- 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)
- 740 EJECTOR (S/N: 3F71-UP; 3T71-UP)
Introduction
Revision | Summary of Changes in M0072352 |
03 | Added serial prefixes and updated copyright and intro |
02 | Added relief valve guidelines. |
01 | Added torque values. |
00 | Initial release |
© 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) (12) |
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.
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
NOTICE |
---|
Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
References | |
---|---|
Media Number | Title |
SEBF8187 | Reuse And Salvage Guidelines, "Standardized Parts Marking Procedures" |
SEBF8193 | Reuse And Salvage Guidelines, "Reusability of Drive Train Gears" |
Tooling and Equipment
NOTICE |
---|
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Table 3 contains the items that are needed to complete the repair procedures in this guideline.
Required Tooling and Equipment | ||
---|---|---|
Part Number | Description | Designation |
(1) | Personal Protective Equipment (PPE) | Personal Protection |
Holder (Disc Pad) | Surface
Preparation / De-burring |
|
Disc (Coarse) | Surface
Preparation / De-burring |
|
Grinding Wheel (F-Grade)
(120 Grit) |
Surface
Preparation / De-burring |
|
Flapper Wheel (2" x 1" 180 grit) |
Surface
Preparation / De-burring |
|
Wheel Adapter | Tooling | |
Seal Pick | Gear/ Shaft
Step Inspection |
|
Eye Loupe | Inspection | |
Surface Reconditioning Pad | Surface
Preparation / De-burring |
|
Metal Marking Pen | Parts Marking | |
Die Grinder | Surface
Preparation / De-burring |
|
Right Angle Die Grinder | Surface
Preparation / De-burring |
|
White LED Pen Light | Light source | |
Flapper Wheel (2" x 1" 180 grit) |
Surface
Preparation / De-burring |
|
Flapper Wheel (2" x 1" 240 grit) |
Surface
Preparation / De-burring |
|
Blue LED Pen Light | Light source | |
Paper Towel | General Cleaning |
(1) | Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards. |
(2) | Available in the United States only. |
Prepare the Area for Inspection
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. |
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 |
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.
NOTICE |
---|
Do not use a number metal stamp set to mark parts. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure. |
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 (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 |
Front of Pump
Illustration 8 | g06093954 |
(2) Pump Housing
(3) Low-Pressure Planet Gear Shaft (4) Relief Valve (5) Identify Pump Serial Number on the Front of Pump (6) High-Pressure Planet Gear Shaft |
Pump Serial Number | Batch Number |
<133 | Batch 1/2 |
133–1050 | Batch 3 |
1051–2018 | Batch 4 |
2019–2458 | Batch 5 |
>2458 | Batch 6 |
Relief Valve
Illustration 9 | g06093985 |
Relief Valve |
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 |
Illustration 11 | g06080210 |
Pump Back side (Retaining Plate side) contacts (12) |
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 |