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Brake Accumulator - Test and Charge (RENR6015-03)

SMCS - 4263 i02239680

Test Procedure PIP

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202 1018
Prepare the machine for testing by completing the procedure that is specified in the Service
Manual module Testing and Adjusting, "Machine Preparation for Troubleshooting" for the
machine that is being serviced.
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1. Turn the engine start switch key to the ON position.

2. Disengage the parking brake.

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Illustration 1 g01129121

3. Brake oil pressure indicator (2) should come ON if the brake oil is not at normal operating
pressure.

4. Start the engine. Run the engine at half speed for two minutes in order to increase the
accumulator pressure. Brake oil pressure indicator (2) should turn OFF. Stop the engine.

5. Turn the engine start switch key to the ON position. Apply the service brake pedal and
release the service brake pedal until brake oil pressure indicator (2) comes ON. This

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decreases the pressure in the brake accumulators. A minimum of five applications of the
service brake pedal are required.
6. Parking brake indicator (1) will turn ON when brake oil pressure indicator (2) turns ON.

7. If brake oil pressure indicator (2) comes ON with less than five applications of the brake, use
the following procedure to charge the brake accumulators.

Illustration 2 g00835111
(3) Brake accumulator for the front brakes. (4) Brake accumulator for the rear brakes.
The two brake accumulators are located on the right side of the machine. The brake
accumulators are positioned next to the hydraulic tank.

Charge Procedure

Dry nitrogen is the only gas approved for use in the

accumulators. The charging of oxygen gas in an accumulator
will cause an explosion. An explosion can be eliminated by
using nitrogen gas cylinders with standard CGA (Compressed
Gas Association, Inc.) No. 580 connectors. When nitrogen gas is
ordered, make sure to order the cylinders with CGA No. 580
connectors.

Do not rely on color codes or other methods of identification to

tell the difference between nitrogen and oxygen cylinders. In any
application, never use an adapter to connect your nitrogen
charging group to a valve outlet used on both nitrogen, oxygen,
or other gas cylinders. BE SURE YOU USE DRY NITROGEN
(99.8% purity).

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and
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repair of the product. Be prepared to collect the fluid with

suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer

Service Tool Catalog" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.

Table 1

Required Tools
Part Number Description
7S-5437 Nitrogen Charging Equipment

Stop the engine. Depress the brake pedal repeatedly until there is no brake pressure.

To ensure that the nitrogen charge is correct, each brake accumulator piston must be at the
bottom of the accumulator cylinder. Nitrogen gas pressure varies with the temperature. To obtain
the most accurate nitrogen charge, the temperature of each accumulator must be identical to the
air temperature around the accumulators.

If an accumulator has less than half of the required amount of precharge pressure, use the
following procedure to recharge the accumulator. This procedure prevents trapping a quantity of
oil in the accumulator which will give an inaccurate precharge reading.

1. Charge the accumulator.

2. Operate the service brakes several times.

3. Charge the accumulator again.

However, the temperature of the accumulators could be higher than the air temperature around
the accumulators. In this case, the temperature of the accumulator should be used instead of the
surrounding air temperature.

Note: The pressures in the following table are for an ambient air temperature of 21°C (70°F).
Adjust the pressure for other ambient conditions, as required.

Table 2

Accumulator Precharge Pressure/Temperature Relationship for the 5500 kPa (800 psi)
Service Brake Accumulators
Temperature Pressure
−7°C (20°F) 5000 kPa (726 psi)
−1°C (30°F) 5105 kPa (741 psi)

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4°C (40°F) 5235 kPa (760 psi)

10°C (50°F) 5340 kPa (775 psi)
16°C (60°F) 5420 kPa (787 psi)
21°C (70°F) 5500 kPa (798 psi)
27°C (80°F) 5605 kPa (813 psi)
32°C (90°F) 5735 kPa (832 psi)
38°C (100°F) 5840 kPa (848 psi)
43°C (110°F) 5920 kPa (859 psi)
49°C (120°F) 6000 kPa (871 psi)

Illustration 3 g00107133
Nitrogen Charging Equipment
(1) Nipple. (2) Coupling assembly. (3) Pressure gauge. (4) Hose assembly. (5) Coupling assembly. (6) Nipple. (7)
Valve. (8) Pressure gauge. (9) Regulator assembly. (10) Pressure regulating screw. (11) Chuck for the nitrogen
cylinder valve. (12) Valve handle. (13) Chuck. (14) Hose assembly.

1. Apply the service brakes 20 to 30 times. This will release any pressure that may be in the
brake accumulators.

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Illustration 4 g01129122
Brake Accumulator
(15) Brake accumulator. (16) Bracket. (17) Bolts. (18) Washers.
2. Remove the bolts (17) and the washers (18). Remove the bracket (16).

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Illustration 5 g01129123
Brake Accumulator
(19) Cover. (20) Cap.
3. Remove cover (19) from the brake accumulator. Remove cap (20) from the valve assembly
on the brake accumulator.

4. Use a 0 to 13800 kPa (0 to 2000 psi) pressure gauge (8) to check the nitrogen charge in the
brake accumulator.

5. Install chuck (13) onto the nitrogen charging valve for the brake accumulator.

6. OPEN valve (7) and charge line (14) to the correct precharge. Refer to Table 2.

7. Turn valve handle (12) completely in the clockwise direction. Check the temperature of the
air around the brake accumulator. The reading on the pressure gauge must be within the
tolerances in Table 2.

8. If the reading on the pressure gauge is too high, slowly OPEN valve (7) in order to lower the
pressure. If the reading on the pressure gauge is too low, use the following procedure to
charge the brake accumulator:

a. Connect a hose from the nitrogen cylinder to valve (7).

b. CLOSE valve (7) and OPEN the valve on the nitrogen cylinder. Adjust screw (10) on
regulator assembly (9) until pressure gauge (3) is at the correct charging pressure.
Refer to Table 2 for the correct charging pressure.

c. OPEN valve (7) and charge the brake accumulator. Then, CLOSE valve (7). If pressure
gauge (8) and pressure gauge (3) show the same reading and the readings do not
change, the brake accumulator has the correct charge.
If the pressure reading on gauge (8) decreases, OPEN valve (7) and allow more
nitrogen to fill the brake accumulator.

Perform this procedure until pressure gauge (8) and pressure gauge (3) show the same
reading. Make sure that neither reading changes when valve (7) is closed.

9. CLOSE valve (7). CLOSE the valve on the nitrogen cylinder.

10. Turn valve (12) on chuck (13) OUTWARD in the counterclockwise direction. Remove the
test equipment.

11. Perform this procedure for the other brake accumulator.

Charge Procedure for Rebuilt Brake Accumulator

It is necessary to remove all air from the nitrogen chamber of the brake accumulator. When the
brake accumulator is rebuilt, add approximately 1.9 L (0.5 US gal) of SAE 10W hydraulic oil in

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the nitrogen chamber of the brake accumulator. This oil will be used to help remove the air out of
the nitrogen chamber of the brake accumulator. The oil will also put a lubricant at the top seal of
the brake accumulator piston. Install the brake accumulator on the machine. Then charge the
brake accumulator with the following procedure:

NOTICE
Low nitrogen charge can cause early pump failure because of
short cycle times between the cut-in and cut-out operations of
the brake accumulator charging valve.

1. Use the same equipment for checking nitrogen charge in the brake accumulator.

2. Turn valve (12) on chuck (13) in the clockwise direction. Open valve (7).

3. Start the engine. Run the engine until normal operating temperature is reached. The
hydraulic oil will flow into the bottom of the brake accumulator. The oil will push the air out of
the top through the test equipment. When the oil flow stops, the top of the brake
accumulator will be free of air.

4. CLOSE valve (7) completely.

5. Stop the engine. Apply the service brake pedal several times. This will permit the oil
pressure in the system to be removed. The piston will be at the top in the brake
accumulator.

6. Put a charge of nitrogen in the brake accumulator. Follow the procedure in Steps 8 through
11 in the "Charge Procedure". This procedure will increase the accumulator charging cycle,
because the piston in the brake accumulator must be moved to the bottom. The oil must be
moved out of the brake accumulator.

PIP-10181735
2024/07/30
05:29:31+03:00
i01613362
© 2024 Caterpillar Inc.

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