928H USAF 10K ATFL RSB00001-UP (MACHINE) POWERED BY C6.6 Engine(SEB...

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Shutdown SIS

Previous Screen

Product:  WHEEL LOADER 
Model:  928H WHEEL LOADER RSB 
Configuration: 928H USAF 10K ATFL RSB00001-UP (MACHINE) POWERED BY C6.6 Engine 

Special Instruction
Accumulator Discharging and Charging Procedures{0738, 4263, 4264, 4331, 5077,
5077, 5081, 7474}
Media Number -REHS5464-06 Publication Date -19/06/2014 Date Updated -19/06/2014

i05837426

Accumulator Discharging and Charging Procedures{0738,

4263, 4264, 4331, 5077, 5077, 5081, 7474}
SMCS - 0738-R6; 4263-R6; 4264-R6; 4331-R6; 5077-R6; 5081-R6; 7474-R6

Caterpillar Products: All

Introduction

Pressurized System!

Hydraulic accumulators contain gas and oil under high pressure. DO

NOT disconnect lines or disassemble any component of a pressurized
accumulator. All gas pre-charge must be removed from the
accumulator as instructed by the service manual before servicing 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.

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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.

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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, NENG2500, "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.

The information in this instruction will provide the instructions for discharging and charging
accumulators. Accumulators on Caterpillar products contain one of several different charging valves.
Before attempting to discharge any accumulator, determine which charging valve is on your
accumulator and the correct procedure for discharging.

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:

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Type 1

Illustration 1 g02729754

Illustration 2 g03203036

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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

Illustration 3 g02729772

This type of valve opens by turning a hex nut (2). The valve contains no core.

Type 3

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Illustration 4 g02729823

This type of valve also opens by turning a hex nut (4). This valve also contains a spring loaded core
(3), similar to the Schrader valve. Turning the nut and depressing the core are both necessary to open
the valve.

Type 4

Illustration 5 g02730308

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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

Illustration 6 g01624351

Tooling (D)

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Illustration 7 g02146997

Tooling (F)

Illustration 8 g03330551

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
D4 1 8S-4599 Coupling As
D5 1 2S-5244 Fitting
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

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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

Illustration 9 g01624351

Tooling (D) 175-5507 Nitrogen Charging Group

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Illustration 10 g02730373

(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) .

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6. Turn valve handle of nitrogen charging chuck (D9 or D10) in the clockwise direction in order to
open nitrogen charging valve (8). Turning the valve handle will release all of 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.

7. Turn valve handle of nitrogen charging chuck (D9 or D10) in the clockwise direction in order to
open nitrogen charging valve (8) .

8. Read pressure gauge (D7) in order 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.

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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 in order to charge
the accumulator.

1. Identify the correct nitrogen charging chuck.

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.

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 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 in
order 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 it helps 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.

Accumulators with Type 2 Valve

Discharge Procedure

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Illustration 11 g01624351

Tooling (D) 175-5507 Nitrogen Charging Group

Illustration 12 g02730534

(10) Cap

(11) Hex nut

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(12) Nitrogen charging valve

1. Identify the correct nitrogen charging chuck.

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.

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

5. Attach nitrogen charging chuck (D9 or D10) to nitrogen charging valve (12) .

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 of 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 protective cap (10) on nitrogen charging valve (12) .

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 (12) .

5. Attach hose assembly (D11) between nitrogen charging chuck (D9 or D10) and the tee. Install
needle 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.

7. 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.

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8. Read pressure gauge (D7) in order 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 regulator (D8) 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, 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.

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 in order to charge
the accumulator.

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.

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

5. Attach nitrogen charging chuck (D9 or D10) to nitrogen charging valve (12) .

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.

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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 it helps 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.

Accumulators with Type 3 Valve

Discharge Procedure

Illustration 13 g01624351

Tooling (D) 175-5507 Nitrogen Charging Group

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Illustration 14 g02730628

(13) Cap

(14) Hex nut

(15) Nitrogen charging valve

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 (15) will not be opened
when 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) .

5. Hold nitrogen charging valve (15) with one wrench. Turn hex nut (14) with a second wrench in
a counterclockwise direction.

Loosening the nut opens nitrogen charging valve (15). Three turns will fully open the valve.

6. Turn valve handle of nitrogen charging chuck (D9 or D10) in the clockwise direction to open
nitrogen charging valve (15). Loosening nut (14) and opening the valve will release all of the
nitrogen from the accumulator through hose assembly (D11) .

Testing and Charging Procedure for the Accumulator Precharge Pressure

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

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 (15) .

5. Attach hose assembly (D11) between nitrogen charging chuck (D9 or D10) and the tee. Install
needle 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.

7. Hold nitrogen charging valve (15) with one wrench. Turn hex nut (14) with a second wrench in
a counterclockwise direction.

Loosening the nut opens nitrogen charging valve (14). Three turns will fully open the valve.

8. Turn valve handle of nitrogen charging chuck (D9 or D10) in the clockwise direction in order to
open nitrogen charging valve (15) .

9. Read pressure gauge (D7) in order to determine the charge pressure in the accumulator. If
charging is needed, attach regulator (D8) to a nitrogen tank.

10. Adjust pressure regulating screw on regulator (D8) 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.

11. Open needle valve (D6). Nitrogen will flow from the regulator to the accumulator. When gauge
(D7) reads the correct pressure, close needle valve (D6) .

12. Allow the temperature of the accumulator to stabilize. Recheck the precharge pressure at the
stabilized 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

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clockwise direction. Tightening the nut closes nitrogen charging valve (15). 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 in order to charge
the accumulator.

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.

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

5. Attach nitrogen charging chuck (D9 or D10) to nitrogen charging valve (15) .

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.

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 it helps 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.

Accumulators with Type 4 Valve

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Discharge Procedure

Illustration 15 g03330551

Tooling (D) 175-5507 Nitrogen Charging Group

Tooling (H)

Tooling (J)

Tooling (K)

Note: The recommended accumulator charging group for Type 4 valves is 152-2023 Nitrogen
Charging Fitting Gp . 9U-6740 Accumulator Charging Gp may also be used for Type 4 valves. In
some cases, the threads on the tooling nut in 9U-6740 Accumulator Charging Gp is too long for the
threads on the accumulator making it impossible 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 in order to create a
proper seal.

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Illustration 16 g02713418

Detail of Tooling (H)

(H1) Tee handle

(H2) Manual purge valve

(H3) Cap nut

(H4) Check valve

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Illustration 17 g02730659

(16) Cap

(17) Screw

1. Turn manual purge valve (H2) in the clockwise direction to close the purge valve.

2. Remove cap (16) from charging valve. In many cases, Tooling (H) will not be able to apply
enough force to break loose vent screw (17). If necessary, use an Allen wrench to break loose
and retighten the vent screw. Turn the vent screw counterclockwise to loosen the screw.

3. Attach tooling (H) to charging valve.

4. Turn tee handle (H1) in the counterclockwise direction to open screw (17). Carefully open
manual purge valve (H2). Release pressure slowly until the gas pressure is discharged.

5. Close the manual purge valve (H2) .

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. Before connecting tooling, close manual purge valve (H2) on tooling (H). Turn valve (H2) in
the clockwise direction to close the valve.

2. Before connecting tooling, close needle valve (D6). Turn the valve handle in the clockwise
direction to close the valve.

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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 tooling (F) to determine the correct temperature.

5. Remove cap (16) from the nitrogen charging valve. In many cases, Tooling (H) will not be able
to apply enough force to break loose vent screw (17). If necessary, use an Allen wrench to
break loose and retighten the vent screw. Turn the vent screw counterclockwise to loosen the
screw.

6. Attach tooling (H) to the nitrogen charging valve. Hand tighten cap nut (H3) .

7. Open manual purge valve (H2). 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) .

8. Turn tee handle (H1) a maximum of three turns in the counterclockwise direction. The gauge on
tooling (H) will show the gas precharge pressure.

9. Open the shutoff valve on the nitrogen tank. Slowly open needle valve (D6) .

10. 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.

11. 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 nitrogen charging valve.

12. 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 accumulator. Remove regulator (D8) 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 in order to charge
the accumulator.

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.

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3. Remove cap (16) from the nitrogen charging valve. In many cases, Tooling (H) will not be able
to apply enough force to break loose vent screw (17). If necessary, use an Allen wrench to
break loose and retighten the vent screw. Turn the vent screw counterclockwise to loosen the
screw.

4. Attach tooling (H) to the nitrogen charging valve. Hand tighten cap nut (H3) .

5. Open manual purge valve (H2) .

6. 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 it helps with lubrication.

7. Close manual purge valve (H2) .

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.

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