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SERV2719
November 2001
STUDENT MATERIALS
735
MODULE OBJECTIVES
1. Given the Lab A worksheet, class notes, and a 735 or 740 Articulated
Truck, locate and identify the brake system components during a lab
exercise.
3. Given class notes and all reference material, identify the brake
hydraulic system components on a hydraulic schematic during a
posttest.
4. Given class notes and all reference material, explain the function of
the 735 and 740 Articulated Truck Brake system components on a
posttest.
BACKGROUND This lab measures your ability to identify the Brake System components
INFORMATION for the 735/740 Articulated Trucks.
______Lab A Worksheets
______Pen or pencil
INDIVIDUAL EXERCISE Use the "Lab A: Brake System Component Identification Worksheet"
during the presentation to take notes on the location and function of each
component.
In the lab, use the Lab A Worksheet to identify the brake system
components by matching the lettered or numbered tags on the components
with the names on the worksheet.
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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.
BACKGROUND This lab measures your ability to perform testing and adjusting procedures
INFORMATION on the brake system for the 735/740 Articulated Trucks.
______Lab B Worksheet
______Lab B Handout
______Mechanic's tools
GROUP EXERCISE Perform visual checks of the brake system and indicate your findings on
the appropriate area of the lab worksheet.
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Enter the correct specifications from the Service Manual Module on the
lab worksheet.
If the parking brake solenoid is suspected to be faulty, what check should be done first?
A. Current check
B. Resistance check
C. Voltage check
D. Connect the solenoid to the battery and listen for a "click"
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FRONT AXLE
SERVICE BRAKE
PRESSURE BRAKE SYSTEM
PRESSURE
DIRECTIONS Use the service manual and class notes to complete the case study.
Answer the questions on the Case Study Worksheet. Discuss the exercise
with the instructor after you have answered the case study questions.
SITUATION The operator of a 735 Articulated Truck reported to his supervisor that he
had to press extremely hard on the brake pedal to stop the machine. He
told the supervisor that the problem had been present for a couple of days
and is present at all speeds.
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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 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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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 four things that could
be checked. 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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Tooling needed:
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.
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.
BACKGROUND Course materials and class notes may be used when taking the posttest.
INFORMATION
Do not consult with others during the posttest.
Brake System Oil Pressure Switch A. Allows the parking brake to be released when
the engine is not running.
Check and Pressure Reducing Valve C. Compensates for wear in the service brakes.
Service Brake Control Valve G. Directs oil to the parking brake actuator to
release the parking brakes.
Parking Brake Accumulator
H. Sends a signal to the Caterpillar Monitoring
system which illuminates an indicator light if
Brake Pump brake oil pressure is too low.
BACKGROUND Course materials and class notes may be used when taking the posttest.
INFORMATION
Do not consult with others during the posttest.
EXERCISE Identify the Brake System components by listing the names of the
components next to the appropriate letter on the posttest.
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SERV2719
D E
TO
FROM HOIST SUSPENSION
CONTROL SYSTEM
FRONT CENTER
VALVE
BRAKES N BRAKES
J I
A H
B L
M K G
C
O O
TO HOIST
CONTROL VALVE
- 18 -
F
FRONT CENTER
BRAKES BRAKES
P P
D E
Student Materials
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Directions: Fill in the blanks next to the terms with the correct letter.
Temperature sensor
Brake pump
Slack adjuster