Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators
GAS VALVE
(Cylindrical Steel Shell w/ Flush Ends and Internal Piston) (Fabricated w/Threaded or Welded End Caps) WARNING:
Accumulators, gas bottles and hydraulic systems are inherently dangerous due to high pressure gases and uids. DO NOT ATTEMPT to maintain these systems unless adequately trained, have experience with the items and systems in question, and can recognize the potential risks involved if mishandled. Always wear appropriate safety equipment. READ & UNDERSTAND ALL INSTRUCTIONS PRIOR TO SERVICING & MAINTAINING ACCUMULATOR!
END CAP
GAS CHAMBER
PISTON SEAL
PISTON
FLUID CHAMBER END CAP FLUID PORT
TROUBLE SHOOTING The most prevalent concern with accumulators is the loss of pre-charge pressure. Since accumulators function only due to the differential pressure of the compressed gas and the uid utilized, any variation in the pre-charge will result in operating difculties or the loss of functionality. Additionally, since there is no visual way of determining whether an accumulator is functioning properly without the addition of optional indicating rods, proximity sensors or transducers, the regular checking of pre-charge pressure becomes critical to good performance. Fluid cleanliness and ltration is critical to operational performance and service life. Tobul recommends all uid be ltered to <10 microns or better, with all lters being properly maintained. Contamination in the hydraulic system will ow into the accumulator, where particulates are a direct cause of accelerated seal wear and eventual bore damage. A loss of nitrogen gas pre-charge may occur due to, but not limited to, gas valve leakage or internal seal wear or damage, potentially to both seals and cylinder bore. Some symptoms of these conditions are: 1. Lack of functionality of the accumulator; 2. Inability to maintain pre-charge pressure; 3. Gurgling/bubbling of the uid reservoir nitrogen gas leaking past seals into system; 4. Piston contacting gas end cap while operating - Insufcient pre-charge allows the piston to impact the gas end, causing internal damage and eventual failure.
Always use two wrenches when loosening military style gas valve! Hold base stationary while loosening upper jam nut
Phone: 803-245-5111
Fax: 803-245-2636
Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com
Nitrogen gas leakage from the gas valve can occur if the valve is not tightened securely; also, if dual wrenches are not used when loosening a jam-nut style gas valve (Military style or strut type) the lower nut can break free and allow the gas pressure to force the o-ring seal out. If the valve body is simply re-tightened, there is a distinct possibility that the o-ring will be cut and/or damaged by the valve body, and the o-ring will not seal properly. When loosening this type of valve, hold the base of the valve securely with one wrench, while loosening the upper jam nut with another. It may be necessary to employ a gooseneck type bent wrench to secure the valve base while rotating the upper nut if the valve base is recessed. Another application-related concern is uid build-up in the gas end of an accumulator. When an application requires an extremely fast discharge/down-stroke of an accumulator, the seals can hydroplane down the cylinder
walls, leaving a thin lm of uid. If the upstroke of the piston due to the input of the pressurized uid is substantially slower than the discharge stroke, the piston seals will seal tighter to the bore, scraping off the thin uid lm and collecting it in the gas end. This will be indicated by an increasing pre-charge pressure, and can be dealt with by bleeding off the accumulated uid and maintaining the correct pre-charge level. Bleeder kits are available as a production option from Tobul. Another concern is the mounting of the accumulator and any vibration to which it may be subject. Vertical mounting is preferred, with gas end up. While a unit will function with gas end down, the accumulator becomes a sump for any and all contaminants that may be present in the system. Additionally, units must be secured using mounting brackets and as free from vibration as possible. Never utilize the system plumbing as the sole mounting for a unit, no matter the size.
Disassembly NOTE: It is good practice to disassemble and assemble accumulators in a clean area to keep all parts free of foreign matter.
1. Follow instructions for checking pre-charge, then release all pre-charge pressure.
3. Remove gas valve.
2. Drain balance of hydraulic uid remaining in accumulator when it is disconnected from system.
Phone: 803-245-5111
Fax: 803-245-2636
4. Remove safety rupture valve from end cap if installed. 5. Remove end caps by turning cap counter-clockwise. On smaller units, there are either at surfaces for use of a wrench or two tapped holes for inserting screws so that a bar can be used.
7. Examine seals on piston and end caps for sign of damage. Inspect closely for score marks or cuts. Excessive cuts on seals would warrant a very through examination of metal surfaces for damage. 8. Clean all metal parts with an approved cleaning solvent and dry with soft clean material. 9. Inspect cylinder bore for damage due to foreign material getting into the hydraulic system. All scratches must be removed from cylinder bore to insure optimum seal service life.
6. To remove the piston, carefully tap with wooden/plastic/padded dowel as it is guided out of the cylinder. Care should be taken not to damage piston or seals on the tube threads. NOTE: NEVER USE AIR PRESSURE TO REMOVE PISTON 10. Inspect piston for damage due to bottoming. 11. Contact Tobul Customer Service/ Sales Engineering for assistance with replacement parts, seal kits, etc.
Phone: 803-245-5111
Fax: 803-245-2636
Re-Assembly NOTE: It is good practice to replace all seals when accumulator is completely disassembled. 1. Wet seals with system uid and assemble into piston groove. Be sure seals are not twisted. NOTE: Tobul utilizes an assembly sleeve to aid insertion of the piston assembly. Contact Tobul Customer Service/ Sales Engineering for additional information, availability and pricing. 4. Assemble back-up ring and o-ring into end cap groove. The back-up ring should be toward the threaded side or outside of the end cap. Apply light grease to the threads and o-ring of the end cap and thread in to cylinder until end cap bottoms out. NOTE: 2. Insert back-up rings carefully so as not to stretch any more than necessary. Insure backup ring gaps are on opposite sides of the piston from each other. 3. Assemble piston carefully into cylinder to avoid cocking or damage to the piston or seal on the threads. If necessary, tap the piston lightly with a soft hammer. Special care should be taken not to pinch the back-up rings. 5. Accumulator is now ready to receive pre-charge. 6. To pre-charge, follow Precharging Procedure instructions. NOTE: Above pictures are representational. Each unit can vary in design, piston and seal conguration and other details.
Contact Tobul Customer Service/Sales Engineering for assistance 803-245-5111
Version 2.0 08.03.09
Phone: 803-245-5111
Fax: 803-245-2636

Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

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Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

FLUID CHAMBER END CAP FLUID PORT

Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com