Flow ESL INTENSIFIER Manual
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Flow ESL INTENSIFIER Manual

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ESL INTENSIFIER
M-310 | REV. G | JANUARY 2009

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Do you have a question about the ESL INTENSIFIER and is the answer not in the manual?

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john morgan
February 17, 2025

the red lights on side of sensors when pump is off only bottom two are illuminated

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1 comments:
Mr. Anderson
February 17, 2025

The bottom two red lights on the Flow ESL Intensifier sensors are illuminated when the pump is off because the system is not pressurized, and no hydraulic movement is occurring. These lights likely indicate a default or standby state when the pump is not actively generating high-pressure water.

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Summary of Contents for Flow ESL INTENSIFIER

  • Page 1 ESL INTENSIFIER M-310 | REV. G | JANUARY 2009...
  • 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 4 Parts list information 32 Safety 4 Ordering parts 32 Related documents 4 Customer Service 32 Technical Service ESL intensifier description Top assemblies 33 Specifications 5 Sub-assemblies 35 Operating principles 5 Check valve Piston assembly 36 Maintenance & service...

  • Page 4: Introduction

    ESL Intensifier Introduction This manual will help you become familiar with your new Flow International equipment. Information was compiled from the most current information available at the time of publication. Safety A comprehensive list of safety precautions is located in your pump manual. These precautions must be reviewed and understood by operating and maintenance personnel before installing, operating or servicing the equipment.

  • Page 5: Esl Intensifier Description

    ESL Intensifier ESL intensifier description Operating principles The ESL intensifier is available in 60,000 psi (4138 bar) and 40,000 psi (2759 bar) output water pressure The intensifier pump consists of a hydraulic system, a ratings. high-pressure water delivery system, and a control sys- tem.

  • Page 6: Periodic Maintenance

    High-pressure U.S. Flow recommends that you use a maintenance and ser- gland nuts (ft-lb) (N-m) vice log to record all service work. Maintenance Log MS-2258 is provided on the CD.

  • Page 7: Troubleshooting

    (0.8 oz/23 ml) per stroke, it is safe to continue to high-pressure water cylinder or check valve main body. operate the pump. See Intensifier Service Notes. M-310 | 7 © Flow International Corporation...

  • Page 8: Using The Troubleshooting Guide

    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. 8 | M-310 © Flow International Corporation...

  • Page 9: Troubleshooting Guide

    2. Install the spare shift cable guide and recheck. Replace any worn parts. High-pressure water plunger has Associated with a drop in output water pressure and flow. Avoid prolonged separated from the oil piston operation under this condition—it will cause severe damage to the intensifier.
  • Page 10 Caution: High-pressure seal rings must be replaced whenever high-pres- sure seals are replaced. Scratched HP water plunger Deep pits or scratches in excess of 10 micro-inches will cause premature high-pressure water seal failure. Replace as necessary. 10 | M-310 © Flow International Corporation...
  • Page 11 Replace HP water cylinder. The cylinder has a limited fatigue life, and will re- quire periodic replacement depending on the application. Premature failure is primarily attributed to scratches caused during assembly or installation. Relap or replace the check valves if the HP water cylinder is replaced. M-310 | 11 © Flow International Corporation...

  • Page 12: Service Procedures

    The following list was compiled from Flow customers, a separate locked cabinet. Substituting tools for technicians, and operators. It can help to lower repair those supplied by or available from Flow is not costs, shorten repair time, and increase component life. recommended.

  • Page 13: Major Parts Of The Intensifier

    ESL Intensifier Major parts of the intensifier High-pressure cylinder assembly Check valve assembly M-310 | 13 © Flow International Corporation...

  • Page 14: High-Pressure Water Cylinder And Seals

    CAUTION If the check valve and end cap do not turn together, the check valve body o-rings can be damaged. If necessary, use a wrench. 14 | M-310 © Flow International Corporation...
  • Page 15 ESL Intensifier 5. Set the end cap aside. Flow recommends that you service the check valves at every regular seal re- High-pressure seal tool kit placement interval, following the procedure in End Cap and Check Valve. When the check valve service is complete, continue with Step 6.
  • Page 16 13. Remove the seal backup sleeve. 14. Carefully clean the high-pressure cylinder and backup sleeve. Note: High-pressure components must be cleaned in a non-residue solvent and allowed to air dry be- fore reassembly. 16 | M-310 © Flow International Corporation...
  • Page 17 A slow, even movement will help keep the o-ring from rolling. Remove the tool, sleeve, and sleeve guide from the cylinder. M-310 | 17 © Flow International Corporation...
  • Page 18 Torquing the cylinder to a value greater than 120 ft-lb (88 N-m) is unnecessary and makes disassembly more difficult. Never use a girth wrench for instal- • lation. 18 | M-310 © Flow International Corporation...
  • Page 19 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. M-310 | 19 © Flow International Corporation...

  • Page 20: End Cap And Check Valve

    Loosen the other end of the tub- ing and move it out of the way. CAUTION Do not bend or flex the high-pressure tubing—it can cause early failure of the tubing. 20 | M-310 © Flow International Corporation...
  • Page 21 Replace the main body if required. 7. Check the corners of the wrench flats on the main body, and file off any burrs to prevent scratching the end cap bore during removal. 21 | M-310 © Flow International Corporation...
  • Page 22 Apply a thin film of Blue Lubricant to the threads of the end cap. M-310 | 22 © Flow International Corporation...
  • Page 23 Record all maintenance work in the service log. When all work is satisfactory remove the Out of Service tag from the main electrical disconnect. The pump is ready for operation. M-310 | 23 © Flow International Corporation...

  • Page 24: Lapping The Sealing Surfaces

    Because of its size and shape, hand-lapping the poppet can round the sealing surface, which causes squealing during operation. Flow recommends using a drill press to lap this part. 24 | M-310 © Flow International Corporation...
  • Page 25 3. Using the wetted 320 grit side of the plate, draw the body along the full length of the abrasive strip once, then rotate it 90° and repeat the score. This final scoring process will help avoid poppet sticking. M-310 | 25 © Flow International Corporation...

  • Page 26: Hydraulic Oil Cylinder, Piston, Plunger, And End Bell

    (more than one drop every 30 seconds). Worn piston seals, allowing excessive oil flow • 1. Shut down the system. around the piston.
  • Page 27 10. Drive the piston and plungers from the cylinder with a soft mallet. Set the parts aside. M-310 | 27 © Flow International Corporation...
  • Page 28 Repeat Steps 14 and 15 for the other end bell, • then set the end bells aside and cover with a lint-free cloth. 28 | M-310 © Flow International Corporation...
  • Page 29 Make sure the T-seals do not get nicked or rolled. Proceed to Step 29, Reassembling the • Note: Stagger the joints on the backup rings as shown intensifier to ensure correct installation (see illustration at top of Page 30). M-310 | 29 © Flow International Corporation...
  • Page 30 27. Apply clean hydraulic oil or Parker Super O-Ring Lube to the seal and install it in the groove oriented with the flared o-ring face toward the outside of the piston. Repeat Steps 22 and 23 for the other plunger. • 30 | M-310 © Flow International Corporation...
  • Page 31 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. M-310 | 31 © Flow International Corporation...

  • Page 32: Parts List Information

    Ordering parts Refer to manual MS-2266, Customer Support. Customer Service Customer Service personnel are located at Flow's head- quarters in Kent, Washington, USA. They provide parts availability and price information, and are available by phone, mail, and fax between 6:30 a.m. and 5:30 p.m.

  • Page 33: Top Assemblies

    Tie rod A-0275-125 O-ring C-1000-1 Low-pressure cylinder A-1606 Compression spring 321276 End cap C-1313-1 OUtlet body A-00633-023 O-ring 015384-1 Inlet poppet A-0275-240 O-ring A-2185 Blue Lubricant* A-00250-240 Backup ring A-3202 Loctite* * not shown M-310 | 33 © Flow International Corporation...
  • Page 34 Outlet body A-1001 Poly pak seal 010564-1 Inlet support A-2838 High-pressure gland A-2839 High-pressure collar 015384-1 Inlet poppet 101 AR A-2185 Blue Lubricant A-4689 Food grade grease 102 AR A-3202 Loctite B-1000-2 Tie rod 34 | M-310 © Flow International Corporation...

  • Page 35: Sub-Assemblies

    015384-1 Inlet poppet 010564-1 Support assembly A-0275-125 O-ring A-1606 Compression spring A-2185 Blue Lubricant * A-3202 Loctite #242 * C-1313-1 Outlet body * not shown 010559-2 40,000 psi valve 010559-3 60,000 psi valve M-310 | 35 © Flow International Corporation...

  • Page 36: 60K Piston Assembly

    Ceramic plunger assy A-0270-300 Snap ring A-00251-18 T-seal 013763-1 (Rev. A) 40K piston assembly Item Part # Description 007201-1 Piston biscuit 006881-1 Biscuit spacer 013458-1 Ceramic plunger assy A-0270-300 Snap ring A-00251-22 T-seal 36 | M-310 © Flow International Corporation...

  • Page 37: Manifold Assembly

    A-1012 Spring A-1713 Compression spring B-1007-1 Actuating plunger B-1611-1 Shift pin A-11215 Shift valve/pilot valve assy (C-2743-1, shift valve & 006869-1, pilot valve) C-5461 Cable guide assembly, RH C-5462 Cable guide assembly, LH M-310 | 37 © Flow International Corporation...
  • Page 38 010558-30 Intensifier assembly 013403-1 Manifold A-0636-23 Connector A-0641-6 Plug A-0641-7 Plug A-18862 Shift valve 011275-1 Sensor assembly B-8346-1 Actuator assembly A-0276-012 Backup ring A-0275-012 O-ring A-0102-16 Screw A-2409 Compression spring B-1702-1 Firing pin 38 | M-310 © Flow International Corporation...

  • Page 39: Kits

    Aluminum disc A-1606 Compression spring B-1868-1 Sleeve installation tool A-0275-125 O-ring B-1867-1 Sleeve guide 005917-1 Outlet poppet B-1866-1 Seal installation tool 004382-1 Insert 004380-1 Retaining screw 015384-1 Inlet poppet 010564-1 Support assembly 013463-1 Packaging M-310 | 39 © Flow International Corporation...

  • Page 40: High-Pressure Seal Kits

    001198-1 (Rev. H) 60K high-pressure seal kit Item Part # Qty Description A-4689 White food grade o-ring lube B-1465-1 Seal ring B-8075-119 O-ring 004406-1 High-pressure seal 004407-1 Seal hoop A-6283-1 Packaging A-6283-2 Bubble pack 40 | M-310 © Flow International Corporation...

  • Page 41: Low-Pressure Seal Kits

    Polymite backup ring A-0275-014 O-ring A-0276-012 Backup ring A-0275-012 O-ring A-0275-013 O-ring A-1001 Poly pak seal A-0275-240 O-ring A-00633-023 O-ring A-0275-211 O-ring A-00251-18 Rod T-seal A-11275 Rod seal A-20257-1 Rexroth o-ring kit A-0275-019 O-ring M-310 | 41 © Flow International Corporation...
  • Page 42 A-0275-014 O-ring A-0275-015 O-ring A-0275-019 O-ring A-0275-020 O-ring A-0275-128 O-ring A-0275-130 O-ring A-0275-211 O-ring A-0275-240 O-ring A-0276-012 Backup ring A-0276-128 Backup ring A-1001 Polypak seal A-14469 Poly seal A-20257-1 O-ring kit, Rexroth valve 42 | M-310 © Flow International Corporation...
  • Page 43 ESL Intensifier Electric shift low-pressure seal kit M-310 | 43 © Flow International Corporation...
  • Page 44 ESL Intensifier Notes 44 | M-310 © Flow International Corporation...

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