Flow ESL INTENSIFIER Manual page 10

ESL Intensifier
Misaligned end bells
5. Oil leaking from manifold/shift valve interface
Defective or worn o-ring seals; loose
shift valve mounting screws
6. Oil leaking from shift valve/pilot valve interface
Defective/worn o-rings, loose pilot
valve mounting screws, or incorrect
torque
7. Water leaking from end bell weep hole
Worn high-pressure water seal
Fractured high-pressure water cylin-
der at the end bell side
Worn high-pressure water plunger
8. Water leaking from end cap weep hole
Worn HP water seal
Damaged low-pressure water seal
o-rings on the check valve body
Fractured high-pressure water cylin-
der
Fractured check valve body
End cap incorrectly assembled to
high-pressure cylinder
9. Short high-pressure water seal life
Excessive clearance between seal
backup ring and HP water plunger
Scratched HP water plunger
10 | M-310
1. Remove intensifier from pump and place on assembly fixture.
2. Loosen tie rods and retorque. Confirm that end bells are aligned correctly.
Retorque the shift valve mounting screws, using torque values in this manual. If
leak doesn't stop, replace interface o-ring seals between manifold and shift
valve.
Retorque pilot valve mounting screws, following the torque values in this man-
ual. If leak won't stop, replace interface o-ring seals between pilot valve and
shift valve.
Replace all high-pressure water seals and seal backup rings. Be careful not to
scratch the water cylinder during seal extraction and insertion.
Replace water cylinder and seals. Be careful not to scratch the high-pressure
water cylinder during seal insertion.
1. Inspect plunger diameter. The diametrical clearance between plunger and
new backup ring must be less than 0.002 inch (0.05 mm). Replace if
scratched, pitted or below tolerance.
2. Replace water seals and seal backup ring.
Replace high-pressure water seal.
Replace water seal o-rings. Do not pinch the o-ring seals when installing check
valve housing.
Replace cylinder and high-pressure seals. After replacement, increase pressure
gradually.
Inspect for fractures. Replace check valve body if required. Replace all water
seals.
Remove end cap and reassemble. Replace HP water seal (if damaged).
1. Remove HP water cylinder. Replace all HP water seals (backup ring, seal,
hoop, and o-ring).
2. Examine HP plunger. Replace if diameter is less than specified or if surface
roughness is greater than 4 micro-inch RMS.
Caution: High-pressure seal rings must be replaced whenever high-pres-
sure seals are replaced.
Deep pits or scratches in excess of 10 micro-inches will cause premature
high-pressure water seal failure. Replace as necessary.
© Flow International Corporation