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Disassembling the intensifier

1. Shut down the system.

WARNING

Place the main electrical disconnect in the OFF

position and bleed down the high-pressure lines.

Place an “Out of Service” tag on the main electrical

disconnect and lock it out. Failure to do so can cause

equipment damage or injury to personnel.

2. Disconnect the high-pressure tubing from the intensi-

fier outlet adapter and move it out of the way.

3. Disconnect the supply water hose from the end cap.

4. Install the pressure loading tool on the tie rods, being

careful to correctly locate the tool piston step in the
end cap counterbore.

CAUTION

Make sure the tool piston step is fully engaged in the

counterbore before continuing. Failure to do so can damage

the end cap or the 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 washers.

6. Install the tool washers and nuts on the tie rod ends

and run up hand tight to the tool.

7. Connect the hand pump hose to the tool at the

quick-disconnect fitting.

Note:

On some tool models the hand pump hose

does not have a quick-disconnect fitting. If this is the
case, leave the hose attached to the tool at all times
to prevent leaking.

8. Open the pressure-release valve on the hand pump

by turning the valve handle counterclockwise one
turn.

9. Collapse the pressure loading tool using a ratchet

and socket on the tool nuts, tightening all of the nuts
until they are snug against the tool.

Note:

Oil from the tool will flow back to the hand

pump reservoir.

M-376 | 21

CHAPTER 3

Maintenance Procedures

Содержание 94K HYPERPRESSURE

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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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