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Service Training

SERV2717
November 2001

STUDENT MATERIALS

740

PART OF TECHNICAL INSTRUCTION MODULE SERV2717

740 ARTICULATED TRUCK


POWER TRAIN

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Student Materials

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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Student Materials

Lab A: Power Train Hydraulic System Component


Identification
BACKGROUND
INFORMATION

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

Use the "Lab A: Power Train Hydraulic System Component


Identification Worksheet No. 1" during the presentation to take notes on
the location and function of each component.
In the lab, use Lab A Worksheet No. 1 to identify the power train system
components by matching the lettered or numbered tags on the components
with the names on the worksheet.
Use Worksheet No. 2 during the presentation to take notes on the function
of the transmission control valve components. During the lab exercise,
fill in the blanks with the correct letter from the graphic and write the
function for each component.

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Student Materials

Lab A: Power Train Hydraulic System Component Identification


Worksheet No. 1
Directions: Use this worksheet during the presentation to take notes on the location and function of
each component. During the lab exercise, match the tag attached to the component with
the correct name.
Tag No.

Component

___

Transmission Pump Suction Screen


Location:
Function:

___

Transmission Pump
Location:
Function:

___

Transmission Oil Filter


Location:
Function:

___

Transmission Control Lever


Location:
Function:

___

Torque Converter
Location:
Function:

___

Transmission
Location:
Function:

___

Transfer Gear
Location:
Function:

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Student Materials

Lab A: Power Train Hydraulic System Component Identification


Worksheet No. 1 (continued)

Tag No.

Component

___

Drive Shafts (6)


Location:
Function:

___

Final Drives (3)


Location:
Function:

___

Differential and Bevel Gear Cases (3)


Location:
Function:

___

Transmission Actual Gear Switch


Location:
Function:

___

Transmission Oil Cooler


Location:
Function:

___

Transmission/Chassis ECM
Location:
Function:

___

Transmission Oil Filter Bypass Valve


Location:
Function:

___

Solenoid and Relief Valve Group


Location:
Function:

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Student Materials

Lab A: Power Train Hydraulic System Component Identification


Worksheet No. 1 (continued)

Tag No.

Component

___

Transfer Gear Pump


Location:
Function:

___

Transfer Gear Oil Filter


Location:
Function:

___

Transfer Gear Magnetic Screen


Location:
Function:

___

Upshift Solenoid
Location:
Function:

___

Downshift Solenoid
Location:
Function:

___

Torque Converter Lockup Clutch Solenoid


Location:
Function:

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Student Materials

Lab A: Power Train Hydraulic System Component Identification


Worksheet No. 2
Directions: Use this worksheet during the presentation to take notes on the function of the
transmission control valve components. During the lab exercise, use the illustrations on
the next page and fill in the blanks with the correct letter for each component.
Pressure Control Valve
Function:
Selector and Pressure Control Valve
Function:
Torque Converter Lockup Clutch Modulating Valve
Function:
Rotary Actuator
Function:
Torque Converter Inlet Relief Valve
Function:
Pilot Pressure Test Location
Function:
Load Piston Body (Station A)
Function:
Load Piston Body (Station B)
Function:
Load Piston Body (Station C)
Function:
Load Piston Body (Station E)
Function:
Load Piston Body (Station F)
Function:
Load Piston Body (Station G)
Function:
Load Piston Body (Station H)
Function:

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Student Materials

Lab A: Power Train Hydraulic System Component Identification


Worksheet No. 2 (continued)

G
I

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Student Materials

Lab B: Power Train Hydraulic System Testing and


Adjusting
BACKGROUND
INFORMATION

This lab measures your ability to perform various testing and adjusting
procedures on 740 Articulated Truck Power Train Hydraulic System.

INDIVIDUAL EXERCISE

Using the procedures in the 740 Articulated Truck Systems Operation,


Testing and Adjusting module (Form RENR5134) and the Lab B
Handout, locate the power train hydraulic system test point locations and
specifications and record on the Lab B Worksheets.

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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Student Materials

Lab B: Transmission Hydraulic System Pressure Tests Worksheet


Machine Model________________________

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

Transmission Pilot Pressure


Upshift Pressure
Downshift Pressure
Transmission
Lube

High Idle
Low Idle

SPECIFICATIONS

ACTUAL

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Student Materials

Lab B: Transmission Hydraulic System Pressure Tests Worksheet (continued)

740 TRUCK
CLUTCH CHART
CLUTCHES
SPEED
ENGAGED

INITIAL CLUTCH PRESSURE


Load Piston Plug Removed
STATION

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

MAXIMUM CLUTCH PRESSURE


Load Piston Plug Installed

740 TRUCK
CLUTCH CHART

STATION

SPECS

LOW IDLE

HIGH IDLE

ACTUAL
LOW IDLE

HIGH IDLE

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Student Materials

Lab B: Transmission Shift Points Worksheet

MODIFIED SHIFT POINTS AT NOMINAL ENGINE SPEED


UPSHIFT

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

SHIFT POINT AT NOMINAL ENGINE SPEED


UPSHIFT

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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Student Materials

Lab B: Transfer Gear Hydraulic System Pressure Tests Worksheet

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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Student Materials

Lab B: Transmission Hydraulic System Testing Locations Handout

A
B

C
D

Clutch pressures

8. Transmission pilot pressure


A.
B.
C.
D.

Clutch No. 3
Clutch No. 1
Clutch No. 2
Lockup clutch

1
10

11

1.
7.
10.
11.

Torque converter lockup clutch pilot pressure


Transmission pump pressure
Upshift pressure
Downshift pressure

E.
F.
G.
H

Clutch No. 5
Clutch No. 4
Clutch No. 6
Clutch No. 7

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Student Materials

Lab B: Transmission Hydraulic System Testing Locations Handout (continued)

12

6. Torque converter inlet relief pressure


12. Transmission lubrication pressure

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Student Materials

Lab B: Transfer Gear Hydraulic System Testing Locations Handout

13

15

13. Transfer gear lubrication pressure

15. Front axle differential lock test point

17
16

16. Rear axle differential lock test point

17. Center axle differential lock test point

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Student Materials

Lab C: Torque Converter Stall Test


BACKGROUND
INFORMATION

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

Following the procedures in the 725/730/735/740 Articulated Trucks


Power Train Electronic Control Systems Operation, Troubleshooting,
Testing and Adjusting module (Form RENR3442), perform the torque
converter stall test procedure using the Caterpillar Monitoring System.
Answer the worksheet questions after completing the test procedure.

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Student Materials

Lab C: Torque Converter Stall Test Worksheet


1. What Caterpillar Monitoring System submode is used to perform the Torque Converter Stall test?

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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Student Materials

740 Articulated Truck Power Train Hydraulic System Case


Study
DIRECTIONS

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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Student Materials

Power Train Hydraulic System Troubleshooting Worksheet


ISOLATE PROBLEM
Gather Information

The first step in in a troubleshooting process is to gather information


before starting any work on the machine. If possible talk to the operator.
Also, check the repair history of the machine and the Caterpillar Service
Information System (SIS). List at list three questions you would ask an
operator to help in identifying that a problem exists. Possible answers:

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

When troubleshooting always perform a visual inspection first. Look for


the obvious. List at least three typical items that should be inspected
during a visual inspection. Possible answers:

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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Student Materials

Power Train Hydraulic System Troubleshooting Worksheet (continued)


LIST POSSIBLE
FAULTS

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:

Devise tests and


determine root cause

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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Student Materials

Power Train Hydraulic System Troubleshooting Worksheet (continued)

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

After completing the repair, always verify the machine is operating


correctly. List at least three things you would do to make sure the repair
was done correctly.
1.
2.
3.
4.
Complete the service report after finishing the job.

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Student Materials

740 Articulated Truck Power Train System Components


and Functions Posttest
BACKGROUND
INFORMATION

Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.

MATERIALS NEEDED

______740 Articulated Truck Power Train System Components and


Functions Posttest

EXERCISE

Follow the instructions on the posttest.

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Student Materials

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.

1. Transmission Oil Filter Bypass Valve

2. Rotary Actuator

A. Controls transmission hydraulic


system pressure
B. Controls oil flow to the transmission
clutches

3. Torque Converter Lockup Clutch


Solenoid Valve

C. Opens when the transmission oil


filter is plugged and allows oil from
the pump to bypass the filter

4. Torque Converter Inlet Relief Valve

D. Directs oil from the transfer gear


pump to the transfer gear and the
axle differentials

5. Pressure Control Valve

E. Controls the modulation of lockup


clutch engagement
F. Controls the position of the selector
spool

6. Solenoid and Relief Valve Group

G. Ensures sufficient oil pressure in the


torque converter

7. Selector and Pressure Control Valve

H. Directs oil to the rotary actuator

8. Upshift Solenoid

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Student Materials

740 Articulated Truck Selector and Pressure Control Valve


Component Identification Posttest
BACKGROUND
INFORMATION

Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.

MATERIALS NEEDED

______740 Articulated Truck Selector and Pressure Control Valve


Component Identification Posttest

EXERCISE

Identify the Selector and Pressure Control Valve components by listing


the letter designation of the components next to the appropriate
component names on the posttest.

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Student Materials

740 Articulated Truck Selector and Pressure Control Valve Component


Identification Posttest
740 TRANSMISSION
SELECTOR VALVE GROUP
NEUTRAL
A
B

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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Student Materials

740 Articulated Truck Pressure Control Valve Operation


Posttest
BACKGROUND
INFORMATION

Course materials and class notes may be used when taking the posttest.
Do not consult with others during the posttest.

MATERIALS NEEDED

______740 Articulated Truck Pressure Control Valve Operation Posttest

EXERCISE

Follow the instructions on the posttest.

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Student Materials

740 Articulated Truck Pressure Control Valve Operation Posttest


Directions: Multiple Choice. Refer to the pressure control valve station graphic to answer the
following questions. Circle the correct letter(s) indicating the best answer(s) for each question.
TRANSMISSION PLANETARY
VALVE STATION
1

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)