797 Off-Highway Truck Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before the Assembly procedure, the exterior of the component should be thoroughly cleaned. Cleaning will help to prevent dirt from entering the internal mechanism.

Show/hide table

Illustration 1	g06372036

1. Use Tooling (B) to install profile ring (13) onto piston (7) in the location that is shown.

2. Heat profile ring (10) to 150 ° C (302 ° F). Use Tooling (B) to install profile ring (10) with the shoulder toward the oil end of the accumulator.
   Show/hide table

   Illustration 2	g06372039

3. Use Tooling (B) to install O-ring (14) onto piston (7) in the location that is shown.

4. Heat oil wiping ring (11) to 150 ° C (302 ° F). Use Tooling (B) to install oil wiping ring (11) with the shoulder toward the oil end of the accumulator.
   Show/hide table

   Illustration 3	g06372040

5. Install profile ring (12). Install guide rings (9) with the ends displaced by 180 degrees.
   Show/hide table

   Illustration 4	g06372201

   Show/hide table

   Illustration 5	g06372205

6. Lubricate the cylinder wall of accumulator (1) and piston assembly (7) with the lubricant that is being sealed. Use Tooling (C) to install piston assembly (7). Install piston assembly (7) with the hollow side of the piston assembly toward the gas side.

7. Install O-ring seal (6) onto end cap (5). Install O-ring seal (2) onto end cap (3).

8. Use Tooling (A) to screw end cap (5) and end cap (3) into accumulator (1) until flush with the end of accumulator (1). Continue to screw in end cap (5) and end cap (3) until there is enough clearance for the installation of locking pin (8). Install locking pins (8).

9. Install block assembly (4). Tighten block assembly (4) to a torque of 180 +0/-20 N·m (133 +0/-15 lb ft).
   Show/hide table

   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).

10. Charge the accumulator. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures" for the correct procedure to charge the accumulator.

End By:

1. Install the accumulator.