Cone Crusher Accumulator Replacement
A faulty accumulator, either the nitrogen gas escaping to the atmosphere or a leak in the internal bladder, is a serious condition that requires immediate attention. In either instance, the accumulator will completely fill with oil. Since the gas or pre-charge has escaped or leaked from the bladder, the tramp release arrangement will not function properly. Oil that is normally displaced from the tramp release cylinders into the accumulators when uncrushable material or overloads are encountered, cannot compress the nitrogen gas within the accumulator’s bladders, thereby creating excessive forces within the components of the crusher.
The accumulator pre-charge pressure should be checked every 600 hours (3 months). If the accumulator gas pressure is not at its normal pre-charge level or is unable to sustain the recommended level of normal operating pressure, the accumulator should be removed and replaced. Replace a faulty accumulator as follows:
- Shut the power OFF to the power unit motor and LOCKOUT the motor. Then follow the DEPRESSURIZING paragraphs in Section 12. This will vent the pressurized oil at the accumulator side of the cylinders back to the tank. Make sure the pressure gauge in the CAVITY RELEASE PRESSURIZE circuit reaches zero (0) pressure.
- Remove the valve protection plug at the top of the accumulator. Take the inflator/tester and ensure the coupling screwed at its base is compatible with the accumulator valve. Fully unscrew the knurled button on the inflator/tester and make sure the drain plug is closed. Screw the inflator/tester onto the accumulator using the knurled button at the lower part of the inflator/tester. Screw the knurled button onto the inflator/tester. Put back the valve protection plug and open the bleed screw, until emptying nitrogen (pressure gauge reads «0»). Remove the inflator/tester.
- Remove the hex nuts, lock washers, and capscrews from the clamp segment around the accumulator body and remove the clamp segment from the accumulator bracket. Attach a sling around the accumulator and to a suitable lifting device.
- Position a large pipe or adjustable wrench around the union at the top of the accumulator and turn the accumulator clockwise until it is free to be removed.
- Liberally coat the threads on the pipe union and the inside threads of the replacement or rebuilt accumulator with a suitable pipe thread compound. Then screw the union into the accumulator.
- Carefully position the replacement accumulator and union next to the tramp release cylinder and turn the accumulator union into the cylinder threaded connection being careful that the accumulator is going on straight and is not cross-threaded. Tighten firmly.
- Install the clamp segment and attach the hardware.
- Pre-charge the replacement accumulator according to the instructions in the CHECKING PRECHARGE PRESSURE AND CHARGING THE ACCUMULATOR. The accumulator can be damaged if oil pressure is applied before correctly pre-charging with nitrogen.
- After the accumulator is installed and all connections completed, bleed the system to remove any entrapped air. Then pressurize the system and check for leaks. HYDRAULIC SYSTEMS for instructions on bleeding and pressure testing the hydraulic system.
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