WORK INSTRUCTIONS

TITLE: Suppressor Gas Pressure Check and Charge

Instruction Number: Revision: A

Description: How to check and apply gas pressure to the hydraulic noise suppressor.
Make: Wilkes & McLean
Applicable Product(s):
Model: WM-3081 and WM-5081
© 2012 Quantum Marine Engineering of Florida & Quantum Controls BV

Table of Contents
Warnings and Precautions ............................................................................................................................ 2
Warnings ................................................................................................................................................... 2
Vessel Status ............................................................................................................................................. 2
Background ................................................................................................................................................... 3
Suppressor Gas Charge Pressure .............................................................................................................. 3
Suppressor Charging Valve ....................................................................................................................... 4
Getting Started.............................................................................................................................................. 5
Equipment ................................................................................................................................................. 5
Charging kit ........................................................................................................................................... 5
Reference Material ................................................................................................................................... 7
Time to Complete ..................................................................................................................................... 7
Instructions ................................................................................................................................................... 8
Prepare to Check Gas Pressure ................................................................................................................. 8
Check Gas Pressure ................................................................................................................................... 9
Remove Charging Tool or Charge Checking Tool ...................................................................................... 9
Determine Need for Charging ................................................................................................................... 9
Purge Air from the Charging Tool Hoses ................................................................................................. 10
Connect Charging Tool to Suppressor..................................................................................................... 10
Charge the Suppressor ............................................................................................................................ 11
Conduct Quality Checks .......................................................................................................................... 12
Re-instate Original Conditions ................................................................................................................ 12

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
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 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Warnings and Precautions
Warnings
These instructions involve handling of high pressure gas. Take appropriate precautions. Refer to gas
bottle for additional warnings and handling instructions.

Vessel Status
These tasks require the stabilizer system to be shut down and hydraulic pressure depleted. It is
recommended to perform this task while the vessel is dockside or at anchor.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
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 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Background
Suppressor Gas Charge Pressure
The hydraulic noise suppressor reduces noise by dampening hydraulic oil pulsations emanating from the
hydraulic pumps. The most important element to the suppressor’s performance is a bladder internal to
the suppressor. See illustration below.

Figure 1: Cross-section view of suppressor. Hydraulic oil is shown in orange. Charge gas is shown in blue.

This bladder deflects each time it is hit with an oil pulsation. This deflection absorbs noise-producing
energy, resulting in noise reduction. The ability of the bladder to deflect depends upon the pressure of
the charged gas within the bladder. Too much gas pressure results in a stiff bladder, which cannot
deflect with the oil pulsations. Too little gas pressure results in a limp bladder that is immediately
deflected with oil pressure, and has no room to deflect further for the oil pulsations. Quantum has
performed numerous tests to determine the gas charge pressure required for optimal noise reduction.
This optimal pressure setting is listed in the hydraulic system drawings provided in the Quantum
manual, and is provided on a label on the suppressor.

Please note that Quantum’s tests for this purpose were performed on the hydraulic power unit in
Quantum’s test facility. However, the size, length, and material of piping used to plumb hydraulic oil
from the hydraulic power unit can affect the noise. The gas charge pressure required for optimal noise
reduction in the onboard installation may be as much as 20 bar [300 psi] higher than the set pressure
indicated in Quantum’s drawings and labeled on the suppressor.

Quantum recommends operating the system with the suppressor gas charge pressure at the pressure
indicated on the suppressor and in the hydraulic system drawings. If at this pressure, the noise from the
hydraulic system is excessive, find your vessel’s optimal suppressor gas charge pressure by increasing
the gas pressure in 3 bar [50 psi] increments until the noise is reduced to an acceptable level. The gas
pressure should not exceed 70% of the hydraulic system working pressure.

The hydraulic noise suppressor targets a very specific noise frequency range. Loss of as little as 3 bar
[50psi] in gas pressure can have an impact on noise levels.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 3 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Suppressor Charging Valve
The hydraulic noise suppressor is fitted with a charging valve, located in the charging port at mid-length
on the suppressor body. This charging valve is used to check and apply gas pressure to the suppressor.
Four of the valve’s features are immediately visible when looking at the valve: valve cap, valve stem,
swivel hex, and body hex.

Figure 2: Suppressor charging valve with prominent features labeled

The valve cap is simply a dust cap, used to help avoid dirt build-up within the valve. The valve stem is
the actual valve. The swivel hex is one of the mechanisms used to open the valve. The body hex is used
to secure the valve in the suppressor.

The charging valve actually contains two valves: a poppet and a Schrader valve. As can be seen in the
illustration below, the lower end of the valve stem is a poppet, which is raised to seat against the valve
body hex and creates a seal. The poppet and valve stem are raised and lowered by the swivel hex.
Unfortunately, if too much torque is used on the swivel hex, the poppet can be damaged, allowing a gas
leak.

Figure 3: Cross section of suppressor charging valve (left) and top view of charging valve (right)

Suppressors supplied prior to 2010 relied solely on the poppet seal, and were prone to gas leakage. In
2010, Quantum implemented a design change to the suppressor charging valve, adding a Schrader valve
within the valve stem. The Schrader valve is opened by depressing the plunger within the valve stem.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 4 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Getting Started

Equipment
Before beginning work, ensure that the following equipment is on site and available:

Item Type Quantity Source

Hydraulic
Suppressor1 Existing part 1
power unit
Charging kit, containing:2
A. Charging tool
B. Charge checking tool
C. Gas bottle adapter – CGA-580 Special tool 1 Quantum
Gas bottle adapter – DIN-477-10
Gas bottle adapter – BS-341 No3
D. Leak-Tek
Wrench: 17mm [11/16”] Tool 1 Customer
Wrench: 19mm [3/4"] Tool 1 Customer
Wrench: (choose one as applicable)3
 26 mm [1”] for BSP-341 No3 adapter
 28 mm [1-1/8”] for CGA-580 adapter Tool 1 Customer
 32 mm [1-1/4”] for DIN-477-10 adapter
 Adjustable wrench for any adapter
Bottle of compressed nitrogen4 Consumable 1 bottle Customer
Pen and paper Consumable 1 Customer
Personal protective
Safety glasses 1 Customer
equipment (PPE)

Charging kit
The charging kit is a special tool provided by Quantum with
the original equipment delivery.

The charging kit contains a myriad of items used to check and

apply gas pressure to the hydraulic noise suppressor. These
items are described and illustrated in the following pages.

Figure 4: Charging kit case

1
Suppressor does not need to be removed from hydraulic power unit to perform these tasks.
2
The charging kit is supplied by Quantum with original equipment delivery.
3
The wrench used to install the charging tool onto the nitrogen bottle depends upon the nitrogen bottle valve.
4
Compressed nitrogen must be in gas form (not liquid), and should be a purity grade of 4.8 (99.998% nitrogen) to avoid
corrosion. Required bottle volume and pressure can be calculated by Pbottle*Vbottle = Psuppressor * (Vsuppressor + Vbottle),
3
with Vsuppressor = 0.7 liter [42 in ]. For a bottle rated at 140 bar [2000 psi], bottle volume of 2 liters [0.5 US gallon] is
needed per suppressor.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 5 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
A. Charging Tool: A special tool used to check and charge gas pressure. Because use of the
charging tool to check gas pressure results in loss of gas pressure, when using the charging tool
to check gas pressure, be prepared to also charge gas pressure.

Figure 5: Charging tool with prominent features labeled

Figure 6: Charging connection with prominent features labeled

Figure 7: Gauge block with prominent features labeled

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 6 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
B. Charge Checking Tool: A special tool used to check gas pressure. Using the charging tool to
check gas pressure results in a substantial depletion of gas charge pressure. The charge
checking tool reduces the pressure loss. The charge checking tool has been added to the
Quantum charging kit for original equipment deliveries beginning in 2011. The charge checking
tool is also available for purchase from Quantum.

Figure 8: Charge checking tool with prominent features labeled

C. Gas Bottle Adapter: A fitting assembly used to connect the bottle connection end of the
charging tool to the bottle of compressed nitrogen. Quantum has historically provided an
adapter type (CGA-580) appropriate for connection to standard American nitrogen bottles. Two
additional adapter types, DIN-477 and BS-341, are included in the charging kit for equipment
deliveries beginning in 2011. These adapters are also available for purchase from Quantum.

Figure 9: Nitrogen bottle adapters provided by Quantum. The American CGA-580 connector (left) is provided
installed on the charging tool. The DIN-477 (middle) and BS-341 (right) adapters are provided loose in the charging
kit. All adapters are illustrated above with the bottle connection to the right.

D. Leak-Tec: A yellow fluid used to locate small gas leaks. Leak-Tec has been added to the
Quantum charging kit for original equipment deliveries beginning in 2011. Leak-Tec is also
available for purchase from Quantum.

Figure 10: Bottle of Leak-Tec

Reference Material
Prior to beginning work, consult the required suppressor charge pressure, found in hydraulic schematic
or piping arrangement from Quantum-supplied manual OR physically labeled on the suppressor.

Time to Complete
With full accessibility to all components, it should take 15 minutes to check suppressor (Steps 1-13) and
an additional 15 minutes to charge the suppressor (Steps 14-32), per suppressor.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 7 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Instructions

Prepare to Check Gas Pressure

1. Put on safety glasses and take safety precautions as appropriate.
2. Bleed hydraulic pressure from the main hydraulic system. Refer to Quantum’s instructions on
relieving main hydraulic system pressure.
NOTE: Failure to relieve hydraulic system pressure before checking gas pressure will yield
inaccurate readings. Failure to do so before applying gas pressure charge will result in a
deceptive gas pressure; the functional gas pressure will be much less than what is applied.
3. Unscrew the yellow valve cap from the suppressor charging valve.
4. Visually inspect suppressor charging valve for oil seepage at the top of the charging valve:
a. If no oil seepage is noted, continue to Step 5 below.
b. If a drop or more of oil seepage is noted emerging from the charging valve, the
suppressor bladder is damaged. The suppressor will no longer hold the gas charge.
Replace or rebuild suppressor, or contact Quantum for service.
5. Thread spigot (on charging tool or charge checking tool) snuggly onto suppressor charging valve:
a. Use a 17 mm [11/16”] wrench.
b. Do not over-tighten. Spigot material is soft and threads can strip easily.

Figure 11: Spigot on Charging Tool (left) and Charge Checking Tool (right) installed on suppressor charging valve

6. If using charging tool, ensure that the charging tool valves are in the following status:
a. Gauge Isolation Valve: Closed
b. Bleed Valve: Closed
c. Charging Isolation Valve: Open

NOTE: The process of checking gas pressure results

in a slight pressure loss. When using the charging
tool, the loss is on the order of 14 bar [200 psi],
typically enough to require charging.

Figure 12: Charging tool valve status when

checking gas pressure

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 8 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Check Gas Pressure
7. Turn the swivel hex counter-clockwise to loosen (opening the poppet valve).
NOTE: Over loosening the swivel hex will damage internal valve. To reduce chance of damage,
take the following precautions:
a. Ensure that the body hex remains stationary.
b. Total swivel hex travel should be about 2 full turns.
c. Use a 19 mm [3/4”] wrench to crack open the swivel hex.
d. Turn the swivel hex fully by hand until it stops.
e. Use the wrench to engage swivel hex an additional 1/16 of a turn (about 20⁰).
8. Turn the “T” handle fully clockwise (to open the internal Schrader valve).
9. Check and record existing pressure.
NOTE: The process of checking gas pressure results in a slight pressure loss. When using the
charge checking tool, the loss is typically on the order of 3 bar [50 psi]. When using the
charging tool, the loss is typically on the order of 14 bar [200 psi].

Remove Charging Tool or Charge Checking Tool

10. Turn the “T” handle fully counter-clockwise (to close internal Schrader valve).
11. Turn the swivel hex clockwise to tighten (closing poppet valve).
NOTE: Over tightening the swivel hex will damage internal valve. To reduce chance of
damage, take the following precautions:
a. Ensure that the body hex remains stationary.
b. Total swivel hex travel should be about 2 full turns.
c. Use a 19 mm [3/4”] wrench to loosen the swivel hex.
d. Turn the swivel hex fully by hand until it stops.
e. Use the wrench to engage swivel hex an additional 1/16 of a turn (about 20⁰).
12. Unthread the spigot from the suppressor charging valve:
a. Use 17 mm [11/16”] wrench to loosen.

Determine Need for Charging

13. Compare recorded charge pressure from Step 9 with required charge pressure in Quantum
supplied hydraulic schematic or piping arrangement drawing OR as labeled on suppressor:
a. Using charging tool: Is recorded pressure 14 bar – 20 bar [200 psi - 300 psi] higher than
required charging pressure?
b. Using charge checking tool: Is recorded pressure at or above required charge pressure?
c. If the answer to a or b above is “YES”, charge is sufficient. Proceed to Step 33.
d. If the answer to a or b above is “NO”, suppressor needs to be charged. Proceed to Step
14 or contact Quantum for service.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 9 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Purge Air from the Charging Tool Hoses
14. Connect bottle connection of charging tool to valve on
bottle of nitrogen:
a. For the supplied American CGA-580 adapter,
use a 28 mm [1-1/8”] wrench.
b. For the supplied German DIN-477 adapter, use a
32 mm [1-1/4”] wrench.
c. For the supplied BS-341 adapter, a 26 mm Figure 13: Gas bottle valve
[1”] wrench is required.
15. Ensure that the charging tool valves are in the following status:
a. Gauge Isolation Valve: Open
b. Bleed Valve: Closed
c. Charging Isolation valve: Closed
16. Open valve on nitrogen bottle.
17. Read the pressure on the gauge.
NOTE: Ensure that pressure in the nitrogen bottle is
above the required charge pressure.
18. Close valve on nitrogen bottle.
19. Purge air from line by:
a. Open charging isolation valve to allow a burst
of gas to escape.
b. Quickly close the charging isolation valve.
NOTE: The pressure on the gauge is reduced Figure 14: Charging tool valve status
by less than 70 bar [1000 psi] in this process.

Connect Charging Tool to Suppressor

20. Thread spigot of charging tool snuggly onto suppressor charging valve:
a. Use a 17 mm [11/16”] wrench.
b. Do not over-tighten. Spigot material is soft and threads can strip easily.
NOTE: Take care to keep the charging tool hoses stationary during charging process; too
much movement can loosen the spigot connection to the charging valve.

Figure 15: Spigot on charging tool installed on suppressor charging valve

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 10 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
21. Turn the swivel hex counter-clockwise to loosen (opening the poppet valve).
NOTE: Over loosening the swivel hex will damage internal valve. To reduce chance of damage,
take the following precautions:
a. Ensure that the body hex remains stationary.
b. Total swivel hex travel should be about 2 full turns.
c. Use a 19 mm [3/4”] wrench to crack open the swivel hex.
d. Turn the swivel hex fully by hand until it stops.
e. Use the wrench to engage swivel hex an additional 1/16 of a turn (about 20⁰).
22. Turn the “T” handle fully clockwise (to open the internal Schrader valve).

Charge the Suppressor

23. Slowly open the valve on the nitrogen bottle.
24. Allow the pressure to build up to the required charge pressure.
NOTE: If using a charging tool with a relief valve, the relief valve will open to limit the pressure
in the charging tool to the pressure indicated on the valve.

Figure 16: Example of relief valve fitted on some charging tools per Survey requirement

25. Close the valve on the nitrogen bottle.

26. Open the charging isolation valve. The pressure indicated on the charging tool gauge will
decrease as the gas is allowed into the suppressor.
27. Slowly open the valve on the nitrogen bottle, until the charging tool gauge reads approximately
3 bar [50 psi] higher than the required charge pressure.
28. Close the valve on the nitrogen bottle.
29. Turn the “T” handle fully counter-clockwise (to close internal Schrader valve).
30. Turn the swivel hex clockwise to tighten (closing poppet valve).
NOTE: Over tightening the swivel hex will damage internal valve. To reduce chance of
damage, take the following precautions:
a. Ensure that the body hex remains stationary.
b. Total swivel hex travel should be about 2 full turns.
c. Use a 19 mm [3/4”] wrench to loosen the swivel hex.
d. Turn the swivel hex fully by hand until it stops.
e. Use the wrench to engage swivel hex an additional 1/16 of a turn (about 20⁰).
31. Open the bleed valve on the charging valve block to release remaining gas from charging tool.
32. Unthread charging spigot from charging valve using 17 mm [11/16”] wrench.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 11 of 12
 Suppressor Gas Pressure Check and Charge, Rev A
WORK INSTRUCTIONS
Conduct Quality Checks
33. Listen for “hiss” sound of leaking gas:
a. If no leaks are detected, proceed to Step 34.
b. If leaking gas is detected, check connections in the following order until sound subsides:
i. Tighten swivel hex
ii. Check that plunger inside the suppressor charging valve is not stuck open
iii. Tighten body hex
c. If sound remains, the charging valve is damaged and will not hold the gas charge.
Replace the suppressor charging valve or contact Quantum for service.
34. Test suppressor charging valve for small gas leaks. Apply Leak-Tec fluid or equivalent to the
three (3) possible leak points on the suppressor charging valve, as illustrated below.

Figure 17: Leak-Tec application to suppressor charging valve.

Apply the Leak-Tec all the way around each potential leak point seam. A gas leak will be
indicated by bubbles in the Leak-Tec:
a. If no leaks are detected, proceed to Step 35.
b. If a leak is detected, replace suppressor charging valve or contact Quantum for service.
35. Note any damaged threads on the spigot and suppressor charging valve stem:
a. If threads appear fully intact, proceed to Step 36.
b. If any damaged threads are evident, future pressure checks or charges may be difficult.
Contact Quantum to replace the charging tool, charge checking tool, or suppressor
charging valve, as appropriate.

Re-instate Original Conditions

36. Install the yellow valve cap onto the suppressor charging valve.
37. Unthread charging tool from nitrogen bottle.
38. Re-apply hydraulic system pressure. Refer to Quantum’s instructions on relieving main
hydraulic system pressure.

All information contained within this document remains the absolute property of the Quantum Group. Any use of the information for other than the intended purpose is expressly forbidden.
3790 SW 30th Avenue · Fort Lauderdale, Florida 33312 · USA Phone: +1 954-587-4205 Fax: +1 954-587-4259 www.quantumhydraulic.com
Industriestraat 5 · 6361 HD Nuth · The Netherlands Phone: +31 045-577-8430 Fax: +31 045-577-8431 www.quantumcontrols.nl 12 of 12