CX38 Transmission Pump Inspection Guideline {0374, 0599, 0700, 0722, 3030, 3066} Caterpillar

Articulated Truck

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

740 EJECTOR (S/N: 3F71-UP; 3T71-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 guideline is for the use of Cat 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 Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost reductions. 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 Reuse and Salvage Guideline 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.

Summary

Illustration 1	g06080059
(1) 353-8939 Pump Assembly (12) 387-2975 Center Manifold

This guideline provides the procedures that are necessary to inspect and determine the reusability of the transmission pumps in the CX38 transmissions. This guideline explains the procedure for inspecting individual components. Never install a part that is shown in this guideline as a part that cannot be used again.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs.

Important Safety Information

Illustration 2	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

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 below.

Illustration 3	g00008666

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 "NOTICE" 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 power end 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 power end. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the power end unsafe.

The information, the specifications, and the illustrations that exist in this guideline 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. Cat dealers can supply the most current information.

Service Letters and Technical Information Bulletins

References

Tooling and Equipment

Table 3 contains the items that are needed to complete the repair procedures in this guideline.

Prepare the Area for Inspection

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 4	g03721203
Typical burr removal tooling. (A) Right Angle Die Grinder (B) Die Grinder (C) ( D) ( E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft (F) ( G) Flapper Wheels

Note: Clean exterior of transmission pump prior to disassembly to minimize cross-contamination

• Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect.

• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• If the component cannot be inspected immediately after cleaning, put gear oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

Standardized Parts Marking

Reference: Refer to Reuse And Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures" for additional information regarding marking procedures.

Note: Mark the component on a surface that does not wear. This surface should be near the part number. Use metal marking pen for all marking.

The procedure for marking includes a code that will identify the number of rebuilds and the number of hours on each rebuild.

Illustration 5	g03885120
Illustration 5 shows code (1-15). The first number (1) indicates that the component had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the component at the time of rebuild.

Illustration 6	g03885129
Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the component had been rebuilt twice. The second number (10) indicates that there were 10,000 hours on the component at the time of rebuild.

This coding can be used by all dealers and will help with identification at time of rebuild. Identification can be especially helpful if units that have been rebuilt are sold into different territories. As new overhauls are completed, the previous markings should be left on the part. To obtain the total number of hours for the component in Illustration, 6 add first and second rebuild hours. In this example the component has a total of 22,000 hours.

Inspection of Transmission Pump

Illustration 7	g06087169
(2) Pump Housing (3) Low-Pressure Planet Gear Shaft (4) Relief Valve 4750 kPa (689 psi). Torque relief valve to 80.0 ± 8.0 N·m (59.0 ± 5.90 lb ft) (6) High-Pressure Planet Gear Shaft (7) Low-Pressure Suction Side (8) Sun Gear (9) Low-Pressure Planet Gear (10) Low-Pressure Output Side (11) High-Pressure Suction Side (13) High-Pressure Planet Gear (14) High-Pressure Output Side (15) Retaining Plate (16) M6 Bolt- Torque bolts to 8.0 ± 1.0 N·m (5.90 ± 0.74 lb ft)

Front of Pump

Illustration 8	g06093954
(2) Pump Housing (3) Low-Pressure Planet Gear Shaft (4) Relief Valve 4750 kPa (689 psi). Torque relief valve to 80.0 ± 8.0 N·m (59.0 ± 5.90 lb ft) (5) Identify Pump Serial Number on the Front of Pump (6) High-Pressure Planet Gear Shaft

Relief Valve

Illustration 9	g06093985
Relief Valve 4750 kPa (689 psi). Torque relief valve to 80.0 ± 8.0 N·m (59.0 ± 5.90 lb ft)

It is recommended that the relief valve be removed, cleaned, and inspected using the below guidelines.

• Check to see if there are marks left by debris on the plunger sealing surface. The sealing area is the radial cylindrical surface of the plunger and the radial seat in the housing.

Back of Pump

Illustration 10	g06087179
(7) Low-Pressure Suction Side (8) Sun Gear (9) Low-Pressure Planet Gear (10) Low-Pressure Output Side (11) High-Pressure Suction Side (13) High-Pressure Planet Gear (14) High-Pressure Output Side (15) Retaining Plate (16) M6 Bolt- Torque bolts to 8.0 ± 1.0 N·m (5.90 ± 0.74 lb ft)

Illustration 11	g06080210
Pump Back side (Retaining Plate side) contacts (12) 387-2975 Center Manifold

Gears

Illustration 12	g06080785
The gear shows signs of pitting. Replace the gear if any signs of pitting. DO NOT USE THE GEAR AGAIN

Illustration 13	g06080801
The gear shows polishing of teeth that does not result in significant change to gear tooth profile. USE THE GEAR AGAIN

Illustration 14	g06080835
The gear shows wearing on coating. Contact pattern is fairly centered on tooth. USE THE GEAR AGAIN

Illustration 15	g06081030
The gear shows centered contact pattern. No contact on the unloaded sides of teeth. USE THE GEAR AGAIN

Illustration 16	g06081068
Light wear on tips of teeth: shallow scratches. USE THE GEAR AGAIN

Illustration 17	g06081060
Heavy wear on tips of teeth: deep scratches. DO NOT USE THE GEAR AGAIN

Illustration 18	g06080914
Minimal wear on planet gear face. USE THE GEAR AGAIN

Illustration 19	g06080940
Significant wear on planet gear face. DO NOT USE THE GEAR AGAIN

Illustration 20	g06080950
Light scratches on planet gear face. USE THE GEAR AGAIN

Illustration 21	g06080964
Light scratches on gear teeth. USE THE GEAR AGAIN

Illustration 22	g06080970
Deep scratches on gear teeth. DO NOT USE THE GEAR AGAIN

Illustration 23	g06080982
Spotting of phosphate coating. USE THE GEAR AGAIN

Illustration 24	g06081007
Light scratches on sun gear face. USE THE GEAR AGAIN

Illustration 25	g06081000
Deep scratches on sun gear face. DO NOT USE THE GEAR AGAIN

Illustration 26	g06081018
Wear on sun gear tang. USE THE GEAR AGAIN

Illustration 27	g06093346
During pump assembly, ensure that planet gears are assembled with chamfer side facing the housing.

Pump Housing

Illustration 28	g06081083
Light wear in planet bore. USE THE PUMP HOUSING AGAIN

Illustration 29	g06081173
Heavy wear in planet bore. DO NOT USE THE PUMP HOUSING AGAIN

Illustration 30	g06081181
Noticeable abrasive wear due to debris in planet bore. DO NOT USE THE PUMP HOUSING AGAIN

Illustration 31	g06081188
Heat marks in planet bore. DO NOT USE THE PUMP HOUSING AGAIN

Illustration 32	g06081288
Minimal wear in sun bore. USE THE PUMP HOUSING AGAIN

Illustration 33	g06081292
Heavy contact in sun bore. DO NOT USE THE PUMP HOUSING AGAIN

Illustration 34	g06081303
Evidence of contact on one side of sun bore. DO NOT USE THE PUMP HOUSING AGAIN

Retaining Plate

Some wear on the retaining plate is acceptable, most retaining plates will show wear. If there is plate wear there should ideally be no corresponding wear on the gear faces, but light wear is acceptable.

The pump needs to be replaced if there is significant wear on the plate that is accompanied by significant wear on the gear faces.

Illustration 35	g06081668
Light wear on plate and corresponding light wear on gear faces (Preferably there is no wear on gear faces, but some light wear is acceptable). USE THE RETAINING PLATE AGAIN Notice that the plate wear is heavier in some areas than in others, this is common. Uneven plate wear is fine as long as there is not significant corresponding wear on the gear faces.

Illustration 36	g06081333
Significant wear on plate and corresponding significant wear on gear face. DO NOT USE THE RETAINING PLATE AGAIN