OPERATING AND MAINTENANCE INSTRUCTIONS ON TOBUL ACCUMULATORS

INSTALLATION:
The accumulator in a hydraulic circuit should be place as near as practical to the source of shock or potential energy need. Normally an accumulator should be installed in a vertical position with the oil connection down. If space is not available, it may be installed horizontally; however, reduced life will be incurred. Piston type accumulators will have a decrease in piston steel life. The weight of the piston will press at the 6 oclock position increasing seal wear. By far the largest problem is contamination entering the accumulator and settling inside the bore. Bladder types have an increase risk of the bladder bag floating, which traps usable fluid inside. The bladder can be pinched by the poppet valve closing, which ruptures the bladder. Horizontal position requires more care when draining the fluid from the accumulator. When installing an accumulator using u bolt type clamps, care should be exercised so as not to distort the cylinder with excessive squeeze. Welding hangers to the cylinder is not recommended. Mounting brackets are available from TOBUL. The hydraulic fluid used must be kept free of foreign matter to prevent damaging the cylinder wall or the piston sealing rings. For maximum seal life, the fluid should be filtered to 10 microns or less. It is not advisable to change the hydraulic fluid from that which the accumulator was originally purchased without checking its compatibility with the seal materials.

PRECHARGING PROCEDURE
GENERAL INFORMATION:
The condition of the accumulator is primarily determined by periodic checking of the precharge pressure. Hydraulic accumulators are pressure vessels and only qualified personnel should perform maintenance. Drain all fluid completely from accumulator before performing any maintenance. DO NOT weld or braze directly on accumulator shell. DO NOT use automotive type valve cores in high pressure accumulator gas valves. The most accurate precharge readings can be taken when fluid pressure is at 0 psig. Always observe the maximum working pressure and operating temperature ranges.

DO NOT USE OXYGEN FOR PRECHARGING ACCUMULATOR!

BLADDER ACCUMULATORS:
Remove valve protection guard and valve cap from accumulator. CAUTION! Be sure valve on high pressure nitrogen supply is securely closed. To charge the accumulator, use a charging hose and gauge assembly similar to TOBUL P/N GG2527F rated for 3,000 psig (higher pressures available). Attach hose assembly to nitrogen supply and the gas chuck to tank valve on gauge assembly. Attach gas cock on gauge assembly to Page 1

(BLADDER ACCUM. CONTINUED)

gas valve on accumulator. TOBUL accumulators are equipped with several different types of gas valves (some have a valve core, others do not). If the gas valve has a double lock nut, loosen nut by turning counter-clockwise approximately 2 turns or until nut touches gas cock fitting. SLOWLY open valve on nitrogen supply and allow the gas to flow in to accumulator. Once the desired gas precharge pressure has been reached, close valve on nitrogen supply, then turn lock nut on gas valve (if applicable) clockwise until tight. Turn T-handle on gas cock counter-clockwise. Open drain cock to relieve hose pressure; disconnect gauge assembly from accumulator. Replace gas valve cap and protective guard. NOTE: Allow accumulator to rest about 10-15 minutes after gas precharging. This will allow gas temperature to adjust and equalize. Recheck gas precharge pressure and adjust if necessary. Check accumulator gas valve for any leaks with soapy water. Always wear safety glasses.

PISTON ACCUMULATORS:
Consult the pressure volume curve to determine the optimum precharge setting. (It is suggested that this be 100 psig below minimum system operating pressure.) The accumulator size for any system should be of sufficient capacity to prevent the piston from bottoming during operation. TOBULS accumulator sizing and selection software can be used to determine the proper precharge pressure with appropriate temperature compensation. The accumulator gas valve has a guard over it which must be removed when the accumulator is to be charged or checked. Remove the (2) 3/8 socket head screws with and an Allen wrench. CAUTION! Be sure valve on high pressure nitrogen supply is securely closed. To charge the accumulator, use a charging hose and gauge assembly similar to TOBUL P/N GG2527F rated for 3,000 psig (higher pressures available). Attach hose assembly to nitrogen supply and the gas chuck to tank valve on gauge assembly. Attach gas cock on gauge assembly to gas valve on accumulator. TOBUL accumulators are equipped with several types of gas valves (some have valve core, some do not). If the gas valve has a double lock nut, loosen by turning counter clock wise approximately 2 turns or until nut touches gas cock fitting. Open by rotating the gas cock T-handle clockwise while holding the bottom fitting. SLOWLY open valve on nitrogen supply and allow the gas to flow in to accumulator, Once desired gas precharge pressure has been reached, close valve on nitrogen supply, then turn lock nut on gas valve (if applicable) clockwise until tight. Turn T-handle on gas cock counterclockwise. Open drain cock to relieve hose pressure; disconnect gauge assembly from accumulator. Replace gas valve cap, guard, and 3/8 cap screws. Disconnect hose assembly from nitrogen supply. NOTE: Allow accumulator to rest about 10-15 minutes after gas precharging. This will allow the gas temperature to adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks with soapy water. Always wear safety glasses.

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MAINTENANCE
CHECKING PRECHARGE PRESSURE GENERAL INFORMATION: The condition of the accumulator is primarily determined by periodic checking of prechare pressure. Only qualified personnel should perform maintenance. Nitrogen gas precharge pressure should be checked at least once during the first week of operation. The precharge pressure and ambient temperature should be recorded at installation. If there is no loss of gas precharge pressure, it should be rechecked in approximately 4 months. Thereafter, it should be checked annually. BLADDER AND PISTON ACCUMULATORS: The same procedure applies to both types of accumulators. Be sure pressure is 0 psig on hydraulic end before checking precharge. PISTON TYPE ONLY-Generally, an increase in pressure (after allowing for any appreciable temperature variation) indicates a gradual leakage of fluid into the gas side. Conversely, a decrease in precharge pressure means leakage of gas into the fluid side. The amount of leakage will depend upon piston velocity. For very rapid cycling, check the precharge pressure monthly. 1. To check or adjust precharge pressure, HYDRAULIC PRESSURE MUST BE REDUCED TO 0 PSIG. Precharge pressure should be checked periodically at regular intervals following original installation. Charging and checking should be done with an accumulator gauge assembly similar to TOBUL P/N GG2527F rated for 3,000 psig (higher pressures available). 2. Remove gas guard as per precharging procedure instruction on either bladder or piston type (whichever applies). 3. Attach gauge assembly to accumulator gas valve. 4. After making sure drain cock is closed, depress gas valve core by turning the Thandle on the gas cock clockwise. Gas Pressure can now be read on gauge. 5. To reduce pressure, open drain cock carefully, allowing gas to escape until desired pressure is obtained. NOTE: Allow accumulator to rest about 10-15 minutes after gas precharging. This will allow gas temperature to adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks with soapy water. Always wear safety glasses.

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DISASSEMBLY
PISTON TYPE: 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 precharge, then release all precharge pressure. 2. Drain balance of hydraulic fluid remaining in accumulator when it is disconnected from system. 3. Remove gas valve. 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 flat surfaces for wrenching or two tapped holes for inserting screws so that a bar can be used. 6. To remove the piston, carefully tap with wooden dowel as it is guided out of the cylinder. Care should be taken not to damage piston or seals on threads of tube. 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. 10. Inspect piston for damage due to bottoming.

REASSEMBLING
PISTON: 1. It is good practice to replace all seals when accumulator is completely disassembled. 2. Wet seals with system fluid and assemble into piston groove. Be sure seals are not twisted. 3. Insert back-up rings carefully so as not to stretch any more than necessary.

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(Piston Type Continued) 4. 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. 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. 6. Apply light grease to the threads and o-ring of the end cap and thread in to cylinder until end cap bottoms out. 7. Accumulator is now ready to receive precharge. 8. To precharge, follow Precharging Procedure instructions.

DISASSEMBLING
BLADDER TYPE: 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 precharge, then release all precharge pressure. 2. Drain balance of hydraulic fluid that may be remaining in accumulator when it is disconnected form system. 3. Securely clamp the accumulator. 4. Remove bladder stem lock nut, nameplate, and gas valve from the top of the accumulator when it is disconnected from system. 5. Remove the lock nut from the bottom of the accumulator using a spanner wrench. Next remove spacer. 6. Push the plug and poppet assembly into accumulator shell. 7. Insert hand into accumulator shell and remove back up, o-ring and metal back-up ring from plug. Remove anti-extrusion from plug, then fold in half and slide through shell opening. Remove poppet plug assembly from shell. 8. Remove poppet plug assembly shell. 9. Insert hand into the bottom of the accumulator shell opening. Compress bladder by Page 5

(Bladder Type Continued) hand to eliminate as much air volume as possible. 10. Pull the old or damaged bladder out of the bottom of the accumulator shell.

REASSEMBLE
BLADDER TYPE: 1. Remove gas valve or valve core from new bladder. 2. Lubricate the inside of the shell and the outside of the bladder with clean system fluid. Also pour additional amount of fluid in the shell to act as a cushion. 3. Attach the bladder pull rod to the bladder system. Pull the rod and bladder through the shell fluid port. Pull bladder stem out through the valve stem opening on the opposite end of the shell. 4. Slid the nameplate and lock nut over pull rod and thread on to bladder stem. Tighten lock nut. Remove the bladder pull rod. 5. Slide the plug/poppet (poppet first) into the accumulator shell. Fold the anti-extrusion ring in half and slide it through the oil port opening. Place the anti-extrusion ring on the plug and poppet assemble with its stainless steel ring facing toward the shell opening. 6. Pull plug through accumulator shell opening. Using both hands, pull plug hard until it seats into position on shell opening. 7. Install gas valve or valve core into bladder stem. Using dry nitrogen, SLOWLY inflate the bladder bag with 5-10 psig of pressure to set and half plug and poppet assembly in place. 8. Install metal washer onto plug and poppet assembly. Push into shell opening until bottomed out. 9. Install o-ring over plug poppet assembly and push into shell opening until bottomed out. DO NOT ROLL OR TWIST O-RING WHEN INSTALLING. Lubricate o-ring with system fluid or grease before installation. 10. Install back up and spacer with small shoulder towards the accumulator shell. 11. Install lock nut on plug and poppet assembly and tighten securely with a spanner wrench.

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(Bladder Type Continued) 12. Replace bleeder plug in to plug and poppet assembly. 13. For precharging refer to Precharging Procedure for bladder type. NOTES:

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TOBUL ACCUMULATOR, INC. 186 ACCUMULATOR STREET BAMBERG, SC 29003 Telephone 803-245-5111 Fax 803-245-2636 U.S.A. O&M-720 7/95