Troubleshooting & Maintenance

Piston-Type Hydraulic Accumulators

GAS VALVE
(Cylindrical Steel Shell w/ Flush Ends and Internal Piston)
(Fabricated w/Threaded or Welded End Caps) END CAP

GAS
WARNING: CHAMBER
Accumulators, gas bottles and hydraulic systems are inherently
dangerous due to high pressure gases and fluids. DO NOT
ATTEMPT to maintain these systems unless adequately
PISTON
trained, have experience with the items and systems in SEAL
PISTON

question, and can recognize the potential risks involved if

mishandled. Always wear appropriate safety equipment. FLUID
READ & UNDERSTAND ALL INSTRUCTIONS PRIOR CHAMBER

TO SERVICING & MAINTAINING ACCUMULATOR! END CAP

FLUID
PORT

TROUBLE SHOOTING

The most prevalent concern with accumulators Some symptoms of these conditions are:
is the loss of pre-charge pressure. Since 1. Lack of functionality of the accumulator;
accumulators function only due to the differential 2. Inability to maintain pre-charge pressure;
pressure of the compressed gas and the fluid 3. Gurgling/bubbling of the fluid reservoir –
utilized, any variation in the pre-charge will nitrogen gas leaking past seals into system;
result in operating difficulties or the loss of 4. Piston contacting gas end cap while
functionality. Additionally, since there is no visual operating - Insufficient pre-charge allows
way of determining whether an accumulator the piston to impact the gas end, causing
is functioning properly without the addition of internal damage and eventual failure.
optional indicating rods, proximity sensors or
transducers, the regular checking of pre-charge
pressure becomes critical to good performance.
Fluid cleanliness and filtration is critical to
operational performance and service life.
Tobul recommends all fluid be filtered to <10
microns or better, with all filters being properly
maintained. Contamination in the hydraulic
system will flow 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 Always use two wrenches when loosening
leakage or internal seal wear or damage, military style gas valve! Hold base
potentially to both seals and cylinder bore. stationary while loosening upper jam nut

Phone: 803-245-5111 Fax: 803-245-2636 Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com 1
Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

Nitrogen gas leakage from the gas valve can walls, leaving a thin film of fluid. If the
occur if the valve is not tightened securely; also, upstroke of the piston due to the input of the
if dual wrenches are not used when loosening a pressurized fluid is substantially slower than
jam-nut style gas valve (“Military style” or “strut the discharge stroke, the piston seals will
type”) the lower nut can break free and allow seal tighter to the bore, scraping off the thin
the gas pressure to force the o-ring seal out. If fluid film and collecting it in the gas end. This
the valve body is simply re-tightened, there is will be indicated by an increasing pre-charge
a distinct possibility that the o-ring will be cut pressure, and can be dealt with by bleeding
and/or damaged by the valve body, and the off the accumulated fluid and maintaining
o-ring will not seal properly. When loosening the correct pre-charge level. Bleeder kits are
this type of valve, hold the base of the valve available as a production option from Tobul.
securely with one wrench, while loosening Another concern is the mounting of the
the upper jam nut with another. It may be accumulator and any vibration to which it may be
necessary to employ a ‘gooseneck’ type bent subject. Vertical mounting is preferred, with gas
wrench to secure the valve base while rotating end up. While a unit will function with gas end
the upper nut if the valve base is recessed. down, the accumulator becomes a sump for any
Another application-related concern is fluid and all contaminants that may be present in the
build-up in the gas end of an accumulator. system. Additionally, units must be secured using
When an application requires an extremely mounting brackets and as free from vibration as
fast discharge/down-stroke of an accumulator, possible. Never utilize the system plumbing as
the seals can ‘hydroplane’ down the cylinder 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, 3. Remove gas valve.

then release all pre-charge pressure.

2. Drain balance of hydraulic fluid

remaining in accumulator when it
is disconnected from system.

Phone: 803-245-5111 Fax: 803-245-2636 Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com 2
Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

4. Remove safety rupture valve 7. Examine seals on piston and end

from end cap if installed. caps for sign of damage. Inspect closely
for score marks or cuts. Excessive cuts
5. Remove end caps on seals would warrant a very through
by turning cap examination of metal surfaces for damage.
counter-clockwise.
On smaller units, 8. Clean all metal parts with an approved
there are either flat cleaning solvent and dry
surfaces for use with soft clean material.
of a wrench or
two tapped holes 9. Inspect cylinder bore for damage due to
for inserting foreign material getting into the hydraulic
screws so that a system. All scratches must be removed
bar can be used. 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 Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com 3
Troubleshooting & Maintenance Piston-Type Hydraulic Accumulators

Re-Assembly

NOTE: It is good practice to replace all seals NOTE: Tobul utilizes an “assembly sleeve”
when accumulator is completely disassembled. to aid insertion of the piston assembly.
Contact Tobul Customer Service/
1. Wet seals with system fluid and assemble into Sales Engineering for additional
piston groove. Be sure seals are not twisted. 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 “Pre-

charging Procedure” instructions.

NOTE: Above pictures are representational.

Each unit can vary in design, piston and
seal configuration 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 Tobul Accumulator, Inc. Bamberg, SC USA www.Tobul.com 4