FOR TRAINING REFERENCE ONLY

ALWAYS USE THE LATEST COMPLETE MANUAL WHEN PERFORMING MAINTENANCE

Main te nance Pro ce dure A

Using the Pressure Loading Tool to Assemble and
Disassemble the 87K Intensifier

Tools required The pressure loading tool

Pressure loading tool kit (019251-1)
The following procedures use a special tool created es-
½ in. drive torque wrench
pecially for the 87K intensifier. You must read and un -
½ in. drive ratchet derstand these usage notes before attempting any
1 58 in. crow’s foot wrench (½ in. drive) maintenance procedure that requires the use of this
1 58 in. socket (½ in. drive) tool. Failure to do so could damage the tool and/or the
1½ in. socket (½ drive) component being serviced. Such damage is not covered
1 in. open-end wrench by warranty.
7
8 in. open-end wrench
11
16 in. open-end wrench
Food grade grease (A-4689)
Blue Lubricant (A-2185)
Anti-Seize (A-10039)

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 21

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

Usage and ser vice notes

• The pressure loading tool is a delicate instrument
and must be handled with care.
• Use only approved hydraulic oil in the hand pump.
• It is critical that service technicians be trained in the
assembly and disassembly procedures of the 87K in-
tensifier before they use the pressure loading tool.
• Do not use the pressure loading tool for anything
other than the assembly and disassembly of the 87K
intensifier.
• It is important to collapse the tool (push the piston
fully into its cylinder) before each use as described in
this section, to prevent accidental loading of the
snap-ring that holds the piston in the tool.
• To read the pressure gauge accurately, place your eye
so that the needle lines up with (on top of) its reflec-
tion in the mirror strip on the gauge face. This will
prevent errors caused by viewing the gauge at an
angle.
• For ease of use and to prevent damage, FLOW rec-
ommends that you mount the hand pump perma-
nently to a rigid cart. When not in use, cover the cart
with a dust cover and store in a clean location.
• When storing the pressure hose, do not kink or bend
it.
• Always keep dust caps in place on the quick discon-
nect fittings when the tool is not in use.
• Once a year, the pressure gauge of the tool should
be calibrated by a qualified laboratory (Note: This is
not the same as zeroing the gauge).

22 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Assembling the 87K intensifier

See the above illustrations for parts identification, and a 4. Install the tool washers and nuts on the tie rod ends
visual description of how the tool assembles to the tie and run up hand tight to the tool.
rods of the intensifier. 5. Connect the hand pump hose to the tool at the
1. Apply anti-seize (A-10039) to all exposed threads of quick-disconnect fitting (see below).
each tie rod. Apply anti-seize to the threads of the Note: On some tool models the hand pump hose
end cap nuts and tool nuts and the contacting faces does not have a quick-disconnect fitting. If this is the
of the nuts and their washers. case, leave the hose attached to the tool at all times
2. With the high-pressure seal assembly, high-pressure to prevent leaking.
cylinder, filler tube, check valve assembly, and end
cap in place, install the end cap washers and nuts on
the tie rods and run up hand tight to the end cap.
3. Install the tool on the tie rods and locate the tool pis-
ton step in the end cap counterbore.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 23

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Open the pressure-release valve on the hand pump 11. Bleed off the remaining tool pressure by opening the
by turning the valve handle counterclockwise one pump pressure-release valve.
turn. 12. Remove the hand pump hose from the tool at the
7. Collapse the pressure loading tool using a ratchet quick-disconnect fitting.
and socket on the tool nuts. In the pattern shown Note: On some tool models the hand pump hose
below, torque the tool nuts to 20 ft-lb (27 N-m), then does not have a quick-disconnect fitting. In this case,
to 50 ft-lb (67.8 N-m). the hose should be left attached to the tool at all
Note: Water from the tool will flow back to the times to prevent leaking.
hand pump reservoir.
13. Remove the pressure loading tool nuts and washers.
Remove the tool.

8. Close the hand pump pressure-release valve by turn -

ing the valve handle clockwise until tight.
9. Pump the tool to 9200 psi (634 bar).
10. Run up the end cap nuts by hand. Using a torque
wrench with a crow’s foot end, torque in the pattern
indicated (see illustration below) to 50 ft-lb
(67.8 N-m).
Watch the pressure gauge—as the nuts are torqued,
the pressure gauge will show a decrease in pressure.

24 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Disassembling the 87K intensifier

1. Shut down the system. 6. Connect the hand pump hose to the tool at the
quick-disconnect fitting.
WARNING Note: On some tool models the hand pump hose
Place the main electrical disconnect in the OFF does not have a quick-disconnect fitting. If this is the
position and bleed down the high-pressure lines. case, leave the hose attached to the tool at all times
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
to prevent leaking.
equipment damage or injury to personnel.

2. Disconnect the high-pressure tubing from the inten-

sifier outlet adapter and move it out of the way.
3. Disconnect the supply water hose from the end cap.
4. Install the pressure loading tool on the tie rods, being
careful to correctly locate the tool piston step in the
end cap counterbore.

7. Open the pressure-release valve on the hand pump

by turning the valve handle counterclockwise one
turn.
8. Collapse the pressure loading tool using a ratchet
and socket on the tool nuts, tightening all of the nuts
until they are snug against the tool.
Note: Water from the tool will flow back to the hand
pump reservoir.

5. Install the tool washers and nuts on the tie rod ends
and run up hand tight to the tool.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 25

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

9. Again using the ratchet and socket, back off the tool 15. Remove the pressure loading tool nuts and washers,
nuts exactly one full turn. then remove the tool.
Note: Failure to back off the tool nuts will make it 16. Remove the end cap nuts and washers.
impossible to remove the tool from the tie rod.
10. Close the hand pump pressure-release valve by turn -
ing the valve handle clockwise until tight.
11. Pump the tool to the 9200 psi (634 bar) mark on the
pressure gauge.
Note: It will take 60 to 70 pumps before pressure
will begin to build.
12. Loosen the four end cap nuts and back off two full
turns.
13. Bleed off the tool pressure by opening the pump
pressure-release valve.
14. Remove the hand pump hose from the tool at the
quick-disconnect fitting.
Note: On some tool models the hand pump hose
does not have a quick-disconnect fitting. If this is the
case, leave the hose attached to the tool at all times
to prevent leaking.

26 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY

Main te nance Pro ce dure B

Replacing the 87K Intensifier High-Pressure Seal

Service notes
Flow recommends that all high-pressure seals on the in- 5. Note the orientation of the check valve body by ob-
tensifier be serviced at the same time. This will help serving the position of the eccentrically positioned
prevent unnecessary downtime. outlet body relative to the intensifier. This is impor-
tant when reinstalling the check valve body—correct
orientation is critical to ensure the correct fit of
Tools required
high-pressure tubing, which is affected by the eccen-
1” open-end wrench tricity of the outlet body.
7 in. open-end wrench
8
Note: The check valve body is usually positioned
11
16 in. open-end wrench with the outlet body away from the intensifier mani-
Flat-head screwdriver fold block (see below), but this may vary on some
intensifiers.

014623-1 Long-block intensifier

Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel.

2. Disconnect the inlet water hose from the end cap. 020070-1 Short-block intensifier
3. Using two wrenches, disconnect the high-pressure
tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
way.
4. Unload the intensifier tie rods.
• See Maintenance Procedure A, Disassembling
the 87K Intensifier

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 27

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Remove the end cap from the tie rods. Note that the 8. Pry the seal carrier away from the end bell using a
check valve assembly will stay inside the end cap be- flat-bladed screwdriver in the groove provided, as
cause of compression of the o-ring on the check shown.
valve body. Once the seal carrier is away from the end bell, slide
Note: Unless check valve maintenance is necessary it off the ceramic plunger by hand.
(Maintenance Procedure D) you do not need to re-
move the check valve assembly from the end cap.

7. Remove the high-pressure cylinder and filler tube

from the intensifier end bell. Rocking the cylinder
gently while pulling will help separate the cylinder
from the end bell.
9. Place the new seal carrier assembly onto the plunger.
CAUTION Using the filler tube as a tool, push the assembly
When the cylinder is clear of the end bell, pull it along the plunger until it butts against the end bell
straight out to avoid contact with the plunger. face.
Otherwise, you could damage the ceramic plunger.

28 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

10. Slide the high-pressure cylinder over the ceramic 12. Reinstall the check valve assembly and end cap to-
plunger and into the end bell bushing. A slight rock- gether by sliding the end cap along the tie rods and
ing motion will help ease the cylinder into position. 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.

11. Install the filler tube in the high-pressure cylinder.

CAUTION
Make sure the filler tube is oriented correctly.
There is a wall inside the tube that must be at the outermost
end of the tube when it is inserted. Failure to orient the tube 13. Reload the intensifier tie rods.
correctly will damage the intensifier assembly.
• See Maintenance Procedure A, Assembling the
87K Intensifier

14. Reconnect the high-pressure tubing and the inlet wa-

ter hose.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 29

 FOR TRAINING REFERENCE ONLY

Main te nance Pro ce dure C

Replacing the 87K Intensifier High-Pressure Cylinder

Service notes 4. Unload the intensifier tie rods.

• FLOW recommends that you service both of the • See Maintenance Procedure A, Disassembling
high-pressure cylinders on the intensifier at the same the 87K Intensifier
time. This will prevent unnecessary downtime.
• Cylinder failures that occur at the conical sealing sur- 5. Note the orientation of the check valve body by ob-
faces of the cylinder can cause failures of the check serving the position of the eccentrically positioned
valve body (014420-1) or seal carrier (016482-1). outlet body relative to the intensifier. This is impor-
While the intensifier is open, it is a good idea to in- tant when reinstalling the check valve body—correct
spect the sealing surfaces of these components. orientation is critical to ensure the correct fit of
high-pressure tubing, which is affected by the eccen-
Tools required tricity of the outlet body.

1” open-end wrench
Note: The check valve body is usually positioned so
with the outlet body away from the intensifier mani-
7
8 in. open-end wrench
fold block, but this may vary on some intensifiers.
11
16 in. open-end wrench
014623-1 Long-block intensifier

Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel. 020070-1 Short-block intensifier

2. Disconnect the inlet water hose from the end cap.

3. Using two wrenches, disconnect the high-pressure
tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
way.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 31

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Remove the end cap from the tie rods. The check 8. Slide the high-pressure cylinder over the ceramic
valve assembly will remain inside the end cap due to plunger and into the end bell bushing. A slight rock-
the compression of the o-ring on the check valve ing motion will help ease the cylinder into position.
body.
Note: Unless check valve maintenance is necessary
(Maintenance Procedure D) you do not need to re-
move the check valve assembly from the end cap.

9. Reinstall the filler tube in the new high-pressure

cylinder.

CAUTION
Make sure the filler tube is oriented correctly.
7. Remove the high-pressure cylinder and filler tube There is a wall inside the tube that must be at the outermost
from the intensifier end bell. Rocking the cylinder end of the tube when it is inserted. Failure to orient the tube
correctly will damage the intensifier assembly.
gently while pulling will help separate the cylinder
from the end bell.

CAUTION
When the cylinder is clear of the end bell, pull it
straight out to avoid contact with the ceramic plunger. Other-
wise, you could damage the plunger.

32 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

10. 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.

11. Reload the intensifier tie rods.

• See Maintenance Procedure A, Assembling the
87K Intensifier
12. Reconnect the high-pressure tubing and the inlet wa-
ter hose.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 33

 FOR TRAINING REFERENCE ONLY

Main te nance Pro ce dure D

Replacing the Check Valve Body Assembly
Servicing the Inlet Components of the Check Valve Body Assembly

Service notes
There are three ways to service the high-pressure inlet
check valve:
• D-1: Replacing the entire check valve body • D-3: Lapping the check valve body face and the
assembly inlet poppet
• D-2: Lapping the check valve body face and replac-
ing the inlet poppet

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 35

 FOR TRAINING REFERENCE ONLY
87K 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,
maintain the perpendicularity of the face to the compo-
nent axis, and maintain these minimum dimensions:
• Shoulder of the check valve body: minimum height
of 0.475 in. (12.06 mm)
• Check valve inlet poppet: minimum thickness of
0.120 in. (3.048 mm)
• The retaining screw thread depth of the check valve
body may need to be increased. This increase shall
not exceed 0.01 in. (0.25 mm) at any time.

36 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Maintenance Procedure D1
Replacing the check valve body assembly
Service notes 5. Note the orientation of the check valve body by ob-
serving the position of the eccentrically positioned
Before performing this procedure, review Using the
outlet body relative to the intensifier. This is impor-
pressure loading tool on Page 21.
tant when reinstalling the check valve body—correct
orientation is critical to ensure the correct fit of
Tools required high-pressure tubing, which is affected by the eccen-
1 in. open-end wrench tricity of the outlet body.
7
8 in. open-end wrench Note: The check valve body is usually positioned
11 in. open-end wrench with the outlet body away from the intensifier mani-
16
fold block, but this may vary on some intensifiers.
Food grade grease (A-4689)
014623-1 Long-block intensifier
Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel.

020070-1 Short-block intensifier

2. Disconnect the inlet water hose from the end cap.
3. Using two wrenches, disconnect the high-pressure
tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
way.
4. Unload the intensifier tie rods
• See Maintenance Procedure A, Disassembling
the 87K Intensifier

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 37

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Remove the end cap from the tie rods. Note that 9. Make sure the conical sealing surfaces of the check
compression of the o-ring on the check valve body valve assembly and the end cap are clean and free of
will keep the check valve assembly in the end cap. debris.
Install the new check valve assembly by pushing it
into the end cap as indicated. Take care to align the
check valve assembly with the correct orientation as
explained in Step 5.

7. Remove the old check valve assembly from the end

cap by pushing on the outlet adapter (see illustration
10. Reinstall the end cap (complete with check valve
below).
body assembly) by sliding it along the tie rods and
Set the old check valve assembly aside. guiding the high-pressure cylinder into the bronze
bushing of the end cap.

8. Remove the o-ring from the new check valve body.

Lubricate the o-ring with food grade grease (A-4689)
and reinstall it.

11. Reload the intensifier tie rods

• See Maintenance Procedure A, Assembling the
87K Intensifier
12. Reconnect the high-pressure tubing and the inlet wa-
ter hose.

38 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Maintenance Procedure D2
Lapping the check valve body face and
installing the inlet replacement kit
Tools required 3. Using two wrenches, disconnect the high-pressure
½ in. drive torque wrench tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
¼ in. drive torque wrench
way.
1¼ in. socket (½ in. drive) and handle
4. Unload the intensifier tie rods.
5
16 in. socket (¼ drive)
1 in. open-end wrench • See Maintenance Procedure A, Disassembling
7 in. open-end wrench
the 87K Intensifier
8
11
16 in. open-end wrench
5 in. open-end wrench
5. Note the orientation of the check valve body by ob-
16
serving the position of the eccentrically positioned
Lapping kit (B-1813-3)
outlet body relative to the intensifier. This is impor-
Check valve inlet replacement kit (014884-1) tant when reinstalling the check valve body—correct
Food grade grease (A-4689) orientation is critical to ensure the correct fit of
Blue Lubricant (A-2185) high-pressure tubing, which is affected by the eccen-
Loctite #242 (A-3202) tricity of the outlet body.
Note: The check valve body is usually positioned
with the outlet body away from the intensifier mani-
fold block, but this may vary on some intensifiers.

Check valve inlet replacement kit 014623-1 Long-block intensifier

020070-1 Short-block intensifier

Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel.

2. Disconnect the inlet water hose from the end cap.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 39

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Remove the end cap from the tie rods. Note that 9. Using a 5 16 in. open-end wrench, remove the inlet
compression of the o-ring on the check valve body screw from the face of the check valve body.
will hold the check valve assembly inside the end Remove the inlet check valve support and the inlet
cap. poppet.
10. Clamp the check valve assembly in the soft-jawed
vise, holding the assembly on the flats of the check
valve body.
Using a 1¼ in. socket wrench, remove the outlet
adapter from the check valve body. Remove the out-
let check valve poppet, compression spring, check
valve seat, and outlet spring seat and set aside. Also
remove the large o-ring from the check valve body
and set it aside.

7. Remove the check valve

assembly from the end cap
by pushing on the outlet
adapter (see illustration at
right). Set the end cap
aside.

8. In a soft-jawed vise, clamp the check valve assembly

on the flats machined into the body.
Lapping the check valve body

Lap ping notes

• The dimensions for the check valve body listed at the
beginning of Maintenance Procedure D are the mini-
mum allowed. You can re-use the check valve body
down to these dimensions, but you must discard the
check valve body if it becomes smaller.
• Hand lapping, machining, machine grinding, polish-
ing, or a combination thereof are usually all accept-
able ways to remove surface imperfections from
components before final lapping.

40 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

11. Install the check valve body lapping tool (014853-1) 15. Carefully clean the newly-lapped check valve body
around the check valve nose. Place the assembly, with clean solvent such as isopropyl alcohol. Dry and
end face down, on a flat surface. Slide the tool down re-inspect the part.
as far as it will go, until the check valve body and
tool end faces are flush. Tighten the lapping tool CAUTION
Lapping debris remaining after incomplete cleaning
onto the check valve body.
will result in reduced component life.

Installing the check valve inlet replacement kit

16. Set out and inspect the components of the check
valve inlet replacement kit (014884-1).
17. Apply one drop of Loctite #242 to the threads of the
new retainer screw. Position the new inlet check
valve support and new poppet on the main body,
with the pin of the inlet check valve support in its lo-
cating hole.
12. Attach a 320 grit abrasive strip to one side of the Insert the retainer screw and tighten to 40 in-lb,
glass plate, and a 600 grit strip to the other side. (4.52 N-m).
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.

13. Turn the lapping plate over and place a few drops of
water on the 600 grit side of the plate. Lap the check
valve body in a figure-8 pattern until the body is
evenly polished.
14. To avoid poppet sticking problems, turn the lapping
plate back over to the 320 grit side and draw the 18. Lubricate the o-ring (removed from the check valve
check valve body in a straight line along the abrasive body in Step 10) with food grade grease (A-4689).
strip once, then rotate the body 90° and repeat the Replace the o-ring on the check valve body.
score.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 41

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

19. Clean the outlet check valve seat, outlet poppet, com- 21. Clean and inspect all surfaces in the end cap.
pression spring, outlet spring seat and the threads and Lubricate the bore of the end cap with food
bore of the outlet adapter with solvent. See parts grade lubricant as shown.
identified below.
Apply a small amount of Blue
Lubricant to the outlet adapter
threads and the conical surfaces
of the outlet check valve seat.

20. Assemble the outlet components of the check valve body.

Thread the outlet adapter onto the check valve body.
Secure hand tight, then torque the assembly to 200 ft-lb
(271.2 N-m) with a calibrated torque wrench. Install the new check valve assembly by pushing
it into the end cap. Take care to align the check
valve assembly with the correct orientation as
previously noted in Step 5.

22. Reinstall the end cap (complete with check

valve body assembly) by sliding the body along
the tie rods and guiding the high- pressure cylin-
der into the bronze bushing of the end cap.

23. Reload the intensifier tie rods.

• See Maintenance Procedure A, Assembling
the 87K Intensifier

24. Reconnect the high-pressure tubing and the

inlet water hose.

42 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Maintenance Procedure D3
Lapping the check valve body face and inlet poppet
Tools required 3. Using two wrenches, disconnect the high-pressure
½ in. drive torque wrench tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
¼ in. drive torque wrench
way.
1¼ in. socket (½ in. drive) and handle
4. Unload the intensifier tie rods.
5
16 in. socket (¼ drive)
1 in. open-end wrench • See Maintenance Procedure A, Disassembling
7 in. open-end wrench
the 87K Intensifier
8
11
16 in. open-end wrench
5 in. open-end wrench
5. Note the orientation of the check valve body by ob-
16
serving the position of the eccentrically positioned
Lapping kit (B-1813-3)
outlet body relative to the intensifier. This is impor-
Check valve inlet replacement kit (014884-1) tant when reinstalling the check valve body—correct
Food grade grease (A-4689) orientation is critical to ensure the correct fit of
Blue Lubricant (A-2185) high-pressure tubing, which is affected by the eccen-
Loctite 242 (A-3202) tricity of the outlet body.
Note: The check valve body is usually positioned
with the outlet body away from the intensifier mani-
fold block, but this may vary on some intensifiers.

Check valve inlet replacement kit 014623-1 Long-block intensifier

020070-1 Short-block intensifier

Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel.

2. Disconnect the inlet water hose from the end cap.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 43

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

6. Remove the end cap from the tie rods. Note that 8. In a soft-jawed vise, clamp the check valve assembly
compression of the o-ring on the check valve body on the flats machined into the body.
will keep the check valve assembly in the end cap.

9. Using a 5 16 in. open-end wrench, remove the inlet

screw from the face of the check valve body.
Remove and discard the inlet screw, inlet check
valve support, and inlet poppet.
10. Clamp the check valve assembly in the soft-jawed
vice, holding the assembly on the flats of the check
7. Remove the check valve assembly from the end cap valve body. Using a 1¼ in. socket wrench, remove
by pushing on the outlet adapter. Set the end cap the outlet adapter from the check valve body.
aside. Remove the outlet check valve poppet, compression
spring, check valve seat, and outlet spring seat and
set aside. Also remove the large o-ring from the
check valve body and set it aside.

44 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Lapping the check valve body 14. To avoid poppet sticking problems, turn the lapping
plate back over to the 320 grit side and draw the
Check valve body lapping notes: check valve body along the abrasive strip once, then
• The dimensions for the check valve body listed at the rotate it 90° and repeat the score.
beginning of Maintenance Procedure D are the mini-
mum allowed. You can re-use the check valve body
down to these dimensions, but you must discard the
check valve body if it becomes smaller.
• Hand lapping, machining, machine grinding, polish-
ing, or a combination thereof are usually all accept-
able ways to remove surface imperfections from
components before final lapping.

11. Install the check valve body lapping tool (014853-1)

around the check valve nose. Place the assembly,
end face down, on a flat surface. Slide the tool down
as far as it will go, until the check valve body and
tool end faces are flush. Tighten the lapping tool
onto the check valve body. 15. Clean the newly-lapped check valve body with clean
solvent such as isopropyl alcohol. Dry and re-inspect
the part.

CAUTION
Any lapping debris that remains after incomplete
cleaning will result in reduced component life.

12. Attach a 320 grit abrasive strip to one side of the

glass plate, and a 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.

13. Turn the lapping plate over and place a few drops of
water on the 600 grit side of the plate. Lap the check
valve body in a figure-8 pattern until the check valve
body is evenly polished.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 45

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

Lapping the inlet poppet

Poppet lapping notes:

Reinstalling parts
• The dimension for the inlet poppet listed at the be-
ginning of Maintenance Procedure D is the minimum 19. Apply one drop of Loctite #242 to the threads of the
allowed. The poppet can be re-used down to these retainer screw. Position the inlet check valve support
dimensions, but it must be discarded if it becomes and poppet on the main body with the pin of the in-
smaller. let check valve support in its locating hole.
Insert the retainer screw and tighten to 40 in-lb
• Hand lapping, machining, machine grinding, polish-
(4.52 N-m).
ing, or a combination of these methods are usually
all acceptable ways to remove surface imperfections
from components before final lapping.

16. Place a few drops of water on the 320 grit side of the
lapping plate. Lap the inlet poppet in a figure-8 pat-
tern until all surface imperfections have been
removed.

17. Turn the lapping plate over and place a few drops of 20. Lubricate the o-ring (removed from the check valve
water on the 600 grit side of the plate. Lap the inlet body in Step 8) with food grade grease (A-4689).
poppet in a figure-8 pattern until the check valve Replace the o-ring on the check valve body.
seat is evenly polished.
18. Clean the newly-lapped inlet poppet with clean sol-
vent such as isopropyl alcohol. Dry and re-inspect
the part.

CAUTION
Lapping debris remaining after incomplete cleaning
will result in reduced component life.

21. Clean the outlet check valve seat, outlet poppet,

compression spring, outlet spring seat and the
threads and bore of the outlet adapter with solvent.
Apply a small amount of Blue Lubricant to the outlet
adapter threads and the conical surfaces of the outlet
check valve seat.

46 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

22. Assemble the outlet components of the check valve 24. Reinstall the end cap complete with check valve
body as shown. Thread the outlet adapter onto the body assembly by sliding along the tie rods and guid-
check valve body. Secure hand tight, then torque the ing the high-pressure cylinder into the bronze bush-
assembly to 200 ft-lb (271.2 N-m) with a calibrated ing of the end cap.
torque wrench.

25. Reload the intensifier tie rods.

• See Maintenance Procedure A, Assembling the
87K Intensifier
23. Clean and inspect all surfaces in the end cap.
Lubricate the bore of the end cap with food grade
lubricant (see below). Install the new check valve as- 26. Reconnect the high-pressure tubing and the inlet
sembly by pushing it into the end cap, taking care to water hose.
align the check valve assembly with the correct ori-
entation as previously described in Step 5.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 47

 FOR TRAINING REFERENCE ONLY

Main te nance Pro ce dure E

Servicing and Replacing the Outlet Check Valve Components
(Outlet Poppet and Check Valve Seat)

Service notes
There are two ways to do this service:
• E1: Replacing the outlet poppet and
check valve seat
• E2: Lapping the outlet poppet and
check valve seat

014885-1
Outlet replacement kit

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

Notes about lapping

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,
maintain the relationship of the face to the component
axis, and maintain these minimum dimensions:
• Outlet poppet: minimum length of 0.607 in.
(15.42 mm)
• Outlet check valve seat: minimum thickness of
0.635 in. (16.13 mm)

50 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Maintenance Procedure E1
Replacing the outlet poppet and check valve seat

Tools required 4. Remove the outlet poppet, compression spring, and

1¼ in. socket (½ in. drive) and handle outlet spring seat from the outlet adapter. Discard
the poppet and spring, but set the spring seat aside.
1 in. open-end wrench
7
8 in. open-end wrench
11
16 in. open-end wrench
Check valve outlet replacement kit (014885-1)
Blue Lubricant (A-2185)

Service steps
1. Shut down the system.
5. Remove the check valve seat from the check valve
WARNING body.
Place the main electrical disconnect in the OFF Note: The check valve seat can be difficult to re-
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical move. If necessary, insert the sharpened end of a
disconnect and lock it out. Failure to do so can cause small dowel or a sharp pencil into the check valve
equipment damage or injury to personnel. seat. Push until the check valve seat is fixed to the
dowel, then pull it out.
2. Using two wrenches, disconnect the high-pressure
tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
way.
3. Using a 1¼ in. socket and handle, unscrew the out-
let adapter from the check valve body.

6. Using fresh solvent, clean the threads and bore of

the outlet adapter and check valve body.

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

7. Lay out and inspect all components of the outlet 10. Thread the outlet adapter into the check valve body.
check valve replacement kit. Torque to 200 ft-lb (271.2 N-m).
8. Apply a small amount of Blue Lubricant to the
threads of the outlet adapter and insert the old
spring seat, new compression spring, and new outlet
poppet into the bore in the order shown.

9. Apply Blue Lubricant to

the surfaces of the new 11. Reconnect the high-pressure tubing and the inlet wa-
outlet check valve seat as ter hose.
shown and insert it into
the bore of the check
valve body.

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.

52 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Maintenance Procedure E2
Lapping the outlet check valve components

Tools required 4. Remove the check valve seat from the check valve
1¼ in. socket (½ in. drive) and handle body.
1 in. open-end wrench Note: The check valve seat can be difficult to
7 in. open-end wrench remove. If necessary, insert the sharpened end of a
8
small dowel or a sharp pencil into the check valve
11
16 in. open-end wrench
seat. Push until the check valve seat is fixed to the
Lapping kit (B-1813-3)
dowel, then pull it out.
Blue Lubricant (A-2185)
5. Remove the outlet poppet from the outlet adapter,
Drill press
being careful not to lose the compression spring or
outlet spring seat.

Service steps
1. Shut down the system.

WARNING
Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
Place an “Out of Service” tag on the main electrical
disconnect and lock it out. Failure to do so can cause
equipment damage or injury to personnel.

2. Using two wrenches, disconnect the high-pressure

tubing from the check valve outlet adapter. Loosen
the other end of the tubing and move it out of the
way.
3. Using a 1¼ in. socket and handle, unscrew the out- Lapping the check valve seat
let adapter from the check valve body. 6. Install the check valve seat into the check valve seat
lapping tool (014871-1) and place on a flat surface.
Apply vertical pressure to the check valve seat and
tool, then tighten the lapping tool onto the check
valve seat. Note: It is important that the faces of the
check valve seat and tool are flush with one another.

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

7. Attach a 320 grit abrasive strip to one side of Lapping the outlet poppet
the glass plate, and a 600 grit strip to the other In order to achieve maximum performance and life, the seal-
side.
ing surface must be flat and have no radial grinding or lapping
Place a few drops of water on the 320 grit side marks. Because of its shape and small size, hand lapping the
of the lapping plate and lap the check valve poppet can round the sealing surface, which causes squealing
seat in a figure-8 pattern until all surface im- during operation. FLOW recommends using a drill press to
perfections have been removed. lap this part.
8. Turn the lapping plate over and place a few
drops of water on the 600 grit side of the plate. 10. Make sure the drill chuck is square to the table and se-
Lap the check valve seat in a figure-8 pattern curely fastened so it does not wobble.
on the 600 grit side until the check valve seat is 11. Insert the chamfered end of the poppet into the chuck up
evenly polished. to the shoulder, then secure it.

9. To avoid poppet sticking problems, turn the

lapping plate back over to the 320 grit side
and draw the check valve seat along the
abrasive strip once, then rotate it 90° and
repeat the score.

12. Place the lapping glass on the drill press table with the 320
grit paper up.
13. Place a few drops of water on the lapping plate.
Start the drill press and lower the poppet onto the glass
plate, moving the lapping plate in a figure-8 pattern under
the poppet. Lap until all surface imperfections have been
removed.

CAUTION
DO NOT lap with 600 grit abrasive.
A polished sealing surface can
cause the poppet to stick.

54 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

Reassembly 17. Thread the outlet adapter into the check valve body.
14. Using clean solvent, clean all lapped components Torque to 200 ft-lb (271.2 N-m).
and the threads and bore of the outlet adapter.

CAUTION
Lapping debris remaining after incomplete
cleaning will result in reduced component life.

15. Apply a small amount of Blue Lubricant to the

threads of the outlet adapter and insert the spring
seat, compression spring, and the newly lapped out-
let poppet into the bore, as shown.

18. Reconnect the high-pressure tubing and the inlet wa-

ter hose.

16. Apply Blue Lubricant to

the surfaces of the check
valve seat as indicated and
insert it into the bore of
the check valve body.

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 seat.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 55

 FOR TRAINING REFERENCE ONLY

Main te nance Pro ce dure F

Servicing the Low-Pressure Components

Tools required Service steps

Low-pressure assembly fixture plate (014030-1) 1. Shut down the system.
Torque multiplier
1½ in. socket (½ in. drive) and handle WARNING
1 58 in. socket (½ in. drive) Place the main electrical disconnect in the OFF
position and bleed down the high-pressure lines.
½ in. drive torque wrench
Place an “Out of Service” tag on the main electrical
½ in. drive ratchet disconnect and lock it out. Failure to do so can cause
1 in. open-end wrench equipment damage or injury to personnel.
7
8 in. open-end wrench
11
16 in. open-end wrench 2. Disconnect the inlet water hoses from the end caps.
Flat-head screwdriver 3. Using two wrenches, disconnect the high-pressure
Check valve outlet replacement kit (014885-1) tubing from the check valve outlet bodies. Loosen
Shift pin tool assembly (002228-2) the other ends and move the tubing out of the way.
Rub ber mal let 4. Unload the intensifier high-pressure tie rods at
4x 3
8 -16 UNC threaded screws both ends of the intensifier.
Blue Lubricant (A-2185) • See Maintenance Procedure A, Disassembling
Food-grade grease (A-4689) the 87K Intensifier
Anti-seize (A-10039)
Parker Super O-ring Lube (200006)

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

5. Note the orientation of the check valve body by ob- 6. At one end of the intensifier, remove the end cap
serving the position of the eccentrically positioned from the tie rods. The check valve assembly will re-
outlet body relative to the intensifier. This is impor- main in the end cap due to the compression of the
tant when reinstalling the check valve body—correct o-ring on the check valve body.
orientation is critical to ensure the correct fit of Note: Unless check valve maintenance is necessary
high-pressure tubing, which is affected by the eccen- (Maintenance Procedure D) it is not necessary to re-
tricity of the outlet body. move the check valve assembly from the end cap.
Note: The check valve bodies are usually positioned
with the outlet bodies away from the intensifier man-
ifold block, but this may vary on some intensifiers.

014623-1 Long-block intensifier

7. Remove the high-pressure cylinder and filler tube

020070-1 Short-block intensifier from the intensifier end bell. Rocking the cylinder
gently while pulling outward is helpful in separating
the cylinder from the end bell. When the cylinder is
clear of the end bell pull it straight out to avoid the
ceramic plunger.

58 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

8. Pry the seal carrier away from the end bell using a 11. Loosen the screws that hold the manifold to the in-
flat-bladed screwdriver in the groove provided, as tensifier, then separate the two assemblies. Drain oil
shown. from the intensifier ports.
Once the seal carrier is away from the end bell, re- If the intensifier is not connected to a hydraulic res-
move it by hand by sliding it along the ceramic ervoir, simply disconnect the hydraulic hose fittings
plunger. from each end bell.
Discard the used seal carrier, o-ring, and high-pres- 014623-1 Long-block intensifier
sure seal.

9. Repeat Steps 6–8 on the other end of the intensifier.

020070-1 Short-block intensifier
10. Remove the shift sensors. Use the shift pin tool to re-
move the shift pins. Refer to your pump manual for
detailed instructions.

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

12. Securely bolt the fixture plate (014030-1) to a sturdy 14. Use the ratchet handle and torque multiplier (as
workbench. shown below) to loosen the tie rod nuts at one end
of the low-pressure cylinder assembly.
WARNING Loosen the nuts in the figure-8 pattern shown below,
Failure to properly mount the intensifier assembly turning each nut no more than ¼ turn, repeating the
fixture or secure the intensifier to the intensifier sequence until nuts are loose. This will avoid over-
fixture could allow the parts to unexpectedly
tip and fall, causing serious bodily injury.
loading of the tie rods or nuts. Remove the tie rods,
nuts, and washers and set aside.

Place the intensifier on the low-pressure assembly

fixture plate with the manifold surface facing down.
Secure the intensifier to the fixture from below, using
four 3 8 -16 UNC threaded screws.

15. Remove the cap screws that hold one end bell to the
intensifier assembly fixture. Using a mallet, tap the
end bell free of the cylinder. Remove the end bell
and set it aside.

13. Remove the high-pressure tie rods.

If a tie rod is tight, use two nuts tightened 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.

60 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

16. Remove the cylinder from the other end bell. The 19. Clean the hydraulic cylinder, end bells, oil seal spac-
piston and plungers can stay with the cylinder. ers and snap rings. All service must be completed in
Do not use a screwdriver to pry the cylinder from a clean, well-lit area.
the end bell. Inspect the parts for the following:
• Make sure the oil seal spacers are not warped or
nicked.
• Make sure the snap rings are not bent and that they
still have the appropriate tension.
• Check the end bells for damage to the sealing sur-
faces and grooves, and a damaged or out-of-round
shift pin hole.
• Clean all surfaces of the low-pressure cylinder and
inspect for any signs of damage or fatigue. Inspect
the inner surface by looking through the cylinder an-
gled toward a brightly lit white surface. If there is any
damage to this surface that can be felt with a finger-
nail, discard the cylinder.

CAUTION
Do not reassemble the intensifier with a cylinder
that has a damaged inner surface.
17. Use a soft mallet to drive the piston and plungers
from the cylinder. Set the parts aside. Sharp burrs on the beveled edge of the cylinder ID
can damage the end bell o-ring and backup ring when
the parts are assembled. Such damage can lead to immediate
End bells seal failure and excessive hydraulic oil loss.
18. Remove the snap ring, spacer and oil seal from one
20. Apply clean hydraulic oil or Parker Super O-ring
end bell bore. Remove the large diameter o-ring and
Lube to a new oil seal and install it in an end bell
back-up ring from the end bell.
with the spring insert visible. (See orientation in illus-
CAUTION tration below, and in Step 18.)
Do not use a sharp tool to remove Take care not to collapse the oil seal spring insert
these parts—it will damage the parts.
when installing. Place the spacer on top of the seal
and install the snap ring.
Repeat this step for the other end bell.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 61

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

21. Apply clean hydraulic oil or Parker Super O-ring 23. Remove the snap ring and retainer (blow air down
Lube to the new backup ring. Locate the molding between the plunger and the retainer bore to loosen
marks, and install the backup ring so the molding the retainer). Remove the plunger by hand.
marks face the end bell. Lubricate the new o-ring • Repeat for the other plunger. Set plungers
and place it in the groove on top of the backup ring. aside.
The o-ring must be outside of the backup ring, facing
the low-pressure cylinder.

22. Repeat Steps 20–21 for the other end bell, then set
both end bells aside and cover with a lint-free cloth.
24. Remove the T-seals from the piston. Do not scratch
the piston sealing surfaces.
Piston and plungers
25. Clean all parts of the piston assembly. Make sure oil,
Disassemble the piston and plungers for any of these dirt, and burrs are removed from all surfaces.
reasons:
Notes:
• One or both of the plungers need to be replaced.
• Inspect the plungers carefully. Nicks, scratches,
• The piston needs to be replaced. or pits will cause premature failure of high-
• A plunger has excessive lateral movement relative to pressure seals.
the piston biscuit. (Excessive lateral movement is • Plungers cannot be reworked in the field.
anything over 18 in. off center line at the plunger tip.) Contact FLOW Technical Service for informa-
tion on factory re work of plungers.
If any of the above apply, continue with Step 23. • Inspect the piston for cracks; replace as
Otherwise, skip to Step 29. needed.

62 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

26. Lubricate the new T-seals and backup rings with Low-pressure cylinder
Parker O-Ring Lube (200006). Place two backup 29. Apply clean hydraulic oil or Parker Super O-Ring
rings and one T-seal in each piston groove. The
Lube to one new seal and the inside of the low-
T-seal must be in the middle of the two backup rings. pressure cylinder. Install the seal onto the piston with
the flared (o-ring) face toward the outside of the
piston.

27. Apply clean hydraulic oil or Parker Super O-Ring

Lube to the head of the plunger. Insert the plunger
into the counter bore in the piston, using a soft mal-
let if needed. Make sure the T-seals do not get
nicked or rolled.
Slide the spacer over the plunger with the large end
facing in. Install the snap ring into the groove. 30. Slide the piston and plunger assembly containing
one seal into the cylinder so that the empty groove
enters the cylinder first. Use a soft-faced mallet
where necessary.

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.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 63

 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

31. Continue sliding the piston into the cylinder until the 34. Mount an end bell to the assembly fixture. Insert two
empty seal groove on the piston exits the other end fixture plate screws and fasten finger tight.
of the cylinder. Note: The backup ring and o-ring were lubricated
CAUTION
and installed in Step 21.
If the seal starts to come out of the end of the
cylinder, do not force it back against the flare.
Instead, push the whole piston assembly through and start
again, this time stopping before the seal appears.

32. Apply clean hydraulic oil or Parker Super O-Ring to

the seal and install it in the groove on the piston,
making sure the flared o-ring face is toward the out-
side of the piston.

35. Apply clean hydraulic oil or Parker Super O-Ring

Lube to both plungers. Install the cylinder by insert-
ing the plunger into the end bell.

33. Slide the piston and plunger back into the cylinder.
Take care when the seal is being compressed as it
enters the cylinder—the seal can easily be damaged
by rough handling at this point.
Note: Centering the piston will make intensifier
re-assembly easier.

Set the cylinder containing the piston and plunger as-

sembly aside. 36. Slide the remaining end bell over the other plunger
and seat it on the assembly fixture.

64 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

37. Apply anti-seize lubricant (A-10039) to one end of 39. Draw the low-pressure cylinder carefully onto the
the low-pressure tie rods and to the faces of the end bells by tightening the nuts evenly in a figure-8
washers and nuts. Run the nuts onto the tie rods un - pattern, as shown below. Be careful not to nick the
til they bottom out, then slide the tie rods through seals and back-up rings. There must be no seal or
the two end bells. back-up ring debris visible at the cylinder/end bell
interface. Be sure to check for any problems before
continuing.
Following the figure-8 pattern shown below, torque
all nuts evenly to 20 ft-lb (27 N-m) to seat all parts.

40. Loosen and remove nuts and washers from both

ends of the tie rods.
41. Visually center the tie rods between the end bells,
leaving the same number of tie rod threads exposed
on both sides of the assembly. Apply anti-seize lubri-
cant to the faces of all mating components.
Center and hold the tie rods in place while installing
38. Apply anti-seize lubricant to the exposed threads of the washers and nuts onto the tie rods. Secure the
the tie rods and the faces of the washers and nuts. nuts hand tight.
Install the nuts onto the tie rods hand tight.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-376 | 65

 FOR TRAINING REFERENCE ONLY

SB-0216
87K Low Pressure Cylinder Tie Rod Final Torque

Introduction
An error has been detected on p. 66 of M-376. The final torque for the tie rods is 535 ft-lbs.

Affected Systems
All 87K intensifiers on HyperJet and StoneCrafter pumps.

Instructions
The manual should read:
Using the torque wrench (and the torque multiplier when necessary) tighten the nuts not more
than ¼ turn at a time, following the figure-8 sequence. Torque all four nuts at one end to 200 ft-
lb (271 N-m), then to 400 ft-lb (542 N-m), then to 535 ft-lb (725 N-m).

Lifecycle
Creation Date: 11/30/2007
Most Recent Review Date: 11/30/2007
Active Period: 12 months (11/30/2008)

SB-0216 Rev A Status PRODUCTION 1 of 1

 2008 Flow International Corporation UNCONTROLLED COPY PRINTED 1/9/08
FOR TRAINING REFERENCE ONLY
 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

42. Insert the second pair of fixture plate screws into the 45. Lubricate the manifold o-rings (shown on the follow-
second end bell and tighten both screws to 30 ft-lb ing illustration) with food grade grease and place
(41 N-m). The bolts must hold the end bells tight them in the end bells. Bring the hydraulic manifold
against the fixture to prevent any misalignment. and the intensifier together and secure them with the
Retighten the tie rod nuts to 20 ft-lb (27 N-m) to original cap screws. Tighten the cap screws to
keep the end bells seated. 35 ft-lb (47 N-m).
If your intensifier does not connect directly to the
43. Tighten the tie rod nuts at one end of the tie rods hydraulic manifold, simply replace the hydraulic
only, while restraining the nuts on the other end us- lines. Take care to ensure proper lubrication and
ing a suitable wrench, moving from one nut to the placement of the o-rings.
next in a figure-8 pattern (shown below).
014623-1 Long-block intensifier
Note: You must follow the torque pattern shown
(1-2-3-4). Correctly moving from nut 2 to nut 3
crosses the LONG dimension of the rectangular end
bell. DO NOT substitute with the pattern 1-2-4-3.
Using the torque wrench (and the torque multiplier
when necessary) tighten the nuts not more than ¼
turn at a time, following the figure-8 sequence.
Torque all four nuts at one end to 200 ft-lb
(271 N-m), then 400 ft-lb (542 N-m), then 600 ft-lb
(812 N-m), and finally to 720 ft-lb (975 N-m).

020070-1 Short-block intensifier

44. Remove the intensifier from the assembly fixture and

install on the pump frame.

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 FOR TRAINING REFERENCE ONLY CHAPTER 3
Maintenance Procedures

46. Apply anti-seize to all threads of the high-pressure tie 49. Install the high-pressure cylinder by sliding it over the
rods and thread into the nuts (hand tight) as shown ceramic plunger and into the end bell bushing.
below. A slight rocking motion will help ease the cylinder
into position.

47. Install shift pins and shift sensors. Refer to your pump 50. Install the filler tube in the high-pressure cylinder.
manual for detailed instructions.
CAUTION
Make sure the filler tube is oriented correctly.
There is a wall inside the tube that must be at the outermost
end of the tube when it is inserted. Failure to orient the tube
correctly will damage the intensifier assembly.

48. Place the seal carrier assembly onto the plunger end,
then using the filler tube as a tool, push the assembly
along the plunger until it butts against the end bell
face. Verify that the dynamic seal is still fully seated
in the seal carrier.

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 FOR TRAINING REFERENCE ONLY
87K INTENSIFIER

51. Reinstall the check valve assembly and end cap by

sliding it 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 previously noted in Step 5.

52. Repeat Steps 48–53 at the other end of the

intensifier.
53. Reload the intensifier tie rods.
• See Maintenance Procedure A, Assembling the
87K Intensifier
54. Reconnect the high-pressure tubing and the inlet
water hoses.

68 | M-376 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 4
Service

Servicing the bleed-down valve Service steps

This service procedure is for bleed-down valve WARNING

020314. You will need the 015084-1 bleed-down valve Place the main electrical disconnect in the OFF
repair kit. 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.
Troubleshooting
Problem Cause Note: Make notes or sketches of the location and ori-
entation of all components during disassembly to use as
Unable to build water pressure* High-pressure valve a guide for reassembly later.
High stroke rate failure
Hard shifting 1. Remove the hydraulic hose from the oil port of the
Water leaking from weep holes bleed-down valve.
Oil leaking from weep holes Actuator failure 2. Remove the gland nut that connects the water drain
Unable to build water pressure* Solenoid valve
tubing to the bleed-down valve.
failure 3. Remove the gland nut from the high-pressure water
* Lack of water pressure is more likely caused by
inlet port of the valve main body. Remove the
high-pressure valve failure than by solenoid valve failure. high-pressure water pressure sensor from the valve
body.
4. Remove the valve from the pump bracket and place
it on a clean workbench.
5. Separate the actuator body from the high-pressure
valve.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-390 | 41

 FOR TRAINING REFERENCE ONLY
HYPERJET™ 50 AND HYPERJET™ 100

6. Remove the adapter from the high-pressure body. 20. Apply blue lubricant to the threads, then install the
adapter into the valve body. Torque to 125 ft-lb
7. Remove and discard the high-pressure seat.
(170 N-m).
8. Remove and discard the high-pressure seal assembly
21. Thread the actuator body into the high-pressure
(poppet, seal, back-up ring, o-ring, and bearing).
valve assembly and tighten.
9. Remove the oil port adapter and use a 3 16 -in. dowel
22. Reinstall the bleed-down valve on the pump bracket
(or similar) to push the piston insert and piston out
and insert the gland nut in the high-pressure inlet
of the actuator body through the oil port.
port in the side of the valve. Torque the gland nut to
10. Remove and discard the o-ring and back-up ring 35 ft-lb (47 N-m).
from the piston.
23. Install the gland nut that connects the water drain
11. Clean the remaining parts in an ultrasonic cleaner. tubing to the bleed-down valve, and reinstall the
Check the parts for nicks and burrs; replace as high-pressure water pressure sensor.
necessary.
24. Reattach the hydraulic hose to the oil port of the
12. Lubricate a new o-ring, back-up ring, and the inner bleed-down valve.
surface of the actuator body with Parker Super O
Ring Lube or equivalent. Return the intensifier pump to operation. Correct any
13. Install the new o-ring and back-up ring on the actua- water or oil leaks.
tor piston with the back-up ring towards the insert
end of the piston. Install the insert into the piston,
then install the piston assembly into the actuator
body until seated.
Note: Avoid damaging the o-ring on the threads and
inside corners of the actuator body.
14. Replace the oil port adapter in the actuator body.
15. Lubricate the poppet, seal, o-ring, and bearing with
White Food Grade O Ring Lube.
16. Install the o-ring onto the high-pressure seal and
then install the seal onto the poppet with the o-ring
towards the pointed end of the poppet.
17. Install the new bearing and back-up ring onto the
poppet with the bearing on the pointed end side
and the back-up ring on the opposite side of the
seal. Then insert the assembly into the high-pressure
body through the actuator port (largest diameter
thread).
18. Push the back-up ring down until seated against the
flat bottom of the port.
19. Install the high-pressure seat in the high-pressure
body, applying Blue Lubricant to mating surfaces.
Note: The seat is symmetrical and either face may
be inserted first.

42 | M-390 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY CHAPTER 3
End Effector

Servicing the on/off valve Repairing the valve

You will need these tools and parts for any of the on/off 4. Place the assembly in the soft-jaw vise; unscrew the
valve service procedures: valve body nut from the valve body. This will sepa-
rate the valve and actuator from the cutting head and
• Set of crescent wrenches (standard size)
expose the poppet seat.
• Soft-jaw vise
• Work bench
• 014988-1 Seal kit
• A-2185 Blue Lubricant
• A-4689 Food grade o-ring lube (white)
• 019623 Seal installation tool kit

Removing the valve

WARNING
Shut down the system and bleed all high-pressure
from the system. Turn off the high-pressure water
and high-pressure water pump. Close the hand valve
between the pump and the cutting head.

1. Turn off air to the valve and disconnect the pneu-

matic line.
5. An o-ring helps hold the poppet seat in place.
2. Disconnect the high-pressure plumbing from the Remove the o-ring and the poppet seat should fall
valve body. out from the valve body. Discard the seat and o-ring.
3. Open the DWJ clamp and remove the entire cutting Note: If the seat does not fall out when you tap the
head assembly, including the valve and actuator. Take nozzle body, use your finger or the wooden dowel to
the assembly to a clean workbench for any repair help loosen the seat.
procedures.
6. Unscrew the valve body from the actuator assembly.
Set the actuator assembly aside.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-391 | 35

 FOR TRAINING REFERENCE ONLY
HYPERJET™ IFB

7. Place the assembly tool (from the tool kit) against the 10. Put together the new seal assembly.
poppet tip and push it out from the valve body. a. Slide the bearing onto the poppet.
b. Place the small high-pressure o-ring on the
high-pressure seal.
c. Push the seal onto the poppet with the o-ring
toward the point of the poppet.
d. Slide the backup ring into place against the
high-pressure seal.
The seal assembly should be approximately centered
on the poppet.

The bearing, high-pressure seal, and backup ring

should come out with the poppet. If not, push the
bearing, seal, and backup ring out of the valve body
in the same direction as you pushed the poppet.
Discard the poppet, seal, o-ring, and backup ring.
8. Clean any foreign material from the inside and out-
side of the valve body.
9. Apply a thin film of white food grade o-ring lube
(A-4689) to the new poppet, o-rings, seal, bearing,
and backup ring (from kit 014988-1)
11. Slide the poppet seal assembly into the actuator end
of the high-pressure valve body, pointed end first.

36 | M-391 FOR TRAINING REFERENCE ONLY © Flow International Corporation

 FOR TRAINING REFERENCE ONLY

SB-0217
87K On/Off Valve Connection Torque

Introduction
An error has been detected in the manuals for 87K Hyperjet® and StoneCrafter®. The final torque for the
connection between the on/off valve body and the nozzle body should be 35-40 ft-lb (47-54 N-m).

Affected Manuals
! M-366, IFB2 with HyPlex® Pump. Page 83
! M-368, IFB2 with 50i-S Pump. Page 69
! M-378, IFB2 with 100i-D Pump. Page 71
! M-391, Hyperjet® Integrated Flying Bridge. Page 37

Instructions
The manual should read:
Re-assemble the nozzle body to the valve body. This high-pressure connection requires about
35-40 ft-lb (47-54 N-m) of torque.

Lifecycle
Creation Date: 3/27/08
Most Recent Review Date: 3/27/08
Active Period: 12 months (3/27/09)

SB-0217 Rev A Status PRODUCTION 1 of 1

2008 Flow International Corporation UNCONTROLLED COPY PRINTED 4/3/08
FOR TRAINING REFERENCE ONLY
 FOR TRAINING REFERENCE ONLY CHAPTER 3
End Effector

12. Apply a small amount of Blue Reinstalling the valve

Lubricant (A-2185) to the
threads of the actuator. WARNING
Make sure the high-pressure pump is OFF and
Reinstall the actuator assem- the hand valve between the high-pressure
bly to the valve body. pump and the cutting head is CLOSED.
13. Apply a small amount of Blue
Lubricant to both sides of the 16. Attach the pneumatic control line to the valve actua-
new poppet seat. Install the tor assembly and turn “ON” the air to open the
poppet seat into the valve valve.
body. Push the o-ring into the 17. With the valve in the open position, align the valve
groove to hold the poppet with the high-pressure tubing so that the weep tube
seat in place. and high-pressure tubing point toward the front of
the machine.
14. Apply a small amount of Blue Lubricant to the exter-
nal threads of the valve body and thread it onto the 18. Tighten the connection between the nozzle body
nozzle body by tightening the valve body nut. Leave and the valve body nut to 70–80 ft-lb (95–110 N-m).
this connection hand-tight for now. Once the connection is tight, turn off the air to close
the valve.
Note: Opening the valve before tightening this con-
nection reduces the possibility of galling between the
poppet and seat interface and reduces the force re-
quired as you are not working against the high spring
force of the actuator.

19. Attach the high-pressure tubing to the valve. Be care-

ful not to over-torque this connection.
20. Open the hand valve between the high-pressure
water source and the cutting head.

Turn on the high-pressure water source and slowly raise

the pressure while checking for leaks. Manually actuate
the valve a few times to make sure it is operating
correctly.

15. Reinstall the cutting head and on/off valve assembly

to its original location on the machine by clamping
the cutting head in place.

© Flow International Corporation FOR TRAINING REFERENCE ONLY M-391 | 37