HAB00018 ACCUMULATOR

HAB00018
ACCUMULATOR ASSEMBLY

SPECIFICATIONS FOR DISMANTLING AND ASSEMBLING

Dismantling
General Information
The regulations that apply at the point of installation of the accumulator must always be
observed (e.g. accident prevention regulations for pressure vessels).
Never retighten or slacken threaded connectors if the hydraulic system is pressurized.
Before removing an accumulator, the hydraulic system must be turned off and
depressurized. Close all ports in order to prevent hydraulic liquid from running out and
contaminating.

Note: The hydraulic system taken out of operation must be made safe such that no unauthorized
person can switch it on.

The accumulator should be repaired using the sets of seals and wearing parts given in the
spare parts list.
When repairing, maximum cleanliness is necessary. The work bench must be kept free of
dirt (metal swarf and chips etc.)
The dismantled parts must be protected from any kind of damage.
Improper discharge of nitrogen from the accumulator bladder often leads to the gas valve
being damaged. This can happen, for example, if one attempts to reduce the pressure in
the accumulator bladder by removing the gas valve instead of by depressing the pin. This
can cause the valve stem to tear out.
Damaged bladders cannot be repaired. They should be replaced using the sets of
replacement parts.

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 HAB00018 ACCUMULATOR

Tools And Aids

Gas-valve Remover

FIGURE 1

FIGURE 2

Clamp accumulator in vise (using two flat iron strips for the accumulator).

Gas Valve

FIGURE 3

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Unscrew valve guard, remove valve cap and seal ring.

FIGURE 4

Blow off nitrogen: depress pin.

FIGURE 5

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Unscrew and with draw valve element.

FIGURE 6

Slacken hexagon nut on gas valve.

FIGURE 7

Unscrew bleeder screw.

Liquid Valve

FIGURE 8

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Undo slotted nut with hook wrench.

FIGURE 9

Remove support ring, seal ring and washer.

FIGURE 10

Remove retaining ring.

FIGURE 11

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Grip rubber ring.

FIGURE 12

Extract rubber ring.

FIGURE 13

Remove liquid valve from the shell.

FIGURE 14

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Remove nut and name-plate cap. Slightly fold bladder and pull out while twisting
slightly. If bladder is slippery, hold with rag.
Cleaning:
Wash parts with, for example. trichlorotrifluoroethylene or cold cleansing agent.
Dry parts.
Please note the following when cleaning with trichlorotrifluoroethylene or
perchloroethylene:
Accumulator bladder. O-ring and, rubber ring may not be washed with these. For
parts made of butyl and viton, methylated spirits or water can be used. For parts
made of perbunan, tricnlorotrifluoroethylene or cleaning petrol can be used.

FIGURE 15

Examination
Screw in valve element. Inflate accumulator bladder with compressed air to 1.7 times its
size in the case of perbunan (black) and to 1.4 times its size in the case of butyl (brown).

Accumulator bladder

FIGURE 16

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Brush over accumulator bladder with soap solution. If soap bubbles are formed, discard.
Exhaust the air immediately after the test. Unscrew and remove the valve element.

FIGURE 17

Examine complete liquid valve for damage and check that the spring functions properly.
In the case of accumulators used for water. check particularly for rust spots.

Liquid Valve

FIGURE 18

Examine inside and outside of shells. Look out especially for damage to the plastic
coating on the inside of certain types of shell.

Shells

FIGURE 19

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Assembly
General Information
Only nitrogen may be used. Never charge with oxygen or air. Danger of explosion.
Attention must be paid to the information given on the nameplate cap. The nitrogen pre-
charge pressure specified by the machine manufacturer must always be maintained.
Assembly Instructions
Wet bladder and inside of shell with liquid. Fold bladder and screw assembly rod into the
gas valve.

Accumulator Bladder

FIGURE 20

Carefully insert bladder

FIGURE 21

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Dip valve into the specified pressure liquid and place complete in the accumulator. Fold
the rubber ring, introduce it into the shell and push onto the valve body. In the shell,
center the retaining ring onto the rubber ring and pull the valve body outwards.

Liquid Valve

FIGURE 22

Dip new valve element in oil and screw in. Fill bladder with compressed air while
centering liquid valve and retaining ring. Screw in nut at gas valve.

Gas Valve

FIGURE 23

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Wind adhesive tape around thread. Slip over support washer (steel). Push seal ring
uniformly into inside of shell using blunted screwdriver. Mound support ring (plastics).

FIGURE 24

Tighten slotted nut. Screw in bleeder screw with new seal ring (observe torque). Release
air from the bladder.

FIGURE 25

Fill in the liquid permitted for the particular accumulator (approx. 1/10 of the
accumulator content). Roll bottle. Accumulator bladder and internal wall of bottle must
be well wetted. Allow liquid to drain off again.

FIGURE 26

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Specifications And Information For Special Cases:

Hydraulic Accumulator For Use With Water
Since the original test is performed with oil, it is necessary in certain cases (e.g. in
systems with drinking water) for the accumulator to be cleaned before being put into
service. Cleaning must be performed as follows: Observe regulations for handling
inflammable liquids.
• Relieve gas pressure.

• Fill bottle (on the liquid side) 2/3 full with cleaning petrol (perbunan bladder).
Introduce compressed air tube through liquid valve (cover valve aperture with rag).

• Blow in compressed air. After 2-3 minutes pour out cleaning petrol.

• Repeat rinse.

• The fine film of oil on the accumulator bladder can be removed by rinsing again with
soapy water.
Downstream Nitrogen Bottle
If large quantities are drawn off and the pressure difference is small, nitrogen bottles can
be connected downstream. The charge pressure characteristics thus obtain a sharper slope,
i.e., the oil volume available can be drawn off at a lower pressure drop.
If discharging or charging is rapid (adiabatic) it is pointless to connect a nitrogen bottle
because the additional gas volume has no effect as a result of the restrictive action of the
connecting line. It must be ensured in particular that the charge pressure is maintained as
otherwise the bladder will be over loaded.
In order to prevent the bladder failing immediately when overloaded, however, a shut-off
valve is provided at the gas connection shutting off the line to the nitrogen bottle and
preventing greater deformation of the bladder (FIGURE 27)
Additionally, if the connecting line breaks between accumulator and gas bottle. the
escaping gas causes the valve to close. The accumulator discharges until the accumulator
bladder bears against and seals the valve. A sudden pressure drop with the known
consequences is thus avoided.

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 HAB00018 ACCUMULATOR

FIGURE 27

Oil Filling In Accumulator Bladders

In order to avoid excessive deformation, oil can be filled into the accumulator bladder. As
a result, an incompressible residue volume remains in the accumulator bladder even in the
case of high-pressure rations.
• Advantage: Higher pressure ratio can be allowed.

• Disadvantage: Capacity of the accumulator is reduced.

Instructions for filling oil into accumulator bladders:

• Filling arrangement for oil:
An intermediate vessel, with a capacity of 0.5 to 1 litre and capable of
withstanding at least 5 bar pressure, should be mounted oil-tight on the gas valve
of the accumulator whose valve element has previously been removed. A nipple
for connecting a compressed air line is screwed in gas-tight into the upper opening
of the intermediate vessel.
• Filling:
Using a funnel, measured sub-quantities of the hydraulic liquid to be filled is
poured into the intermediate vessel. The compressed air line is then connected and
compressed air is used to force the oil out of the intermediate vessel into the
accumulator bladder. This process is repeated until the required quantity of oil has
been filled.

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Nitrogen Charging Of Hydraulic Accumulators With Charge

Pressures >150bar Gauge Pressure

Hydraulic accumulators approved for maximum pressures of up to 315bar can
require a charge pressure p1>=150 bar (p1=nitrogen pre-charge pressure).
Commercially, nitrogen bottles up to 200bar are approved. There is thus no
difficulty in charging up to 200bar. If the charge pressure p1>=200bar and the
nitrogen bottle charge<=200 bar, a circuit arrangement as shown in is required for
the charging operation.
Charging With Gas Requirements
• A circuit arrangement (e.g. oil reservoir with hydraulic pump. adjustable pres-
sure limiting valve, flow control valve D1, and pressure gauge M2).
• An auxiliary accumulator
• A connector with non-return valve fitted.
• The charging device.
• Hoses
• Adapters for nitrogen bottle
• Cross-type screw fitting for pipe diameter 6 mm, nominal pressure 400bar
gauge.
• Connecting pipe 6 mm dia. with cutting ring and lock nut for nominal pressure
400bar.
Charging Operation
• Connect charging device to the hydraulic accumulator to be filled. Connect
auxiliary accumulator (without gas valve) and gas bottles to the HY circuit as
shown in Fig. 29.
• Open valves V1 until no further pressure increase is shown on the pressure
gauge M1. Close valves V1.
NOTE: The pressure indication on the pressure gauge M1 may not be less than 140bar
gauge pressure (danger of damaging the auxiliary accumulator bladder).

• Open flow control valve D1. Allow pump to run. Slowly close DI and read
charge pressure on pressure gauge M1. Switch off pump. If the desired charge
pressure is not reached during a charging operation, then it must be repeated
as often as necessary. After each charging operation carefully open bleeder
valve on the charging device and reduce pressure to approx. 140bar (necessary
in order to check the gas bottle contents at the next charge).

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NOTE: In order to be able to reach the charge pressure, a sufficient number of nitrogen bottles are
required. The auxiliary accumulator may also be a HY piston accumulator with suitable volume
and operating pressure (max. 315bar).

• After the charging operation, open flow control valve D1 until no more pres-
sure is shown on M2. Allow nitrogen in the hose to escape through the bleeder
valve on the charging device until M1 indicates no pressure.

Safety Valves
According to German accident prevention regulations, each accumulator shell must be
provided with a suitable safety valve. These valves are tested in the factory in accordance
with TOV (technical inspector) instructions. A certificate for the component symbol is
supplied with each safety valve. After repair the safety valves and connection blocks must
be checked. accepted and sealed by the TOV (Bosch seal is inadmissible).

FIGURE 28

FIGURE 29

Storing Accumulator Bladders

Accumulator bladders must be stored in a dark room, cool and dry. They should not be
located near electrically operated machines (ozone formation). Hang up the bladders
filled with air on the gas valve (no greater that atmospheric pressure) and use them in the
order of manufacturing dates (stamped on to the gas valve).

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Notes For Sealing

The valve guard can be sealed to protect against unauthorized modification of the pre-
charge pressure.
Fitting
Take both wire ends through the hole in the valve guard. fit seal (resting directly
on the valve guard). Firmly tighten both wire ends, wind them together and then
seal.
The lower wire end must always be in the angle greater than 0° referred to the
valve guard direction of rotation 'slack'.

FIGURE 30

Transportation Of Hydraulic Accumulators

The valve guard can be sealed to protect against unauthorized modification of the pre-
charge pressure.

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Troubleshooting
Type of damage: Cause: Repair:

Charge pressure drop due to:

• External leaks: Seal under the screw plug is Fit new seal.
defective
Gas can escape through the screw
plug.
• Internal leaks: • Charge pressure too small, The causes to the left are
Gas mixes with the hydraulic Diaphragm is punched Maintenance or layout faults
oil. Through on the gas side. Eliminate causes, install new
• Discharge velocity is >8m/sec. Diaphragm-type accumulator.
This results in the diaphragm being
pierced on the liquid side
mushroom unbuttons.
• Intake velocity is >8m/sec. The
button in the diaphragm is
unbuttoned.

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HMP00121 PISTON MOTOR

HMP00121

PISTON MOTOR

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