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SB-0259  Rev A   Status: PRODUCTION 

 

1 of 10

 

 2011   Flow International Corporation 

UNCONTROLLED COPY 

PRINTED 7/29/11

 

 

SB-0259 

Installing the HyPlex® Prime 

Major Maintenance Kit

 

 

 

Introduction 

Use the procedure in this service bulletin when installing the Major Maintenance Kit on your HyPlex 
Prime pump. This service is performed at every fourth required maintenance interval for the life of the 
equipment. The complete major maintenance kit schedule is listed in your FLOW service manual. 

Tools 

You will need the following tools: 

 

Pressure loading tool (049512-1) 

 

Combination wrenches (14 mm to 32 mm) 

 

½ in. drive socket set (14 mm to 32 mm) 

 

½ in. torque wrench (10 to 200 ft-lb) 

Note:

 You may need two torque wrenches. 

 

Feeler gauge set 

 

Screwdriver set 

 

Snap-ring pliers 

 

0-1 in. micrometer or dial caliper 

 

3/8 in. hex bit 

 

½ in. hex bit 

Repair kit 

Major maintenance kit, 050624-2 

 

CAUTION 

Failure to follow these step-by-step instructions and the procedures in your FLOW  

service manual could result in premature failure or damage to the equipment. 

 

Note

: All components should be clean and free of debris prior to assembly. Keeping the work area clean 

is important while working on the equipment.   

Summary of Contents for 050624-2

Page 1: ...Tools You will need the following tools Pressure loading tool 049512 1 Combination wrenches 14 mm to 32 mm in drive socket set 14 mm to 32 mm in torque wrench 10 to 200 ft lb Note You may need two tor...

Page 2: ...to access the tie rods Place the manifold and PCV assembly combination aside Unload the tie rods with the pressure loading tool 3 Make sure the pressure loading tool plunger is fully retracted Instal...

Page 3: ...he 22 mm 7 8 in combination wrench if needed 9 Repeat steps 3 8 for the remaining positions For each of the three high pressure cylinders 10 Remove the end cap high pressure cylinder inlet poppet spri...

Page 4: ...etain the cage Discard the outlet poppet and guide outlet poppet spring and outlet poppet seat Lap inlet face of check valve body 18 Use the glass lapping plate from the tool kit and lapping paper fro...

Page 5: ...2 Place the outlet poppet spring around the guide The spring should be loose on the guide 3 Place the assembly into the outlet cage along with the outlet poppet seat 4 Hold the outlet cage assembly up...

Page 6: ...ch and plunger nut tool check plunger nut torque Torque to 20 ft lb 27 N m 2 Rotate the sheave to fully extend the next plunger to be checked Repeat for the remaining plungers When finished wipe off a...

Page 7: ...e plungers are clean and free of any damage or scratches before installing the dynamic seal carriers The subplate adapter seal carrier interface must be clean and free of debris 4 Slide the dynamic se...

Page 8: ...p spring back while installing If it does the inlet poppet can be pinched causing damage Make sure all the split bearings bushings are completely seated in the end cap Incorrect installation will caus...

Page 9: ...l firmly seated against the end caps These nuts must be fully bottomed out against the washers end caps Note Do not use wrenches when threading the primary nuts down 4 Use the socket wrench to remove...

Page 10: ...nd completely drain the oil 2 Re install the drain plug or oil temperature sensor and fill the crankcase with recommended oil refer to Chapter 1 of your service manual 3 For HyPlex Prime Plus only Cli...

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