Flow 94K HYPERPRESSURE Manual

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94K HYPERPRESSURE™

INTENSIFIER

M-376 | REV. G | JUNE 2012

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Page 1 94K HYPERPRESSURE™ INTENSIFIER M-376 | REV. G | JUNE 2012...
Page 2 Due to continuing product improvement, the information contained in this document is subject to change without notice. Flow International Corporation shall not be held liable for technical or editorial omissions made herein, nor for any incidental or consequential damage resulting from the use of this material.
Page 3: Table Of Contents
Introduction 94K HyperPressure™ Intensifier Chapter 1. Intensifier Description Maintenance Procedure D Replacing the Check Valve Body Assembly and Physical specifications 5 Servicing the Inlet Components of the Check Valve Functional specifications 6 Body Assembly 31 Operating principles 6 Service notes 31 Lapping notes 32 Chapter 2.
Page 5: Chapter 1. Intensifier Description
CHAPTER 1 Intensifier Description This manual will help you become familiar with your new Flow International (Flow) equipment. Information was compiled from the most current information available at the time of publication. Physical specifications 014623-1 or -3 Long-block intensifier 020070-1 Short-block intensifier (HyperPressure) (Pressure Vessel Application) Width .
Page 6: Functional Specifications
94K HYPERPRESSURE INTENSIFIER Functional specifications Type of shift ......electric Output pressure... 94,000 psi (6483 bar) Intensification ratio .
Page 7: Chapter 2. Safety
Safety precautions CAUTION Highlights an operating condition or service Flow designed your high-pressure waterjet cutting procedure that can lead to impaired system system and related equipment with safety in mind. operation or equipment damage. Throughout the manual, safety precautions and warnings for specific operations are highlighted.
Page 8: Safety Tips
94K HYPERPRESSURE INTENSIFIER Safety tips Be alert at all times when working around the • equipment. Do not allow the waterjet stream to touch any part of • Clear all tools, parts, and rags from moving parts your body—it will cause serious injury.
Page 9: Protective Clothing
Do not touch weep holes with your bare hands or try • Flow recommends that work-site safety personnel ap- to stop water by plugging the holes. prove all safety equipment and clothing for everyone Remember that the waterjet stream is a knife. Do not •...
Page 10: Emergency Medical Information
94K HYPERPRESSURE INTENSIFIER Hearing protection Emergency medical information Operators and other personnel ex- • Anyone who receives equipment-related injuries while posed to noise levels of more than operating high-pressure water equipment should be 90 dBa for more than 1 hour must given immediate hospital attention.
Page 11: Chapter 3. Maintenance Procedures
It will help minimize unscheduled down time, maximize equipment use, and eliminate unsafe operat- ing conditions. Flow recommends that you use a maintenance and ser- vice log to record all service work. Maintenance tips Stock enough spare parts to minimize down time •...
Page 12: Replacement Parts Diagram & Table
A, D2 015384-1 Table references * Flow recommends changing components on both sides of the intensifier at the same time. **Use low-pressure piston 011304-1 on the long-block intensifier (052919-10); use low-pressure piston 020080-1 on the short-block intensifier (020070). AR = as required 12 | M-376 ©...
Page 13 – – – 042102-1 Outlet adapter – – – – – 042101-1 Check valve assembly – – – – 020071-1 Note: Items 9–15 are the components parts of Item 16, Check valve assembly M-376 | 13 © Flow International Corporation...
Page 15: Intensifier Service Notes
CHAPTER 3 Maintenance Procedures Intensifier service notes The following list was compiled from Flow customers Keep all intensifier tools supplied with the pump in a • and Field Service Engineers. Following these suggestions separate, locked cabinet. Substituting tools for those...
Page 17: Maintenance Procedure A
The pressure loading tool Pressure loading tool kit (042512-3) The following procedures use a special tool created especially for the 94K HyperPressure intensifier. You must read and understand these ½ in. drive torque wrench usage notes before attempting any maintenance procedure that re- ½...
Page 18 Inspect the tool piston stop for damage. Replace if it • is not flat. DO NOT grind to remove damage. For ease of use and to prevent damage, Flow recom- • mends that you mount the hand pump permanently to a rigid cart. When not in use, cover the cart with a dust cover and store in a clean location.
Page 19: Assembling The Intensifier
Failure to do so can damage the end cap or the pressure loading tool. 4. Install the tool washers and nuts on the tie rod ends and run up hand tight to the tool. M-376 | 19 © Flow International Corporation...
Page 20 In the pattern shown be- low, torque the tool nuts to 20 ft-lb (27 N-m), then to 50 ft-lb (67.8 N-m). Note: Oil from the tool will flow back to the hand 11. Bleed off the remaining tool pressure by opening the pump reservoir.
Page 21: Disassembling The Intensifier
Note: Oil from the tool will flow back to the hand pump reservoir. 5. Thoroughly clean the tie rods to ensure no old anti-seize lubricant remains.
Page 22 94K HYPERPRESSURE INTENSIFIER 10. Using the ratchet and socket, back off the tool nuts 16. Remove the hand pump hose from the tool at the exactly one full turn. quick-disconnect fitting. Note: On some tool models the hand pump hose CAUTION does not have a quick-disconnect fitting.
Page 23: Maintenance Procedure B Replacing The Intensifier High-Pressure Seal
Maintenance Procedure B Replacing the Intensifier High-Pressure Seal Service notes Service steps Flow recommends that all high-pressure seals on the in- 1. Shut down the system. tensifier be serviced at the same time. This will help prevent unnecessary downtime. WARNING Place the main electrical disconnect in the OFF position and bleed down the high-pressure lines.
Page 24 94K HYPERPRESSURE INTENSIFIER 014623-1 or -3 Long-block intensifier 6. Remove the end cap from the tie rods. Note that the (StoneCrafter) check valve assembly will stay inside the end cap be- cause of compression of the o-ring on the check valve body.
Page 25 10. Place the new seal carrier assembly onto the plunger. Using the filler tube as a tool, push the assembly along the plunger until it butts against the end bell face. M-376 | 25 © Flow International Corporation...
Page 26 94K HYPERPRESSURE INTENSIFIER 13. Reinstall the check valve assembly and end cap to- gether by sliding the end cap along the tie rods and guiding the high-pressure cylinder into the bronze bushing of the end cap. Take care to align the check valve assembly with the correct orientation as previ- ously noted in Step 5.
Page 27: Maintenance Procedure C Replacing The Intensifier High-Pressure Cylinder
Maintenance Procedure C Replacing the Intensifier High-Pressure Cylinder Service notes Service steps Flow recommends that you service both of the 1. Shut down the system. • high-pressure cylinders on the intensifier at the same time. This will prevent unnecessary downtime.
Page 28 94K HYPERPRESSURE INTENSIFIER 014623-1or -3 Long-block intensifier 6. Remove the end cap from the tie rods. The check valve (StoneCrafter) assembly will remain inside the end cap due to com- pression of the o-ring on the check valve body. Note: Unless check valve maintenance is necessary (Maintenance Procedure D), you do not need to remove the check valve assembly from the end cap.
Page 29 Intensifier 14. Reconnect the high-pressure tubing and the inlet water hose. 11. Thoroughly clean the tie rods, nuts, and washers to remove the old anti-seize lubricant. M-376 | 29 © Flow International Corporation...
Page 31: Maintenance Procedure D
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 face and install- • ing the inlet replacement kit M-376 | 31 © Flow International Corporation...
Page 32: Lapping Notes
94K HYPERPRESSURE INTENSIFIER Lapping notes When lapping any component, if the sealing surface cannot easily be restored by the lapping techniques de- scribed in this section, you can machine it flat before lapping as long as you machine only the sealing surface,...
Page 33: Maintenance Procedure D1
Check valve orientation of both the long-block and short-block intensifiers is shown on the next page. M-376 | 33 © Flow International Corporation...
Page 34 94K HYPERPRESSURE INTENSIFIER 014623-1or -3 Long-block intensifier 7. Remove the end cap from the tie rods. Note that (StoneCrafter) compression of the o-ring on the check valve body will keep the check valve assembly in the end cap. 020070-1 Short-block intensifier (HyperPressure) 8.
Page 35 14. Reload the intensifier tie rods. See Maintenance Procedure A, Assembling the • Intensifier 15. Reconnect the high-pressure tubing and the inlet water 12. Remove the old anti-seize from the tie rods, hose. nuts, and washers. M-376 | 35 © Flow International Corporation...
Page 37: Maintenance Procedure D2
Check valve orientation of both the long-block and short-block intensifiers is shown on the next page. M-376 | 37 © Flow International Corporation...
Page 38 94K HYPERPRESSURE INTENSIFIER 014623-1or -3 Long-block intensifier 7. Remove the end cap from the tie rods. Note that (StoneCrafter) compression of the o-ring on the check valve body will hold the check valve assembly inside the end cap. 020070-1 Short-block intensifier (HyperPressure) 8.
Page 39 600 grit strip to the other side. Place a few drops of water on the 320 grit side of the lapping plate. Lap the check valve body in a figure-8 pattern until all surface imperfections have been removed. M-376 | 39 © Flow International Corporation...
Page 40 94K HYPERPRESSURE INTENSIFIER 15. Turn the lapping plate over and place a few drops of Installing the check valve inlet replacement kit water on the 600 grit side of the plate. Lap the check 18. Set out and inspect the components of the check valve body in a figure-8 pattern until the body is valve inlet replacement kit (014884-1).
Page 41 • Install the new check valve assembly by pushing it Intensifier into the end cap. Take care to align the check valve assembly with the correct orientation as previously noted in Step 6. M-376 | 41 © Flow International Corporation...
Page 42 94K HYPERPRESSURE INTENSIFIER 27. Torque the outlet adapter to 200 ft-lb (271.2 N-m). Note: The outlet adapter 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 hose.
Page 43: Maintenance Procedure E
Maintenance Procedure E Servicing and Replacing the Outlet Check Valve Components (Outlet Poppet and Check Valve Seat) 014885-1 Outlet replacement kit M-376 | 43 © Flow International Corporation...
Page 44: Tools Required
94K HYPERPRESSURE INTENSIFIER Tools required 4. Remove the outlet poppet, compression spring, and outlet spring seat from the outlet adapter. Discard 1¼ in. socket (½ in. drive) and handle the poppet and spring, but set the spring seat aside. 1 in. open-end wrench in.
Page 45 Make sure the coned end is pointing out once in- stalled, and that there is no Blue Lubricant on the sealing face of the outlet check valve seat. M-376 | 45 © Flow International Corporation...
Page 47: Maintenance Procedure F Servicing The Low-Pressure Components
Check valve orientation of both the long-block and short-block intensifiers is shown on the next page. M-376 | 47 © Flow International Corporation...
Page 48 94K HYPERPRESSURE INTENSIFIER 014623-1 or -3 Long-block intensifier 6. At one end of the intensifier, remove the end cap from (StoneCrafter) the tie rods. The check valve assembly will remain in the end cap due to the compression of the o-ring on the check valve body.
Page 49 9. Repeat Steps 6–8 on the other end of the intensifier. 10. Remove the shift sensors. Use the shift pin tool to remove the shift pins. Refer to your pump manual for detailed instructions. M-376 | 49 © Flow International Corporation...
Page 50 94K HYPERPRESSURE INTENSIFIER 014623-1 or -3 Long-block intensifier 11. Loosen the screws that hold the manifold to (StoneCrafter) the intensifier, then separate the two assem- blies. Drain oil from the intensifier ports. If the intensifier is not connected to a hy- draulic manifold, simply disconnect the hy- draulic hose fittings from each end bell.
Page 51 Secure the intensifier to the fixture from below: For the long-block intensifier (StoneCrafter), • use four -16 UNC threaded screws. For the short-block intensifier (HyperPressure), • use two 5/8-18 UNF bolts M-376 | 51 © Flow International Corporation...
Page 52 94K HYPERPRESSURE INTENSIFIER 13. Remove the high-pressure tie rods. If a tie rod is tight, use two nuts tight- ened back-to- back on the thread of the tie rod and loosen with an open-ended wrench. CAUTION Do not use a pipe wrench—it will mark the tie rod and cause premature tie rod failure.
Page 53 CAUTION Do not use a sharp tool to remove these parts—it will damage the parts. Repeat this step for the other end bell. M-376 | 53 © Flow International Corporation...
Page 54 Plungers cannot be reworked in the field. • Contact Flow Technical Service for information on Piston and plungers factory rework of plungers. Disassemble the piston and plungers for any of Inspect the piston for cracks; replace as needed.
Page 55 Use a soft-faced mallet where nec- essary. CAUTION Take care when the seal enters the cylinder. It is compressed at this point and can easily be damaged by rough handling. 28. Repeat Steps 23–27 for the other plunger. M-376 | 55 © Flow International Corporation...
Page 56 94K HYPERPRESSURE INTENSIFIER 31. Continue sliding the piston into the cylinder until the 34. Mount an end bell to the assembly fixture. Insert the empty seal groove on the piston exits the other end fixture plate screw(s) and fasten finger tight.
Page 57 Be careful not to nick the seals and back-up rings. There must be no seal or back-up ring debris visible at the cylinder/end bell interface. Be sure to check for any problems before continuing. M-376 | 57 © Flow International Corporation...
Page 58 94K HYPERPRESSURE INTENSIFIER Center and hold the tie rods in place while installing the washers and nuts onto the tie rods. Secure the nuts hand tight. 42. Insert the second fixture plate screw (the long-block intensifier has a pair) into the second end bell.
Page 59 46. Apply anti-seize to all threads of the high-pressure tie rods and thread into the nuts (hand tight). 47. Install shift pins and shift sensors. Refer to your pump manual for detailed instructions. M-376 | 59 © Flow International Corporation...
Page 60 94K HYPERPRESSURE INTENSIFIER 48. Place the seal carrier assembly onto the plunger end, 50. Install the filler tube in the high-pressure cylinder. then using the filler tube as a tool, push the assembly CAUTION along the plunger until it butts against the end bell Make sure the filler tube is oriented correctly.
Page 61 CHAPTER 3 Maintenance Procedures 014623-1 or -3 Long-block intensifier (StoneCrafter) 020070-1 Short-block intensifier (HyperPressure) M-376 | 61 © Flow International Corporation...
Page 63: Chapter 4. Troubleshooting
4. Follow the corrective action procedure. If the symptoms in the chart do not correspond to your malfunction, or if the problem is not resolved or elimi- nated by the recommended corrective action, contact Flow Technical Service. M-376 | 63 © Flow International Corporation...
Page 66 94K HYPERPRESSURE INTENSIFIER Weep hole A WATER LEAKAGE Weep holes and locations are identified on the illustrations on Pages 64-65. Fluid Maintenance Likely problem Other possible symptoms Kit or parts needed procedure Qty. Temp. Incorrect loading of Water leakage from C,B,D,E —...
Page 67 Warm/hot 040015-1 Uneven intensifier stroking • stroke (2 per intensifier) High-pressure seal Pump cannot maintain pressure High-pressure seal cartridge 052190-1 or • failure 040015-1 Uneven intensifier stroking • (2 per intensifier) M-376 | 67 © Flow International Corporation...
Page 68 94K HYPERPRESSURE INTENSIFIER Weep hole C WATER LEAKAGE Weep holes and locations are identified on the illustrations on Pages 64-65. Note: Seal leakage is normal during intensifier operation. This normal leakage can start soon after new seal installa- tion, and does not damage intensifier components. A seal has failed and must be replaced only when the cutting performance becomes unacceptable due to the drop in UHP water pressure caused by the seal leak.
Page 69 Leaks even when pump is stopped Continuous — intensifier tie rods and inlet water pressure exists flow or Cold steady Debris between Leaks even when pump is stopped — drip sealing surfaces and inlet water pressure exists M-376 | 69 © Flow International Corporation...
Page 70 94K HYPERPRESSURE INTENSIFIER Location E WATER LEAKAGE Weep holes and locations are identified on the illustrations on Pages 64-65. Fluid Maintenance Likely problem Other possible symptoms Kit or parts needed procedure Qty. Temp. Incorrect loading of Water leakage from A,B,C,D —...
Page 71 Uneven intensifier stroking • and check valve body described in E1 Continuous Check valve body o-ring Leaks even when pump is stopped O-ring flow or Cold failure and inlet water pressure exists. A-0275-131 steady drip M-376 | 71 © Flow International Corporation...
Page 72 94K HYPERPRESSURE INTENSIFIER Location G WATER LEAKAGE Weep holes and locations are identified on the illustrations on Pages 64-65. Fluid Maintenance Kit or parts Likely problem Other possible symptoms procedure needed Qty. Temp. Pump cannot maintain pressure Insufficient torque between high- •...
Page 73 Oil leakage from Warm Note: a small amount of leakage is normal during operation drip hydraulic shaft seal Small Oil leakage from Low-pressure seal kit periodic Warm — hydraulic shaft seal 013157-1 or 020080-1 flow M-376 | 73 © Flow International Corporation...
Page 74 94K HYPERPRESSURE INTENSIFIER Location I OIL LEAKAGE Weep holes and locations are identified on the illustrations on Pages 66–67. Fluid Maintenance Likely problem Other possible symptoms Kit or parts needed procedure Qty. Temp. Loose manifold Retorque manifold mounting screws as —...
Page 75 Weep holes and locations are identified on the illustra- tions on Pages 66–67. Fluid Maintenance Likely problem Other possible symptoms Kit or parts needed procedure Qty. Temp. Occasional Low-pressure seal kit Warm Worn o-rings — drip 013157 or 020080-1 M-376 | 75 © Flow International Corporation...
Page 76: Other Possible Problems/Symptoms For The Intensifier
94K HYPERPRESSURE INTENSIFIER Other possible problems/symptoms for the intensifier Intensifier does not shift Persistently low seal life High-pressure waterjet on/off valve closed Poor inlet water quality • • Waterjet orifice clogged with debris Worn UHP plungers • • Shift sensor cable is disconnected Pump running at higher than rated pressure •...
Page 77 CHAPTER 5 Parts Lists Intensifier assemblies 014623-1 or -3 and 020070-1 High-pressure end M-376 | 77 © Flow International Corporation...
Page 78: Check Valve Assembly
94K HYPERPRESSURE INTENSIFIER 020071, Check valve assembly 78 | M-376 © Flow International Corporation...
Page 79: Chapter 5. Parts Lists
CHAPTER 5 Parts Lists Low-pressure end For long-block (StoneCrafter) intensifier (014623-1 or -3) M-376 | 79 © Flow International Corporation...
Page 80 94K HYPERPRESSURE INTENSIFIER Low-pressure end For short-block (HyperPressure) intensifier (020070-1) 80 | M-376 © Flow International Corporation...
Page 81: Piston Assembly
CHAPTER 5 Parts Lists Piston assembly 011492-1 (for long-block intensifier, 014623) 020079-1 (for short-block intensifier, 020070) M-376 | 81 © Flow International Corporation...
Page 82: Kits
94K HYPERPRESSURE INTENSIFIER Kits 014884-1 042512-3 Check valve inlet repair kit Pressure loading tool kit # Qty Part # Description # Qty Part# Descriptino 004380-1 Retaining screw 12 1 A-24203-1 Hydraulic hand pump 015834-1 Inlet poppet 23 1 019375-1 010564-1...

Flow 94K HYPERPRESSURE Manual

Chapter 1. Intensifier Description

Chapter 2. Safety

Chapter 3. Maintenance Procedures

Chapter 4. Troubleshooting

Chapter 5. Parts Lists

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Table of Contents