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Installing the pressure control valve (PCV) maintenance kit

Use this procedure when installing the HyPlex Prime pressure control valve maintenance kit. The complete service
schedule for the PCV is located on Page 26.

Every other time you install a Major Maintenance kit, you should also install the PCV Maintenance kit. The poppet,
seat, and static seal described in this procedure are included in the Major Maintenance kit.

Tools

•

Combination wrenches (11–32 mm)

•

1/2-in. torque wrench (0–100 ft-lb)

•

Screwdriver set

•

Allen wrench set

•

Needle nose pliers

•

6 in. soft jaw vise

Maintenance kit

•

PCV maintenance kit, 050625-1

Service notes

•

All parts of the kit should be installed at the same
time - do not replace components individually.

•

All components should be clean and free of debris
prior to assembly. Keeping the work area clean is im-
portant while working on the equipment.

•

Read the entire procedure through before beginning
service, paying particular attention to safety instruc-
tions.

CAUTION

Failure to follow these step-by step instructions could cause

premature parts failure or damage to the equipment.

© Flow International Corporation

M-416 | 79

CHAPTER 4

Service

Summary of Contents for HYPLEX

Page 1: ...HYPLEX PRIME PUMP M 416 REV C MAY 2012 ...

Page 2: ...rial This document contains information protected by copyright No part of this document shall be reproduced in any manner without prior written consent from Flow International Corporation HyPlex HyPlex Hybrid HyPlex Prime and Dynamic Waterjet are registered trademarks of Flow International Corporation Copyright 2011 2012 Flow International Corporation All rights reserved This document is the origi...

Page 3: ...30 hp HyPlex Prime pump maintenance schedule 27 50 hp HyPlex Prime pump maintenance schedule 28 Troubleshooting the HyPlex Prime Premium pump using FlowSENSE 29 FlowSENSE diagnostic codes 30 Troubleshooting the high pressure components 32 Additional troubleshooting tips 32 Weep holes 32 Visual troubleshooting guide for the high pressure components 33 Troubleshooting table 34 Chapter 4 Service Serv...

Page 4: ...all manuals provided with your equipment before installing operating or servicing the equipment This will help avoid creating unsafe conditions or equipment damage The high pressure waterjet system is a powerful cutting tool and must always be treated with respect Warnings cautions and notes Before operating the equipment you must read understand and follow all warnings cautions and notes in this ...

Page 5: ...50Hz Basic package For use with Flow X Y tables prior to those introduced with B R controls Motor starter is not included Standard package For use with B R controlled Flow X Y tables Motor starter is included Plus package For use with B R controlled Flow X Y tables UHP water system pressures are monitored by a pressure transducer and displayed in FlowCUT Auto calibration of UHP pressure control sy...

Page 6: ... filtered to 10 microns Drain 212 F 100 C water at 0 9 gpm 30 hp 212 F 100 C water at 1 5 gpm 50 hp Max UHP orifice size 30 hp 12 orifice 50 hp 16 orifice Voltage Nominal system voltage Horsepower hp Frequency Hz Phase 200 50 200 60 208 60 230 50 240 30 50 60 3 380 60 400 30 50 50 3 480 30 50 60 3 500 60 Not supported Utilization voltage is often referenced which will be 3 5 lower than the nominal...

Page 7: ... Flow International Corporation M 416 7 CHAPTER 1 Equipment Description ...

Page 8: ...8 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 9: ... Flow International Corporation M 416 9 CHAPTER 1 Equipment Description ...

Page 10: ...as controlled by the regulator below the gauge On dual pressure machines this indicates the maximum air pressure setting Low air pressure On dual pressure machines this indicates the minimum air pressure setting Inlet water connection Connect inlet water at recommended specification Air inlet connection Connect inlet air at recommended specifcation PCV to drain Connect a drain line directly to an ...

Page 11: ...F and 70 F 12 7 C and 21 C is recommended for proper pump performance Premature pump component failure is common if water temperatures are outside this range Inlet water chillers should be used if the inlet water temperature is above this range Water interface connections Flow recommends the installation of manual shut off valves in the inlet cooling water line Locate valves as close as possible t...

Page 12: ...Environment requirements Ambient temperature around the pump must be main tained between 45 F and 104 F 7 C and 40 C to ensure proper functioning of the pump High pressure tubing High pressure tubing certified for continuous operation at 60 000 psi 4140 bar is used to route high pressure water from the HyPlex Prime pump to the cutting equip ment Note Refer to manual M 127 Small High pressure Com p...

Page 13: ...lat on the floor and lower the pump onto the center of the mat using a forklift A pallet jack may be also used to locate the pump but the mat should be slid under the pump when suspended with the pallet jack Pallet jacks loaded with the weight of the pump will not roll on the anti vibration mat Do not trim the mat or bolt the pump to the floor through the mat material Flow International Corporatio...

Page 14: ...d by warranty 3 Make sure water lines air lines and drain lines are correctly connected and routed CAUTION Cutting equipment and nozzles must be installed when operating the pump Operating the pump without proper cutting nozzle will damage high pressure components 4 Clear tools parts and rags from around the pump Check in and around the pump for foreign objects and debris 5 Open any operator suppl...

Page 15: ...FlowMaster Stan dard Operate the pump at this pressure for 5 10 minutes while checking for leaks Correct as re quired CAUTION Do not tighten any loose or leaking connections while the pump is operating or while the line is pressurized The pump is now ready for use Starting the Plus and Premium package pumps These are the steps to be performed at the initial startup of a shift 1 Check all connectio...

Page 16: ...then click the Run Machine button to make the routine adjustments ef fective Calibrating the pump control system This applies to the Plus and Premium packages This software routine must be run each time the PCV poppet is replaced and whenever the pump output pressure is significantly off the commanded pressure set ting The routine commands the pump to create pressure at increasing set intervals an...

Page 17: ...Apply compressed air to the 1 micron filter outlet hose Expelled water will be visible at the HP inter face connection at the utilities bulkhead This should expel most remaining water from the HP and LP cir cuits 8 Reattach the hose to the 1 micron filter outlet 9 Drain the water from the inlet water pressure gauge lines at the end opposite the gauge Reattach when all water is expelled 10 Drain th...

Page 18: ...Notes 18 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 19: ...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 cutting many non metallic materials such as composites plastics and wood products Misuse of this equipment or carelessness in its application can be extremely hazardous to operat ing personnel Always treat the waterjet cutting system with respect...

Page 20: ...t Clear all tools parts and rags from moving parts af ter servicing the equipment Electrical system Only a certified electrician shall perform electrical and or electronic troubleshooting and servicing of electrical devices Always assume that power is ON in all electrical sys tems Always check and lock out the main power switches before servicing the equipment Post a sign Maintenance in Progress D...

Page 21: ...leaning equipment and those working nearby should wear the protective clothing and safety devices described in this chapter FLOW recommends that work site safety personnel ap prove all safety equipment and clothing for everyone working around waterjet equipment Eye protection At a minimum operators must wear safety glasses with side shields and a vi sor or goggles and a visor to gaurd against spra...

Page 22: ...pe of injury Therefore all waterjet operating personnel should carry a waterproof emergency medical tag or card that de scribes their work and the nature of injuries inherent in using waterjet cutting devices The card illustrated below can be purchased from Flow International A 8466 The tag or card should contain the following standard information 22 M 416 Flow International Corporation HYPLEX PRI...

Page 23: ... fuse holders or breakers Do not use metal rulers flashlights pencils or tools that have exposed conducting material De energize all equipment before connecting or dis connecting meters or test leads When connecting the volt meter to terminals for measurement use a range higher than the expected voltage Replacement wires must conform to the manufac turer s specifications including proper color cod...

Page 24: ...ar loose clothing or jewelry while working around rotating parts of machinery Pressurized air can drive particles into eyes and skin if handled improperly To prevent injury use appro priate protective equipment and clothing and exer cise extreme caution Torque specifications Refer to the following table when specific torque re quirements are not listed in a service procedure CAUTION Never torque m...

Page 25: ...efore startup Inspect pump high pressure tubing connections and valves for leakage Correct any problems before starting the pump Check the oil level in the pump Check the main electrical disconnect for Out of Ser vice tags and check all around the equipment for in dications of maintenance work in process After startup Listen for unusual sounds as the pump starts and wa ter pressure increases Inspe...

Page 26: ...fac tory set to remind the operator 10 hours before the next required maintenance hour mark these are listed below Maintenance periods by pump hours Every 500 hours for a 30 hp pump and every 300 hours for a 50 hp pump you must install a maintenance kit Complete kit bills of material are in Chapter 5 Complete kit installation procedures are in Chapter 4 26 M 416 Flow International Corporation HYPL...

Page 27: ...ve Service subplate adapter Change PCV poppet seat 3000 Major Maintenance Replace UHP seal rod seal Replace all check valve components Replace UHP cylinder Replace UHP seal carrier Service subplate adapter Change PCV poppet seat PCV Replace PCV plunger Replace bearing assembly seals 3500 Dynamic Seal Replace UHP seal rod seal Lap inlet check valve components 4000 Minor Maintenance Replace UHP seal...

Page 28: ...eeve Service subplate adapter Change PCV poppet seat 1800 Major Maintenance Replace UHP seal rod seal Replace all check valve components Replace UHP cylinder Replace UHP seal carrier Service subplate adapter Change PCV poppet seat PCV Replace PCV plunger Replace bearing assembly seals 2100 Dynamic Seal Replace UHP seal rod seal Lap inlet check valve components 2400 Minor Maintenance Replace UHP se...

Page 29: ...s that will require attention To indicate a warning the positional indicator on the FlowCUT Run Machine screen will blink If a shutdown condition exists a dialog box will appear on the machine console display To investigate the cause for the of the fault and how it can be corrected select Advanced FlowSENSE diagnostic in the FlowCUT menu bar Errors and warnings are indicated in the window More inf...

Page 30: ...wer than specified in the electrical schematic drawing Call Flow Technical Service 27201 Pump is in E Stop condition shutdown Machine M4c or M2c is in E stop condition Follow proper E stop reset procedure M4c or M2c Problem with safety network Call Flow Technical Service 27202 Motor starter shutdown Main circuit breaker has tripped Reset circuit breaker Faulty soft starter Faulty isolation contact...

Page 31: ... and clean poppet seat to remove debris Replace pop pet seat if required Note Debris in the seal can also cause an underpressure problem Control air pressure to PCV set too high Run the Pump Pressure Control System calibration routine Note Max pressure for PCV is 70 psi 4 82 bar Damaged PCV piston Repair replace piston and or piston seals UHP transmitter related problem Inspect the UHP sensor cabl...

Page 32: ...ce kit located in this chapter Additional troubleshooting tips The following tips have been helpful in isolating less com mon system malfunctions and in correcting problems quickly Listen to the machine and watch it operate Learn to recognize the normal noises temperature and oper ating conditions This will increase your ability to no tice any unusual machine behavior Keep a record of all service ...

Page 33: ... Flow International Corporation M 416 33 CHAPTER 3 Maintenance Troubleshooting ...

Page 34: ...s excessive check the following No anti vibration mat Use or replace anti vibration mat Improper belt tension or failed belt s Adjust or replace belts to proper tension see section Tensioning and aligning the belt drive UHP seal or check valve failure Replace components as necessary Crankcase failure Replace crankcase Loss of electrical power leg or the motor is spinning backwards Call a certified...

Page 35: ...amic seal and rod seal Leaking UHP cylinder Inspect for cracks Inspect seal carrier and check valve body contact surfaces for spalling erosion or damage Replace as necessary Replace the cylinder Failed UHP tubing and connections Check gland for proper torque Check collar position Check tubing or fitting for cracks Replace as necessary Check for deformed cone on tubing may indicate over torque Repl...

Page 36: ...ppet and seat Ensure proper plumbing of the PCV drain line Incorrect motor rotation Verify and ensure proper rotation Call a certified electrician to swap polarity on motor Inlet water supply valve or solenoid failure or loose wires Replace valve Tighten wire fittings Check breaker inside electrical control box 2 way air valve failure or loose wiring 2 way air valve override switch is improperly p...

Page 37: ...ter Advanced Diagnostics Ensure proper oil level Verify electrical sensor is functioning prop erly and replace if necessary Replace crankcase if all other options have been exhausted Low inlet water pressure Validate proper operation of inlet solenoid pressure gauges and switches replace if necessary Verify adequate operator supplied water source Check fuses Motor overload shutdown has been trippe...

Page 38: ...der is indicated by labels on the pump frame My pump seems to be running hotter than previously Failed inlet check valve Install a Minor or Major Maintenance Kit Failed outlet check valve Failed UHP seal Low oil level in crankcase Add or replace oil with correct oil see Specifications section Bad or old oil in crankcase Blocked or kinked cooling water hose Re position hose or replace if damaged Ai...

Page 39: ...ntenance Kit Incorrect seal installation Cooling ports clogged insufficient cooling wa ter flow Clean cooling ports Inspect water filters and user supplied water pressure Inlet check valve Improperly lapped components Lap components see Lap the inlet face of the inlet check valve Inlet poppet pinched Install a Minor or Major Maintenance Kit Broken spring Filler tube or sleeve worn out Improper use...

Page 40: ...Notes 40 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 41: ...ystem components Protect all machined and lapped mating surfaces against nicks scratches and burrs Monitor water seepage from end cap weep holes All parts that contain high pressure water cylinder check valve housing tubing are susceptible to stress fatigue accelerated by nicks scratches or other sur face disruptions Replace the damaged components Life expectancy of high pressure water seals and o...

Page 42: ...High pressure components 42 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 43: ... body and against the end cap as shown below Note The threaded plunger of the pressure loading tool must be backed to the stop in order to fully seat the piston within the cylinder 2 Back out the four tool studs 1 4 turn This allows for easy removal of the loading tool after unloading is complete 3 Use a 19 mm 3 4 in socket and ratchet to rotate the tool plunger clockwise until a value of 1500 bar...

Page 44: ...hin the cylinder 2 Use a 19 mm 3 4 in socket and ratchet to rotate the tool plunger clockwise until a value of 1500 bar gauge pressure is reached 3 Run the primary nuts of the pump down by hand until firmly seated against the end caps These nuts must be fully bottomed out against the wash ers end caps Note Do not use wrenches when running the pri mary nuts down 4 Use the socket wrench to remove pr...

Page 45: ...All parts of the kit should be installed at the same time do not replace components individually All components should be clean and free of debris prior to assembly Keeping the work area clean is im portant while working on the equipment Read the entire procedure before beginning service paying particular attention to safety instructions CAUTION Failure to follow these step by step instructions an...

Page 46: ... Slide the dynamic seal carrier off the plunger if it did not come out with the high pressure cylinder Re move and discard the dynamic seal and rod seal CAUTION Use care when removing the dynamic seal and rod seal Do not scratch or nick the seal carrier bores 6 Place the end cap vertically on a work bench with the check valve end up 7 Remove the check valve assembly from the end caps by using two ...

Page 47: ...tly wet the paper with water Place the inlet face of the check valve body against the lapping paper With a light downward pressure lap the body in a figure 8 pattern CAUTION Be very careful not to rock the check valve body while lapping the surface flatness is very critical After 10 12 laps rotate the check valve body 45 and re peat until the surface has a smooth matte finish free of de formation ...

Page 48: ... thin film of Blue Lu bricant to the threads of the outlet cage 5 Carefully thread the check valve body onto the outlet cage assembly 6 Secure the check valve body in the rebuild clamp with the inlet face downward 7 Secure the rebuild clamp in a vise Torque the outlet cage to 30 ft lb 41 N m Repeat Steps 1 7 for the remaining check valves Assemble the end cap 1 Lightly lubricate the check valve o ...

Page 49: ...ith the v shape groove facing up away from the dynamic seal carrier 3 Install the new dynamic seal into the inner diameter of the rod seal making sure the dynamic seal is fully seated against the dynamic seal carrier Note Make sure the plungers are clean and free of any damage or scratches before installing the dy namic seal carriers The subplate adapter seal carrier interface must be clean and fr...

Page 50: ...d Note A small amount of force may be needed to seat the cylinder against the seal carrier Repeat for the remaining high pressure cylinders Assemble the inlet poppet 1 Place the inlet poppet spring over the shouldered side of the inlet poppet 2 Apply pressure to the spring and rotate counter clockwise until it snaps into place Be sure the spring is firmly attached Repeat for remaining inlet poppet...

Page 51: ... sur rounds the inlet poppet and spring Note The filler tube sleeve helps align the poppet with the check valve body and prevents pinching of the poppet between the check valve and the filler tube during assembly 4 Insert the filler tube spring end first into the high pressure cylinder making sure to engage the spring into the dynamic seal Repeat for the remaining filler tubes Flow International C...

Page 52: ... cylinder engages the o ring against the high pressure cylinder 3 Install one of the hex nuts hand tight to prevent the end cap from springing back from the HP cylinder Follow Steps 1 3 to install the other two end caps in the same way then continue with Step 4 4 Apply 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...

Page 53: ...tube 4 Repeat Steps 1 3 for the remaining high pressure tubes 5 Insert one end of the tube into the high pressure port on the manifold and loosely thread the glands in place Repeat for the other two high pressure tubes 6 Loosely thread the other end of each of the three tubes into the end cap ports 7 Once in place tighten all six gland nuts Torque to 40 ft lb 54 N m 8 Reconnect all high and low pr...

Page 54: ...oil temperature sensor or plug and fill the crankcase with oil to the level indicated on the dipstick Recommended oils are listed in Chapter 1 Return the pump to service Follow the startup procedure on Page 14 before return ing the HyPlex Prime pump to service 54 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 55: ...or 6 in soft jaw vise Maintenance kit Minor Maintenance Kit 050624 1 Service notes All parts of the kit should be installed at the same time do not replace components individually All components should be clean and free of debris prior to assembly Keeping the work area clean is im portant while working on the equipment Read the entire procedure before beginning service paying particular attention ...

Page 56: ...inder inlet poppet springs filler tube and sleeve Discard the inlet poppet and spring 5 Remove and discard the o ring from the ID of the high pressure cylinder 6 Slide the dynamic seal carrier off the plunger if it did not come out with the cylinder Remove and discard dynamic seal and rod seal CAUTION Use care when removing dynamic seal and rod seal Do not scratch or nick seal carrier bores 7 Remo...

Page 57: ... end cap Remove the o ring from the check valve assembly 10 Place the check valve body in the provided rebuild clamp Note Do not cover the holes on the outer circum ference of the check valve body to prevent metal from being introduced into the opening 11 Loosen the outlet cage 12 Remove the outlet poppet and guide outlet poppet spring and outlet poppet seat Discard the poppet seat guide and sprin...

Page 58: ... 1 Insert the new outlet poppet into the new outlet poppet guide Note Install poppet into the outlet poppet guide as shown with the radiused back of the outlet poppet going in first The counterbore in the outlet poppet is visible after installation 2 Place the new 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 ...

Page 59: ...lunger to be checked Repeat steps for the remaining plungers When finished wipe off dirt and grease from all three plungers Rebuild the subplate adapter 1 Make sure the tie rods are firmly seated in the subplate Note Hand tight is sufficient 2 With the v shaped face toward the subplate adapter install the new rod seal in the counterbore of the subplate adapter 3 Place the new spacer in the counter...

Page 60: ...of the dynamic seal carrier 3 Install the new dynamic seal into the inner diameter of the rod seal making sure the dynamic seal is fully seated against the dynamic seal carrier Note Make sure the plungers are clean and free of any damage or scratches before installing the dyna mic seal carriers The subplate adapter seal carrier interface must be clean and free of debris 4 Slide the dynamic seal ca...

Page 61: ... downward Note A small amount of force will be needed to seat the cylinder against the seal carrier Repeat for the remaining high pressure cylinders Assemble the inlet poppet 1 Place the new inlet poppet spring over the shoul dered side of the new inlet poppet 2 Apply pressure to the spring and rotate counter clockwise until it snaps into place Be sure the spring is firmly attached Repeat for the ...

Page 62: ...he inlet poppet and spring Note The filler tube sleeve helps align the poppet with the check valve body and prevents pinching of the poppet between the check valve and filler tube during assembly 4 Insert the filler tube spring end first into the high pressure cylinder making sure to engage the spring into the dynamic seal Repeat for the remaining filler tubes 62 M 416 Flow International Corporati...

Page 63: ...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 U...

Page 64: ...Steps 1 3 for the remaining two high pres sure tubes 5 Insert one end of the tube into the high pressure port on the manifold and loosely thread the glands in place Repeat for the other high pressure tubes 6 Loosely thread the other end of each of the three tubes into the end cap ports 7 Once in place tighten all six gland nuts Torque to 40 ft lb 54 N m 8 Reconnect all high and low pressure interf...

Page 65: ...Reinstall the oil temperature sensor or plug and fill the crankcase with oil to the level indicated on the dipstick Recommended oils are listed in Chapter 1 Return the pump to service Follow the startup procedure on Page 14 before return ing the HyPlex Prime pump to service Flow International Corporation M 416 65 CHAPTER 4 Service ...

Page 66: ...Notes 66 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 67: ...driver set Snap ring pliers 3 8 in hex bit in hex bit Rebuild clamp or 6 in soft jaw vise Maintenance kit Major maintenance kit 050624 2 Service notes All parts of the kit should be installed at the same time do not replace components individually All components should be clean and free of debris prior to assembly Keeping the work area clean is im portant while working on the equipment Read the en...

Page 68: ...h pressure cylinder inlet poppet springs filler tube and sleeve 5 Discard the spring and poppet filler tube sleeve and high pressure cylinder 6 Slide the dynamic seal carrier off the plunger if it did not come out with the cylinder Remove and discard the dynamic seal and rod seal CAUTION Use care when removing dynamic seal and rod seal Do not scratch or nick seal carrier bores 7 Remove the subplat...

Page 69: ... assembly 10 Place the check valve body in the provided rebuild clamp Note Do not cover the holes on the outer circum ference of the check valve body to prevent metal from being introduced into the opening 11 Loosen the outlet cage 12 Remove the outlet poppet and guide outlet poppet spring and outlet poppet seat from the outlet cage Retain the cage Discard the outlet poppet and guide outlet poppet...

Page 70: ...o the outlet cage along with the outlet poppet seat 4 Hold the outlet cage assembly upright threaded end of the outlet cage facing up so that the installed components will not fall out Apply a thin film of Blue Lubricant to the threads of the outlet cage 5 Carefully thread the new check valve body onto the outlet cage assembly 6 Secure the check valve body in the rebuild clamp with the inlet face ...

Page 71: ...t plunger to be checked Repeat steps for the remaining plungers When finished wipe off dirt and grease from all plungers Rebuild the subplate adapter 1 Make sure the tie rods are firmly seated in the subplate Note Hand tight is sufficient 2 With the v shaped face towards the subplate adapter install the new rod seal in the counterbore of the subplate adapter 3 Place the new spacer in the counterbo...

Page 72: ...of the dynamic seal carrier 3 Install the new dynamic seal into the inner diameter of the rod seal making sure the dynamic seal is fully seated against the dynamic seal carrier Note Make sure the plungers are clean and free of any damage or scratches before installing the dy namic seal carriers The subplate adapter seal carrier interface must be clean and free of debris 4 Slide the dynamic seal ca...

Page 73: ...ing down ward Note A small amount of force will be needed to seat the cylinder against the seal carrier Repeat for the remaining high pressure cylinders Assemble the inlet poppet 1 Place the new inlet poppet spring over the shoul dered side of the new inlet poppet 2 Apply pressure to the spring and rotate counter clockwise until it snaps into place Be sure the spring is firmly attached Repeat for ...

Page 74: ...he inlet poppet and spring Note The filler tube sleeve helps align the poppet with the check valve body and prevents pinching of the poppet between the check valve and filler tube during assembly 4 Insert the filler tube spring end first into the high pressure cylinder making sure to engage the spring into the dynamic seal Repeat for the remaining filler tubes 74 M 416 Flow International Corporati...

Page 75: ...ed 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 ...

Page 76: ...eps 1 3 for the remaining two high pres sure tubes 5 Insert one end of the tube into the high pressure port on the manifold and loosely thread the glands in place Repeat for the other two high pressure tubes 6 Loosely thread the other end of each of the three tubes into the end cap ports 7 Once in place tighten all six gland nuts Torque to 40 ft lb 54 N m 8 Reconnect all high and low pressure inte...

Page 77: ...Reinstall the oil temperature sensor or plug and fill the crankcase with oil to the level indicated on the dipstick Recommended oils are listed in Chapter 1 Return the pump to service Follow the startup procedure on Page 14 before return ing the HyPlex Prime pump to service Flow International Corporation M 416 77 CHAPTER 4 Service ...

Page 78: ...Notes 78 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 79: ...ch 0 100 ft lb Screwdriver set Allen wrench set Needle nose pliers 6 in soft jaw vise Maintenance kit PCV maintenance kit 050625 1 Service notes All parts of the kit should be installed at the same time do not replace components individually All components should be clean and free of debris prior to assembly Keeping the work area clean is im portant while working on the equipment Read the entire p...

Page 80: ...from the PCV body Note Needle nose pliers may be needed to remove the poppet from the assembly 5 Remove the PCV adapter from the valve body Re move and discard the o rings from the valve body 6 Place the air cylinder in a soft jaw vise Use a 1 1 4 in 32 mm combination wrench to remove the PCV body from the air cylinder 7 Use a hex wrench to remove the four cap screws from the air cylinder Separate...

Page 81: ...plunger and thread into the mounting block until the PCV body is firmly seated No ex treme torque is needed 7 Clean out any debris that remains in the high pres sure port of the manifold 8 Lubricate the two new o rings with food grade grease Place new o rings on the outer diameter of the valve body 9 Install the PCV adapter on the valve body 10 Make sure the static seal ring is installed on the se...

Page 82: ...Notes 82 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 83: ...canister Note This inspection can provide early warning of a change in inlet water quality Filter life and inlet wa ter quality are directly related 6 Clean the canisters and install new filter cartridges CAUTION The 0 5m and 1 0m cartridges must be installed in the correct position as labeled on the pump failure to do so could shorten pump life 7 Re assemble the filter canisters to the filter hou...

Page 84: ... perform a complete service procedure Record the actual hour meter reading when you install the main tenance kit the next scheduled maintenance should take place at the specified number of hours from this reading For example suppose you have a 50 hp pump The Dy namic Seal maintenance interval is every 300 hours The dynamic seal fails at 250 hours 50 hours short of a scheduled maintenance period In...

Page 85: ... cylinder Re move and discard the dynamic seal and rod seal CAUTION Use care when removing the dynamic seal and rod seal Do not scratch or nick the seal carrier bores 6 Inspect the seal carrier and plunger for damage Keep and reuse the seal carrier if undamaged The plunger should not have touched the bore of the seal carrier If there are contact marks on either compo nent replace both components I...

Page 86: ...the dynamic seal carrier 1 Inspect the dynamic seal carrier for cleanliness Make sure the guide bearing of the seal carrier is flush with the face of the carrier and is in good con dition the presence of cracked or loose pieces is reason for replacement Replace the dynamic seal carrier if necessary Clean as necessary 2 Install the rod seal as shown with the v shaped face facing up away from the dy...

Page 87: ... Slide the high pressure cylinder over the plunger as sembly and seat it against the seal carrier Position the cylinders with weep holes facing downward Note A small amount of force may be needed to seat the cylinder against the seal carrier Repeat for the remaining high pressure cylinders Flow International Corporation M 416 87 CHAPTER 4 Service ...

Page 88: ...e inlet poppet can be pinched causing damage 1 Align the end cap so it will slide over the tie rods Carefully slide the end cap towards the HP cylinder until the check valve body makes contact with the inlet poppet 2 Continue to slide the end cap until the high pres sure cylinder engages the o ring in the end cap and the check valve body seats itself against the high pressure cylinder 3 Temporaril...

Page 89: ...be 4 Repeat Steps 1 3 for the remaining two high pres sure tubes 5 Insert one end of the tube into the high pressure port on the manifold and loosely thread the glands in place Repeat for the other two high pressure tubes 6 Loosely thread the other end of each of the three tubes into the end cap ports 7 Once in place tighten all six gland nuts Torque to 40 ft lb 54 N m 8 Reconnect all high and low...

Page 90: ...einstall the oil temperature sensor or plug and fill the crankcase with oil to the level indicated on the dipstick Recommended oils are listed in Chapter 1 Return the pump to service Follow the start up procedure on Page 14 before return ing the HyPlex Prime pump to service Flow International Corporation M 397 90 CHAPTER 5 Service ...

Page 91: ...these can cause the belt to slip If a V belt slips it is not at proper tension and needs to be tightened Do not use subsititute hardware Servicing the belts WARNING Place the main electrical disconnect in the OFF position and bleed down all high pressure lines Place an Out of Service tag on the main electrical disconnect and lock it out Failure to do so can result in equipment damage or injury to ...

Page 92: ...ng to assure repeat able measurements 7 Turn the nut on the tension bar CW to increase ten sion or CCW to decrease tension Tension should be set between 100 and 110 lbs 445 489 N Refer to drawing 049785 When the tension is correct 8 Use a 3 4 in socket to torque the three flanged nuts not attached to the tension bar to the appropriate torque value in the table below Do not tighten the flanged nut ...

Page 93: ... if water droplets are found on the dipstick Crankcase replacement parts Part number Qty Description 015445 1 3 Piston rod seal carrier assembly A 0275 036 3 Seal carrier o ring A 12498 1 Gasket Replacing the piston rod seal assembly The piston rod seal assembly contains three oil seals in stalled in seal carrier and an o ring on the outer diame ter The oil seals cannot be replaced individually th...

Page 94: ...Notes 94 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

Page 95: ...e 050051 X X X X X HyPlex Prime 049785 X Base unit 1 30 hp 230V 460V 60Hz 2 30 hp 380V 50Hz 6 50 hp 230V 460V 60Hz 7 50 hp 380V 50Hz 049657 X Hardware kit 1 Basic package 2 Standard package 3 Basic dual pressure 4 Standard dual pressure 5 Plus package 6 Premium package 050242 X Application package 1 Basic package no covers 2 Extended package covers 3 7 With gauge no covers 4 8 With gauge covers 5 ...

Page 96: ...hp or 50 hp Plus non B R controlled 51 30 hp or 50 hp Premium non B R controlled 049893 X Cable package 1 Basic 30 hp 230V 60Hz 30 hp 460V 60Hz 50 hp 460V 60Hz 50 hp 380V 50Hz 30 hp 380V 50Hz 30 hp 575V 60Hz 50 hp 575V 60Hz 2 On board 30 hp 230V 60Hz 30 hp 460V 60Hz 50 hp 460V 60Hz 50 hp 380V 50Hz 30 hp 380V 50Hz 30 hp 575V 60Hz 50 hp 575V 60Hz 3 Remote 30 hp 230V 60Hz 30 hp 460V 60Hz 50 hp 460V 6...

Page 97: ...tenance bulletin 050624 1 Rev A Minor maintenance kit 30 50 hp pump Qty Part Description 1 3 011051 1 Dynamic seal 2 3 A 00621 33 Rod seal 3 3 011042 1 Inlet poppet 4 3 011040 1 Outlet poppet guide 5 3 011039 1 Outlet poppet 6 3 011041 1 Outlet poppet seat 8 6 A 0275 033 O ring 9 3 A 0275 025 O ring 10 1 A 4689 Food grade grease 11 3 A 9223 Compression spring 12 3 A 12219 Spring 13 3 011350 1 Fill...

Page 98: ... spring 12 3 A 12219 Compression spring 13 3 011350 1 Filler tube sleeve 14 2 A 20386 1 Anti seize lubricant 15 3 A 00720 31 Rod seal 16 1 049656 DWG HP assembly drawing 19 3 044099 1 Seal carrier 21 3 049584 1 High pressure cylinder 22 3 049578 1 Check valve body 27 3 A 0265 062 Internal snap ring 30 3 A 0275 029 HP o ring 32 1 SB 0259 Major maintenance bulle tin 33 6 A 0275 033 O ring 34 1 04214...

Page 99: ...ese parts are not contained in a spares kit but FLOW recom mends that you keep them on hand Water filters A 25216 1 0 5 micron filter A 25216 2 1 micron filter PCV spares 042145 2 PCV poppet seat assembly 050469 1 Rev A Pressure loading tool spares kit Qty Part Description 1 1 049515 1 Oil seal backup ring 2 1 049518 1 Hydraulic oil seal 3 1 A 0275 116 O ring 4 1 A 0275 033 O ring 5 1 A 0276 033 B...

Page 100: ...Notes 100 M 416 Flow International Corporation HYPLEX PRIME PUMP Maintenance Service Manual ...

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