Operation and maintenance manual

Section 250-0060
SM 2160 7-02
5
Braking System - Accumulator
3. Use an inspection lamp to check the bore of
accumulator cylinder (12) for scratches or scoring. Minor
nicks, scratches or light scoring of the bore can be
removed by using crocus cloth. Dress the bore until all
apparent imperfections have been removed. Replace
complete accumulator assembly if the inside of cylinder
(12) is excessively scored or worn.
4. Inspect threads in end cap (10) and threads in
cylinder (12) for damage. Replace all parts worn or
damaged beyond repair.
ASSEMBLY
Numbers in parentheses refer to Fig. 1.
1. Lubricate ‘O’ ring (9), wear rings (8), backup rings
(6), 'V' section ring (7) and inside of cylinder (12) with
hydraulic oil prior to assembly.
2. Install new 'V' section ring (7), backup rings (6) and
wear rings (8) on piston (5).
3. Insert piston (5) into cylinder (12) with cupped end
facing the open end of the cylinder. Do not let
'V' section ring (7) drag on cylinder threads. Use a
hammer and wood block to tap piston into place until
all of piston is 50 mm (2.0 in) below beginning of
honed bore. Keep pressure against piston while
tapping 'V' section ring (7) through the bore chamfer,
otherwise piston will bounce back, damaging the
'V' section ring.
4. Install new 'O' ring (9) on end cap (10) and install
end cap (10) in cylinder (12). Tighten cap so that it is
flush with the end of cylinder (12) within 1.59 - 2.38 mm
(0.0625 - 0.0938 in) above or below.
5. Install charging valve (1). Tighten locknut (1D)
clockwise to 11 Nm (100 lbf in) to close charging
valve, insert valve core (1B), replace valve cap (1A)
and tighten finger tight.
6. Test accumulator hydraulically for leakage or failure
at 255 - 276 bar (3 700 - 4 000 lbf/in²). Discharge after
testing.
INSTALLATION
Numbers in parentheses refer to Fig. 3.
Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
1. Position accumulators on mounting bracket with the
oil inlet ports downward.
2. Attach clamps (4) securely with washers (3) and
bolts (1 & 2).
3. Remove caps installed at removal and install
hydraulic lines securely to the oil inlet port at the
bottom of the accumulators.
4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
section.
5. Check oil level in hydraulic tank and add oil as
required. Refer to Section 230-0040, HYDRAULIC
TANK, for correct fill level and Section 300-0020,
LUBRICATION SYSTEM, for oil specification.
6. Place the battery master switch in the 'On' position,
start the engine and check for leaks. Tighten lines and
fittings as required. Remove wheel blocks.
MAINTENANCE
Inspect accumulator assembly for leaks. If leaks are
found, disassemble and replace all 'O' rings and seals.
Inspect hydraulic lines for wear and leaks. Replace/
tighten lines as required.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the charging assembly kit and other
general service tools required. These tools are
available from your dealer.