Bench Test Procedure for 735C, 740C, 745C, 740 Ejector, 745, and 740 GCArticulated Truck Transmission {3030, 3073, 3167} Caterpillar

Articulated Truck

735C (S/N: LFJ1-UP; TFJ1-UP)

740 EJECTOR (S/N: 3F71-UP; 3T71-UP)

740 GC (S/N: 3F81-UP; 3T81-UP)

740C EJECTOR (S/N: LFN1-UP; TFN1-UP)

745 (S/N: 3F61-UP; 3T61-UP)

745C (S/N: LFK1-UP; TFK1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This document is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This document contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this document are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This document must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The “WARNING” Safety Alert Symbol is shown in illustration below.

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This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOT" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this document are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Collecting the Test Data

Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure.

Tools Needed

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.

Installation Procedure

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1. Install Tooling (A) to the test bench.
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2. Use a hoist to install the transmission onto Tooling (A). The weight of the transmission is (2000 lb).
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3. Install Tooling (B) to both sides of the transmission to prevent movement during testing.
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4. Install Tooling (C) to the input end of the transmission.
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5. Install Tooling (D) to the input end of the transmission.
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6. Use a hoist to install Tooling (E) to Tooling (D).
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7. Adjust and tighten collet on Tooling (E).

   Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmission on Hydraulic Test Bench" for additional information.

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8. Install Tooling (F) onto Tooling (E).
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9. Install Tooling (G) onto Tooling (F).

10. Use hoist and pry bars to slide the transmission forward to align with the input drive shaft.
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11. Connect the input drive shaft to Tooling (G).
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12. Close and latch drive shaft guard.
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13. Tighten all four castle nuts and jack bolts.
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    Sump oil return port

14. Remove cover (1).
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    Gravity Feed

15. Remove plug (2).
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    (3) Pump (out) (4) Controls (in)

16. Remove plugs (3) and (4).
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    (5) Lube (in) (6) Torque Converter (out)

17. Remove covers (5) and (6).
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    Gravity Feed

18. Install Tooling (J).
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    Pump (out)

19. Install Tooling (K).
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    Pump (out)

20. Install Tooling (L) to Tooling (K).
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    Controls (in)

21. Install Tooling (M)
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    Torque Converter (out)

22. Install Tooling (N).
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23. Install Tooling (P) onto Tooling (N).
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    Lube (in)

24. Install Tooling (Q).
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    Oil Supply

25. Connect Hose Assembly (7) from Gravity Fill to Tooling (J)
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    Pump (out)

26. Connect Hose Assembly (8) from Tooling (L) to No. 1 flow meter inlet.
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    Controls (in)

27. Connect Hose Assembly (9) from the No. 1 flow meter outlet to Tooling (M).
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    Torque Converter (out)

28. Connect Hose Assembly (10) from Tooling (P) to No. 2 flow meter inlet.
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    Lube (in)

29. Connect Hose Assembly (11) from the No. 2 flow meter outlet to Tooling (Q).
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    Spindle Lube

30. Connect Hose Assembly (12) to Tooling (E).
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    0 - 5516 kPa (0 - 800 psi) (13) Pump Pressure (14) Controls Pressure

31. Connect pressure gauges to pressure taps (13) and (14).
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    0 - 965 kPa (0 - 140 psi) (15) Torque Converter (out) Pressure (16) Lube (in) Pressure (17) Torque Converter (in) Pressure

32. Connect pressure gauges to pressure taps (15), (16), and (17).
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    0 - 3448 kPa (0 - 500 psi) (18) Clutch 5 (19) Clutch 4

33. Connect pressure gauges to pressure taps (18) and (19).
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    0 - 3448 kPa (0 - 500 psi) (20) Clutch 6 (21) Clutch 3 (22) Clutch 2 (23) Clutch 1 (24) Lockup Clutch

34. Connect pressure gauges to pressure taps (20), (21), (22), (23), and (24).
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35. Install Tooling (R) to the transmission.
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36. Connect Tooling (R) to Tooling (S).
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37. Connect Tooling (S) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Articulated Trucks”.

2. Select “735C - 24V”, "740C - 24V", "745C - 24V", "740 EJ, 745, or "740 GC.

Harness Test

1. Make sure Tooling (R) is properly connected.

2. Use Tooling (S) to perform the harness test.

3. Record values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Check

1. If you are using SAE 10W oil, warm the oil to (125 °F). If you are using Mobil DTE11 oil, warm the oil to (95 °F). Maintain this temperature for the duration of the test.

2. Open gravity feed and wait for transmission to fill to sump return port level.

   Note: Monitor oil level in transmission during test. Adjust gravity feed to accommodate constant flow coming from sump return port.

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3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 25 rpm.

4. The lubrication pressure must be minimum of 7 (1 psi).

   Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.

5. Shift the transmission through all gears to eliminate air from the transmission controls.

6. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	CL 1	CL 2	CL 3	CL 4	CL 5	CL 6	LU
   N	X			X
   F1			X	X		X
   F2	X		X	X			X
   F3		X	X	X			X
   F4			X		X	X	X
   F5	X		X		X		X
   F6		X	X		X		X
   F7	X	X			X		X
   F8	X	X	X				X
   F9		X	X			X	X
   R1	X			X		X
   R2	X				X	X	X

7. With the transmission in NEUTRAL, check Pump flow, Lube flow, Pump pressure, Controls pressure, Torque Converter Inlet pressure, Torque Converter Outlet pressure, and Lube pressure.

8. Record the values in Table 8.

9. Confirm the values in Table 7.

10. Increase the input rotation to 2100 ± 25 rpm and repeat Steps 7 through 9.

11. Stop input rotation.

Torque Converter Block Test

1. Adjust the input rotation to 700 ± 25 rpm.

2. Make sure that the transmission is in NEUTRAL.

3. Use Tooling (P) to block flow temporarily at the converter outlet.

4. Record Torque Converter inlet pressure in Table 10.

   Note: To prevent running the transmission dry, the maximum block time is 10 seconds.

5. Open Tooling (P).

6. Confirm pressures with Table 9.

Pump Relief Valve Check

1. Adjust the input rotation to 700 ± 25 rpm.

2. Make sure that the transmission is in NEUTRAL.

3. Use Tooling (L) to restrict Pump Flow while monitoring pump pressure for relief valve to open. 30 ± 4 L (8 ± 1 US gpm).

4. Relief valve should open at approximately 30 ± 11 L (8 ± 3 US gpm)

5. Record value in Table 12.

6. Confirm value with Table 11.

Lube Relief Valve Check

1. With the transmission in NEUTRAL, adjust input rotation to 700 ± 25 rpm.

2. Slowly increase the input rotation.

3. At approximately 1600 rpm, lube relief valve should open at 241 (35 psi).

4. As the input rotation is increased to 2100 rpm, lube pressure should remain at 186 (27 psi) minimum and 241 (35 psi) maximum.

5. Record values in Table 13.

eMRV Check

1. Adjust input rotation to 700 ± 25 rpm.

2. With the transmission in NEUTRAL, raise the input rotation to 1200 rpm.

3. RecordeMRVpressure in Table 15.

4. Select “High Current/Low Pressure”.

   Note: This selection puts high current on the eMRV, you should see the pressure drop on the gauge. Be careful not to leave the transmission in high current state more than 10 seconds to prevent damage to the eMRV.

5. Record eMRV pressure in Table 15.

6. Select "eMRV Normal", to return the eMRV to the normal low current high pressure state.

   Note: This is the normal state to run the test.

7. Confirm values in Table 14.

Low Idle Checks

1. Adjust input rotation to 700 ± 25 rpm.

2. Shift the transmission to FORWARD 1.

3. Record Pump and Lube flow, Pump, Controls, Torque Converter in, Torque Converter (out), and Lube pressure, and Horse Power Loss in Table 17.

4. Confirm values with Table 16.

5. Record all Clutch Pressures in Table 19.

6. Confirm values with Table 18.

7. Shift the transmission through FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, FORWARD 9, REVERSE 1, and REVERSE 2.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

8. Repeat Steps 4 through 7 for each gear range.

High Idle Checks

1. Adjust input rotation to 700 ± 25 rpm.

2. Shift the transmission to FORWARD 1.

3. Adjust the input rotation to 2100 ± 25 rpm.

4. Record Pump and Lube flow, Pump, Controls, Torque Converter in, Torque Converter (out), and Lube pressure, and Horse Power Loss in Table 21.

5. Confirm values with Table 20.

6. Record all Clutch Pressures in Table 23.

7. Confirm values with Table 22.

8. Adjust input rotation to 700 ± 25 rpm.

9. Shift the transmission through FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, FORWARD 9, REVERSE 1, and REVERSE 2.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

10. Repeat Steps 3 through 9.

Contamination Control

1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

2. Record the results in Table 24.

3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

Harness Test

Start Check

Torque Converter Block Test

Pump Relief Valve Check

Lube Relief Valve Check

Note: Max. Pressure: 241 kPa (35 psi).

eMRV Check

Note:

Low Idle Check

High Idle Check

Contamination Control