Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3...

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Product:  WHEEL LOADER 
Model:  966G WHEEL LOADER 3PW00549 
Configuration: Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3PW00001-UP (MACHINE) 

Testing and Adjusting

966G Wheel Loader and 972G
Wheel Loader Braking System
Media Number -RENR2112-04 Publication Date -01/02/2009 Date Updated -11/02/2009

i01512813

Brake Accumulator - Test and Charge

SMCS - 4263-081; 4263-045

Test Procedure
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.

1. Turn the engine start switch key to the ON position.

2. Disengage the parking brake.

Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3... Page 2 of 8

Illustration 1 g00495844

Instrument Panel

(1) Parking brake indicator. (2) Brake oil pressure indicator.

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 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.
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Illustration 2 g00495921

Location of the Brake Accumulators

(3) Brake accumulator for front service brakes. (4) Brake accumulator for rear service brakes.

The accumulators for both the front and the rear service brakes are located just outside the frame on
the left of the machine. Both accumulators are in a vertical position underneath the left platform. The
accumulator for the rear service brakes is outside of the accumulator for the front service brakes.

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
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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.

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 and Temperature Relationship for the
5520 kPa ((800 psi)) Service Brake Accumulators
Temperature Pressure
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-7°C (20°F) 5000 kPa (726 psi)

-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)

Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3... Page 6 of 8

Illustration 3 g00495846

Nitrogen Charging Equipment

(5) Nipple. (6) Coupling assembly. (7) Pressure gauge. (8) Hose assembly. (9) Coupling assembly. (10) Nipple. (11)
Valve. (12) Pressure gauge. (13) Regulator assembly. (14) Pressure regulating screw. (15) Chuck for the nitrogen
cylinder valve. (16) Valve handle. (17) Chuck. (18) Hose assembly.

Illustration 4 g00495850

Brake Accumulator

(19) Cover. (20) Cap.

Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3... Page 7 of 8

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

2. Remove cover (19) from the brake accumulator. Remove cap (20) from the valve assembly on
the brake accumulator.

3. Use a 0 to 13800 kPa (0 to 2000 psi) pressure gauge (12) to check the nitrogen charge in the
brake accumulator.

4. Install chuck (17) onto the nitrogen charging valve for the brake accumulator.

5. OPEN valve (11) and charge line (18) to the correct precharge. Refer to Table 2.

6. Turn valve handle (16) 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.

7. If the reading on the pressure gauge is too high, slowly OPEN valve (11) 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 (11) .

b. CLOSE valve (11) and OPEN the valve on the nitrogen cylinder. Adjust screw (14) on
regulator assembly (13) until pressure gauge (7) is at the correct charging pressure. Refer
to Table 2 for the correct charging pressure.

c. OPEN valve (11) and charge the brake accumulator. Then, CLOSE valve (11). If pressure
gauge (12) 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 (12) decreases, OPEN valve (11) and allow more
nitrogen to fill the brake accumulator.

Perform this procedure until pressure gauge (12) and pressure gauge (7) show the same
reading. Make sure that neither reading changes when valve (11) is closed.

8. CLOSE valve (11). CLOSE the valve on the nitrogen cylinder.

9. Turn valve (16) on chuck (17) OUTWARD in the counterclockwise direction. Remove the test
equipment.

10. 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 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
Parking Brake Ar Custom Product Support Literature for 966G and 972G Wheel Loader 3... Page 8 of 8

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 7 through 10
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.

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