Individual Clutch Modulation (ICM) Control Valves{3065, 3139} Caterpillar

Articulated Truck:

735B (S/N: L4D1-UP; T4P1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP)

740B (S/N: L4E1-UP; T4R1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

D400 PS (S/N: 1MD1-UP)

D400D PS (S/N: 8TF1-UP)

D400E Series 2 (S/N: APF1-UP; 8PS1-UP)

D400E (S/N: 2YR1-UP)

Off-Highway Truck/Tractor:

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP)

768B (S/N: 79S1-UP)

768C (S/N: 02X1-UP)

769 (S/N: 99F1-UP; 35W1-UP)

769B (S/N: 99F1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

772 (S/N: 10S1-UP; 11S1-UP; 80S1-UP)

772B (S/N: 64W1-UP)

773 (S/N: 63G1-UP)

773B (S/N: 63W1-UP)

773D (S/N: 7ER1-UP; 7CS1-UP)

776 (S/N: 14H1-UP; 14W1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP)

777D HAA (S/N: AGY1-UP)

777G (S/N: TNM1-UP; RDR1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

Quarry Truck:

771C (S/N: 3BJ1-UP)

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

773G (S/N: MWH1-UP; JWS1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

775F (S/N: EYG1-UP; DLS1-UP)

775G (S/N: RFM1-UP; MJS1-UP)

Petroleum Transmission:

TH48-E80 (S/N: FRT1-UP)

Underground Articulated Truck:

AD55 (S/N: ANW1-UP; DNW1-UP)

Wheel Tractor-Scraper:

621E (S/N: 6AB1-UP; 6BB1-UP; 2PD1-UP; 2TF1-UP)

621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)

621G (S/N: DBB1-UP; ANG1-UP; KLK1-UP; CEN1-UP; ALP1-UP; CEP1-UP; KJW1-UP; DBX1-UP)

621R (S/N: 12Y1-UP)

621S (S/N: 8KD1-UP)

623E (S/N: 6CB1-UP; 6DB1-UP; 6YF1-UP; 5SG1-UP)

623F (S/N: 5SG1-UP; 6BK1-UP; 3XW1-UP; 5EW1-UP)

623G (S/N: AWB1-UP; DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)

627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 7CG1-UP; 3WJ1-UP)

627F (S/N: 4YK1-UP; 1DL1-UP)

627G (S/N: DBD1-UP; AXF1-UP; AYK1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)

631E Series 2 (S/N: 1AB1-UP; 1BB1-UP; 1NB1-UP; 6PC1-UP; 3ND1-UP)

631E (S/N: 4LD1-UP)

631G (S/N: DFA1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; AXZ1-UP)

633D (S/N: 19W1-UP; 25W1-UP)

633E Series 2 (S/N: 1EB1-UP; 2PS1-UP)

637E Series 2 (S/N: 1FB1-UP; 1HB1-UP; 7CB1-UP)

637E (S/N: 1JB1-UP; 1LB1-UP)

637G (S/N: AWE1-UP; CEH1-UP; CEJ1-UP; DFJ1-UP; CEM1-UP; AYN1-UP; AXT1-UP; DEX1-UP; DEY1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)

657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP)

Introduction

© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

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Summary

The reusability information contained in this guideline was developed for control valves used in the Individual Clutch Modulation (ICM) transmissions. Although there are similarities among all hydraulic valves, do not apply the ICM reusability guidelines to other applications due to different operating environments.

Glossary

Anodized Layer - Anodizing is a chemical hardening process for aluminum. The anodized layer is the hardened surface, and is darker than plain aluminum.

Balance Groove - Balance Grooves are shallow, circumferential grooves machined into a valve spool that: provide lubrication to sides of spool, act as a labyrinth type pressure seal, and center spool in bore.

Frosting - Frosting is a gray, satiny appearance, usually the result of fine abrasive.

Metering - Metering is a theoretical line-to-line condition of a metering spool and of a valve body where the flow and pressure regulation occurs.

Metering Edge - The metering edge is the edge of a spool or body land where metering occurs.

Illustration 1	g02155886
(1) Metering edges

Use again minimum length. Clearance from the plane of the pressure control valve body to the spool is not sliding (right) past the metering edges.

Do not use again. Internal leakage occurs from the spool sliding (right) past the two metering edges. The metering edges are not horizontal across the surface. There are filed down or beveled edges.

Pressure Control Valve Group

Nomenclature

Illustration 2	g02156238
(2) Gallery clean out holes (3) Station housing (4) Shims (5) Pin (6) Modulating orifice (7) Load piston (8) Selector piston (9) Modulation reduction valve (10) Reaction slug

Note: Pressure control valve groups typically consist of six to eight stations. Components and configurations may vary.

Modulating Orifice (6)

The modulating orifices are generally trouble free items and should be replaced only if large pieces of debris are found in the control valve.

Modulation Reduction Valve (9)

Both metering edges must be sharp (0.25 mm (0.010 inch) maximum radius). Nicks or scratches are permitted on metering edges if the scratches do not catch a seal pick pushed across the metering edges.

Frosted surfaces are acceptable.

Illustration 3	g02156253
Modulation reduction valve (1) Metering edges (11) Hole (12) Orifice hole (13) Valve ball

Check valve ball (13) must seal against the seat. Use the following procedure to check the ball seal and refer to Illustration 3:

1. Insert a (oiled) reaction slug into the valve spool.

2. Close off orifice hole (12) .

3. Put a drop of oil in hole (11) .

4. Push reaction slug into the bore, the slug should resist movement.

Use again. If the check valve ball seals against the seat, the valve may be used again.

Illustration 4	g02156275
Modulation reduction valve (14) Scratches near metering edges (15) Scratches away from metering edges

Use again. If longitudinal scratches on the metering edges are not deep enough to catch a seal pick, the modulation reduction valve may be used again.

Note: Scratches on the modulation reduction valve away from the metering edges generally do not cause operational problems.

Illustration 5	g02156277
Modulation reduction valve (16) Frosted surfaces

Use again. Valves with frosted surface are reusable.

Reaction Slug (10)

Reaction slug wear does not generally have an adverse effect on transmission operation.

Illustration 6	g02156279
Reaction slug

Use again. Frosting will not cause functional problems.

Selector Piston (8) and Load Piston (7)

Illustration 7	g02156283
Selector piston (17) Scratched through anodized layer

Do not use again. If the selector or load piston has scratches that have gone through the anodized layer, the piston should not be used again. Refer to Illustration 7.

Illustration 8	g02156284
Load piston (18) Location of the part number

Use again. A depressed area, surrounded by a raised ridge near the part number is a result of the manufacturing process. The depressed area is not an indication of a defective part. Refer to Illustration 8.

Illustration 9	g02156285
Selector piston

Do not use again. If there are any deep scratches that have broken through the anodized layer, the piston should not be used again. Refer to Illustration 9.

Valve Body

Check the bores for excessive wear, such as spalling, pitting, and cracking.

Illustration 10	g02156288
Valve body bore

Do not use again. If any in-line scratches are seen in the bores, the valve body should not be used again. Refer to Illustration 10.

Illustration 11	g02156289
Valve body bore

Do not use again. If any scratches catch a seal pick that is pushed across the bore, the valve body should not be used again. Refer to Illustration 11.

Illustration 12	g02156290
Measuring tool

If no excessive wear is found, use a suitable measuring device to measure the lands of the bores.

The preferred method of measurement is to use an air gauge in order to measure the lands in each bore at three locations. The measurements should be taken 120 degrees apart.

Use the dimension listed in Table 2 to determine if the part can be reused.

Illustration 13	g02156293
Valve body

Note: Measure the valve body bore with a measuring device.

Station Housing (3)

Illustration 14	g02156318
Selector valve bore (19) Porosity (20) Wear steps (21) Band not worn

Do not use again. If any scratches catch a seal pick, the valve should not be used again. If any wear steps can be felt in selector valve bore, the valve should not be used again.

Selector valve bore has wear steps that can be felt. The small holes near the bottom of the bore are casting porosity that are not reason to replace the housing. Refer to Illustration 14.

Illustration 15	g02156319
Selector valve bore (22) Visible wear pattern

Use again. The area at the mouth of the selector bore is made slightly larger than the rest of the bore, and is not a wear step. A wear pattern can be seen in the bore, but no wear steps can be felt. Refer to Illustration 15.

Pins (5)

Remove any burrs before using the pin again.

Note: In order to maintain the correct pressure rise characteristics, Ensure that the pins are installed into the same stations from which the pins were removed.

Illustration 16	g02157025
Pins

Use again. After the removal of burrs, the pin may be used again.

Do not use again. If the pins are mushroomed or peened, the pins should not be used again.`

Shims (4)

Illustration 17	g02157028
Shims

Do not use again. If the shims are not flat or are deformed in any way, the shims should not be used again.

Selector and Pressure Control Valve Group

Nomenclature

Illustration 18	g02156355
Typical example (23) Relief valve (24) Filter (25) Rotary selector pool (26) Drive pin (27) Neutralizer valve (28) Priority reduction valve

Selector Body

Check the bores for excessive wear, such as spalling, pitting, and cracking. If excessive wear is present, do not use the valve body again. No scratches are acceptable in the bores.

Illustration 19	g02156358
Selector and pressure control valve

Illustration 20	g02156360
Rotary selector spool bore

Do not use again. This spool bore was damaged by a loose pin on the rotary selector spool shaft. Refer to Illustration 20.

If there are any damaged areas in the bore that can stop a seal pick, the valve body should not be used again.

Illustration 21	g02156363
Control valve bore

Do not use again. If any scratches on the control valve bore catch a seal pick that is pushed across the surface, the valve body should not be reused. Refer to Illustration 21.

If no excessive wear is found, use a suitable measuring device to measure the lands of the bores.

Illustration 22	g02156290
Measuring tool

The preferred method of measurement is to use an air gauge in order to measure the lands in each bore at three locations. The measurements should be taken 120 degrees apart.

Use the dimensions listed in Table 3 to determine if the part can be reused.

Rotary Selector Spool (25)

An earlier version is pictured. Later spools have balance grooves between each row of holes. Both versions can be used again.

The grinding method used can cause the spool to appear to have been cam ground. Spools with this type of appearance can be used again.

Note: Be sure to clean the filter inside the selector spool (refer to Illustration 18) before assembling the valve group.

Illustration 23	g02156994
Rotary selector spool (29) Cam-ground appearance (A) Charge end of spool

Use again. If there are no scratches that catch a seal pick, the spool may be used again.

Do not use again. If scratches on charge end of spool catch a seal pick that is pushed across the surface, the spool should not be used again.

Drive Pin (26)

Notches or grooves, on the pin head and shank (near the end) usually appear early in pin life. This condition will stop as the pieces "wear in", providing a larger contact area.

The pin must fit tightly into the bore of the rotary selector spool. If loose, the pin can move out of place and drag on the bore of valve body causing a shifting problem.

Push against the drive pin, if drive pin is fits tight in the bore of the spool, use spool assembly again. (Do not press the pin out of the bore.) If drive pin is loose in the bore, a new pin should be installed. Use a new spool assembly, if the bore in the spool assembly has been damaged and a new pin does not fit tightly.

Illustration 24	g02156995
Drive pin (30) Acceptable groove (31) Acceptable notch (32) Not acceptable notch

Do not use again. If, the notch in central part of body could cause the pin to break.

Rotary Actuator Group

Illustration 25	g02156996
Rotary actuator group (33) Actuator vane (34) Shuttle valve

Rotary Actuator Vane

Notches or grooves in the drive pin slot for the rotary actuator vane usually appear early in the service life of the part life. As the pieces "wear in", the notches do not increase and provide a larger contact area.

Illustration 26	g02156998
Rotary actuator vane (35) Wear notches

Use again. Notches in the rotary actuator valve are acceptable.

Inspect the shaft at the end of the drive slot for cracks.

Do not use again. If any rotary actuator vanes have cracks, the rotary actuator should not be used again.

Illustration 27	g02157015
Rotary actuator vane (36) Crack

Do not use again. Cracks at the drive slots are not permitted.

Shuttle Valve

Shake the valve assembly. The check ball must be heard.

Illustration 28	g02157016
Shuttle valve (37) Check ball

Use again. If the check ball can be heard when the valve assembly is shaken, the valve may be used again.

Illustration 29	g02157022
Shuttle valve (38) Frosted surface (39) Pin

Use again. A frosted surface is acceptable.

Do not use again. If the pin moves when pushed, the valve should not be used again.