway Truck

CHAPTER : Power Train

769D - 777D TRANSMISSION

777D Off Highway Truck

CHAPTER : Power Train

777D Off Highway Truck

769D - 777D TRANSMISSION SELECTOR VALVE

777D Off Highway Truck

769C - 777C TRANSMISSION SELECTOR VALVE

777D Off Highway Truck

769D - 777D PRESSURE

BALL CHECK VALVE

LOAD PISTON PLUG

CLUTCH PRESSURE TAP

777D Off Highway Truck

CHAPTER : Power Train

777D Off Highway Truck

777D Off Highway Truck

777D Off Highway Truck

769C - 777C TRANSMISSION

777D Off Highway Truck

CHAPTER : Power Train

777D Off Highway Truck

777D SHIFT MODULATION CYCLE

COMPLETE CLUTCH ENGAGEMENT

INITIAL CLUTCH ENGAGEMENT

777D Off Highway Truck

CHAPTER : Power Train

777C SHIFT MODULATION CYCLE

COMPLETE CLUTCH ENGAGEMENT

INITIAL CLUTCH ENGAGEMENT

777D Off Highway Truck

CHAPTER : Power Train

RESTRICTED LOAD PISTON

HIGH PRIMARY PRESSURE - HARSH

777D Off Highway Truck

CHAPTER : Power Train

777D Off Highway Truck

______ 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 -

777D Off Highway Truck

______ Transmission Filter -

______ Transmission Magnetic Suction Screen -

______ Transmission Oil Cooler -