Service Training

777D Off Highway Truck

OFF-HIGHWAY TRUCK AIR SYSTEM
OIL COOLED FRONT BRAKES (ATTACHMENT)
AIR
COMPRESSOR

AIR DRYER

RELIEF
VALVE

AIR RESERVOIR
(SERVICE)
ONE WAY CHECK VALVE
RELIEF VALVE

GOVERNOR

AIR RESERVOIR
(SERVICE)
CAB ENCLOSURE

DRAIN VALVE

SENSOR FOR
BRAKE AIR
PRESSURE

PRESSURE
PROTECTION VALVE

RELAY
VALVE

DIVERTER
VALVE

RETARDER
CONTROL
VALVE
PRESSURE
SWITCH
STOP LAMP

DOUBLE
CHECK
VALVE

AIR
PRESSURE
GAGE

SERVICE
BRAKE
CONTROL
VALVE

PRESSURE
SWITCH
RET/ SERV TO
EPTCII

SOLENOID
VALVE

PARKING
CONTROL
VALVE

SHUTTLE
VALVE

SECONDARY
CONTROL
VALVE

INVERSION
VALVE
HORN
VALVE

WIPER
MOTOR

AIR RESERVOIR
( SECONDARY )

AIR HORN

WINDSHIELD WIPER VALVE

ONE
WAY
CHECK
VALVE

BRAKE
BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )

PARK/SECONDARY BRAKE
CONTROL VALVE

V. SISTEMA NEUMTICO Y DE FRENOS.

1.
2.
3.
4.

Ubicacin de Componentes
Operacin
Mantenimiento
Pruebas y Ajustes

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

777D UBICACIN DE COMPONENTES DEL

SISTEMA NEUMTICO Y DE FRENOS
BOMBA DE VLVULA DE FRENOS
REMOLQUEDE ESTACIONAMIENTO

VLVULA DOBLE
VLVULA
CHECK
DE INVERSIN

ENFRIADOR DE ACEITE DEL

TC & FRENOS

VLVULA DOUBLE
CHECK
VLVULA DEL
RETARDADOR

SLACK
ADJUSTER

CABINA
VLVULA
RELAY

VLVULA DE FRENOS
VLVULA DE FRENOS
TANQUES DE AIRE
SECUNDARIOS
DE SERVICIO
VLVULA DIVERTER
FRENOS DE SERVICIO
DE REMOLQUE
TANQUE DE FRENOS
VLVULA RATIO
SECUNDARIOS
ENFRIADOR DE ACEITE CILNDROS DE FRENOS Y
LEVANTE Y FRENOS
TANQUE DE RELLENO
VLVULA
PROTECTORA DE
PRESIN
BOMBA DE
REMOLQUE

SECADOR DE AIRE

BOMBA DE
BOMBA DE REFRIGERACIN
BOMBA DE
BARRIDO DEL BOMBA DE
DE FRENOS DELANTEROS
CARGA
CONVERTIDOR DESAPLICACIN
DEL CONVERTIDOR
FRENOS DE
ESTACIONAMIENTO

Pgina:

V-1

Pgina:

OFF-HIGHWAY TRUCK AIR SYSTEM

DISC & CALIPER (STANDARD)

V-2

AIR
COMPRESSOR

AIR DRYER

RELIEF
VALVE

AIR RESERVOIR
(SERVICE)
ONE WAY CHECK VALVE
RELIEF VALVE

GOVERNOR

AIR RESERVOIR
(SERVICE)
DRAIN VALVE

CAB ENCLOSURE
PRESSURE
PROTECTION VALVE

FRONT BRAKE
ON/OFF
VALVE

RELAY
VALVE
(FRONT)

RELAY
VALVE
(REAR)

RETARDER
CONTROL
VALVE

AIR
PRESSURE
GAGE

SERVICE
BRAKE
CONTROL
VALVE

PARKING
CONTROL
VALVE
INVERSION
VALVE

SECONDARY
CONTROL
VALVE

HORN
VALVE
WIPER
MOTOR

AIR RESERVOIR
( SECONDARY )

AIR HORN

WINDSHIELD WIPER VALVE

ONE
WAY
CHECK
VALVE

BRAKE
BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )

PARK/SECONDARY BRAKE
CONTROL VALVE

777D Off Highway Truck

FRONT BRAKE
RATIO VALVE
DOUBLE
CHECK
VALVE

CAPTULO: AIRE Y FRENOS

DOUBLE
CHECK
VALVE

Pgina:

SISTEMA NEUMTICO DE CAMINES FUERA DE CARRETERA

FRENOS DELANTEROS ENFRIADOS POR ACEITE (OPCIONAL)

V-3

COMPRESOR
DE AIRE

SECADOR DE AIRE

VLVULA DE
ALVIOE

TANQUE DEAIRE
(SERVICIO)
VLVULA CHECK
VLV. ALIVIO

GOVERNOR

TANQUE DE AIRE
(SERVICIO)
CABINA

VLVULA DE DRENAJE

SENSOR DE
PRESIN DE
AIRE FRENOS

VLVULA PROTECTORA
DE PRESIN

VLVULA
RELAY

VLVULA
DIVERTER

VLVULA DE
CONTROL
DEL RETARDADOR

VLVULA DE
CONTROL
FRENOS
DE SERVICIO

MEDIDOR DE
PRESIN
DE AIRE

VLVULA
SOLENOIDE

VLVULA DE
CONTROL
FRENOS PARQUEO

VLVULA
SHUTTTLE

VLVULA DE
CONTROL FRENOS
SECUNDARIOS

VLVULA DE
INVERSIN
VLVULA
DEL CLAXON
V LVULA
CH ECK

MOTOR DEL
LIMPIAPARABRISAS

TANQUE DE AIRE
( SECUNDARIO )

CLAXON

VLVULA DEL LIMPIAPARABRISAS

CILNDRO DE
FRENOS
(POSTERIOR )
VLVULA DE CONTROL FRENOS
SECUNDARIOS/ESTACIONAMIENTO

CILNDRO DE
FRENOS
( FRONT )

777D Off Highway Truck

VLVULA
DOBLE
CHECK

SWITCH DE
PRESIN
RET/ SERV A
EPTCII

CAPTULO: AIRE Y FRENOS

SWITCH DE
PRESIN
LAMPARA DE PARADA

Pgina:
V-4

777D
FRENOS DELANTEROS
ENFRIADOS POR ACEITE

777D Off Highway Truck

PISTN

ACEITE
A PRESIN

CAPTULO: AIRE Y FRENOS

ACEITE DE
ENFRIAMIENTO

TAPN DE SERVICIO
PARA DESENSAMBLAJE

Pgina:
V-5

SISTEMA DE CARGA DE AIRE

COMPRESOR
DE AIRE
Y
GOVERNADOR

TANQUE DE AIRE
(SERVICIO)
VLVULA
DE ALIVIO

SECADOR DE AIRE

ONE WAY
CHECK VALVE
TANQUE DE AIRE
(SERVICIO)

MEDIDOR DE
PRESIN DEAIRE

TANQUE DE FRENOS
SECUNDARIOS/ESTACIONAMIENTO

SWITCH
PRESIN BAJA

777D Off Highway Truck

VLVULA
PROTECTORA DE PRESIN

VLVULA DE
DRENAJE

CAPTULO: AIRE Y FRENOS

CABINA

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

COMPRESOR
CARGA

VLVULAS DE
ADMISIN

PUERTO DE DESCARGA
VLVULAS DE
ESCAPE
PISTNES DE
DESCARGA

GOVERNADOR

INGRESO
DE AIRE

COMPRESSOR
DESCARGA
VLVULAS DE
ADMISIN

PUERTO DE DESCARGA
VLVULAS DE
DESCARGA
PISTNES DE
DESCARGA
INGRESO
DE AIRE

GOVERNADOR

Pgina:

V-6

Pgina:

GOVERNADOR DEL COMPRESOR

V-7

POSICINCUT-OUT

POSICIN CUT-IN

PRESSURE
SETTING
SPRING

TORNILLO DE AJUSTE

PISTN
VSTAGO DE
DESCARGA

DESDE LOS PISTNES

DE DESCARGA
DEL COMPRESOR
Y LA VLVULA DE PURGA
DEL SECADOR DE AIRE

ABIERTO

DE LOS
TANQUES DE AIRE

CERRADO
VLVULA DE CARGA
CARGA Y
DESCARGA

A LOS PISTNES
DE DESCARGA
DEL COMPRESOR
Y LA VLVULA
DE PURGA DEL
SECADOR DE AIRE

777D Off Highway Truck

DESCARGA

CAPTULO: AIRE Y FRENOS

PUERTO DE
DESCARGA

Pgina:

SECADOR DE AIRE

V-8

SECADOR DE AIRE

CCLO DE PURGA

CARGA

CHECK DE BOLA
VLVULA CHECK DE BOLA

SALDA DE AIRE
A LOS TAMQUES

AIR OUTLET
TO RESERVOIRS
CHECK DE BOLA
ORIFICIO

ORIFICIO

VLVULA DE
ALVIO

FLTRO DE
ACEITE

FLTRO DE
ACEITE

SUMINISTRO DE AIRE
CALENTADOR
DESDE EL
PUERTO DE DESCARGA
VLVULA
DE PURGA

VLVULA DE
PURGA

VLVULA DE
ALVIO

CALENTADOR

777D Off Highway Truck

AIRE
DESDE EL
COMPRESOR

AIRE
DESDE EL
COMPRESOR

AIRE DESDE EL
PUERTO DE DESCARGA
DEL GOBERNADOR

DESECANTE

CAPTULO: AIRE Y FRENOS

DESECANTE

CHECK DE BOLA

Pgina:

VLVULA PROTECTORA DE PRESIN

V-9

CERRADA

ABIERTA

VLVULA
CERRADA
PARA
P<485kPa

A LOS CIRCUTOS
DE FRENSO DE PARQUEO
/ESTACIONAMIENTO
Y ACCESORIOS

A LOS CIRCUITOS
DE FRENOS DE PARQUEO
/SECUNDARIOS
Y ACCESORIOS

777D Off Highway Truck

SUMINISTRO
DE AIRE

CAPTULO: AIRE Y FRENOS

VLVULA
ABIERTA PARA
P> 550 KPa

Pgina:
V-10

769D-777D
SISTEMA DE FRENOS DE PARQUEO/SECUNDARIOS
FRENOS SECUNDARIOS APLICADOS
VLVULA
RELAY
(FRONTAL) VLVULA
DOBLE
CHECK

VLVULA
INVERSORA

TANQUE DE AIRE FRENOS

SECUNDARIOS/DE PARQUEO

VLVULA DE DESAPLICACIN
DE FRENOS DE ESTACIONAMIENTO/PARQUEO

777D Off Highway Truck

CILNDRO
DE FRENOS
( FRONTAL)

CAPTULO: AIRE Y FRENOS

SWITCH
DE FRENOS
DE
VLVULA DE PARQUEO
FRENOS
SECUNDARIOS

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

VLVULA DE FRENOS
SECUNDARIOS
APLICADOS

DESAPLICADOS

PALANCA
LEVA

LEVA

VALVULA

VALVULA

A LA
VLVULA
DE FRENOS
DE PARQUEO

SUMINISTRO DESCARGA
DE AIRE

A LA
VLVULA
DESCARGA
DE FRENOS SUMINISTRO
DE
AIRE
DE PARQUEO

PARCIALMENTE
APLICADOS

LEVA

VALVULA

A LA
VLVULA
DE FRENOS
DE PARQUEO

Pgina:

V-11

SUMUNISTRO DESCARGA
DE AIRE

Pgina:
V-12

VLVULA DE INVERSIN

FRENOS APLICADOS

FRENOS DESAPLICADOS

PISTN

ASIENTO
DE JEBE
CONTROL
DESDE LA
VLVULA DE
FRENOS SECUNDARIOS

PASAJE DE
SUMUNISTRO
(DESDE EL
TANQUE
DE FRENOS
SECUNDARIOS)

PASAJE DE
DESCARGA

PASAJE DE
SUMINISTRO
(DESDE EL
TANQUE
DE FRENOS
SECUNDARIOS)

PASAJE DE
DESCARGA

777D Off Highway Truck

CHECK)

CAPTULO: AIRE Y FRENOS

PASAJE AL
CILNDRO DE FRENOS
DELANTEROS
(VLVULA DOBLE

Pgina:
V-13

SISTEMA HIDRULICO DE LOS

FRENOS DE ESTACIONAMIENTO
FRENOS DE ESTACIONAMIENTO DESAPLICADOS

PARKING BRAKE
RELIEF VALVE
AL SISTEMA DE ENFRIAMIENTO
DE FRENOS

777D Off Highway Truck

FLTRO DE FRENOS
DE ESTACIONAMIENTO

CAPTULO: AIRE Y FRENOS

BOMBA AL EMBRAGUE LOCKUP

DE DESAPLICACIN
DE FRENOS
DE ESTACIONAMIENTO

SUMINISTRO DE AIRE DESDE

LA VLVULA DE FRENOS DE ESTACIONAMIENTO
Y FRENOS SECUNDARIOS

Pgina:
V-14

SISTEMA DE FRENOS DE SERVICIO/RETARDADOR

FRONT BRAKE VALVE OFF
SERVICE BRAKES ENGAGED
RETARDER RELEASED

ONE WAY
CHECK VALVE

AIR RESERVOIR
(SERVICE)

RELIEF
VALVE

AIR RESERVOIR
(SERVICE)

CAB ENCLOSURE

DRAIN VALVE
RETARDER
VALVE

FRONT BRAKE
RATIO VALVE
SERVICE
BRAKE
CONTROL
VALVE

RELAY
VALVE
(FRONT)

DOUBLE
CHECK
VALVE

DOUBLE
CHECK
VALVE

BRAKE
CYLINDER
( REAR )

BRAKE
CYLINDER
( FRONT )

777D Off Highway Truck

RELAY
VALVE
(REAR)

CAPTULO: AIRE Y FRENOS

FRONT BRAKE
ON/OFF
VALVE

Pgina:
V-15

SISTEMA DE FRENOS DESERVICIO/RETARDADOR

FRENOS DELANTEROS ENFRIADOS POR ACEITE
FRENOS DE SERVICIO APLICADOS
RETARDADOR DESAPLICADO

VLVULA
CHECK

TANQUE DE AIRE
(SERVICIO)

VLVULA DE
ALVIO

TANQUE DE AIRE
(SERVICIO)

CABINA

VLVULA DE DRENAJE
VLVULA DEL
RETARDADOR

VLVULA
DOBLE
CHECK

VLVULA
SHUTTLE

DESDE LA
VLVULA DE
INVERSIN

CILNDRO
CILNDRO
DE FRENOS
DE FRENOS
( POSTERIORES) ( DELANTERO )

777D Off Highway Truck

VLVULA
DE CONTROL
DE FRENOS
DE SERVICIO

CAPTULO: AIRE Y FRENOS

VLVULA
RELAY

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

CALIPER DISC BRAKE

ENGAGED

PISTON

BLEED VALVE

CALIPER
CARRIER LINING
OIL PASSAGE FROM
BRAKE CYLINDER
DISC

Page:

V-16

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

VLVULA DE CONTROL DE FRENOS DE SERVICIO

FRENOS DESAPLICADOS

FRENOS COMPLETAMENTE APLICADOS

RESORTE
DE JEBE
PISTN

DESDE LA
VLVULA
RELAY

HACIA LA
VLVULA
RELAY

VALVULA
SUMINISTRO
DE AIRE
SUMINISTRO
DE AIRE

DESCARGA

PARCIALMENTE APLICADOS
RESORTE
DE JEBE
PISTN
HACIA
LA VLVULA
RELAY

SUMINISTRO
DE AIRE

Pgina:

V-17

VLVULA

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

VLVULA DEL
RETARDADOR
APLICADO

DESAPLICADO

LEVA

LEVA

VLVULA

VLVULA
PISTN

DESDE LA
VLVULA
RELAY

SUMINSTRO
DE AIRE

DESCARGA

A LA SUMINISTRO DESCARGA
VLVULA
DE AIRE
RELAY

PARCIALMENTE
APLICADO

LEVA

VLVULA

A LA
VLVULA
RELAY

Pgina:

V-18

SUMINISTRO
DE AIRE

DESCARGAT

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

VLVULA RELAY DE FRENOS

FRENOS DESAPLICADOS

FRENOS COMPLETAMENTE APLICADOS

DESDE LAS VLVULAS DE FRENOS

DE SERVICIO O RETARDADOR

DESDE LAS VLVULAS DE FRENOS

DE SERVICIO O RETARDADOR

PISTN

PASAJE DE
SUMINISTRO
VLVULA

PASAJE DE
DESCARGA

DESDE LOS CILNDROS

DE FRENOS

PASAJE DE
DESCARGA

(PARCIALMENTE APLICADOS)
DESDE LAS VLVULAS DE FRENOS
DE SERVICIO O RETARDADOR
PISTN

PASAJE DE
SUMINISTRO

VLVULA

EXHAUST
PASSAGE

Pgina:

V-19

A LOS CILNDROS
DE FRENOS

A LOS CILNDROS
DE FRENOS

Pgina:
V-20

VLVULA DOBLE CHECK

SHUTTLE

DESCARGA A LA
VLVULA RELAY

777D Off Highway Truck

PASAJE DE ENTRADA
DESDE LA VLVULA
DE FRENOS DE SERVICIO

CAPTULO: AIRE Y FRENOS

PASAJE DE ENTRADA
DESDE LA VLVULA
DEL RETARDADOR

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

CILNDRO DE FRENOS
FRENOS APLICADOS
SWITCH
PIN
INDICADOR
PISTN
NEUMTICO

DESDE EL
TANQUE
MAKEUP
PISTN

6.6P

ENTRADA
DE AIRE

VLVULA

AL
SLACK
ADJUSTER

RESORTE VSTAGO

CILNDRO DE FRENOS
FRENOS DESAPLICADOS

PISTN
INDICADOR

PIN
INDICADOR

DESDE EL
TANQUE
MAKEUP
PISTN

ENTRADA
DE AIRE

REESORTE

Pgina:

V-21

VSTAGOD

VLVULA

AL
SLACK
ADJUSTER

Pgina:
V-22

SLACK ADJUSTER

FLUJO DE ACEITE
AL CILNDRO
DE FRENOS

FLUJO DE ACEITE
AL CILNDRO PISTN PEQUEO
DE FRENOS
PISTN GRANDE

HACIA LOS
FRENOS
EN LAS RUEDAS

777D Off Highway Truck

HACIA LOS
FRENOS
EN LAS RUEDAS

CAPTULO: AIRE Y FRENOS

DESDE FRENOS
EN LAS
RUEDAS

Pgina:
V-23

TANQUE
MAKEUP
DEL RETORNO DE
REFRIGERACIN DE FRENOS

FRENOS ENFRIADOS
POR ACEITE

PISTN PISTN
GRANDE PEQUEO

SISTEMA HIDRULICO DE FRENOS DE SERVICIO

FRENOS DE SERVICIO APLICADOS

777D Off Highway Truck

SLACK
ADJUSTER

CAPTULO: AIRE Y FRENOS

CILNDRO
DE FRENOS

Pgina:
V-24

SISTEMA DE REMOLQUE
VLVULA DE DESAPLUCACIN
777D DE FRENOS
DE ESTACIONAMIENTO

BOMBA DE DESAPLICACIN
DE FRENOS
DE
ESTACIONAMIENTO

BOMBA DE REMOLQUE

777D Off Highway Truck

BOMBA DE LA
DIRECCIN
SECUNDARIA

CAPTULO: AIRE Y FRENOS

VLVULA
DIVERTER
DE REMOLQUE

Pgina:
V-25

BRAKE OIL
MAKEUP TANK

LEFT
REAR

LEFT
FRONT

BRAKE
CYLINDER

CONVERTER
SCAVENGE

PARKING BRAKE

SLACK
ADJUSTER

PARKING
BRK
RELEASE
PUMP

BRAKE
CYLINDER

ELECTRIC
BRAKE
RELEASE
PUMP

SERV BRAKE

BRAKE HYDRAULIC SYSTEM

RIGHT
REAR

RIGHT
FRONT

777D Off Highway Truck

CONVERTER
CHARGE

CAPTULO: AIRE Y FRENOS

PARKING
BRAKE
RELEASE
VALVE

Pgina:

COOLING SYSTEM

V-26

FRONT BRAKE COOLING

OIL COOLER
HOIST & REAR
BRAKES

PARKING BRAKE
RELEASE VALVE
TORQUE
CONVERTER

DIVERTER
VALVE
PARKING
BRAKE
RELEASE
PUMP

TORQUE
CONVERTER
SCAVENGE
PUMP

OIL
COOLED
REAR
BRAKES

HOIST
PUMP

OIL COOLER
RELIEF
VALVE

OIL COOLER
CONVERTER &
REAR BRAKES

FRONT
BRAKE
COOLING
PUMP

OIL
COOLED
FRONT
BRAKES

777D Off Highway Truck

HOIST
CONTROL
VALVE

PUMP
DRIVE

CAPTULO: AIRE Y FRENOS

TORQUE
CONVERTER
CHARGE
PUMP

Pgina:

BRAKE OIL COOLER DIVERTER VALVE

V-27

TO HOIST
& REAR
BRAKE
COOLER

TO BRAKES

RELAY
VALVE

FROM BRAKE
COOLING PUMPS

SWITCH +
SOLENOID
VALVE

SHUTTLE
VALVE

INVERSION
VALVE

SOLENOID VALVE OPEN IF OIL TEMP < 37.8 C (100F)

BRAKE
BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )

777D Off Highway Truck

AIR FROM RETARDER

OR SERVICE BRAKE VALVE

CAPTULO: AIRE Y FRENOS

DIVERTER
VALVE

777D Off Highway Truck

CAPTULO : AIRE YFRENOS

EJERCCIOS DE LABORATORIO
Hoja de Trabajo del Laboratorio A
Lista de Componentes del Sistema Neumtico y de frenos

Indicacines: Vea la ilustracin. Ubique la letra correcta cerca al componente y d una breve descripcin
de cada uno. Durante la presentacin con slides, use esta hoja de trabajo para tomar notas conforme se explique
la funcin de cada componente.
Ejemplo:

Compresor
Suministra aire al sistema y llena los tanques.

Componentes del Sistema Neumtico y de frenos

______ Gobernador

______ Secador de Aire

______ Tanques de aire

______ Vlvula de Frenos Secundarios

______ Vlvula de Frenos de Servicio

______Vlvula del Retardador

______ Vlvula Ratio de Frenos delanteros (Solo 769D-777D)

______ Vlvula doble check

______ Vlvula Protectora de Presin

Pgina:

V-28

777D Off Highway Truck

CAPTULO : AIRE Y FRENOS

EJERCCIOS DE LABORATORIO
______ Vlvulas Relay

______ Vlvula de inversin (Solo 769D-777D)

______ Vlvula de desaplicacin de frenos de estacionamiento

______ Slack Adjuster(s)

______ Cilndros de frenos

______ Tanque Makeup

______ Bomba de remolque

Pgina:

V-29

777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
Lab B: Brake Holding Capacity
This lab allows you to gain experience testing the air system and brake
holding capacity. The lab exercise will help you determine when brake
service is necessary.
Off-highway Truck
Lab B Worksheet
Operation and Maintenance Manual
Procedure:
Check the brake holding capacity of the parking/secondary brake system
and the service/retarder brake system. With the engine running and air
system pressure at maximum, perform the following:
All other brakes released, ENGAGE the service brakes.
Put the shift lever in FIRST FORWARD.
Gradually increase the engine speed until the machine begins to
move.
Record on Worksheet B the engine rpm shown on the tachometer just
before the machine moves.
Repeat the above procedure with only the retarder ENGAGED.
Repeat the above procedure with only the secondary brakes ENGAGED.
Repeat the above procedure with only the parking brakes ENGAGED.

NOTE: On new machines, the brakes may hold through torque converter
stall. On machines that do not move at torque converter stall, record the
torque converter stall rpm. The brakes must hold to 1200 rpm. If the
brakes do not hold at 1200 rpm, do not operate the truck until the problem
has been repaired.

Page:

V-30

777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
LAB B: BRAKE HOLDING CAPACITY WORKSHEET

Directions: With the engine running, air system pressure at maximum and the shift lever in FIRST
FORWARD, gradually increase the engine speed. Record the engine rpm shown on the tachometer just
before the machine moves.

Service Brakes Engaged

rpm

Retarder Engaged

rpm

Secondary Brakes Engaged

rpm

Parking Brakes Engaged

rpm

Page:

V-31

777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
Lab C: Air System and Brake Diagnostic Testing
This lab allows you to gain experience testing various components of the
air system and brakes. The lab exercise will help you determine which
components are causing a malfunction in the air system and brakes.

TOOLING

Off-highway Truck
Appropriate Service Manual Module
Lab C Worksheet
The following test equipment:
2 - 8T0854 Gauge (0-145 psi)
2 - 8T0856 Gauge (0-870 psi)
1 - 8T0857 Gauge (0-1450 psi)
5 - 6V3989 Nipple
4 - 6V4143 Valved Coupler
4 - 6V3079 Diagnostic Hose
2 - 6J3958 1/8-27 NPTF Union
2 - 2D7325 1/4-18 NPTF Pipe Tee
2 - 6V3966 1/4-18 NPTF Pipe Valved Nipple
2 - 6V3965 9/16 in. SAE Valved Nipple

Procedure:
PROCEDURE
Enter the correct specifications on the lab worksheet.
Perform visual checks of the air system and brakes and indicate the
findings on the appropriate area of the Lab C Worksheet.
Perform the following tests:

Air Compressor Governor Settings

Pressure Protection Valve Setting
Parking Brake Release Valve Setting
Front Brake Ratio Valve Setting (if equipped)
Retarder Valve Setting
Service Brake Oil Pressure (front and rear)
Brake Oil Makeup Tank Refill Operation
Slack Adjuster Operation
Page:

V-32

777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
LAB C: AIR SYSTEM AND BRAKE TESTING WORKSHEET
Machine Model __________________________ Date____________________________________
Serial Number ___________________________ Service Meter Hours________________________
VISUAL CHECKS
Hose Connections __________ Component Damage ___________ Air leaks _____________
PRESSURE TESTS
TEST

SPECIFICATIONS

Air Compressor Governor Settings

ACTUAL

cut-out
cut-in

Pressure Protection Valve Setting

Parking Brake Release Valve Setting
Front Brake Ratio Valve
Setting (if equipped)
Retarder Valve Setting
Service Brake Oil Pressure (front)
Service Brake Oil Pressure (rear)
BRAKE OIL MAKEUP TANK REFILL OPERATION
Flow into the makeup tank is acceptable: YES _______ NO _______

SLACK ADJUSTER OPERATION

Small amount of oil flows from service brake "S" bleed screw: YES _______ NO _______
Service Brake Pressure at "S" Bleed Screw: ___________________ psi
NOTE: Pressure at "S" bleed screw must not be less than 1060 kPa (560 psi)
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777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
Lab D: Brake Release System for Towing
This lab allows you to gain experience testing the brake release system
used for towing. The lab exercise will help you determine if the brake
release system used for towing is functioning correctly.

Off-highway Truck
Appropriate Service Manual Module
Lab D Worksheet
The following test equipment:
1 - 8T0856 Gauge (0-870 psi)
1 - 6V3989 Nipple
2 - 6V4143 Valved Coupler
2 - 6V3079 Diagnostic Hose
1 - 6J3958 1/8-27 NPTF Union
1 - 6V3965 9/16 in. SAE Valved Nipple

Procedure:
Check the brake release system used for towing. Install an
8T0856 Gauge (0-870 psi) on the parking brake release pressure tap on
the rear axle (if equipped) or at the location of the parking brake bleed
screw to measure parking brake release pressure. Use a long gauge hose
so the gauge can be held in the cab. With the parking brake air switch in
the RELEASE position and the key start switch in the ON position,
energize the parking brake release switch on the dash used for towing.
Parking brake release pressure should increase to 3790 kPa (550 psi).
Record the maximum pressure shown on the gauge.
Parking brake release pressure must increase to a minimum of
3170 kPa (460 psi) on 769D and 771D trucks and
3790 kPa (550 psi) on 773D - 793C trucks or the brakes will drag.
NOTE: At least 550 kPa (80 psi) air pressure must be available at the
parking brake release valve to ensure full release of the brakes for towing.

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777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
LAB D: BRAKE RELEASE SYSTEM FOR TOWING WORKSHEET

Directions: Install an 8T0856 Gauge (0-870 psi) on the parking brake release pressure tap on the rear
axle (if equipped) or at the location of the parking brake bleed screw to measure parking brake release
pressure. Use a long gauge hose so the gauge can be held in the cab. With the parking brake air switch
in the RELEASE position and the key start switch in the ON position, energize the parking brake
release switch on the dash used for towing. Record the maximum pressure shown on the gauge.

Parking brake release towing pressure

psi

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777D Off Highway Truck

CHAPTER : AIR & BRAKE

LAB EXERCISES
LAB E: TRACING THE FLOW OF AIR AND OIL IN THE AIR SYSTEM AND BRAKES

PARKING/SECONDARY
BRAKE RELEASE VALVE
PARKING/SECONDARY
AIR RESERVOIR

BRAKE
CYLINDER
( FRONT )

SECONDARY
BRAKE
VALVE

PARKING
BRAKE
AIR
SWITCH

SECONDARY BRAKES ENGAGED

769D-777D
PARKING/SECONDARY BRAKE SYSTEM

INVERSION
VALVE

RELAY
VALVE
(FRONT)

DOUBLE
CHECK
VALVE

Directions: Trace the flow of air and oil during the conditions listed below using different colored
pencils to show each path.

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777D Off Highway Truck

CHAPTER : AIR & BRAKE

POSTTEST
AIR SYSTEM AND BRAKES POSTTEST
Directions: Modified True/False. If a question is false, underline or circle the word or words that make
the statement incorrect and replace with word(s) to make the statement correct.

Example:

1. This is an engine class.

1. All Off-highway Truck rear brake assemblies have two brake pistons--one for the
Service/Retarder brakes and one for the Parking/Secondary brakes.

2. The air compressor governor maintains system air pressure between 415 and 690 kPa
(60 and 100 psi) on all Off-highway Trucks.

3. The desiccant in an air dryer should be checked every 250 hours and changed when
saturated with moisture or contaminants.

4. Even with an air dryer, moisture should be drained from the air reservoirs daily.

5. The pressure protection valve will maintain a minimum of 480 kPa (70 psi) to the service
brakes even if the hose to the wiper switch is broken.

6. When releasing the brakes to tow an Off-highway Truck, air is required to shift the parking
brake release valve spool.

Directions: Multiple Choice. Circle the letter(s) of the best answer(s) for each question.
7. The RED secondary brake lever in the cab engages:
A.
B.
C.
D.

The same brakes as the service brake pedal.

The same brakes as the parking brake switch.
The brakes on all four wheels.
The electric towing motor.

8. The parking brake release valve:

A.
B.
C.
D.

Includes a relief valve that controls the parking brake release pressure.
Controls the pressure for releasing the parking brakes during towing.
Tells the operator where to park at the end of the shift.
Controls the supply oil pressure for the torque converter lockup clutch.
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777D Off Highway Truck

CHAPTER : AIR & BRAKE

POSTTEST
9. On 769D-777D trucks, when the secondary brake lever is pulled, the ________________________
sends supply air to the front service brakes so brakes on all four wheels are engaged.
A.
B.
C.
D.

front brake ratio valve

relay valve
inversion valve
pressure protection valve

10. On 769D-777D trucks, when the service brake pedal is partially engaged, the ________________
ensures that the rear brakes engage before the front brakes.
A.
B.
C.
D.

front brake ratio valve

relay valve
inversion valve
pressure protection valve

11. The brake oil makeup tank is kept full by oil from the ______________________ .
A.
B.
C.
D.

slack adjuster
oil lube truck
parking brake release valve
brake oil cooler lines

12. The purpose of the slack adjuster is to:

A.
B.
C.
D.

keep the seat belt from coming loose.

allow more oil to compensate for brake wear.
keep the parking brakes adjusted automatically.
engage the rear brakes before the front brakes.

13. The brake cylinders operate by:

A.
B.
C.
D.

oil over air.

air over oil.
air over air.
oil over oil.

14. On 777D trucks, when the service/retarder brakes are engaged, the ___________________ sends
brake cooling oil through a cooler(s) that is cooled by the engine aftercooler coolant circuit.
A.
B.
C.
D.

inversion valve
double check valve
relay valve
diverter valve

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777D Off Highway Truck

CHAPTER : AIR & BRAKE

POSTTEST
15. If a loss of oil downstream from the brake cylinders occurs, the ________________ will
illuminate the Brake On LED on the CAT Monitoring System panel.
A.
B.
C.
D.

retarder switch
understroke switch
overstroke switch
brake switch

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777D Off Highway Truck

CHAPTER : AIR & BRAKE

POSTTEST
Directions: Match the component with the correct statement below.

1. Secondary Brake Valve

7. Inversion Valve

2. Retarder Brake Valve

8. Parking Brake Release Valve

3. Pressure Protection Valve

9. Double Check Valve(s)

4. Slack Adjuster(s)

10. Air Dryer

5. Brake Oil Makeup Tank

11. Front Brake Ratio Valve

6. Brake Cylinder(s)

12. Service Brake Valve

Removes contaminants and moisture from the air system.

Allows the operator to modulate the engagement of the parking brakes.
Connected to the brake pedal. Allows the operator to engage the service brakes.
Allows the operator to modulate the engagement of the service brakes.
Allows the rear brakes to engage before the front brakes during light braking applications.
Allows two separate air circuits to share the same air lines. The circuit with the highest air
pressure flows through.
Maintains a minimum of 480 kPa (70 psi) in the service/retarder brake circuit..
Allows the secondary brake system to engage the front service brakes.
Directs brake release supply oil to the parking brakes and controls system pressure for
releasing the parking brakes.
Compensates for brake disc wear by allowing a small volume of oil to flow through and
remain under low pressure at the brake piston.
Converts air pressure to hydraulic energy to engage the service brakes.
Supplies makeup oil for the brake cylinders.

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