938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Accumulator Charging Valve (Brake) - Remove and Install Caterpillar


Accumulator Charging Valve (Brake) - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Start By:

  1. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

  2. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "System Pressure - Release".


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.


------ WARNING! ------

Personal injury can result from the sudden release of high pressure oil.

Be sure the engine has been shut off for a minimum of five minutes to be sure that the accumulator pressure is zero.

The accumulator is filled with dry nitrogen. Do not loosen or remove the valve or cap from the top of the accumulator. A purge screw at the bottom of the accumulator can be used to release the pressure that is left in the system.


------ WARNING! ------

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 attachments have been lowered, 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.


Note: Put identification on all lines and on all hoses for installation purposes. Plug all lines and all hoses. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

  1. Activate the parking brake.


    Illustration 1g00986518

    Note: The brake accumulator is located on the left side of the machine.

  2. Remove bolts (1) and shroud (2).


    Illustration 2g00986519

  3. Disconnect hoses (4). Disconnect harness assembly (3) from reservoir (5).


    Illustration 3g00986520

  4. Remove bolts (6). Remove reservoir (5).


    Illustration 4g00987147


    Illustration 5g00987148

    Note: The cab has been removed for photographic clarity only.

  5. Disconnect hose assemblies (9) and tube assemblies (8) from brake accumulator charging valve (10).

  6. Disconnect harness assembly (7).

  7. Remove bolts (11). Remove brake accumulator charging valve (10).

Installation Procedure

------ WARNING! ------

Personal injury or death can result from improper accumulator charging.

Dry nitrogen is the only gas approved for use in the accumulator. Charging the accumulator with oxygen gas will cause an explosion. This danger will not happen if nitrogen cylinders with standard CGA Compressed Gas Association, Inc.Number 580 connections are used.

When ordering nitrogen gas, be sure that the cylinders are equipped with CGA Number 580 Connections. Do not use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders.

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).


Note: For the correct charging procedure, refer to Testing and Adjusting, "Brake Accumulator - Test and Charge".

Note: The cab has been removed for photographic clarity only.



    Illustration 6g00987147


    Illustration 7g00987148

  1. Install brake accumulator charging valve (10). Install bolts (11).

  2. Connect hose assemblies (9) and tube assemblies (8) to brake accumulator charging valve (10).

  3. Connect harness assembly (7).


    Illustration 8g00986520

  4. Install reservoir (5). Install bolts (6).


    Illustration 9g00986519

  5. Connect harness assembly (3) to reservoir (5). Connect hoses (4).


    Illustration 10g00986518

  6. Install shroud (2) and bolts (1) .

End By:

  1. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

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