R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr...

Página 1 de 8

Cerrar SIS

Pantalla anterior

Producto: LOAD HAUL DUMP

Modelo: R1600G LOAD HAUL DUMP 9YZ
Configuración: R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)

Pruebas y Ajustes
R1600G Load Haul Dump Braking System
Número de medio -KENR8502-00 Fecha de publicación -01/09/2007 Fecha de actualización -24/09/2007

i01775538

Brake Accumulator - Test and Charge

SMCS - 4263-045; 4263-081

Table 1

Required Tools
Part Number Part Description Qty
7S-5437 Nitrogen Charging Group 1

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.

Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.

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,

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 2 de 8

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 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 Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Stop the engine. Release the braking system oil pressure.

Reference: Refer to System Operation, Testing and Adjusting, "System Pressure - Release" for the
machine that is being serviced.

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, the accumulator
should be charged, and then charged again after operating the service brakes several times. This
prevents trapping a quantity of oil in the accumulator which will give an inaccurate precharge
reading.

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: An accumulator precharge pressure of 5515 kPa (800 psi) is required for a brake accumulator
with an ambient air temperature of 21°C (70°F). Use the following table to adjust the pressures for
other ambient conditions, as required.

Table 2

Accumulator Precharge Pressure/Temperature Relationship for the

5515 kPa (800 psi) Service Brake Accumulator

Temperature Pressure (1)

-7°C (20°F) 5000 kPa (726 psi)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 3 de 8

-1°C (30°F) 5105 kPa (741 psi)

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)

(1) ± 70 kPa (10 psi) allowable tolerance on nominal pressure

Test Procedure
1. Depress the service brake pedal at least 25 times to release any oil pressure that may be in the
brake accumulators.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 4 de 8

Illustration 1 g00907668
Service brake accumulator

(1) Cap

(2) Cover

2. Remove cover (2) from the brake accumulator. Remove cap (1) from the valve assembly on
the brake accumulator.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 5 de 8

Illustration 2 g00907670
Parts from the nitrogen charging group

(3) Valve

(4) Pressure gauge

(5) Chuck

(6) Valve handle

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

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

5. Turn valve handle (6) on chuck (5) 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.

6. If the reading on the pressure gauge is too high, slowly OPEN valve (3) 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.

Charge Procedure

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 6 de 8

Illustration 3 g00907671
Nitrogen charging group

(3) Valve

(4) Pressure gauge

(5) Chuck

(6) Valve handle

(7) Pressure gauge

(8) Chuck for the nitrogen cylinder valve

(9) Regulator assembly

(10) Pressure regulating screw

1. Connect a hose from the nitrogen cylinder to valve (3) .

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

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 7 de 8

3. OPEN valve (3) and charge the brake accumulator. Then, CLOSE valve (3). If pressure gauge
(4) and pressure gauge (7) show the same reading and the readings do not change, the brake
accumulator has the correct charge.

If the pressure reading on gauge (4) decreases, OPEN valve (3) and allow more nitrogen to fill
the brake accumulator.

Perform this procedure until pressure gauge (4) and pressure gauge (7) show the same reading.
Make sure that neither reading changes when valve (3) is closed.

4. CLOSE valve (3). CLOSE the valve on the nitrogen cylinder.

5. Turn valve (6) on chuck (5) OUTWARD in the counterclockwise direction. Remove the test
equipment.

6. Perform this procedure for the other brake accumulator.

Charge Procedure for a New or Rebuilt Accumulator

It is necessary to remove all the air from the nitrogen chamber of the brake accumulator. When the
brake accumulator is new or rebuilt, put approximately 0.59 L (0.623 qt) of SAE 10 hydraulic oil in
the nitrogen end of the accumulator. This oil will be used to help remove the air out of the nitrogen
chamber of the brake accumulator and also to put lubricant at the top seal of the accumulator piston.
After the brake accumulator is installed on the machine, charge it as follows:

1. Use the same equipment as used to check the nitrogen charge in the brake accumulator.

2. Install chuck (5) onto the nitrogen charge valve for the brake accumulator.

3. Turn valve handle (6) on chuck (5) completely in the clockwise direction. OPEN valve (3) .

4. Start and run the engine until it reaches the normal operating temperature. As hydraulic oil
goes into the bottom of the brake accumulator, the air and then the oil will be pushed out of the
top through the test equipment. When the oil flow stops, the top of the brake accumulator will
be free of air.

5. CLOSE valve (3) completely.

6. Stop the engine. Release the braking system oil pressure. When there is no nitrogen charge in
the brake accumulator, the piston in the brake accumulator will be at the top of the
accumulator cylinder.

Reference: Refer to System Operation, Testing and Adjusting, "System Pressure - Release"
for the machine that is being serviced.

7. Put a charge of nitrogen into the brake accumulator. Follow the procedure in Steps 1 through 6
in "Charge Procedure". The charging procedure will take longer because the accumulator
piston will have to be moved to the bottom of the accumulator cylinder and the oil will have to
be pushed out of the brake accumulator.

NOTICE

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009
R1600G LOAD HAUL DUMP 9YZ00001-UP (MACHINE)(SEBP5171 - 03) - Estr... Página 8 de 8

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.

Copyright 1993 - 2009 Caterpillar Inc. Sun Jun 14 08:53:53 EST 2009
Todos los derechos reservados.
Red privada para licenciados del SIS.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 14/06/2009