Service Training

SERV2717
November 2001

STUDENT MATERIALS

740

PART OF TECHNICAL INSTRUCTION MODULE SERV2717

740 ARTICULATED TRUCK

POWER TRAIN
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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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Lab A: Power Train Hydraulic System Component

Identification

BACKGROUND This lab measures your ability to identify the Power Train Hydraulic
INFORMATION 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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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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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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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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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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Lab A: Power Train Hydraulic System Component Identification

Worksheet No. 2 (continued)

G C
H D
B A
K J
E

M F

G L
I

M
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Lab B: Power Train Hydraulic System Testing and

Adjusting

BACKGROUND This lab measures your ability to perform various testing and adjusting
INFORMATION 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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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
TEST SPECIFICATIONS ACTUAL
POINT
Pilot
Torque Converter
Low
Initial
Idle
Lockup Clutch
Max

Torque Converter High Idle

Inlet Relief Valve Low Idle

Transmission High Idle

Pump Low Idle
Transmission Pilot Pressure
Upshift Pressure
Downshift Pressure

Transmission High Idle

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

740 TRUCK INITIAL CLUTCH PRESSURE

CLUTCH CHART Load Piston Plug Removed
SPEED CLUTCHES
ENGAGED STATION CLUTCH SPECS ACTUAL

R 1 A 3
N 3 and 7 B 1
1 2 and 6 C 2
2 1 and 6 E 5
3 3 and 6 F 4
4 1 and 5 G 6
5 3 and 5 H 7
6 1 and 4

7 3 and 4

740 TRUCK MAXIMUM CLUTCH PRESSURE

CLUTCH CHART Load Piston Plug Installed
SPECS ACTUAL

STATION CLUTCH LOW IDLE HIGH IDLE LOW IDLE HIGH IDLE

A 3

B 1

C 2

E 5

F 4

G 6

H 7
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Lab B: Transmission Shift Points Worksheet

MODIFIED SHIFT POINTS AT NOMINAL ENGINE SPEED

UPSHIFT SPEC ACTUAL
1C to 1L
1 to 2
2 to 3
3 to 4
4 to 5
5 to 6
6 to 7

DOWNSHIFT SPEC ACTUAL

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
1C to 1L
1 to 2
2 to 3
3 to 4
4 to 5
5 to 6
6 to 7

DOWNSHIFT SPEC ACTUAL

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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Lab B: Transfer Gear Hydraulic System Pressure Tests Worksheet

TEST
TEST SPECIFICATIONS ACTUAL
POINT
Transfer Gear
13
Lubrication Pressure
Low Idle
Supply 13

Axle Differential Front Axle 15

Locks Center Axle 17
Rear Axle 16
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Lab B: Transmission Hydraulic System Testing Locations Handout

A E

8 B F

C G

D H

8. Transmission pilot pressure Clutch pressures

A. Clutch No. 3 E. Clutch No. 5
B. Clutch No. 1 F. Clutch No. 4
C. Clutch No. 2 G. Clutch No. 6
D. Lockup clutch H Clutch No. 7

1
10

11 7

1. Torque converter lockup clutch pilot pressure

7. Transmission pump pressure
10. Upshift pressure
11. Downshift pressure
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Lab B: Transmission Hydraulic System Testing Locations Handout (continued)

12

6. Torque converter inlet relief pressure

12. Transmission lubrication pressure
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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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Lab C: Torque Converter Stall Test

BACKGROUND This lab measures your ability to perform torque converter stall test on the
INFORMATION 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 Following the procedures in the 725/730/735/740 Articulated Trucks

EXERCISE 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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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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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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Power Train Hydraulic System Troubleshooting Worksheet

ISOLATE PROBLEM 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.
Gather Information
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 When troubleshooting always perform a visual inspection first. Look for
Inspection 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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Power Train Hydraulic System Troubleshooting Worksheet (continued)

LIST POSSIBLE The next step in the process is to list all of the possible causes of the
FAULTS 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 Now, create a list of tests that should be performed and describe what the
determine root cause 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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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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740 Articulated Truck Power Train System Components

and Functions Posttest

BACKGROUND Course materials and class notes may be used when taking the posttest.
INFORMATION
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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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 A. Controls transmission hydraulic

2. Rotary Actuator
3. Torque Converter Lockup Clutch
Solenoid Valve
4. Torque Converter Inlet Relief Valve
5. Pressure Control Valve
6. Solenoid and Relief Valve Group
system pressure
B. Controls oil flow to the transmission
clutches
C. Opens when the transmission oil
filter is plugged and allows oil from
the pump to bypass the filter
D. Directs oil from the transfer gear
pump to the transfer gear and the
axle differentials
E. Controls the modulation of lockup
clutch engagement
F. Controls the position of the selector
spool
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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740 Articulated Truck Selector and Pressure Control Valve

Component Identification Posttest

BACKGROUND Course materials and class notes may be used when taking the posttest.
INFORMATION
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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740 Articulated Truck Selector and Pressure Control Valve Component

Identification Posttest

740 TRANSMISSION
SELECTOR VALVE GROUP
NEUTRAL

G
A

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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740 Articulated Truck Pressure Control Valve Operation

Posttest

BACKGROUND Course materials and class notes may be used when taking the posttest.
INFORMATION
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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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 2 3 4 5

10

6
9
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)