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Product: WHEEL LOADER


Model: 938G II WHEEL LOADER RTB
Configuration: 938G II Wheel Loader RTB00001-UP (MACHINE) POWERED
BY 3126B Engine

Testing and Adjusting


938G Series II Wheel Loader and IT38G Series II
Integrated Toolcarrier Braking System
Media Number -RENR6075-02 Publication Date -01/09/2008 Date Updated -26/09/2008

i02658785

Accumulator Charging Valve (Brake) - Test and Adjust


SMCS - 4264-025; 4264-081

Table 1

Required Tools
Part Number Description Qty
1U-5481 Pressure Gauge Group 1

Personal injury or death can result if two persons are not used in the
following procedure.

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.

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Note: There are two separate procedures that may be used to check the operation of the brake
accumulator charging valve and the operation of several associated components. Both procedures should
be used.

"Procedure 1" is a quick method for checking the cutout pressure. This procedure also indicates whether
the service brake oil pressure switch and the brake oil pressure indicator operate correctly. The
procedure provides an estimate of the accumulator precharge pressure and an estimate of the number of
brake applications before the brake oil pressure indicator turns on.

"Procedure 2" determines whether the cut-in pressure and the cutout pressure are correct. This procedure
also provides the required steps for adjusting the brake accumulator charging valve.

NOTICE
If the machine is equipped with secondary steering, the power for the
secondary steering motor must be temporarily disconnected.

Failure to disconnect power to the secondary steering motor before


performing Procedure 1 and Procedure 2 may cause the secondary
steering motor to fail prematurely.

Use the following procedure to disconnect power to the secondary


steering motor.

Procedure To Disconnect Power To The Secondary Steering


Motor

Illustration 1 g00279597
(1) Tilt hood actuator switch.

1. Tilt hood actuator switch (1) is located on the right rear side of the machine. Raise the access

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cover for the switch. To raise the engine hood, pull up on the switch handle and then push the
switch handle to one side.

Illustration 2 g00280017
Disconnect Switch

2. Insert the key for disconnect switch (2) . Turn the key counterclockwise in order to disconnect
power for the machine.

3. Remove the key from the disconnect switch. Place a "DO NOT OPERATE" tag on the
disconnect switch.

Illustration 3 g00280037
(3) Terminal. (4) Wire.

4. Carefully slide the rubber boot off terminal (3) . Use a 19.0 mm (0.75 inch) wrench to remove the
nut that secures wire (4) to terminal (3) .

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5. Wrap electrical tape around the exposed end of wire (4) . Install the nut that was removed in Step
4, but do not tighten the nut.

6. Insert the key for disconnect switch (2) . Turn the key clockwise in order to connect power for the
machine.

7. Remove the "DO NOT OPERATE" tag.

Procedure 1
1. Stop the engine. Engage the parking brake. Depress the brake pedal repeatedly until there is no
brake oil pressure.

Illustration 4 g00279590
Brake Components

(1) Test port. (2) Accumulator for the rear service brakes. (3) Accumulator for the front service brakes. (4)
Accumulator charging valve.

Note: The cab has been removed for photographic clarity only.

2. Connect a 0 to 40000 kPa (0 to 5800 psi) pressure gauge to test port (1) on brake accumulator
charging valve (4) .

3. Observe the pressure gauge. Before you start the engine, the oil pressure must be 0 kPa (0 psi).

4. Start the engine. Allow the oil pressure to increase to the cutout pressure. The correct cutout
pressure is 14485 ± 345 kPa (2100 ± 50 psi).

Note: The correct cut-in pressure is 11725 ± 345 kPa (1700 ± 50 psi).

5. After the brake accumulators have been completely charged and the correct cutout pressure has
been obtained, stop the engine.

6. Turn the engine start switch to the ON position, but do not start the engine.

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7. Apply the service brakes repeatedly. Pause for two seconds between brake applications. Count the
number of applications while you observe the pressure gauge.

Illustration 5 g00934865
(5) Brake oil pressure indicator.

Illustration 6 g00280033
(6) Service brake oil pressure switch. (7) Accumulator charging valve.

8. When the reading on the pressure gauge decreases to 8960 ± 345 kPa (1300 ± 50 psi), brake oil
pressure indicator (5) will turn on. This indicates the operational status of the indicator and of
service brake oil pressure switch (6) . Service brake oil pressure switch (6) is located next to
accumulator charging valve (7) . The accumulator charging valve is located on the left side of the
machine beneath the cab platform.

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9. Continue to apply the service brakes and pause for two seconds between brake applications. When
the pressure drops off rapidly, this indicates the approximate nitrogen precharge pressure in the
brake accumulators.

10. Determine the number of brake applications that were required before the sudden pressure drop in
Step 9. This number should be more than six times.

11. If the cutout pressure is not within the specification, complete Steps 7 through 11 in "Procedure
2". If the nitrogen precharge pressure is not within the specification, refer to Testing and
Adjusting, "Brake Accumulator - Test and Charge".

Procedure 2
Note: The same operating conditions and the same precautions as "Procedure 1" should be followed.
This includes disconnecting power to the secondary steering motor if the machine is equipped with
secondary steering.

1. Stop the engine. Engage the parking brake. Depress the brake pedal repeatedly until there is no
brake oil pressure.

Illustration 7 g00279590
Brake Components

(1) Test port. (2) Accumulator for the rear service brakes. (3) Accumulator for the front service brakes. (4)
Accumulator charging valve.

Note: The cab has been removed for photographic clarity only.

2. Connect a 0 to 40000 kPa (0 to 5800 psi) pressure gauge to test port (1) on brake accumulator
charging valve (4) .

3. Observe the pressure gauge. Before you start the engine, the oil pressure must be 0 kPa (0 psi).

4. Start the engine and immediately raise the engine rpm to high idle. Watch for a pause in the
increase of oil pressure. Record the reading on the pressure gauge when this occurs. This is the

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approximate nitrogen precharge pressure in the brake accumulators. If the nitrogen precharge
pressure is not within the specification, refer to Testing and Adjusting, "Brake Accumulator - Test
and Charge".

5. The oil pressure must increase to a maximum. Record this pressure also. This is the cutout
pressure of the brake accumulator charging valve. The correct cutout pressure is 14485 ± 345 kPa
(2100 ± 50 psi).

Note: The correct cut-in pressure is 11725 ± 345 kPa (1700 ± 50 psi).

6. Apply the service brakes repeatedly while the engine is running. Verify a consistent pressure drop.
At the point of the specified cut-in, the pressure begins to increase quickly.

7. If the cut-in pressure and the cutout pressure are not within the specification, stop the engine and
completely release all oil pressure from the brake circuit by depressing the brake pedal repeatedly.
Loosen the hydraulic tank filler cap in order to make sure that there is no residual pressure in the
hydraulic oil tank.

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Illustration 8 g00280036
Accumulator Charging Valve

(5) Cover for the adjustment screw. (6) Relief valve. (7) Port for the brake oil pressure switch. (8) Accumulator port
for the rear brakes. (9) Outlet to the hydraulic oil tank. (10) Accumulator port for the front brakes. (11) Plug. (12)
Inlet from the brake pump.

Note: Machines that are equipped with the traction control system use a 135-4391 Accumulator
Charging Valve . Both of the accumulator valves are similar.

8. Remove the cover for adjustment screw (5) .

Note: The charging limits will move together. The range between cut-in pressure and the cutout
pressure is not adjustable.

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9. Turn the hex plug under cover (5) by 1/4 turn. Turning the hex plug clockwise will increase the
cut-in pressure and the cutout pressure. Turning the hex plug counterclockwise will decrease the
cut-in pressure and the cutout pressure.

10. Install cover (5) and tighten the hydraulic tank filler cap.

11. Start the engine. Make sure that the cut-in pressure and the cutout pressure are within the
specifications. If the pressures are not within the specifications, repeat Steps 7 through 11.

If the cut-in pressure and the cutout pressure cannot be adjusted within the specifications, replace
the brake accumulator charging valve.

12. Refer to Step 4 in the "Procedure To Disconnect Power To The Secondary Steering Motor".
Attach wire (4) onto terminal (3) .

Copyright 1993 - 2017 Caterpillar Inc. Thu Aug 17 15:37:43 EST 2017
All Rights Reserved.
Private Network For SIS Licensees.

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