96 - 3
Accumulator
Dismantling and Assembly
Dismantling
! DANGER
Before disconnecting or dismantling the accumulator
discharge all gas pressure. Failure to comply can cause
rapid discharge of gas and/or hydraulic fluid which can
result in death, personal injury and damage to the
machine.
HYD 2-5
1 Check that the accumulator has been discharged, refer
to Service Procedures, Smooth Ride System -
Charging/Discharging the Accumulator.
2 Secure the accumulator in horizontal position.
! CAUTION
The gas end cap (cap with gas valve) must be removed
before the hydraulic end cap. This allows any residual
pressure to escape through the safety vent holes. If the
hydraulic end cap is removed first the piston will cover
the safety vent holes, which could result in the piston
being forced out under pressure which may result in
personal injury.
HYD 2-6
3 Fit three pins into the holes in gas end cap 4, using a
long bar working against the pins unscrew the end cap.
4 Fit three pins into the holes in hydraulic end cap 5,
using a long bar working against the pins unscrew the
end cap.
5 Remove and discard ‘O’ rings and back up rings from
end caps.
6 Remove the piston 6 by pushing from the hydraulic end
with a bar.
! CAUTION
Do not remove the piston by applying compressed air at
the opposite end.
HYD 2-7
7 Remove piston seal and ‘O’ rings.
Inspection
Inspect piston for cracks, burrs around the ‘O’ ring grooves,
or damage. Examine the body bore 1, using a light, for
scratches or scoring. Inspect end caps for damaged threads
or burrs on ‘O’ ring grooves.
Minor nicks, scratches or light scoring of the body bore may
be removed by using a very fine paper. Dress the bore until
all apparent imperfections have been removed.
All seals and ‘O’ rings must discarded and new ones fitted.
Assembly
1 Coat all internal components with clean hydraulic oil.
2 Fit piston seal 9, teflon back up rings 10 and seals 11.
3 Fit piston assembly into bore 1 with hollow side
towards the gas end. Do not let piston seal drag on
threads, the piston must go into the bore exactly
square and very slowly. The piston is a tight fit, use a
hammer and a block of wood to tap the piston until all
of the piston is 2in. (50mm) below the beginning of
honed bore.
Note: Keep pressure on the piston while tapping through
the bore chamfer, otherwise the piston will bounce back,
damaging the piston ring.
4 Fit end cap back up seal 7. Make sure the seal is fitted
with leading edge A pointing in a counter clockwise
direction otherwise the seal will bind when the end cap
is fitted.
5 Fit end cap ‘O’ rings 8, it is important that seals 7 and 8
are fitted in the correct position in relation to each other
to prevent leaks.
6 Fit end caps 4 and 5, use pins and a long bar. Make
sure the gas end cap is fitted to the correct end, piston
hollow end to gas side.
Note: The end caps will stop against the chamfer leading
into the honed bore, ‘O’ ring sealing is not dependent upon
cap tightness.
7 Use new ‘O’ ring 13 and fit the gas valve 12.
Section E Hydraulics
9803/3280
Section E
96 - 3
Issue 1
Smooth Ride System
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