Service Training

SERV2719
November 2001

STUDENT MATERIALS

735

PART OF TECHNICAL INSTRUCTION MODULE SERV2719

735/740 ARTICULATED TRUCKS

BRAKE SYSTEM
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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.

2. Given the Service Information System (SIS), an 8T0856 Gauge, an

8T0857 Gauge, and the Lab B worksheet, test the brake pump
pressure, accumulator pressures, parking brake release pressure,
tractor and trailer brake line pressures, and the slack adjuster residual
pressure during a lab exercise. Record the results on the Lab B
worksheet provided.

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.

5. Given a 735 or 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: Brake System Component Identification

BACKGROUND This lab measures your ability to identify the Brake System components
INFORMATION for the 735/740 Articulated Trucks.

MATERIALS NEEDED ______Class notes

______Lab A Worksheets

______735 or 740 Articulated Truck

______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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Lab A: Brake System Component Identification Worksheet

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

___ Service Brake Control Valve

Location:
Function:

___ Service Brakes

Location:
Function:

___ Service Brake Accumulators

Location:
Function:

___ Parking Brake Accumulator

Location:
Function:

___ Parking Brake

Location:
Function:

___ Check and Pressure Reducing Valve

Location:
Function:

___ Brake Pump

Location:
Function:
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Lab A: Brake System Component Identification Worksheet (continued)

Tag No. Component

___ Parking Brake Control Valve

Location:
Function:

___ Parking Brake Pressure Switch

Location:
Function:

___ Service Brake Pressure Switch

Location:
Function:

___ Stop Light Pressure Switch

Location:
Function:

___ Brake System Oil Pressure Switch

Location:
Function:

___ Front Brake System Oil Temperature Sensor

Location:
Function:

___ Center Brake System Oil Temperature Sensor

Location:
Function:

___ Slack Adjusters

Location:
Function:
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Lab B: Brake System Testing and Adjusting

BACKGROUND This lab measures your ability to perform testing and adjusting procedures
INFORMATION on the brake system for the 735/740 Articulated Trucks.

MATERIALS NEEDED ______Class notes

______Lab B Worksheet

______Lab B Handout

______Service Manual Module "735/740 Articulated Trucks Brake

System Operation, Testing and Adjusting" (Form RENR5129)

______735 or 740 Articulated Truck

______Mechanic's tools

The following test equipment:

______2 - 8T0855 Pressure Gauge

______2 - 8T0858 Pressure Gauge

______1 - 175-5507 Nitrogen Charging Group

______1 - 152-2023 Tool Group (Nitrogen Adapter Group)

______3 - 8T0857 Pressure Gauge

______3 - 3J1907 O-ring Seal

______3 - 6V3965 Test Fitting

______3 - 6V4143 Coupler

______3 - 6V3079 Pressure Hose

______2 - 6V4142 Testing Fitting

______2 - 7X0872 Swivel Tee

______1 - 1601726 Plug Gauge

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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Lab B: Brake System Testing and Adjusting

Enter the correct specifications from the Service Manual Module on the
lab worksheet.

Perform the following tests:

• Service Brake Pump Pressure

• Service Brake Accumulator Pressure
• Parking Brake Accumulator Pressure
• Parking Brake Release Pressure
• Tractor Service Brake Line Pressure
• Trailer Service Brake Line Pressure
• Slack Adjuster Residual Pressure
• Service Brake Wear Indicator Check
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Lab B: Brake System Testing and Adjusting Worksheet

Machine Model________________________ Date_____________________

Serial Number_________________________ S.M.H.___________________

BRAKE SYSTEM TESTS

TEST SPECIFICATIONS ACTUAL

Service Brake Pump Pressure

Service Brake Hydraulic Oil

Accumulator Pressure
Front Brake Nitrogen Precharge

Service Brake Hydraulic Oil

Accumulator Pressure
Rear Brake Nitrogen Precharge

Accumulator Pressure Hydraulic Oil

Parking Brake Nitrogen Precharge

Parking Brake Release Pressure

Tractor Service Brake Line Pressure

Trailer Service Brake Line Pressure

Slack Adjuster Residual Pressure

Service Brake Wear Indicator Check

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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Lab B: Brake Hydraulic System Testing Locations Handout

FRONT AXLE
SERVICE BRAKE
PRESSURE BRAKE SYSTEM
PRESSURE

CENTER AXLE SERVICE

BRAKE PRESSURE

Brake pump pressure adjustment Parking brake pressure

Parking brake adjustment plug Slack adjuster test point

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735/740 Articulated Trucks Brake System Case Study

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.

The following exercise is based on a possible field complaint.

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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Brake 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. 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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Brake 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 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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Brake System Troubleshooting Worksheet (continued)

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.

Circle the best response:

If during your tests you discovered that the maximum brake system
pressure was only 6900 kPa (1000 psi). Which one of the following
components would you adjust or replace?
A. Check and pressure reducing valve
B. Service brake control valve
C. Pressure compensator valve
D. Accumulators

What component limits maximum brake system pressure if the pump

compensator valve fails?
A. Crossover relief valves
B. Check and pressure reducing valve
C. Pressure compensator valve
D. Parking brake control valve
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Brake System Troubleshooting Worksheet (continued)

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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735/740 Articulated Trucks Brake 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 ______735/740 Articulated Trucks Brake System Components and

Functions Posttest

EXERCISE Follow the instructions on the posttest.

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735/740 Articulated Trucks Brake System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

Brake System Oil Pressure Switch A. Allows the parking brake to be released when
the engine is not running.

Service Brake Accumulators B. Supplies oil flow to the brake system.

Check and Pressure Reducing Valve C. Compensates for wear in the service brakes.

D. Maintains brake accumulator oil pressure and

Service Brake provides hoist system pilot oil.

E. Supplies the hydraulic energy to engage the

Service Brake Pressure Switch
service brakes.

Parking Brake F. Mounted at the wheels, this is a dry disc and

caliper brake arrangement.

Service Brake Control Valve
Parking Brake Accumulator
Brake Pump
G. Directs oil to the parking brake actuator to
release the parking brakes.
H. Sends a signal to the Caterpillar Monitoring
system which illuminates an indicator light if
brake oil pressure is too low.

I. Sends a signal to the Transmission ECM

Parking Brake Control Valve indicating oil pressure in the service brake
circuit.
Slack Adjuster
J. Directs oil from the check and pressure
reducing valve to the service brakes.

K. Mounted on the transfer drive, it is spring

engaged and hydraulically released.
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735/740 Articulated Trucks Brake System 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 ______735/740 Articulated Trucks Brake System Component

Identification 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

735/740 ARTICULATED TRUCKS BRAKE SYSTEM

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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735/740 Articulated Trucks Brake System Component Identification Posttest

Directions: Fill in the blanks next to the terms with the correct letter.

Parking brake accumulator

Temperature sensor

Brake pump

Center service brake accumulator

Parking brake control valve

Service brake control valve

Slack adjuster

Parking brake pressure switch

Service brake pressure switch

Front service brake accumulator

Front axle brake

Check and pressure reducing valve

Brake oil pressure switch

Parking brake actuator

Center axle brake

Stop light pressure switch