Flow ESL INTENSIFIER Manual page 31

28. Slide the piston and plunger back into the cylinder.
Note: Centering the piston on the plunger will make
reassembly easier.
The seal is going into the cylinder against the flare. Take
care as the seal enters the cylinder—it is compressed at
this point, and can be easily damaged by rough handling.
Set the cylinder containing the piston and plunger
assembly aside.
Reassembling the intensifier
29. Mount an end bell to the assembly fixture using the
cap screws provided. Tighten the cap screws finger
tight. The backup ring and o-ring were lubricated
and installed in Step 15.
30. Apply clean hydraulic oil or Parker Super O-Ring
Lube (200006) to both plungers. Determine the ap-
propriate orientation of the label affixed to the cylin-
der and install the cylinder by inserting the plunger
into the end bell.
31. Mount the remaining end bell to the other plunger.
Secure to the assembly fixture with the cap screws
finger tight.
32. Install tie rods, apply Blue Lubricant to the tie rod
threads. Thread on the elastic stop nuts.
33. Draw the cylinder carefully onto the end bells by
tightening the nuts evenly in a figure-8 pattern (see
below). Be careful not to nick seals and backup
rings.
Notes:
Seal or backup ring debris must not appear at
•
the cylinder/end bell interface. Check for any
problems before continuing.
Torque all nuts evenly to 20 ft-lb (27 N-m) so
•
all parts are seated.
© Flow International Corporation
CAUTION
34. Four cap screws were previously threaded into the
end bells through the intensifier assembly fixture.
Torque all four cap screws to 35 ft-lb (47 N-m), then
back off the two in the slotted holes until they are
– turn tighter than finger tight.
1 1
8 4
The bolts must hold the end bells tight against
the fixture to prevent any misalignment, but they
must not interfere with tightening the tie rod nuts.
35. Using a figure-8 pattern, torque all eight tie rod nuts
to 40 ft-lb (54 N-m), then 60 ft-lb (81 N-m), then
80 ft-lb (108 N-m), then 100 ft-lb (68 N-m), then
120-lb (162 N-m).
Note: These torque specifications are for 'wet' or lu-
bricated tie rod nuts.
36. Install the high-pressure water cylinders and end
caps. See High-pressure water cylinder and seals.
37. Remove the intensifier from the assembly fixture.
38. Lubricate the manifold o-rings and place them in the
end bells.
39. Place the intensifier back into the cabinet and secure
it with the original cap screws. Tighten the cap
screws to 35 ft-lb (47 N-m).
40. Manual shift. Install the shift pins and the shift
cables.
Electric shift. Install the shift pins and the shift
sensors.
For more information see Shift cable and pilot valve
in Chapter 4 of the pump manual.
41. Attach the high-pressure tubing at both ends, then
torque the gland nuts. Attach the water supply lines
at the quick-disconnect fittings.
42. Check for incomplete work and remove tools, parts,
and rags. Start the pump and operate at idle oil pres-
sure for 10-15 minutes with a single jet open. This
allows the intensifier pump unit to stroke gently.
43. Slowly increase pressure to the rated output while
checking for leaks, then stop the pump and inspect
for any leakage. Correct any problems as required.
When all work is satisfactory, remove the Out of Ser-
vice tag from the main electrical disconnect. The pump
is ready for operation.
ESL Intensifier
M-310 | 31