10/20/24, 2:19 PM SIS 2.

2002/08/26 Accumulator Charging Valve (Brake) - Test and Adjust (RENR2199-08)

SMCS - 4264 i01792720

Table 1
Required Tools PPT
202 -1073
Part Number Description

06: 4/10/2 2346

1U-5481 Pressure Gauge Kit

1
RE 9:13+ 0
Personal injury or death can result if two persons are not used

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in the following procedure.

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Escaping fluid under pressure, even a pinhole size leak, can
penetrate body tissue, causing serious injury, and possible

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death. If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of injury.
nc.
Always use a board or cardboard when checking for a leak.

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.

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Complete the procedure in Testing and Adjusting, "Machine Preparation for Troubleshooting" prior
to testing the machine.

"Procedure 1" is a quick method for checking the cut-out pressure. This procedure also indicates
whether the oil pressure switch for the service brakes and the brake oil pressure indicator operate
correctly. The procedure provides an estimate of the accumulator precharge pressure and an
estimate of the number of brake applications before the brake oil pressure indicator turns on.

"Procedure 2" determines whether the cut-in pressure and the cut-out pressure are correct. This
procedure also provides the required steps for adjusting the brake accumulator charging valve.

Procedure 1
1. Stop the engine. Engage the parking brake. Depress the brake pedal repeatedly until there is
no brake oil pressure. This will require more than ten applications of the service brakes.

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Illustration 1 g00917421
Location of the Pressure Ports for the Brake Accumulator Charging Valve
(1) Test Port 1. (2) Test port 2.
2. Connect a 0 to 20700 kPa (0 to 3000 psi) pressure gauge at test port (1) on the outside
accumulator.

3. Observe the pressure gauge. Before you start the engine, the oil pressure must be 0 kPa
(0 psi).

4. Start the engine. Allow the oil pressure to increase to maximum pressure. Record this pressure.
This is the cut-out pressure of the brake accumulator charging valve. The correct cut-out
pressure should be 14485 ± 690 kPa (2100 ± 100 psi).
Note: Cut-out pressures that are measured at the brake control valve will be approximately
490 kPa (71 psi) higher than the pressures measured at the test port due to line losses during
accumulator charging.

5. After the brake accumulators have been completely charged and the cut-out pressure has
been obtained, stop the engine.

6. Turn the engine key start switch to the ON position, but do not start the engine.

Illustration 2 g00916897
Alert Indicator Panel
(3) Brake oil pressure indicator.

7. Apply the service brakes repeatedly. Pause for two seconds before each brake application and
count the number of applications while you observe the pressure gauge until the brake oil

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pressure indicator is activated. Note the gauge pressure and the number of brake pedal
applications.
8. Move the gauge to test port (2) and repeat Steps 3 through 7.

9. Use the accumulator test port (1) or (2) that reached warning pressure with fewer pumps of the
brake pedal for Steps 10 through 12. The pressure at that test port should be 8960 ± 345 kPa
(1300 ± 50 psi) when the brake pressure indicator (3) turns on. This also indicates the
operational status of the brake oil pressure switch for the service brakes. The brake oil
pressure switch is located on the accumulator charging valve.

10. Continue to apply the service brakes, pausing for two seconds before each brake application.
When the pressure drops off rapidly, this indicates the approximate nitrogen precharge
pressure in the brake accumulators.

11. Determine the number of brake applications that were required before the brake oil pressure
indicator turned on in Step 7. This count should be approximately six times for brakes that are
new. The count may be as low as two times for brakes that are worn.
Reference: For information on determining the wear factor of service brakes, refer to Testing
and Adjusting, "Service Brake Discs - Check".

12. If the cut-out pressure is not within the specification, complete Steps 6 through 11 in
"Procedure 2". If the nitrogen precharge pressure is not within the specification, see the
following reference.
Reference: For additional information on charging the brake accumulators, refer to Testing and
Adjusting, "Brake Accumulator - Test and Charge".

Procedure 2
Note: Use the same operational conditions that were used in "Procedure 1". Use the same
precautions that were used in "Procedure 1". Use the same accumulator test port as determined in
Step 9 in "Procedure 1".

1. Stop the engine. Engage the parking brake. Depress the brake pedal repeatedly until there is
no brake oil pressure. This will require more than 10 applications of the service brakes.

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Illustration 3 g00917421
Location of the Pressure Ports for the Brake Accumulator Charging Valve
(1) Test port 1. (2) Test port 2.
2. Connect a 0 to 20700 kPa (0 to 3000 psi) pressure gauge at accumulator test port that was
used in Step 9 in "Procedure 1".

3. Observe the pressure gauge. Before you start the engine, the oil pressure must be 0 kPa
(0 psi).

4. Start the engine. Allow the oil pressure to increase to maximum pressure. Record this pressure.
This is the cut-out pressure of the brake accumulator charging valve. The correct cut-out
pressure should be 14485 ± 690 kPa (2100 ± 100 psi).

5. With the engine in operation, slowly apply the service brakes. Apply the service brakes several
times in succession. Verify that the pressure drops consistently. At the point of the specified

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cut-in, the pressure begins to increase quickly. The cut-in pressure should be 11725 ± 345 kPa
(1700 ± 50 psi).
Note: The charging limits move together. The range between the cut-in pressure and the cut-
out pressure is not adjustable.
6. If the cut-in pressure and the cut-out pressure are not within the specification, stop the engine
and completely release all oil pressure from the brake circuit by depressing the brake pedal
repeatedly. Loosen the hydraulic tank filler cap in order to make sure that there is no residual
pressure in the hydraulic oil tank.

Illustration 4 g00916905
Accumulator Charging Valve
(3) Accumulator port for the front service brakes. (4) Accumulator port for the rear service brakes. (5) Port for the oil
pressure switch for the service brakes. (6) Tank port. (7) Inlet from the brake pump. (8) Flow through port. (9) Cover
for the adjustment screw.

7. Remove the cover (9) for the adjustment screw.

8. Turn the hex screw under cover (9) by a quarter turn. Turning the hex screw clockwise will
increase the cut-in pressure and the cut-out pressure. Turning the hex screw counterclockwise
will decrease the cut-in pressure and the cut-out pressure. This will change the values by
approximately 1800 kPa (260 psi). Adjust the screw, as required.

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9. Install the cover (9) for the adjustment screw, and tighten the hydraulic tank filler cap.

10. Start the engine. Make sure that the cut-in pressure and the cut-out pressure are within the
Cat
specification. If the pressures are not within the specification, repeat Steps 6 through 10.

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11. If the cut-in pressure and the cut-out pressure are not within the specification, the brake

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accumulator charging valve may need to be repaired or replaced.

PPT-10732346
2024/10/20
c.
06:19:07+08:00
i01792720
© 2024 Caterpillar Inc.

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