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SERV2717
November 2001
STUDENT MATERIALS
740
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MODULE OBJECTIVES
All the following objectives require a Caterpillar 740 Articulated Truck.
At the completion of this module, you will be able to:
1. Given the appropriate service manual module, locate and identify the
power train hydraulic system components and record the answers on
the Lab A Worksheet.
2. Given the appropriate service manual module, perform the power train
hydraulic system tests on the machine and record the results on the
Lab B Worksheets.
3. Given a machine, perform the torque converter stall test during a lab
exercise.
4. Given class notes and reference material, explain the functions of the
power train hydraulic components during a posttest.
5. Given class notes and reference material, identify the selector and
pressure control valve components on a graphic cutaway during a
posttest.
6. Given class notes and reference material, correctly answer power train
hydraulic system operation multiple choice questions on a posttest.
7. Given a 740 Articulated Truck, the appropriate service manual
module, class notes, and the case study worksheets, list the possible
answers during each step of the troubleshooting process.
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This lab measures your ability to identify the Power Train Hydraulic
System components for the 740 Articulated Truck.
MATERIALS NEEDED
______Class notes
______Lab A Worksheets
______740 Articulated Truck
______Mechanic's tool box with hand tools
______Pen or pencil
INDIVIDUAL EXERCISE
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Component
___
___
Transmission Pump
Location:
Function:
___
___
___
Torque Converter
Location:
Function:
___
Transmission
Location:
Function:
___
Transfer Gear
Location:
Function:
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Tag No.
Component
___
___
___
___
___
___
Transmission/Chassis ECM
Location:
Function:
___
___
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Tag No.
Component
___
___
___
___
Upshift Solenoid
Location:
Function:
___
Downshift Solenoid
Location:
Function:
___
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G
I
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This lab measures your ability to perform various testing and adjusting
procedures on 740 Articulated Truck Power Train Hydraulic System.
INDIVIDUAL EXERCISE
GROUP EXERCISE
Demonstrate the power train hydraulic system pressure tests using the
procedures in the 740 Articulated Truck Systems Operation, Testing and
Adjusting module (Form RENR5134) and record the results on the Lab B
Worksheets.
MATERIALS NEEDED
______Class notes
______Lab B Worksheets
______Lab B Handout
______740 Power Train Systems Operation, Testing and Adjusting
Service Manual module (Form RENR5134)
______740 Articulated Truck
______Mechanic's tools
______1U5481 Pressure Gauge Group
______1U5482 Pressure Adapter Group (for 1U5481)
______8T5200 Generator and Counter Signal Group
______FT2796 Connector Harness
______6V6064 Transmission Test Cover
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Date_____________________
Serial Number_________________________
S.M.H.___________________
VISUAL CHECKS:
Oil level______________
Oil leaks?____________
Air/water in oil?____________
Pressure Tests
TEST
POINT
TEST
Pilot
Torque Converter
Lockup Clutch
Low
Initial
Idle
Max
Torque Converter
Inlet Relief Valve
High Idle
Transmission
Pump
High Idle
Low Idle
Low Idle
High Idle
Low Idle
SPECIFICATIONS
ACTUAL
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740 TRUCK
CLUTCH CHART
CLUTCHES
SPEED
ENGAGED
CLUTCH
3 and 7
2 and 6
1 and 6
3 and 6
1 and 5
3 and 5
1 and 4
3 and 4
SPECS
CLUTCH
ACTUAL
740 TRUCK
CLUTCH CHART
STATION
SPECS
LOW IDLE
HIGH IDLE
ACTUAL
LOW IDLE
HIGH IDLE
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SPEC
ACTUAL
SPEC
ACTUAL
1C to 1L
1 to 2
2 to 3
3 to 4
4 to 5
5 to 6
6 to 7
DOWNSHIFT
7 to 6
6 to 5
5 to 4
4 to 3
3 to 2
2 to 1
1L to 1T
SPEC
ACTUAL
SPEC
ACTUAL
1C to 1L
1 to 2
2 to 3
3 to 4
4 to 5
5 to 6
6 to 7
DOWNSHIFT
7 to 6
6 to 5
5 to 4
4 to 3
3 to 2
2 to 1
1L to 1T
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TEST
POINT
TEST
Transfer Gear
Lubrication Pressure
Low Idle
Supply
Axle Differential Front Axle
Locks
Center Axle
Rear Axle
13
13
15
17
16
SPECIFICATIONS
ACTUAL
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A
B
C
D
Clutch pressures
Clutch No. 3
Clutch No. 1
Clutch No. 2
Lockup clutch
1
10
11
1.
7.
10.
11.
E.
F.
G.
H
Clutch No. 5
Clutch No. 4
Clutch No. 6
Clutch No. 7
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12
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13
15
17
16
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This lab measures your ability to perform torque converter stall test on the
740 Articulated Truck Power Train Hydraulic System.
MATERIALS NEEDED
______Lab C Worksheet
______740 Articulated Truck
______725/730/735/740 Articulated Trucks Power Train Electronic
Control Systems Operation, Troubleshooting, Testing and
Adjusting module (Form RENR3442).
INDIVIDUAL OR GROUP
EXERCISE
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2. What does "Sc E08" indicate on the Caterpillar Monitoring System, if displayed during the Torque
Converter Stall test?
3 If no errors are detected during the Torque Converter Stall test, what value will the Caterpillar
Monitoring System display?
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You may use the service manual and class notes to complete the exercise.
Answer the questions on the Case Study Worksheet. Discuss the exercise
with the instructor after you have answered the case study questions.
The following case study is based on a possible field complaint.
SITUATION
The operator of a 740 Articulated Truck reported to his supervisor that the
transmission was slipping in third and fifth gear. He told the supervisor
that the problem had been present for a couple of days.
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Verify
Verify the problem exists. Operate the machine to duplicate the problem,
preferably under similar operating conditions. Compare the operation to a
known good machine. Perform sensory checks such as looking, listening,
touching, and smelling to verify a problem exists.
Perform Visual
Inspection
State Problem
After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer:
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The next step in the process is to list all of the possible causes of the
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least three things that could
be causing the problem. Possible answers:
Now, create a list of tests that should be performed and describe what the
tests would determine. Prioritize the tests as to which sequence they
should be performed in. As a general rule, always do the easiest tests
first. Also, list diagnostic tooling required. Identify at least four tests to
perform. (NOTE: the rankings are only suggested.)
Tooling needed:
Tooling needed:
Tooling needed:
Tooling needed:
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Tooling needed:
REPAIR FAULT
After isolating the component, which you suspect from your test results is
causing the problem, either adjust or replace the component.
Circle the best response:
If the modulating valve initial pressure is too low and the load piston
spring rates are correct what step would you perform next?
1. Add shims behind the load piston spring
2. Remove shims from behind the load piston spring
3. Turn the load piston adjustment screw clockwise
4. Turn the load piston adjustment screw counterclockwise
VERIFY REPAIR
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Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.
MATERIALS NEEDED
EXERCISE
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735 Articulated Truck Power Train System Components and Functions Posttest
Directions: Match the component with the function by placing the letter next to the component.
2. Rotary Actuator
8. Upshift Solenoid
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Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.
MATERIALS NEEDED
EXERCISE
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Directions: Fill in the blanks next to the terms with the correct letter.
Main relief valve
Rotary selector spool
Priority reduction valve
Torque converter inlet relief valve
Neutralizer valve
Pilot oil pressure tap
Lubrication pressure tap
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Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.
MATERIALS NEEDED
EXERCISE
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10
7
8
1. When a shift is started, pilot oil from the rotary selector spool flows through which passage.
A. 1
B 2
C. 3
D. 8
2. When the clutch begins to fill, the oil pressure in the clutch is balanced against
____________________.
A. Pilot pressure at the load piston (4)
B. Force of spring (9)
C. Force of springs (5)
D. Slug (10)
3. The force of springs (5) and ___________________ control the amount of time for the clutch to
reach maximum pressure.
A. Pilot pressure
B. Pump pressure
C. Force of spring (9)
D. Size of the load piston orifice (7)
4. What controls the amount of time necessary for the clutch to release?
A. Force of springs (5)
B. Decay orifice (6)
C. Force of spring (9)
D. Load piston orifice (7)