Chargue and Discharger Accomulators

27/10/2018 Media Search - REHS5464 - Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077,
077, 5077, 5081, 7474}
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Special Instruction
Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077, 5081,
7474}
Media Number -REHS5464-14 Publication Date -21/07/2015 Date Updated -25/09/2018
i07528516
Accumulator Discharging and Charging Procedures {0738, 4263, 4264,

4331, 5077, 5077, 5081, 7474}
SMCS - 0738; 4263; 4264; 4331; 5077-R6 ; 5077; 5081; 7474
Caterpillar Products
All
Introduction
The information in this instruction will provide the instructions for discharging and charging accumulators for
Caterpillar machines. For accumulator information for tool attachment applications, refer to your tool manual for
your specific application.
Safety Section
Hydraulic circuits must be adequately bled of any residual pressure

before proceeding with hydraulic repairs. Make sure adequate personal
protective equipment (safety glasses, face shield, gloves) is being worn
when initially disconnecting hydraulic fittings. Insure that there is no
load resting on the circuit to prevent serious injury or death due to
falling loads. Pressurized hydraulic fluid can penetrate the skin,
resulting in serious illness or death.
Pressurized System!
Hydraulic accumulators contain gas and oil under high pressure. DO

NOT disconnect lines or disassemble any component of a pressurized
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27/10/2018 Media Search - REHS5464 - Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077, 5081, 7474}
accumulator. All gas pre-charge must be removed from the accumulator

as instructed by the service manual before servicing or disposing of the
accumulator or any accumulator component.
Failure to follow the instructions and warnings could result in personal

injury or death.
Only use dry nitrogen gas to recharge accumulators. See your Cat
dealer for special equipment and detailed information for accumulator
service and charging.
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).
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.
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.
Sudden movement or accidental starting of the machine can cause

personal injury or death to persons on or near the machine.
To prevent personal injury or death, perform the following:
Park the machine on a smooth, level surface.
Lower the work tool to the ground and engage the parking brake.
Stop the engine and remove the key.
Block the wheels and install the steering frame lock.
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, PERJ1017, "Dealer Service Tool Catalog"

for tools and supplies suitable to collect and contain fluids on Cat®
products.
Dispose of all fluids according to local regulations and mandates.
Note: Check each accumulator for nitrogen leakage at all potential leak points. A nitrogen leak is difficult to
detect. A solution that consists of soap and water can be used to detect leaks. Make sure that there is no leakage
around the gas valve base and at the top of the gas valve. Make sure that the gas valve caps are in place. Also, on
piston accumulators, check the joint between the end caps and the shell as well as at the base of any other
additional access ports that may have been added to the end caps.
Identification of Charging Valves

Identification of the charging valve is critical for safe discharging of the accumulator. Charging valves on
Caterpillar equipment include the following types:
Type 1
Illustration 1 g02729754
This type of valve is a standard Schrader valve. This valve is opened by depressing a spring-loaded core (1) with
the charging chuck of the nitrogen charging equipment.
Type 2
This type of valve opens by turning a hex nut (2). The valve contains no core.
Type 3
This is an ACP type valve that also contains a spring loaded core (3), similar to the Schrader valve. This valve is
opened by depressing the spring-loaded core (3) with the charging chuck of the nitrogen charging element.
Type 4
This type of valve is larger than the other three types and has 28 mm threads (5). This valve is opened by turning
a screw (6) which is contained in the valve body.
Required Tools
Tooling (D)
Tooling (F)
Tooling (D), Tooling (H), Tooling (J), and Tooling (K)
Table 1
Tool Item Qty Part No Description
D 175-5507 Nitrogen Charging Group
D1 1 8S-4600 Fitting
D2 1 8S-1506 Coupling As
D3 1 162-4147 Hose As
D6 1 1S-8937 Needle Valve
Pressure Gauge
D7 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
D8 1 162-4146 Regulator
D9 1 7S-5106 Chuck
D10 1 1S-8938 Chuck

D11 1 1S-8941 Hose As
F 349-4200 Thermometer
9U-6740 Accumulator Charging Gp

H
152-2023 Nitrogen Charging Fitting Gp(1)
J 334-1071 Adapter
K 9U-6741 Adapter
(1) Recommended for Type 4 Valves
Accumulators with Type 1 Valve

Discharge Procedure
Table 2

D3 1 162-4147 Hose As
Pressure Gauge
D7 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
D9 1 7S-5106 Chuck
D10 1 1S-8938 Chuck

D11 1 1S-8941 Hose As
Tooling (D) 175-5507 Nitrogen Charging Group
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(7) Cap
(8) Nitrogen charging valve
(9) Core
1. Identify the correct nitrogen charging chuck.
2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).
3. Turn valve handle of nitrogen charging chuck (D9) or (D10) all the way in the counterclockwise direction.
Note: Turning the valve handle will ensure that nitrogen charging valve (8) will not be opened when
nitrogen charging chuck (D9) or (D10) is attached.
4. Remove cap (7) from the nitrogen charging valve (8).
5. Attach nitrogen charging chuck (D9) or (D10) to nitrogen charging valve (8).
6. Turn valve handle of nitrogen charging chuck (D9) or (D10) in the clockwise direction to open nitrogen
charging valve (8). Turning the valve handle will release all the nitrogen from the accumulator through
hose assembly (D11).
Testing and Charging Procedure for the Accumulator Precharge Pressure
Note: Test the accumulator precharge pressure when the machine is not running and all pressure has been
released from the hydraulic system. Make certain that hydraulic pressure at the accumulator is at zero. At this
point the piston will be bottomed at the hydraulic end. For information on releasing the system pressure, refer to
the Operation and Maintenance Manual for the machine.
1. Remove cap (7) on nitrogen charging valve (8).
2. Identify the correct nitrogen charging chuck (D9) or (D10).
3. Turn the valve handle of nitrogen charging chuck (D9) or (D10) all the way in the counterclockwise
direction.
4. Attach nitrogen charging chuck (D9) or (D10) and hose assembly (D11) to nitrogen charging valve (8).
5. Attach hose assembly (D11) between nitrogen charging chuck (D9) or (D10) and the tee. Install needle
valve (D6) to the tee. Refer to Illustration 9. Install pressure gauge (D7) in the remaining open port on the
tee.
6. Turn the valve handle for needle valve (D6) all the way in the clockwise direction. Completely turning the
valve handle will ensure the needle valve (D6) is closed.
charging valve (8).
8. Read pressure gauge (D7) to determine the charge pressure in the accumulator. If charging is needed,
attach regulator (D8) to a nitrogen tank.
9. Adjust pressure regulating screw on the regulator to obtain the correct pressure reading on the gauge.
Refer to the Testing and Adjusting manual for your machine to obtain the correct pressure.
Note: If the machine has been running for some time, the temperature of the accumulator may be different
from the ambient temperature of the outside air. Refer to the table in your machine Testing & Adjusting
information for the proper pressure for your machine. Use tooling (F) to determine the current temperature
of the accumulator.
10. Open needle valve (D6). Nitrogen will flow from the regulator to the accumulator. When gauge (D7) reads
the correct pressure, close needle valve (D6).
11. Allow the temperature of the accumulator to stabilize. Recheck the precharge pressure at the stabilized
temperature.
12. Once the accumulator is charged, turn the valve handle of chuck (D9) or (D10) counterclockwise
completely. Remove chuck (D9) or (D10). Remove the regulator from the nitrogen tank.
Accumulator Charge Procedure for a Rebuilt Piston Type Accumulator

When the accumulator has been rebuilt, the air must be removed from the upper nitrogen chamber of the
accumulator. Use hydraulic oil to help remove the air from the upper nitrogen chamber of the accumulator and to
lubricate the top seal of the piston in the accumulator. The piston within the accumulator is typically cupped on
the nitrogen side. Fill the upper nitrogen chamber of the accumulator with enough hydraulic oil to cover the top
of the piston.
After the installation of the rebuilt accumulator is complete, use the following steps to charge the accumulator.
2. Attach hose assembly (D11) to nitrogen charging chuck (D9 or D10).
3. Turn the valve handle of nitrogen charging chuck (D9 or D10) all the way in the counterclockwise
direction.
nitrogen charging chuck (D9 or D10) is attached.
4. Remove cap (7) from nitrogen charging valve (8).
5. Attach nitrogen charging chuck (D9 or D10) to nitrogen charging valve (8).
6. Turn the valve handle of nitrogen charging chuck (D9 or D10) in the clockwise direction to open nitrogen
charging valve (8).
7. Start the engine and allow the engine to run until the engine is warm. Activate the system for the
accumulator.
Hydraulic oil will flow into the bottom of the accumulator. The air will first be forced out of the upper
chamber of the accumulator through the test equipment. Then, the hydraulic oil will be forced out of the
upper chamber of the accumulator through the test equipment. When the hydraulic oil stops flowing out of
the top of the accumulator, the upper chamber of the accumulator will contain no air.
Note: A small amount of hydraulic oil will remain inside the accumulator. The small amount of hydraulic
oil on the nitrogen side is acceptable and will help with lubrication.
8. Charge the accumulator according to the procedure in "Testing and Charging Procedure for the
Accumulator Precharge Pressure". Rebuilt accumulators require longer charging times. New accumulators
require less charging time. When the accumulator has been rebuilt, the piston is located in the top of the
cylinder. The piston will be forced to the bottom of the cylinder during the charging procedure.

Discharge Procedure
Table 3
D3 1 162-4147 Hose As
Pressure Gauge
D7 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
D9 1 7S-5106 Chuck
D10 1 1S-8938 Chuck
D11 1 1S-8941 Hose As

(10) Cap
(11) Hex nut
direction.
6. Hold nitrogen charging valve (12) with one wrench. Turn hex nut (11) with a second wrench in a
counterclockwise direction.
Loosening the nut opens nitrogen charging valve (12). Three turns will fully open the valve. Opening the
valve will release all the nitrogen from the accumulator through hose assembly (D11).

1. Remove protective cap (10) on nitrogen charging valve (12).
direction.
valve (D6) on the tee. Refer to Illustration 11. Install pressure gauge (D8) in the remaining open port on
the tee.
6. Turn the valve handle for needle valve (D6) all the way in the clockwise direction. Completely turning the
valve handle will ensure the needle valve (D6) is closed.
Loosening the nut opens nitrogen charging valve (12). Three turns will fully open the valve.
9. Adjust pressure regulating screw on regulator (D8) to obtain the correct pressure reading on the gauge.
of the accumulator.
temperature.
12. Once the accumulator is charged, hold nitrogen charging valve (12) with one wrench. Turn hex nut (11)
with a second wrench in a clockwise direction. Tightening the nut closes nitrogen charging valve (12).
Remove chuck (D9) or (D10). Remove regulator (D8) from the nitrogen tank.
of the piston.
accumulator.

Discharge Procedure
Table 4
D3 1 162-4147 Hose As
Pressure Gauge
D7 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
D9 1 7S-5106 Chuck
D10 1 1S-8938 Chuck

D11 1 1S-8941 Hose As
(13) Cap
(14) Hex nut
nitrogen charging chuck (D9) or (D10) is attached.
4. Remove cap (13) from nitrogen charging valve (15). Attach nitrogen charging chuck (D9) or (D10) to
nitrogen charging valve (15).
charging valve (15). Loosening nut (14) and opening the valve will release all the nitrogen from the
accumulator through hose assembly (D11).
1. Remove protective cap (13) on nitrogen charging valve (15).
direction.
valve (D6) on the tee. Refer to Illustration 13. Install pressure gauge (D8) in the remaining open port on
the tee.
6. Turn the valve handle for needle valve (D6) all the way in the clockwise direction.
Completely turning the valve handle will ensure the needle valve (D6) is closed.
charging valve (15).
10. Adjust pressure regulating screw on regulator (D8) to obtain the correct pressure reading on the gauge.
of the accumulator.
temperature.
13. Once the accumulator is charged, turn the valve handle counterclockwise completely. Hold nitrogen
charging valve (15) with one wrench. Turn hex nut (14) with a second wrench in a clockwise direction.
Tightening the nut closes nitrogen charging valve (15). Remove chuck (D9) or (D10). Remove the
regulator from the nitrogen tank.

of the piston.
6. Hold nitrogen charging valve (15) with one wrench. Turn hex nut (14) in a counterclockwise direction
with a second wrench. Loosening the hex nut (14) opens nitrogen charging valve (15). Three turns
counterclockwise will fully open the valve.
accumulator.

Discharge Procedure
Table 5
Accumulator with Type 4 Valve
D3 1 162-4147 Hose As
Pressure Gauge
D7 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
D9 1 7S-5106 Chuck
D10 1 1S-8938 Chuck
D11 1 1S-8941 Hose As
9U-6740 Accumulator Charging Gp

H
152-2023 Nitrogen Charging Fitting Gp(1)
J 334-1071 Adapter
K 9U-6741 Adapter
(1) Recommended for Type 4 Valves
Tooling (H)
Tooling (J)
Tooling (K)
Note: The recommended accumulator charging group for Type 4 valves is 152-2023 Nitrogen Charging Fitting
Gp. The 9U-6740 Accumulator Charging Gp may also be used for Type 4 valves. Sometimes, the threads on the
tooling nut in 9U-6740 Accumulator Charging Gp are too long to have a proper seal. In such cases, the
technician may need to add washers to the tooling nut in 9U-6740 Accumulator Charging Gp to create a proper
seal.
Detail of Tooling (H)
( H1) Tee handle
(H2) Manual purge valve
(H3) Cap nut
(H4) Check valve
(16) Cap
(17) Vent Screw
Note: Make sure adequate personal protective equipment (safety glasses, face shield, hand gloves) is being worn
prior to discharge or charge an accumulator.
1. Turn manual purge valve (H2) in the clockwise direction to close the purge valve.
2. Remove cap (16) from the charging valve.
If the vent screw is loosened more than one quarter turn, the vent screw
could become a projectile which could result in physical injury.
NOTICE
Over-tightening vent screw (17) above 20 N·m (15 lb ft) can damage
vent screw (17). Damage to vent screw (17) may not allow the tooling
(H) to relieve accumulator pressure and required an extra procedure.
Contact DSN for more details.
3. Ensure the vent screw (17) is completely closed.Do not over tighten.
4. Use a 6 mm (0.24 inch) Allen wrench to loosen vent screw (17) one quarter turn. Retighten vent screw
(17) to one quarter turn with the fingers.
5. Attach tooling (H) to the charging valve.
6. Turn tee handle (H1) in the counterclockwise direction to open vent screw (17). Carefully open manual
purge valve (H2). Release pressure slowly until the gas pressure is discharged.
7. Close the manual purge valve (H2).
1. Before connecting the tooling, close manual purge valve (H2) on tooling (H). Turn manual purge valve
(H2) in the clockwise direction to close manual purge valve (H2).
2. Before connecting the tooling, close needle valve (D6). Turn the needle valve handle in the clockwise
direction to close the needle valve.
3. Assemble tooling (D), tooling (H), tooling (J), and tooling (K). Refer to Illustration 15.
4. Install regulator assembly (D8) on the nitrogen tank valve. Adjust the screw on regulator (D8) to set the
appropriate charge pressure. Refer to the Test and Adjust manual for your machine to determine the
appropriate charge pressure. Use thermometer tooling (F) to determine the correct temperature.
NOTICE
8. Hand tighten cap nut (H3) to the charging valve.
9. Open needle valve (D6). Allow nitrogen flow to purge air from the lines through the purge valve. After the
air is purged, close manual purge valve (H2). Close needle valve (D6)
10. Turn tee handle (H1) a maximum of three turns in the counterclockwise direction. The gauge on tooling
(H) will show the gas precharge pressure.
11. Open the shutoff valve on the nitrogen tank. Slowly open needle valve (D6).
12. Precharge the accumulator slowly. Charging too quickly may damage the accumulator. When the desired
pressure is reached, close needle valve (D6). Close the shutoff valve on the nitrogen tank.
13. Allow the temperature of the accumulator to stabilize, then recheck the pressure. When the desired
pressure is reached, turn tee handle (H1) to close the charging valve.
14. Open needle valve (D6). Slowly open manual purge valve (H2) to allow pressure in the charging
equipment to purge off. When no pressure remains in the lines, close manual purge valve (H2). Remove
cap nut (H3) from the charging valve. Remove regulator (D8) from the nitrogen tank.
NOTICE
vent screw (17). Damage of vent screw (17) may cause improper to
relieve accumulator pressure.
15. Use a to tighten vent screw (17) to a torque of 20 N·m (15 lb ft).
16. Install cap (16). Hand tighten cap (16).
Additional Information Regarding Type 4 Valve Accumulator Pre-Charge Pressure

Adjustments
Check the accumulator for following two conditions:
1. The accumulator has existing pre-charge (accumulator is exhibiting either low-precharge or high-
precharge condition):
a. When charging an accumulator that has an existing gas pre-charge or discharging an accumulator to
lower pre-charge, allow 10 minutes after recharging for the gas temperature and pressure to stabilize
and then recheck to ensure that pressure matches appropriate values.
2. The accumulator has no initial gas pre-charge (accumulator is exhibiting complete discharge condition):
View showing accumulator gas valve assembly
(A) Ring seal
(B) 6 mm Allen wrench
(C) Socket head cap screw
a. Remove ring seal (A) from the accumulator gas valve assembly and replace with new 222-5765
Ring Seal. Lubricate the new ring seal with mineral oil before installing in the accumulator gas
valve assembly.
Note: Use a 6 mm (0.24 inch) Allen wrench to overcome the initial torque on the socket head cap
screw to ensure proper engagement to the screw head. Refer to Illustration 18.
Use a 6 mm (0.24 inch) Allen wrench (B) to tighten socket head cap screw (C) to a torque of
20 N·m (14.75 lb ft).
Note: DO NOT over-torque above 20 N·m (14.75 lb ft).
b. When charging an accumulator that has no initial gas pre-charge, allow 20 to 30 minutes after
recharging for the gas temperature and pressure to stabilize and then recheck to ensure that pressure
matches appropriate values.

of the piston.
1. Before connecting tooling, close needle valve (D6). Turn the valve handle in the clockwise direction to
close the valve.
2. Assemble tooling (D), tooling (H), tooling (J), and tooling (K). Refer to Illustration 15.
NOTICE
6. Hand tighten cap nut (H3).
7. Open manual purge valve (H2).
accumulator.
9. Close manual purge valve (H2).
Copyright 1993 - 2018 Caterpillar Inc. Sat Oct 27 2018 06:00:04 GMT-0500 (hora estándar de Colombia)
All Rights Reserved.
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27/10/2018 Media Search - REHS5464 - Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077,

077, 5077, 5081, 7474}

Accumulator Discharging and Charging Procedures {0738, 4263, 4264,

Hydraulic circuits must be adequately bled of any residual pressure

Hydraulic accumulators contain gas and oil under high pressure. DO

accumulator. All gas pre-charge must be removed from the accumulator

Failure to follow the instructions and warnings could result in personal

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

Always use a board or cardboard when checking for a leak.

Sudden movement or accidental starting of the machine can cause

To prevent personal injury or death, perform the following:

Park the machine on a smooth, level surface.

Stop the engine and remove the key.

Block the wheels and install the steering frame lock.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog"

Dispose of all fluids according to local regulations and mandates.

Identification of Charging Valves

D10 1 1S-8938 Chuck

9U-6740 Accumulator Charging Gp

Accumulators with Type 1 Valve

Tool Item Qty Part No Description

D10 1 1S-8938 Chuck

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).

4. Remove cap (7) from the nitrogen charging valve (8).

Testing and Charging Procedure for the Accumulator Precharge Pressure

1. Remove cap (7) on nitrogen charging valve (8).

2. Identify the correct nitrogen charging chuck (D9) or (D10).

Accumulator Charge Procedure for a Rebuilt Piston Type Accumulator

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9 or D10).

4. Remove cap (7) from nitrogen charging valve (8).

Accumulators with Type 2 Valve

D11 1 1S-8941 Hose As

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).

4. Remove cap (10) from nitrogen charging valve (12).

Testing and Charging Procedure for the Accumulator Precharge Pressure

1. Remove protective cap (10) on nitrogen charging valve (12).

2. Identify the correct nitrogen charging chuck (D9) or (D10).

Accumulator Charge Procedure for a Rebuilt Piston Type Accumulator

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).

4. Remove cap (10) from nitrogen charging valve (12).

Accumulators with Type 3 Valve

D10 1 1S-8938 Chuck

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).

Testing and Charging Procedure for the Accumulator Precharge Pressure

1. Remove protective cap (13) on nitrogen charging valve (15).

2. Identify the correct nitrogen charging chuck (D9) or (D10).

Accumulator Charge Procedure for a Rebuilt Piston Type Accumulator

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (D11) to nitrogen charging chuck (D9) or (D10).

4. Remove cap (13) from nitrogen charging valve (15).

Accumulators with Type 4 Valve

9U-6740 Accumulator Charging Gp

2. Remove cap (16) from the charging valve.

5. Attach tooling (H) to the charging valve.

7. Close the manual purge valve (H2).

Testing and Charging Procedure for the Accumulator Precharge Pressure

5. Remove cap (16) from the charging valve.

8. Hand tighten cap nut (H3) to the charging valve.