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94K HYPERPRESSURE™
INTENSIFIER

M-376 | REV. G | JUNE 2012

Summary of Contents for 94K HYPERPRESSURE

Page 1: ...94K HYPERPRESSURE INTENSIFIER M 376 REV G JUNE 2012...

Page 2: ...ting from the use of this material This document contains information protected by copyright No part of this document shall be reproduced in any manner without prior written consent from Flow Internat...

Page 3: ...ier High Pressure Cylinder 27 Service notes 27 Tools required 27 Maintenance Procedure D Replacing the Check Valve Body Assembly and Servicing the Inlet Components of the Check Valve Body Assembly 31...

Page 4: ...Notes 4 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 5: ...t the time of publication Physical specifications 014623 1 or 3 Long block intensifier Pressure Vessel Application Width 11 5 x 12 in 292 x 304 mm Length 40 5 in 1028 7 mm Weight Intensifier 265 lb 12...

Page 6: ...er is pressurized by using the fluid pressure in tensification principle Hydraulic oil pressure acting on the piston results in a force on the plunger which pres surizes the water in the small chamber...

Page 7: ...st treat the system as they would treat any high speed cutting tool Although the waterjet may appear harmless it is a high energy cutting tool capable of cut ting many non metallic materials such as c...

Page 8: ...rious injury to personnel or damage to the equipment Shield and bundle equipment hoses and cables so they do not obstruct the operator s freedom of movement Be alert at all times when working around t...

Page 9: ...e equipment and use only original manufacturer replacement parts Follow the manufacturer s system startup procedure to ensure safe operation Use care when lifting equipment covers during operation Pro...

Page 10: ...t to cut Emergency medical information Anyone who receives equipment related injuries while operating high pressure water equipment should be given immediate hospital attention Because it is vital tha...

Page 11: ...a maintenance and ser vice log to record all service work Maintenance tips Stock enough spare parts to minimize down time and help avoid rush part orders Practice good housekeeping Assign a complete s...

Page 12: ...A F Low pressure piston 011304 1 Low pressure seal kit 013157 1 or 020080 1 4 Low pressure seal kit 013157 1 1 AR A F Low pressure seal kit 013157 1 5 High pressure plunger assembly 010253 1 2 AR A F...

Page 13: ...0275 131 2 AR 11 Check valve seat 014388 1 2 AR A E Check valve outlet replacement kit 014885 1 12 Outlet poppet 011309 1 2 13 Compression spring A 1606 2 14 Outlet spring seat 042102 1 2 AR 15 Outlet...

Page 14: ...Replacement parts 14 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 15: ...Clean parts thoroughly then apply new lube Do not substitute another product All parts that contain high pressure water cylinder check valve body tubing are susceptible to stress fa tigue accelerated...

Page 16: ...Notes 16 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 17: ...wrench 13 16 in open end wrench Food grade grease A 4689 Blue Lubricant A 2185 Anti seize A 10039 The pressure loading tool The following procedures use a special tool created especially for the 94K...

Page 18: ...inder before each use as described in this section to prevent accidental separation of the tool Inspect the tool piston stop for damage Replace if it is not flat DO NOT grind to remove damage For ease...

Page 19: ...re seal assembly high pressure cylinder filler tube check valve assembly and end cap in place install the end cap washers and nuts on the tie rods and run up hand tight to the end cap 3 Install the to...

Page 20: ...edle falls off the mark re tighten the pump pres sure relief valve and bring the pressure back up to the 9200 psi 634 bar mark 10 Run up the end cap nuts by hand Using a torque wrench with a crow s fo...

Page 21: ...e pressure loading tool 5 Thoroughly clean the tie rods to ensure no old anti seize lubricant remains Apply fresh anti seize to the threads at the end of the tie rods and on both sides of the tool was...

Page 22: ...f the nee dle falls off the mark retighten the pump pressure relief valve and bring pressure back up to the 9200 psi 634 bar mark 14 Loosen the four end cap nuts and back off two full turns 15 Bleed o...

Page 23: ...wo wrenches disconnect the high pressure tubing from the check valve outlet adapter Loosen the other end of the tubing and move it out of the way 4 Unload the intensifier tie rods See Maintenance Proc...

Page 24: ...necessary Maintenance Procedure D you do not need to re move the check valve assembly from the end cap 7 Remove the high pressure cylinder and filler tube from the intensifier end bell Rocking the cy...

Page 25: ...g the plunger until it butts against the end bell face 11 Slide the high pressure cylinder over the ceramic plunger and into the end bell bushing A slight rock ing motion will help ease the cylinder i...

Page 26: ...nze bushing of the end cap Take care to align the check valve assembly with the correct orientation as previ ously noted in Step 5 14 Reload the intensifier tie rods See Maintenance Procedure A Assemb...

Page 27: ...to do so can cause equipment damage or injury to personnel 2 Disconnect the inlet water hose from the end cap 3 Using two wrenches disconnect the high pressure tubing from the check valve outlet adap...

Page 28: ...sary Maintenance Procedure D you do not need to remove the check valve assembly from the end cap 7 Remove the high pressure cylinder and filler tube from the intensifier end bell Rocking the cylinder...

Page 29: ...o orient the tube correctly will damage the intensifier assembly 11 Thoroughly clean the tie rods nuts and washers to remove the old anti seize lubricant 12 Reinstall the check valve assembly and end...

Page 30: ...Notes 30 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 31: ...mponents of the Check Valve Body Assembly Service notes There are two ways to service the high pressure inlet check valve D 1 Replacing the check valve body assembly D 2 Lapping the check valve body f...

Page 32: ...rpendicularity of the face to the compo nent axis and maintain these minimum dimensions Shoulder of the check valve body minimum height of 0 475 in 12 06 mm Check valve inlet poppet minimum thickness...

Page 33: ...lve outlet adapter Loosen the other end of the tubing and move it out of the way 4 Using a 1 in socket loosen the outlet adapter from the check valve body do not remove it at this point 5 Unload the i...

Page 34: ...ve assembly in the end cap 8 Remove the old check valve assembly from the end cap by pushing on the outlet adapter see illustration below Set the old check valve assembly aside 9 Clean and inspect the...

Page 35: ...lve assembly with the correct orientation as explained in Step 5 12 Remove the old anti seize from the tie rods nuts and washers 13 Reinstall the end cap complete with check valve body as sembly by sl...

Page 36: ...Notes 36 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 37: ...njury to personnel 2 Disconnect the inlet water hose from the end cap 3 Using two wrenches disconnect the high pressure tubing from the check valve outlet adapter Loosen the other end of the tubing an...

Page 38: ...on the check valve body will hold the check valve assembly inside the end cap 8 Remove the check valve assembly from the end cap by pushing on the outlet adapter see illustration at right Set the end...

Page 39: ...mum allowed You can re use the check valve body down to these dimensions but you must discard the check valve body if it becomes smaller Hand lapping machining machine grinding polishing or a combinat...

Page 40: ...ut and inspect the components of the check valve inlet replacement kit 014884 1 19 Apply one drop of Loctite 242 to the threads of the new retainer screw Position the new inlet check valve support and...

Page 41: ...ew check valve assembly by pushing it into the end cap Take care to align the check valve assembly with the correct orientation as previously noted in Step 6 24 Remove the old anti seize from the tie...

Page 42: ...ter should be torqued on the workbench not when installed Torquing when in stalled can disturb the sealing surface and could cause galling 28 Reconnect the high pressure tubing and the inlet water hos...

Page 43: ...Maintenance Procedure E Servicing and Replacing the Outlet Check Valve Components Outlet Poppet and Check Valve Seat Flow International Corporation M 376 43 014885 1 Outlet replacement kit...

Page 44: ...adapter Loosen the other end of the tubing and move it out of the way 3 Using a 1 in socket and handle unscrew the out let adapter from the check valve body 4 Remove the outlet poppet compression spr...

Page 45: ...icant to the surfaces of the new outlet check valve seat as shown and in sert it into the bore of the check valve body Make sure the coned end is pointing out once in stalled and that there is no Blue...

Page 46: ...Notes 46 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 47: ...mage or injury to personnel 2 Disconnect the inlet water hoses from the end caps 3 Using two wrenches disconnect the high pressure tubing from the check valve outlet bodies Loosen the other ends and m...

Page 48: ...ss check valve maintenance is necessary Maintenance Procedure D it is not necessary to re move the check valve assembly from the end cap 7 Remove the high pressure cylinder and filler tube from the in...

Page 49: ...hand by sliding it along the ceramic plunger Discard the used seal carrier o ring and high pressure seal 9 Repeat Steps 6 8 on the other end of the intensifier 10 Remove the shift sensors Use the shif...

Page 50: ...end bell Short block HyperPressure intensifier only After Step 11 remove the bolts from the bottom of the intensifier so it will come off the pump The best approach is to remove the two bolts on the...

Page 51: ...ly tip and fall causing serious bodily injury Place the intensifier on the low pressure assembly fixture plate with the manifold surface facing down Secure the intensifier to the fixture from below Fo...

Page 52: ...s at one end of the low pressure cylinder assembly Loosen the nuts in the figure 8 pat tern shown below turning each nut no more than turn at a time re peating the sequence until nuts are loose This w...

Page 53: ...t and that they still have the appropriate tension Check the end bells for damage to the sealing sur faces and grooves and a damaged or out of round shift pin hole Clean all surfaces of the low pressu...

Page 54: ...movement rela tive to the piston biscuit Excessive lateral movement is anything over 1 8 in off center line at the plunger tip If any of the above apply continue with Step 23 Otherwise skip to Step 2...

Page 55: ...the snap ring into the groove 28 Repeat Steps 23 27 for the other plunger Low pressure cylinder 29 Apply clean hydraulic oil or Parker Super O Ring Lube to one new seal and the inside of the low press...

Page 56: ...mpressed as it en ters the cylinder the seal can easily be damaged by rough handling at this point Note Centering the piston will make intensifier re assembly easier Set the cylinder containing the pi...

Page 57: ...carefully onto the end bells by tightening the nuts evenly in a figure 8 pattern as shown below Be careful not to nick the seals and back up rings There must be no seal or back up ring debris visible...

Page 58: ...NOT substitute with the pattern 1 2 4 3 Using the torque wrench and the torque multiplier when necessary tighten the nuts not more than turn at a time following the figure 8 sequence Notes for using...

Page 59: ...intensifier does not connect directly to the hydraulic mani fold simply replace the hydraulic lines Take care to ensure proper lubrication and placement of the o rings Short block HyperPressure intens...

Page 60: ...that must be at the outermost end of the tube when it is inserted Failure to orient the tube correctly will damage the intensifier assembly 51 Reinstall the check valve assembly and end cap by slidin...

Page 61: ...014623 1 or 3 Long block intensifier StoneCrafter 020070 1 Short block intensifier HyperPressure Flow International Corporation M 376 61 CHAPTER 3 Maintenance Procedures...

Page 62: ...Notes 62 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 63: ...ons Corrective actions The corrective action listed on a troubleshooting table is a condensed summary of the service required to rem edy the problem When you encounter a malfunction 1 Carefully and pr...

Page 64: ...64 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 65: ...Flow International Corporation M 376 65 CHAPTER 4 Troubleshooting...

Page 66: ...tain pressure Uneven intensifier stroking A D Check valve assembly 020071 1 Large flow with each stroke Hot warm High pressure cylinder failure Pump cannot maintain pressure Uneven intensifier strokin...

Page 67: ...ressure seal cartridge 052190 1 or 040015 1 2 per intensifier Small drip with each stroke Warm High pressure seal leakage Note a small amount of leakage is normal during operation Large flow with each...

Page 68: ...0592 1 2 per intensifier Large flow with each stroke OR energetic leakage Warm hot High pressure cylinder failure Pump cannot maintain pressure Uneven intensifier stroking A C High pressure cylinder 0...

Page 69: ...intain pressure Uneven intensifier stroking A D Check valve assembly 020071 1 Large flow with each stroke Hot warm High pressure cylinder failure Pump cannot maintain pressure Uneven intensifier strok...

Page 70: ...with each stroke Warm High pressure seal leakage Note a small amount of leakage is normal during operation High pressure cylinder failure Pump cannot maintain pressure Uneven intensifier stroking A C...

Page 71: ...in pressure Uneven intensifier stroking Torque adapter to 200 ft lb as described in E1 Large flow with each stroke Warm hot Outlet insert failure Pump cannot maintain pressure Uneven intensifier strok...

Page 72: ...ngth of tubing Pump cannot maintain pressure Uneven intensifier stroking High pressure tubing failure or failed outlet adapter Pump cannot maintain pressure Uneven intensifier stroking Large flow with...

Page 73: ...h pressure cylinder failure Pump cannot maintain pressure Uneven intensifier stroking A C High pressure cylinder 020592 1 2 per intensifier Seal carrier failure Pump cannot maintain pressure Uneven in...

Page 74: ...problem Other possible symptoms Maintenance procedure Kit or parts needed Qty Temp Occasional drip Warm Loose pilot valve mounting screws Retorque pilot valve mounting screws as described in your pump...

Page 75: ...ift sensor mounting screws as described in your pump manual Worn o rings Service o rings as described in your pump manual Location M OIL LEAKAGE Weep holes and locations are identified on the illustra...

Page 76: ...essure tubing or on off valve Failed inlet or outlet check valve poppets Hydraulic pressure setting is too low Failed hydraulic pump Failed main system relief valve Intensifier strokes noticeably fast...

Page 77: ...CHAPTER 5 Parts Lists Intensifier assemblies 014623 1 or 3 and 020070 1 High pressure end Flow International Corporation M 376 77...

Page 78: ...020071 Check valve assembly 78 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 79: ...Low pressure end For long block StoneCrafter intensifier 014623 1 or 3 Flow International Corporation M 376 79 CHAPTER 5 Parts Lists...

Page 80: ...Low pressure end For short block HyperPressure intensifier 020070 1 80 M 376 Flow International Corporation 94K HYPERPRESSURE INTENSIFIER...

Page 81: ...Piston assembly 011492 1 for long block intensifier 014623 020079 1 for short block intensifier 020070 Flow International Corporation M 376 81 CHAPTER 5 Parts Lists...

Page 82: ...24 1 014713 1 Piston 25 4 007100 1 Washer 26 4 040358 1 Nut 27 1 A 0275 157 O ring 28 1 A 0276 157 Back up ring 29 1 A 19813 1 Crowfoot 30 1 A 20283 31 Crate 31 1 A 23704 1 Socket wrench 32 1 SB 0195...

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