- Caterpillar Products
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Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
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Think Safety | |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. The section provides useful information on individual parts, tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts Section is a reference for parts identification and available part numbers.
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
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Personal Protection/Important Information | |
Prohibited Action
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No Smoking |
Hazard Avoidance
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Crushing Hazard (foot) |
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Crushing Hazard (hand) |
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Pinch Point |
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Fire Hazard |
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Electrical Shock - Hazard |
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Fire Hazard |
Safety Section
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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 or disposing of 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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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. |
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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, "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. |
Contact Information
For product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
References
UENR0445, 336E Hybrid Excavator Systems Testing, and Adjusting Manual
NEHS0742-02 Assembly of 175-5507 and 361-3889 Nitrogen Charging Groups
REHS5464 Accumulator Discharging and Charging Procedures
General Information Section
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| Illustration 3 | g03813730 |
| Specifications | |
| Dimensions (inches) | 30 L x 12 D x 12 H |
| Weight | 60 lbs |
| Displacement Per Cycle | 3.1 cu in |
| Maximum Outlet Pressure | 2900 psi (200 bar) |
| Safety Relief Valve Setting | 3100 psi (214 bar) |
Introduction
The 455-0126 Nitrogen Booster Pump Group is used to charge and fill nitrogen accumulators on Cat machines.
The Unit is designed to boost directly from cascade cylinders or a high-pressure compressor storage cylinder to outlet pressures of 2900 psi (200 bar).
The Unit ensures full 2900 psi (200 bar) fills even if the supply storage pressure drops as low as 300 psi (21 bar).
The unit is operated with a low-pressure conventional air compressor or "Bootstrap" directly from the high-pressure nitrogen storage supply. The high-pressure section of the booster is cooled by the drive exhaust air and operates dry, non-lubricated. In the shop air drive mode, non-contaminated outlet gas is assured because of complete dual vented separation from the drive section. All items are mounted on a painted aluminum tubular frame, and include dual carry handles, with valves and gauges line mounted onto the booster.
Note: A license may be required to use the Nitrogen Booster Group in your region. Check local regulations before using the Nitrogen Booster Group.
The Unit is warranted for one year from the date of purchase or 18 months from the date of production. For more information on warranty, contact Hydraulics International.
| Key Features |
| Single acting double drive gas booster configuration model 5G-SD-60-X-T |
| Automatic control to stop the booster when the outlet pressure exceeds set point, preselected pressure set at 2900 psi (200 bar)(adjustable) |
| Manual start and stop |
| High-pressure air controls (HP regulator, relief valve, inlet, and regulated outlet gauges and on/off valve) |
| Low-pressure drive inlet port with on/off valve |
| Safety relief valve set at 3100 psi (214 bar) (adjustable) |
| Gas inlet and outlet gauges |
Required Tools
- Nitrogen Booster Group
- Infrared Thermometer, Part Number 164-3310
- Nitrogen Charging Group, Part Number 175-5507 or 361-3889
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| Illustration 4 | g06041986 |
| Qty | Part Number | Description |
| 2 | Nipple Quick Disconnect | |
| 2 | Coupling Assembly Quick Disconnect | |
| 1 | Hose Assembly | |
| 2 | Adapter | |
Overall Description
This system is contained on a flat mounting plate with a carry bar suitable for portability.
Nitrogen Gas System: Reference Illustrations 5 and 7, and Table 4. The unit is designed to accept nitrogen inlet pressures from standard industrial cylinders up to 2900 psi (200 bar). This gas is fed directly across the high-pressure check valves in the booster Item 1 (P-1), on to the gas outlet port. The system is also connected to a high pressure reducing regulator, Item 6(R-1), where the system is regulated to approximately 125 psi (8.6 bar) and then piped to the booster Item 1 (P-1) drive inlet to provide the power for cycling.
Alternate Air Drive: The 1/2 NPT air inlet is provided for use with plant air pressure for drive, if available, to conserve nitrogen. Air inlet pressures may be up to 150 psi (10 bar). Minimum would be 1/60th of desired maximum nitrogen output pressure.
Output Pressure Controls: Item 1 (P-1) booster will automatically cycle when Item 5 (V-1) ball valve is opened (to either nitrogen or air for drive). Cycle speed can also be controlled with Item 5 (V-1). Cycling Item 1 (P-1) booster will build nitrogen pressure into any device connected to gas outlet up to a maximum of approximately 60 x drive pressure.
Pilot Cutoff Valve: Item 2 (PCV-1), provides positive control of maximum booster Item 1 (P-1) output pressure independent of drive pressure. The system is factory preset at 2900 psi (200 bar) (214 bar), but may be adjusted as desired between 1500 (103 bar) and 2900 psi (200 bar) (214 bar).
Safety Relief Valve: Item 3 (RV-1), is set at the factory at a nominal 3100 psi (214 bar), but may be adjusted as desired between 1000 (69 bar) and 3100 psi (690 bar).
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Not all components used in the following procedures are rated to the same capacity as can be generated by Item 1 (P-1). It is not recommended to exceed factory limits set for Item 2 (PCV-1) and Item 3 (RV-1) without re-evaluating all system components for rated capacity. Safety Relief Valve (Item 3) (RV-1) should never be set higher than maximum working pressure of accumulator to be charged. |
Bill of Materials
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| Illustration 5 | g06062584 |
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455-0126 Nitrogen Booster System (All dimensions are in inches.) | |
| Nitrogen Booster System Bill of Materials (Illustration 6 and 7) | ||||
| Item No. | Qty. | Part No. | Item Name | Description |
| 1 | 1 | 141242-200-1 | 5G-SD-60-X Gas Booster (P1) | Increases pressure to output if supply pressure is insufficient. |
| 2 | 1 | 141242-200-2 | PCV-E100 Pilot Cutoff Valve (PCV-1) | Automatic start/stop control of booster at preselected output pressure. |
| 3 | 1 | 141242-200-3 | RVG-100 Relief Valve (RV-1) | Sets maximum pressure for the output port independent of any other control, set at 3300 psi |
| 4 | 1 | 141242-200-4 | Relief Valve (RV-2) | Protects booster drive from overpressure, set at 140 psi |
| 5 | 1 | 141242-200-5 | 1/2" Ball Valve (V-1) | Manual start/stop/throttle control for booster drive. |
| 6 | 1 | 141242-200-6 | Regulator (R-1) | Sets drive pressure if nitrogen is used for drive. Set at 125 psi (8.6 bar) |
| 7 | 1 | 141242-200-7 | Gauge 0-4000 psi (PG-1) | Nitrogen Supply Cylinder Pressure Gauge (0-276 bar) |
| 8 | 1 | 141242-200-8 | Gauge 0-200 psi (PG-2) | Gauge for Drive Pressure, either Nitrogen or Air (0-14 bar) |
| 9 | 1 | 141242-200-9 | Gauge 0-5000 psi (PG-3) | Output Pressure Gauge (0-345 bar) |
| 10 | 1 | 141242-200-10 | Check Valve 1/2 NPT (CV-1) | Prevents nitrogen back flow out the air drive inlet. |
| 11 | 1 | 141242-200-11 | Skid | Portable base plate with dual carrying handles. |
| 12 | 4 | 141242-200-12 | Rubber Mounts | Prevents slipping and dampens vibration when booster Item 1 (P-1) is operating. |
Initial Setup and Additional Accessories Required
| NOTICE |
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Refer to REHS5464 Accumulator Discharging and Charging Procedures during accumulator servicing. If nitrogen supply cylinder pressure is below desired accumulator pre-charge, see additional steps below to add Nitrogen Booster Pump Group (455-0126). Ensure that any existing setup is in a zero pressure state with all lines discharged and Nitrogen Supply Cylinder Main Valve fully closed before proceeding. |
Preparing Nitrogen Booster Pump Group (455-0126)
- Place the Nitrogen Booster Pump Group (455-0126) on the floor or other stable surface, as close as feasible to the accumulator to be serviced.
- Set up and install additional accessories as described to prepare Nitrogen Booster for use.
Adding Nitrogen Booster to an existing Accumulator Setup utilizing (175-5507) Nitrogen Charging Group and reference setup document REHS5464
Note: All references that start with the letter "D" are from the images found in REHS5464.
- Connect Nitrogen Booster Group in line with one of the existing accumulator setups from REHS5464 by doing the following steps. (Setup depends on accumulator serviced.)
- Disconnect Hose Assembly (D3) from the Nitrogen Regulator Group (D8).
- Reconnect Nitrogen Regulator Group (D8) to Nitrogen Booster Inlet Port with Hose Assembly (162-4147) assembled in step two.
- Reconnect Hose Assembly (D3) to the Nitrogen Booster Outlet Port with Quick Couple already installed.
- If plant air pressure is convenient, install a 1/2 NPT along with air filter/water trap and air hose at the air inlet port of the Nitrogen Booster Group. Turn the knob on the Nitrogen Regulator, Item 6 (R-1) counter-clockwise until closed. If plant air is not available, use Nitrogen Regulator, Item 6 (R-1) to set nitrogen inlet pressure to 125 psi (8.6 bar) to drive pump.
Tool Operation
- Slowly cycle booster Item 1 (P-1) by opening Item 5 (V-1) Ball Valve while observing output pressure on Item 9 (PG-3) gauge. Close Item 5 (V-1) Ball Valve when Item 9 (PG-3) gauge reads the correct pressure to the accumulator. Ensure Needle Valve (D-6) is closed as well.
Note: If Item 2 (PCV-1) Pilot Cutoff Valve is set for correct accumulator precharge pressure, booster Item 1 (P-1) should stop cycling automatically when reaching the correct pressure. You will still need to close Item 5 (V-1) Ball Valve and Needle Valve (D-6) when correct pressure is reached and the booster stops cycling.
- Shut off nitrogen supply cylinder main valve.
- Close accumulator valve. Slowly release pressure between Needle Valve (D6) and Chuck (D9). Gauge (D7) should read zero pressure. Disconnect the output line completely from the accumulator.
- Release the rest of the system pressure by slowly opening Needle Valve (D6), Item 9 (PG-3) gauge on booster unit should now read zero.
- Remove all connections and return nitrogen bottle to safe storage condition.
| NOTICE |
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If the accumulator precharge pressures are standardized to a single value for a high percentage of the use of the booster system, preset the Item 2 (PCV-1) pilot cutoff valve (preset at 3100 psi for this application) to stop the booster item 1 (P-1). |
Schematic
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| Illustration 6 | g06062090 |
Storage
Inlet, output, and drive connecting lines may be stored with the booster unit for convenience and ready accessibility, provided that all open ends are plugged or capped to prevent entry of any contaminants. If connecting lines are stored elsewhere, plug or cap all ports on the booster system.
Periodic Maintenance
- Individual Components. No periodic maintenance is recommended for any other components in the system except the booster drive cycling valve. Therefore all tubing can be left undisturbed removing the risk of contamination from careless handling.
- Gas Booster Drive Cycling Valve. This spool valve will require periodic lubrication with light grease, silicone, or moly disulphide base (recommended). It has been designed for easy accessibility.
- Frequency of Cycling Spool Lubrication. The user will be guided by experience. Regreasing may be needed once weekly or once annually or somewhere in between depending on the frequency of usage and the condition of the drive air or gas. Presuming the use of clean, dry nitrogen for drive gas, the lube frequency for the cycling spool/O-ring assembly could be often. This is because dry nitrogen tends to carry off all traces of lubrication soon when a significant volume of drive gas has been consumed across this cycling valve.
The symptom will be cycling slowdown and erratic operation. The user should note the time elapsed since the previous lubrication of the spool/O-ring assembly. This will enable the user to anticipate the next need for lubrication, which can then be scheduled during a normal off time rather than interrupt the operation of the system while charging accumulators.
- Repairs. No components except Item 1 (P-1) booster should require repair or seal replacement over the life of the system unless damaged by accident or contaminated gas.
In general, periodic seal replacement without symptoms indicating excessive wear or leakage is not recommended.
For Seal Kit replacement part numbers, see Service Repair Parts section.
Service Repair Parts
| Service Repair Parts | |
| Part No. | Name |
| 455-0127 | Nitrogen Booster Air Seal Kit |
| 455-0129 | Nitrogen Booster Gas Seal Kit |
Frequently Asked Questions
Question: How does nitrogen gas pressure in the accumulator vary with temperature?
Gas pressure is variable with temperature. Check the temperature of the air around the accumulator. To check the amount of charge in an accumulator, the accumulator must be at the same temperature as the surrounding air. Refer to Table 6.
Note: The temperature of the accumulator may change as the accumulator is being charged due to the expansion or compression of the nitrogen charge. You may need to charge the accumulator in several steps to ensure a correct charge.
| Charge Pressures and Temperatures | |
| Temperature | Pressure |
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Declaration of Conformity
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| Illustration 7 | g03796881 |