Flow HYPLEX, Manual, Page: 63 / 100

Install the end cap
CAUTION
It is important to install the end cap in one fluid motion
toward the crankcase. Do not let the end cap move away
from the high-pressure cylinder while installing. If it does,
the inlet poppet can be pinched, causing damage.
1. Align the end cap so it will slide over the tie rods,
then carefully slide the end cap towards the HP cyl-
inder until the check valve body makes contact with
the inlet poppet.
2. Continue to slide the end cap until the high-pressure
cylinder engages the o-ring in the end cap and the
check valve body seats against the high-pressure
cylinder.
3. Temporarily install one of the hex nuts, hand tight,
to prevent the end cap from springing back.
Follow Steps 1–3 to install the other two end caps in the
same way, then continue with Step 4.
4. Apply a thin coat of anti-seize compound to both
sides of the washers and to the tie rod threads.
5. Install washers and hex nuts hand tight.
6. Remove the temporarily installed hex nuts. Apply
anti-seize to both sides of the washers and threads,
then reinstall the nuts.
7. Use the pressure loading tool to load the tie rods
(see Loading the tie rods on Page 44).
Replace the PCV poppet and seat
1. Remove the air supply line from the PCV actuator,
and the drain line from the outlet adapter.
2. Remove all high-pressure lines from the manifold.
3. Place the manifold in a soft-jaw vise
4. Use a 1-1/4 in. wrench to remove the PCV from the
manifold. remove the outlet adapter from the PCV
body.
5. Remove and discard the poppet, seat, and seal ring
from the PCV body.
Note: Needle nose pliers may be needed to remove
the poppet from the assembly.
6. Lube the outlet adapter o-rings and slide onto the
PCV body.
7. Make sure the static seal ring is installed on the seat
and loosely install the new poppet into the seat.
Note: Do not press poppet into the seat.
8. Place poppet and seat assembly into the end of the
valve body.
Lubricate the PCV body threads with Blue Lube and
thread the PCV assembly into the high-pressure
manifold. Tighten to 190 ft-lb (258 N-m).
9. Remove the manifold assembly from the vise.
© Flow International Corporation
M-416 | 63
CHAPTER 4
Service