Flow ESL INTENSIFIER Manual page 19

30. Tighten the cylinder using a strap wrench. The strap
wrench is torque limiting—it will begin to slip after it
reaches a certain torque.
DO NOT grip the cylinder with any sharp-toothed tool. Surface
scratches and gouges will lead to early part failure.
31. Make sure the end cap check valves were inspected and
lapped as required. Apply a small amount of Blue Lubri-
cant to the check valve body shoulder face. Apply a thin
coat of Blue Lubricant to the end cap threads.
32. Remove the seal guide and aluminum disk from the cyl-
inder (as installed in Step 25). Thread the end cap onto
the cylinder, making sure the check valve rotates with
the end cap as an assembly.
Make sure the check valve fitting, which is drilled off
center, is oriented as originally installed. Back off the end
cap turn if the check valve must be rotated to avoid
1
2
damaging the seal and o-rings, then re-tighten. Installing
the high-pressure tubing is easier if the check valve is in
the original position.
33. Torque the end cap by tapping on the spanner wrench
with a mallet or 8 oz. hammer. Do not exceed 100 ft-lb
(75 N-m).
Note: The high-pressure seals are fully functional at a
torque value only slightly more than hand tight. Do not
over tighten—torquing the end cap higher than 100 ft-lb
(75 N-m) is unnecessary and makes disassembly more
difficult.
© Flow International Corporation
CAUTION
34. Using two wrenches, connect the high-pressure
tubing at both ends and connect the supply wa-
ter hose at the quick disconnect fitting.
35. Remove tools, parts, and rags from around the
pump. Make sure the covers are closed.
CAUTION
Make sure everyone near the equipment knows
that you are starting it. Do not try to correct leakage
problems while the pump is operating or if
there is high-pressure water in the system.
36. Turn the pressure control knob fully counter-
clockwise to the lowest pressure setting and start
the pump.
37. Operate the pump at idle oil pressure
[400–700 psi (27–48 bar)] for five minutes while
checking for leaks and listening for any unusual
sounds.
38. Increase the pressure to 1000 psi (68 bar) and
check for leaks. Increase the pressure in 500 psi
increments every few minutes until the maxi-
mum rated pressure is achieved. Continue to
operate the pump 7–10 minutes while checking
for leaks and other problems.
39. Shut down the system and check for leaks,
unsecured lines, and any unfinished work.
40. Confirm that all work is satisfactory and remove
the Out of Service tag from the main electrical
disconnect.
The pump is ready for operation. Record all
mainte-
nance work in the Intensifier Pump Maintenance
and Service Log (MS-2258), located in your intensi-
fier pump manual.
ESL Intensifier
M-310 | 19