416E Backhoe Loader Hydraulic and Steering System Caterpillar


Ride Control Accumulator - Test and Charge

Usage:

416E BWC

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

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).

----------------------

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

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.

----------------------


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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.


Before any tests are performed, visually inspect the complete hydraulic system for oil leaks and damaged parts. Refer to Testing and Adjusting, "Visual Inspection". Before any tests are performed, prepare the machine for troubleshooting. Refer to Testing and Adjusting, "Machine Preparation for Troubleshooting".

  1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.

  1. Lower the loader bucket to the ground. Stop the engine.

  1. Engage the parking brake.

  1. Place chocks in front of the wheels and behind the wheels.

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

  1. Move the control levers to all positions in order to release the pressure in the hydraulic system.

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



    Illustration 1g01804516

    (A) Location of the Accumulator




    Illustration 2g00557001

    Accumulator

    (1) Screws. (2) Valve. (3) Valve cap. (4) Protector.

  1. Remove one screw (1) and rotate the protector (4). Remove valve cap (3) .



    Illustration 3g00509122

    Group for nitrogen charging

    (5) Pressure gauge. (6) Valve. (7) Pressure gauge. (8) Regulator assembly. (9) Pressure regulating screw. (10) Nipple assembly for the nitrogen cylinder valve. (11) Valve handle. (12) Chuck.

  1. Turn the valve (6) completely in the clockwise direction. Turn the valve handle (11) completely in the counterclockwise direction.

  1. Install the chuck (12) to the valve (2) .

  1. Turn the valve handle (11) completely in the clockwise direction. The reading on the pressure gauge (7) should be 1860 ± 34.5 kPa (270 ± 5.0 psi).

  1. If the reading on the pressure gauge is too high, repeat steps 5 through 7. This ensures that there is no hydraulic oil in the accumulator. If the pressure is still high, slowly open valve (6) in order to lower the pressure. If the reading on the pressure gauge is too low, use the following procedure to charge the ride control accumulator:

    1. Connect the nipple assembly (10) to the nitrogen cylinder.

    1. Open the valve on the nitrogen cylinder. Adjust screw (9) on the regulator assembly (8) until the reading on pressure gauge (5) is 1860 ± 34.5 kPa (270 ± 5.0 psi).

    1. Open valve (6) and charge the ride control accumulator. Then, close valve (6). If pressure gauge (7) and pressure gauge (5) show the same reading and the readings do not change, the ride control accumulator has the correct charge.

      If the pressure reading on gauge (7) decreases, open valve (6) and allow more nitrogen to fill the accumulator.

      Perform this procedure until pressure gauge (7) and pressure gauge (5) show the same reading. Make sure that neither reading changes when valve (6) is closed.

  1. Close valve (6). Close the valve on the nitrogen cylinder.

  1. Turn the valve handle (11) completely in the counterclockwise direction.

  1. Remove the chuck (12) from the valve (2) .

  1. Open the valve (6). This will release the pressure between the valve (6) and the valve on the nitrogen cylinder. Remove the nipple assembly (10) from the nitrogen cylinder.



    Illustration 4g00557001

    Accumulator

    (1) Screws. (2) Valve. (3) Valve cap. (4) Protector.

  1. Install the valve cap (3). Rotate protector (4) and one screw (1). Tighten valve cap (3) to 1.6 ± .01 N·m (14 ± 0.09 lb in).

  1. Remove the chocks.

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