Service Training

MALAGA

777D Off Highway Truck

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

AIR AIR DRYER

COMPRESSOR RELIEF
AIR RESERVOIR VALVE
(SERVICE)
ONE WAY CHECK VALVE
RELIEF VALVE
GOVERNOR

AIR RESERVOIR
(SERVICE)

DRAIN VALVE
CAB ENCLOSURE SENSOR FOR
BRAKE AIR
PRESSURE PRESSURE
PROTECTION VALVE
RELAY DIVERTER
VALVE
VALVE
RETARDER
CONTROL
VALVE

PRESSURE
SWITCH PRESSURE
STOP LAMP SWITCH
RET/ SERV TO
EPTCII SOLENOID
DOUBLE
VALVE
CHECK
VALVE
PARKING
CONTROL
VALVE
SHUTTLE
VALVE
AIR
SERVICE SECONDARY
CONTROL
PRESSURE BRAKE VALVE
GAGE CONTROL
VALVE INVERSION
VALVE
HORN
VALVE
WIPER
ONE
MOTOR WAY
CHECK
AIR RESERVOIR VALVE
AIR HORN ( SECONDARY ) BRAKE BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )

WINDSHIELD WIPER VALVE PARK/SECONDARY BRAKE

CONTROL VALVE

V. AIR & BRAKE SYSTEM.

1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

777D AIR & BRAKE SYSTEM

COMPONENT LOCATIONS

TOWING PARKING BRAKE

PUMP RELEASE VALVE DOUBLE CHECK
INVERSION VALVE
VALVE

OIL COOLER
TC & BRAKES

SLACK
DOUBLE ADJUSTER
CHECK VALVE CAB
RETARDER RELAY
VALVE VALVE

SECONDARY
VALVE SERVICE SERVICE AIR
BRAKE VALVE RESERVOIRS TOWING DIVERTER
SECONDARY AIR VALVE
RATIO VALVE
RESERVOIR
OIL COOLER BRAKE CYLINDERS AND
HOIST & BRAKES MAKE UP TANK

PRESSURE
PROTECTION
VALVE
TOWING AIR DRYER
PUMP

CONVERTER FRONTBRAKE
SCAVENGE PARKING CONVERTER
CHARGE COOLING PUMP
PUMP BRAKE
RELEASE PUMP
PUMP

Page: V-1
Page:

OFF-HIGHWAY TRUCK AIR SYSTEM

DISC & CALIPER (STANDARD)
V-2

AIR AIR DRYER

COMPRESSOR RELIEF
AIR RESERVOIR VALVE
(SERVICE)
ONE WAY CHECK VALVE
RELIEF VALVE
GOVERNOR

AIR RESERVOIR
(SERVICE)

CAB ENCLOSURE DRAIN VALVE

PRESSURE
PROTECTION VALVE

FRONT BRAKE RELAY

ON/OFF RELAY VALVE
RETARDER VALVE (FRONT)
VALVE
CONTROL (REAR)
VALVE DOUBLE
CHECK

CHAPTER: AIR & BRAKE

VALVE

FRONT BRAKE

777D Off Highway Truck

RATIO VALVE
DOUBLE
CHECK
VALVE
PARKING
CONTROL
VALVE
INVERSION
AIR
SERVICE SECONDARY
CONTROL VALVE
PRESSURE BRAKE VALVE
GAGE CONTROL
VALVE

HORN
VALVE
WIPER
ONE
MOTOR WAY
CHECK BRAKE BRAKE
AIR RESERVOIR VALVE CYLINDER CYLINDER
AIR HORN ( SECONDARY ) ( REAR ) ( FRONT )

PARK/SECONDARY BRAKE
WINDSHIELD WIPER VALVE CONTROL VALVE
Page:

OFF-HIGHWAY TRUCK AIR SYSTEM

OIL COOLED FRONT BRAKES (ATTACHMENT)
V-3

AIR AIR DRYER

COMPRESSOR RELIEF
AIR RESERVOIR VALVE
(SERVICE)
ONE WAY CHECK VALVE
RELIEF VALVE
GOVERNOR

AIR RESERVOIR
(SERVICE)

DRAIN VALVE
CAB ENCLOSURE SENSOR FOR
BRAKE AIR
PRESSURE PRESSURE
PROTECTION VALVE
RELAY DIVERTER
VALVE
VALVE
RETARDER
CONTROL
VALVE

CHAPTER: AIR & BRAKE

PRESSURE
SWITCH PRESSURE
STOP LAMP SWITCH
RET/ SERV TO
EPTCII SOLENOID

777D Off Highway Truck

DOUBLE
VALVE
CHECK
VALVE
PARKING
CONTROL
VALVE
SHUTTLE
VALVE
AIR
SERVICE SECONDARY
CONTROL
PRESSURE BRAKE VALVE
GAGE CONTROL
VALVE INVERSION
VALVE
HORN
VALVE
WIPER
ONE
MOTOR WAY
CHECK
AIR RESERVOIR VALVE
AIR HORN ( SECONDARY ) BRAKE BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )

WINDSHIELD WIPER VALVE PARK/SECONDARY BRAKE

CONTROL VALVE
Page:

777D
V-4

FRONT BRAKE
OIL COOLED

CHAPTER: AIR & BRAKE

777D Off Highway Truck
COOLING
DISASSEMBLY OIL
SERVICE PLUG
PRESSURE
PISTON OIL
Page:

AIR CHARGING SYSTEM

V-5

AIR
COMPRESSOR
AND
GOVERNOR
AIR RESERVOIR
(SERVICE)
ONE WAY
AIR DRYER CHECK VALVE
RELIEF
VALVE
AIR RESERVOIR
(SERVICE)

CHAPTER: AIR & BRAKE

DRAIN
CAB ENCLOSURE VALVE
LOW AIR

777D Off Highway Truck

PRESSURE SWITCH
PROTECTION VALVE
AIR PRESSURE
GAGE

PARKING/SECONDARY
RESERVOIR
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

AIR COMPRESSOR
CHARGING

INLET
VALVES OUTLET PORT
OUTLET
VALVES

UNLOADER
GOVERNOR PISTONS

AIR
INLET

AIR COMPRESSOR
UNLOADED

INLET
VALVES AIR OUTLET
OUTLET
VALVES

UNLOADER
PISTONS

AIR
INLET
GOVERNOR

Page: V-6
Page:

AIR COMPRESSOR GOVERNOR

V-7

CUT-IN POSITION CUT-OUT POSITION

PRESSURE
SETTING ADJUSTMENT SCREW
SPRING
EXHAUST

CHAPTER: AIR & BRAKE

PORT
EXHAUST

777D Off Highway Truck

PISTON

EXHAUST
STEM FROM AIR
COMPRESSOR
UNLOADER PISTONS
AND AIR DRYER
PURGE VALVE TO AIR
COMPRESSOR
UNLOADER
PISTONS AND
OPEN AIR DRYER
FROM PURGE VALVE

CLOSED
AIR RESERVOIRS
INLET AND
EXHAUST
VALVE
Page:
V-8

AIR DRYER AIR DRYER

PURGE CYCLE
CHARGING

BALL CHECK

BALL CHECK
AIR OUTLET
TO RESERVOIRS
AIR OUTLET
TO RESERVOIRS

BALL CHECK
ORIFICE ORIFICE BALL CHECK

CHAPTER: AIR & BRAKE

DESICCANT DESICCANT

777D Off Highway Truck

AIR INLET AIR INLET
FROM FROM
AIR COMPRESSOR AIR COMPRESSOR

RELIEF RELIEF
VALVE OIL VALVE
OIL
FILTER FILTER

AIR SUPPLY
AIR SUPPLY HEATER FROM GOVERNOR HEATER
FROM GOVERNOR UNLOADER PORT
UNLOADER PORT
PURGE
VALVE PURGE
VALVE
Page:

PRESSURE PROTECTION VALVE

V-9

CLOSED OPEN

VALVE
OPEN IF
P> 550 KPa

CHAPTER: AIR & BRAKE

777D Off Highway Truck
VALVE
CLOSED
SUPPLY IF
AIR P<485kPa

TO
PARKING/SECONDARY
& ACCESORIES
CIRCUITS TO
PARKING/SECONDARY
& ACCESORIES
CIRCUITS
Page:
V-10

769D-777D
PARKING/SECONDARY BRAKE SYSTEM
SECONDARY BRAKES ENGAGED

RELAY
VALVE
(FRONT) DOUBLE
CHECK
VALVE

PARKING
BRAKE
AIR INVERSION
SECONDARY SWITCH VALVE
BRAKE

CHAPTER: AIR & BRAKE

VALVE

777D Off Highway Truck

BRAKE
CYLINDER
( FRONT )

PARKING/SECONDARY
AIR RESERVOIR PARKING/SECONDARY
BRAKE RELEASE VALVE
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

SECONDARY BRAKE
VALVE
ENGAGED RELEASED

LEVER
CAM
CAM

VALVE VALVE

TO TO
PARKING PARKING EXHAUST
AIR EXHAUST BRAKE AIR
BRAKE SUPPLY
VALVE SUPPLY VALVE

PARTIALLY
ENGAGED

CAM

VALVE

TO
PARKING
BRAKE AIR EXHAUST
VALVE SUPPLY
Page: V-11
Page:
V-12

INVERSION VALVE

BRAKES RELEASED BRAKES ENGAGED

PISTON

PASSAGE TO

CHAPTER: AIR & BRAKE

FRONT BRAKE
CYLINDER
(DOUBLE CHECK

777D Off Highway Truck

VALVE)

RUBBER
SEAT
CONTROL SUPPLY
FROM
SECONDARY PASSAGE
BRAKE VALVE
EXHAUST (FROM
SECONDARY
PASSAGE AIR EXHAUST
SUPPLY RESERVOIR)
PASSAGE PASSAGE
(FROM
SECONDARY
AIR
RESERVOIR)
Page:
V-13

PARKING BRAKE
HYDRAULIC SYSTEM
PARKING BRAKES RELEASED

PARKING BRAKE
RELIEF VALVE

TO BRAKE AIR SUPPLY

COOLING SYSTEM FROM PARKING BRAKE VALVE
AND SECONDARY BRAKE VALVE

CHAPTER: AIR & BRAKE

PARKING TO LOCKUP CLUTCH

777D Off Highway Truck

BRAKE
RELEASE
PUMP

PARKING BRAKE
RELEASE FILTER
Page:
V-14

SERVICE/RETARDER BRAKE SYSTEM

FRONT BRAKE VALVE OFF
SERVICE BRAKES ENGAGED
RETARDER RELEASED AIR RESERVOIR RELIEF
ONE WAY (SERVICE) VALVE
CHECK VALVE

AIR RESERVOIR
CAB ENCLOSURE (SERVICE)

DRAIN VALVE

RETARDER
FRONT BRAKE

CHAPTER: AIR & BRAKE

VALVE
ON/OFF
VALVE RELAY
RELAY VALVE

777D Off Highway Truck

VALVE (FRONT)
(REAR)

FRONT BRAKE DOUBLE

RATIO VALVE CHECK
DOUBLE VALVE
SERVICE CHECK
BRAKE
CONTROL VALVE
VALVE

BRAKE BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )
Page:

SERVICE/RETARDER BRAKE SYSTEM

V-15

FRONT BRAKE COOLING

SERVICE BRAKES ENGAGED
RETARDER RELEASED AIR RESERVOIR RELIEF
ONE WAY (SERVICE) VALVE
CHECK VALVE

AIR RESERVOIR
CAB ENCLOSURE (SERVICE)

DRAIN VALVE

RETARDER
VALVE

CHAPTER: AIR & BRAKE

RELAY
VALVE

777D Off Highway Truck

SERVICE DOUBLE
BRAKE CHECK
CONTROL VALVE SHUTTLE
VALVE VALVE

FROM
INVERSION
VALVE

BRAKE BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

CALIPER DISC BRAKE

ENGAGED

PISTON

BLEED VALVE

CALIPER
CARRIER LINING
OIL PASSAGE FROM
BRAKE CYLINDER

DISC

Page: V-16
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

SERVICE BRAKE CONTROL VALVE

BRAKES RELEASED BRAKES FULLY ENGAGED

RUBBER
SPRING
PISTON

FROM
RELAY
VALVE
TO
RELAY
VALVE
VALVE

SUPPLY
AIR
SUPPLY
AIR

EXHAUST

PARTIALLY ENGAGED
RUBBER
SPRING
PISTON

TO
RELAY
VALVE

SUPPLY
AIR
VALVE

Page: V-17
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

RETARDER
VALVE
RELEASED ENGAGED

CAM CAM

VALVE
VALVE

PISTON

FROM AIR
TO AIR EXHAUST
RELAY EXHAUST RELAY SUPPLY
SUPPLY VALVE
VALVE

PARTIALLY
ENGAGED

CAM

VALVE

TO
RELAY AIR EXHAUST
VALVE SUPPLY

Page: V-18
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

BRAKE RELAY VALVE

BRAKES RELEASED BRAKES FULLY ENGAGED

FROM SERVICE BRAKE VALVE FROM SERVICE BRAKE VALVE
OR RETARDER VALVE OR RETARDER VALVE

PISTON

SUPPLY
PASSAGE

VALVE

TO BRAKE
FROM BRAKE CYLINDERS
EXHAUST CYLINDERS EXHAUST
PASSAGE PASSAGE

(PARTIALLY ENGAGED)
FROM SERVICE BRAKE VALVE
OR RETARDER VALVE

PISTON

SUPPLY
PASSAGE

VALVE

EXHAUST TO BRAKE
PASSAGE CYLINDERS

Page: V-19
Page:

DOUBLE CHECK VALVE

V-20

SHUTTLE

CHAPTER: AIR & BRAKE

INLET PASSAGE INLET PASSAGE
FROM RETARDER FROM SERVICE
VALVE BRAKE VALVE

777D Off Highway Truck

OUTLET TO
RELAY VALVE
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

BRAKE CYLINDER
BRAKES ENGAGED
SWITCH
INDICATOR
AIR ROD
PISTON FROM
MAKEUP
TANK POWER
PISTON

P 6.6P
AIR
INLET
TO
SLACK
VALVE ADJUSTER

SPRING ROD

BRAKE CYLINDER
BRAKES RELEASED

AIR INDICATOR
ROD FROM
PISTON MAKEUP
TANK
POWER
PISTON

AIR
INLET

TO
SLACK
VALVE ADJUSTER
SPRING ROD

Page: V-21
Page:
V-22

BRAKE SLACK ADJUSTER

OIL FLOW OIL FLOW

TO BRAKE SMALL PISTON FROM BRAKE
CYLINDER CYLINDER
LARGE PISTON

FROM

CHAPTER: AIR & BRAKE

WHEEL
BRAKES

777D Off Highway Truck

TO
WHEEL TO
BRAKES WHEEL
BRAKES

BRAKES RELEASED BRAKES ENGAGED

Page:
V-23

BRAKE MAKEUP
OIL TANK
FROM BRAKE
COOLING RETURN OIL COOLED
BRAKES

LARGE SMALL
PISTON PISTON

CHAPTER: AIR & BRAKE

BRAKE
CYLINDER

777D Off Highway Truck

SLACK
ADJUSTER

SERVICE BRAKE HYDRAULIC SYSTEM

SERVICE BRAKES ENGAGED
Page:

TOWING SYSTEM
V-24

777D PARKING BRAKE

RELEASE VALVE

PARKING
BRAKE
RELEASE
PUMP

CHAPTER: AIR & BRAKE

777D Off Highway Truck
TOWING
DIVERTER
VALVE

SECONDARY
STEERING
PUMP

TOWING PUMP
Page:
V-25

LEFT BRAKE OIL

REAR MAKEUP TANK

LEFT
FRONT

BRAKE CONVERTER
CYLINDER SCAVENGE

PARKING
BRAKE
RELEASE

CHAPTER: AIR & BRAKE

VALVE

CONVERTER

777D Off Highway Truck

CHARGE
BRAKE
PARKING
CYLINDER
PARKING BRAKE

BRK
RELEASE ELECTRIC
PUMP M BRAKE
RELEASE
PUMP

SLACK
ADJUSTER
SERV BRAKE
BRAKE HYDRAULIC SYSTEM RIGHT
RIGHT FRONT
REAR
Page:

COOLING SYSTEM
V-26

OIL COOLER
FRONT BRAKE COOLING HOIST & REAR
PARKING BRAKE BRAKES
RELEASE VALVE

TORQUE
CONVERTER

DIVERTER
VALVE
PARKING
BRAKE
RELEASE
PUMP PUMP
TORQUE DRIVE
CONVERTER
CHARGE
PUMP

CHAPTER: AIR & BRAKE

TORQUE
CONVERTER OIL
SCAVENGE COOLED
HOIST PUMP REAR

777D Off Highway Truck

CONTROL BRAKES
VALVE

HOIST
PUMP
OIL
COOLED
FRONT
BRAKES

FRONT
OIL COOLER BRAKE
CONVERTER & COOLING
OIL COOLER PUMP
RELIEF REAR BRAKES
VALVE
Page:

BRAKE OIL COOLER DIVERTER VALVE

V-27

TO HOIST
& REAR
BRAKE TO BRAKES
COOLER

DIVERTER
VALVE

CHAPTER: AIR & BRAKE

777D Off Highway Truck
RELAY SWITCH +
AIR FROM RETARDER VALVE SOLENOID
VALVE
OR SERVICE BRAKE VALVE FROM BRAKE
COOLING PUMPS
SHUTTLE
VALVE

INVERSION
VALVE

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

BRAKE BRAKE
CYLINDER CYLINDER
( REAR ) ( FRONT )
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

LAB EXERCISES
Lab A Worksheet

Air System and Brake Component Reference Checklist

Directions: Refer to the Handout Illustration. Place the correct letter next to the component and give a
brief description of each. During the slide presentation, use this worksheet to take notes as the function
of each component is explained.

Example: A Air Compressor

Supplies the air system and fills the air reservoirs.

Air System and Brake Components

______ Air Compressor Governor

______ Air Dryer

______ Air Reservoirs

______ Secondary Brake Valve

______ Service Brake Valve

______ Retarder Brake Valve

______ Front Brake Ratio Valve (769C-777C only)

______ Double Check Valve(s)

______ Pressure Protection Valve

Page: V-28
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

LAB EXERCISES

______ Relay Valve(s)

______ Inversion Valve (769C-777C only)

______ Parking Brake Release Valve

______ Slack Adjuster(s)

______ Brake Cylinder(s)

______ Brake Oil Makeup Tank

______ Towing Pump

Page: 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.

Off-highway Truck
Appropriate Service Manual Module
Lab C Worksheet
The following test equipment:
TOOLING 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 ACTUAL

Air Compressor Governor Settings 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)
Page: V-33
 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.

Page: V-34
 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

Page: V-35
 777D Off Highway Truck
CHAPTER : AIR & BRAKE

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

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

DOUBLE
CHECK
VALVE
(FRONT)
RELAY
VALVE

CYLINDER
( FRONT )
BRAKE

BRAKE RELEASE VALVE

PARKING/SECONDARY
INVERSION
VALVE
PARKING/SECONDARY BRAKE SYSTEM
SECONDARY BRAKES ENGAGED
769D-777D

PARKING/SECONDARY
AIR RESERVOIR
PARKING

SWITCH
BRAKE
AIR
SECONDARY
BRAKE
VALVE

Page: V-36
 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: F 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. The same brakes as the service brake pedal.
B. The same brakes as the parking brake switch.
C. The brakes on all four wheels.
D. The electric towing motor.

8. The parking brake release valve:

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

Page: V-37
 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. front brake ratio valve
B. relay valve
C. inversion valve
D. 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. front brake ratio valve
B. relay valve
C. inversion valve
D. pressure protection valve

11. The brake oil makeup tank is kept full by oil from the ______________________ .
A. slack adjuster
B. oil lube truck
C. parking brake release valve
D. brake oil cooler lines

12. The purpose of the slack adjuster is to:

A. keep the seat belt from coming loose.
B. allow more oil to compensate for brake wear.
C. keep the parking brakes adjusted automatically.
D. engage the rear brakes before the front brakes.

13. The brake cylinders operate by:

A. oil over air.
B. air over oil.
C. air over air.
D. 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. inversion valve
B. double check valve
C. relay valve
D. diverter valve

Page: V-38
 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. retarder switch
B. understroke switch
C. overstroke switch
D. brake switch

Page: V-39
 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.

Page: V-40