Hydraulic oil cylinder, piston, plunger, and end bell
The double-acting hydraulic oil cylinder is located be-
tween two high-pressure water cylinders. When the
cylinder and end bells require service, one or more of
the following conditions will be present:
•
Excessive oil leakage from the end bell weep
hole or the joint between cylinder and end
bell (more than one drop every 30 seconds).
•
Worn piston seals, allowing excessive oil flow
around the piston.
•
A jammed piston or detached plunger.
All service must be performed in a clean, well-lit area.
The intensifier must be removed from the pump and
disassembled on a workbench. An experienced techni-
cian using the correct tools and procedures can com-
plete the procedure in 2½–3 hours.
Tools required
You will need the intensifier assembly fixture
(C-2217-1) for this procedure. The fixture is used dur-
ing reassembly to align the end bells square with each
other and minimize the chance of o-ring damage as the
cylinder is being drawn onto the end bells. Misaligned
end bells can cause the oil manifold to leak or even
break.
Service steps
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 may
result in equipment damage or injury to personnel.
1. Shut down the system.
2. Disconnect the supply water hoses at the quick-
disconnect fittings. Using two wrenches, disconnect
the high-pressure water lines from the check valve
outlet bodies. Loosen the other ends of the tubing
and move them out of the way.
CAUTION
Do not bend or flex the high-pressure tubing.
Such stress may cause early failure of the tubing.
3. Remove the high-pressure cylinders and end caps as
described in
High-pressure water cylinder and seals
.
4.
Manual shift.
Remove the shift cables and actuating
pins from the intensifier and set aside. Remove the
shift pins using the shift pin tool (002228-1).
Electric shift.
Remove the shift sensors. Use the shift
pin tool to remove the shift pins.
26 | M-310
© Flow International Corporation
ESL Intensifier
