TH210 and TH215 Telehandlers Machine Systems Caterpillar

Brake Accumulator - Remove and Install

Usage:

Removal Procedure

Start By:

Apply the foot brake valve several times in order to relieve the pressure in the brake system. Refer to Systems Operation, Testing and Adjusting, RENR5156, "Machine Preparation for Troubleshooting".

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At operating temperature, the hydraulic tank is hot and under pressure.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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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.

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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.

Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the oil system.

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Illustration 1	g00934970

Disconnect electrical wires (1) for the pressure switch on the accumulator. Place identification marks on the electrical wires in order to identify the correct connections for the electrical wires for the purpose of installation.

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Illustration 2	g00934969

Remove bolts (3) and the washers that secure plate (2) to the frame of the machine. Remove bolt (5) and the washer that connects ground strap (4) to the machine. Move the ground strap to one side.

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Illustration 3	g00934973

Remove bolts (7), the nuts and the washers in order to disconnect hydraulic fan valve (6) from plate (2) .

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Illustration 4	g00934974

lower plate (2) as far as possible in order to expose the accumulator.

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Illustration 5	g00934975

Disconnect hoses (8) from the accumulator before removing plate (2) and the accumulator from the machine.

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Illustration 6	g00934976

Place plate (2) and the accumulator on a suitable bench.

Make a note of the orientation of tee (9) to the accumulator for the purpose of installation. Remove the tee and the attached switch.

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Illustration 7	g00935046

Remove union fitting (10) .

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Illustration 8	g00935049

Remove nut (11) before removing the accumulator from plate (2) .

Installation Procedure

Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

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Illustration 9	g00935049

Position the accumulator to plate (2) before installing nut (11) .

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Illustration 10	g00935046

Install union fitting (10) .

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Illustration 11	g00935080

Install tee (9) and the attached switch. Ensure that the tee is in the correct orientation to the accumulator. Refer to the note that was made during the installation procedure.

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Illustration 12	g00934974

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Illustration 13	g00934975

Position plate (2) under the machine. Raise the end of the plate with the accumulator in order to connect hoses (8) .

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Illustration 14	g00934973

Raise plate (2) to hydraulic fan valve (6) before installing bolts (7), the nuts and the washers that secure the hydraulic fan valve and the plate together.

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Illustration 15	g00934969

Install bolts (3) and the washers that secure plate (2) to the frame of the machine. Position ground strap (4) to the frame of the machine before installing bolt (5) and the washer that secures the ground strap in place.

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Illustration 16	g00934970

Connect electrical wires (1) for the pressure switch on the accumulator. Use the identification marks that were placed on the electrical wires during the removal procedure in order to identify the correct connections for the electrical wires.

End By:

Purge the service brake system of air. Refer to System Operations, Testing and AdjustingRENR5156, "Service Brake Air - Purge".
Check the hydraulic tank oil level. Refer to Operation and Maintenance Manual, "Hydraulic Tank - Check Oil Level".