HYPLEX® PRIME PUMP

M-416 | REV. C | MAY 2012

HYPLEX PRIME PUMP
Maintenance & Service Manual

Due to continuing product improvement, the information contained in this document is subject to change without
notice. Flow International Corporation (Flow) 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.
This document contains information protected by copyright. No part of this document shall be reproduced in any
manner without prior written consent from Flow International Corporation.
HyPlex®, HyPlex® Hybrid, HyPlex® Prime, and Dynamic Waterjet® are registered trademarks of Flow International
Corporation.
© Copyright 2011-2012 Flow International Corporation. All rights reserved.

This document is the original, non-translated version.

2 | M-416 © Flow International Corporation

 INTRODUCTION

HyPlex Prime Pump

Chapter 1. Equipment Description Visual troubleshooting guide for

the high-pressure components 33
Features 5
Troubleshooting table 34
Specifications 6
Interface illustrations 7
Chapter 4. Service
Interface labels 10
Water requirements 11 Servicing the high-pressure pump 41
Air requirements 12 Service tips & notes 41
Environment requirements 12 High-pressure components illustration 42
High-pressure tubing 12 Using the pressure loading tool 43
Anti-vibration mat 13 Installing the Dynamic Seal Maintenance kit 45
Startup procedure 14 Installing the Minor Maintenance kit 55
Temperature input offset adjustment routine 16 Installing the Major Maintenance kit 67
Calibrating the pump control system 16 Installing the pressure control valve (PCV)
Maintenance kit 79
Preparing the HyPlex Prime pump for
shipping or storage 17 Changing the filter elements 83
Replacing the dynamic seal and plunger 84
Chapter 2. Safety Tensioning and aligning the belt drive 91
Servicing the belt 91
Safety precautions 19
Servicing the crankcase 93
Warnings, cautions, and notes 19
Safety tips 20
Chapter 5. Engineering Drawings
Protective clothing 21
Emergency medical information 22 Drawing lists 95
Maintenance kits 97
Chapter 3. Maintenance & Troubleshooting Tools 99
Recommended spares 99
Periodic maintenance 23
General precautions 23
Inspection & maintenance schedules 25
Routine daily checks 25
Mandatory maintenance schedules 26
30 hp HyPlex Prime pump maintenance schedule 27
50 hp HyPlex Prime pump maintenance schedule 28
Troubleshooting the HyPlex Prime Premium pump
using FlowSENSE 29
FlowSENSE diagnostic codes 30
Troubleshooting the high-pressure components 32
Additional troubleshooting tips 32
Weep holes 32

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HYPLEX PRIME
Maintenance & Service Manual

Introduction
The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. It
was compiled from the most current information available at the time of publication and is intended to cover the most
common configurations. Your equipment was shipped with other documents and drawings. Refer to these drawings
when using the service procedures in this manual.

Safety
All operating personnel and service technicians must read and follow the comprehensive list of safety precautions in all
manuals provided with your equipment before installing, operating, or servicing the equipment. This will help avoid
creating unsafe conditions or equipment damage.
The high-pressure waterjet system is a powerful cutting tool and must always be treated with respect.

Warnings, cautions, and notes

Before operating the equipment, you must read, understand, and follow all warnings, cautions, and notes in this man-
ual. They are defined as follows:

WARNING
Highlights an operating or service procedure or condition that can
result in death or serious injury to personnel.

CAUTION
Highlights an operating or service procedure or condition that can
lead to impaired system operation or equipment damage.

Note: Highlights an operating or service procedure or condition that is essential for efficient operation and service.

4 | M-416 © Flow International Corporation

 CHAPTER 1
Equipment Description
The HyPlex Prime pump is a powerful, ultrahigh-pressure waterjet cutting tool designed for minimum maintenance
and reliable performance. The pump has an operating pressure of 55,000 psi (3790 bar), and a maximum generated
pressure of 60,000 psi (4140 bar).

Base features Basic package

• Triplex pump For use with Flow X-Y tables prior to those introduced with B&R
controls.
• Totally-enclosed, fan cooled (TEFC) motor
• Motor starter is not included
• Manually adjustable output pressures from
1000–55,000 psi, dual-pressure control optional
Standard package
• Dual filter system removes particles larger than
0.5 microns absolute For use with B&R-controlled Flow X-Y tables.
• Available in 30 or 50 hp motor, 60Hz or 50Hz • Motor starter is included

Plus package
For use with B&R-controlled Flow X-Y tables.
• UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
• Auto-calibration of UHP pressure control system
• Motor starter is included

Premium package
For use with B&R-controlled Flow X-Y tables.
• UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
• Auto-calibration of UHP pressure control system
• Motor starter is included
• FlowSENSE, an early warning system for critical parts

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Specifications
Contact FLOW Technical Service for further information.
Also see the system drawings in Chapter 5. Voltage

Nominal
Dimensions system Horsepower Frequency Phase
(with covers closed) 60 L x 40 W x 41 in. H voltage ** (hp) (Hz)
................................1524 L x 1016 W x 1042 mm H 200 * 50 *
(with covers open) 60 L x 40 W x 52 in. H
200 * 60 *
................................1524 L x 1016 W x 1321 mm H
208 * 60 *
Nominal crankcase RPM 50Hz 60Hz 230 * 50 *
30 hp....................................................716 709
50 hp..................................................1154 1114 240 30/50 60 3

Operating pressure ...................55,000 psi (3790 bar) 380 * 60 *

Max. generated pressure ..........60,000 psi (4140 bar) 400 30/50 50 3

480 30/50 60 3
Filtration provided...............0.5 micron and 1 micron
500 * 60 *
Min. required inlet water flow rate
* Not supported.
30 hp ...............................................2 gpm @ 57 psi
** Utilization voltage is often referenced, which will be
50 hp ...............................................3 gpm @ 65 psi 3-5% lower than the nominal system voltage. Where
referenced, the utilization voltage is equivalent to the
Low inlet water pressure switch threshold nameplate voltage of a product.
........................................................................ £ 15 psi
To ensure proper inlet water pressure, a boost pump may
be required. Crankcase oil
Req. inlet water temperature range Use of Shell Morlina 100 Hydraulic Oil (ISO 100) is
.........................................55°F–70°F (12.7°C–21°C) recommended, but other manufacturer's equivalents
If plant inlet water temperature is outside of this range, can be used.
contact Flow Technical Service
When operating the pump in an environment with an
Air.........................................90–120 psi (6.2-8.3 bar) ambient temperature greater than 86°F (30°C), a
heavier oil is recommended to be used. Contact Flow
....................................dry and filtered to 10 microns
Technical Services for additional information.

Drain............212°F (100°C) water at 0.9 gpm (30 hp) Reservoir 2.0 qt (1.9 liter)
.....................212°F (100°C) water at 1.5 gpm (50 hp) capacity Maintain oil level between the high and low
level marks on the dipstick.

Max. UHP orifice size

30 hp .......................................................-12 orifice
50 hp .......................................................-16 orifice

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 CHAPTER 1
Equipment Description

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HYPLEX PRIME PUMP
Maintenance & Service Manual

8 | M-416 © Flow International Corporation

 CHAPTER 1
Equipment Description

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Interface labels

Inlet water pressure (post filter)

This gauge indicates water pressure after the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.

Inlet water pressure (pre filter)

This gauge indicates water pressure before the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.

High air pressure

This gauge indicates the air pressure supplied to the UHP pressure control
valve (PCV) as controlled by the regulator below the gauge.
On dual-pressure machines: this indicates the maximum air pressure setting.

Low air pressure

On dual-pressure machines, this indicates the minimum air pressure setting.

Inlet water connection

Connect inlet water at recommended specification.

Air inlet connection

Connect inlet air at recommended specifcation.

PCV to drain
Connect a drain line directly to an outlet drain at recommended specifica-
tions.
CAUTION

To ensure that the PCV does not suffer damage due to siphoned catcher tank
water, connect the PCV drain line directly to an outlet drain,
or suspend the line above the catcher tank water level.

High-pressure water outlet

Outlet port for ultrahigh-pressure (UHP) water.

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 CHAPTER 1
Equipment Description

Water requirements
The HyPlex Prime pump requires a single source of Water interface connections
water, and one drain line.
Flow recommends the installation of manual shut-off
valves in the inlet/cooling water line. Locate valves as close
Water quality as possible to the pump interface connection to make
CAUTION them easier to service.
A high concentration of dissolved solids in the inlet water Water inlet lines must be non-corrosive pipe or rubber
(especially silicates and calcium) can reduce waterjet hose. Rubber hose (per SAE Standard 20R1, 30R1, or
nozzle life. If water quality is poor and filtration will not
correct it, the customer must add additional water equivalent) is recommended.
treatment equipment. Contact Flow Technical Service Water inlet lines (from the filtering system to the pump)
for more information. must be as short as possible and must be PVC, copper, or
Flow recommends the use of a water softener to equivalent. Do not use galvanized iron piping or black
pre-treat the cutting water. Water quality should be iron—it can introduce minerals to the water, which can
maintained to within the following limits: shorten component life.

• Total disolved solids: 17 ppm • Connect inlet water line to pump bulkhead.

• Water pH: between 6.5 and 9.5 • Connect proper drain line to PCV bulkhead outlet.
CAUTIONS
Additional water quality requirements are specified in To ensure that the PCV does not suffer damage due to
the Inlet Water Quality document provided at pre-in- siphoned catcher tank water, connect the PCV drain line
stallation. directly to an outlet drain above the water line,
or suspend the line above the catcher tank water level.

Water flow rate Water exiting the PCV drain line is hot.

Systems should be sized for 150% of your pump ca-

pacity, and should match your intended maximum
duty cycle.

Water temperature
An inlet water temperature of between 55°F and 70°F
(12.7°C and 21°C) is recommended for proper pump
performance. Premature pump component failure is
common if water temperatures are outside this range.
Inlet water chillers should be used if the inlet water
temperature is above this range.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Air requirements High-pressure tubing

The HyPlex Prime pump requires a source of air be- High-pressure tubing certified for continuous operation
tween 90 and 120 psi (6.2 and 8.3 bar). The air must be at 60,000 psi (4140 bar) is used to route high-pressure
dry and filtered to 10 microns. water from the HyPlex Prime pump to the cutting equip-
On the Basic and Standard versions of the pump, the ment.
manual air regulator should be adjusted and set at the Note: Refer to manual M-127, Small High-pressure Com-
point at which 55,000 psi water pressure is achieved ponents for more information on high-pressure tubing,
with the correct orifice installed and the nozzle open. components, and related service.

Environment requirements
Ambient temperature around the pump must be main-
tained between 45°F and 104°F (7°C and 40°C) to
ensure proper functioning of the pump.

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 CHAPTER 1
Equipment Description

Anti-vibration mat
The anti-vibration mat is essential for the stability of the
HyPlex Prime pump and the reduction of pump vibra-
tion. The pump should be centered on the mat with no
part of the pump touching the floor beneath.
Place the mat flat on the floor and lower the pump onto
the center of the mat using a forklift.
A pallet jack may be also used to locate the pump, but
the mat should be slid under the pump when suspended
with the pallet jack. Pallet jacks loaded with the weight
of the pump will not roll on the anti-vibration mat.
Do not trim the mat or bolt the pump to the floor
through the mat material.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Startup procedure
Preparing the pump for startup
Follow this procedure to make sure the pump is ready
for operation:
• Before the beginning of a shift
• After initial installation
• After installation of one of the HyPlex Prime
maintenance kits

1. Flush debris from all water supply hoses before con-

necting them to the pump.
CAUTION
Debris in the water supply line can cause
extensive damage to high-pressure components.
Such damage IS NOT covered by warranty.

2. Fill the pump case with a recommended oil (see the

list on Page 6). Fill the oil reservoir to the fill mark.
CAUTION
Never operate the pump without oil or with dirty oil—
this can cause extensive damage and
IS NOT covered by warranty.

3. Make sure water lines, air lines, and drain lines are
correctly connected and routed.
CAUTION
Cutting equipment and nozzles must be installed when
operating the pump. Operating the pump without proper
cutting nozzle will damage high-pressure components.

4. Clear tools, parts, and rags from around the pump.

Check in and around the pump for foreign objects
and debris.
5. Open any operator-supplied inlet water and air
valves; check all connections for leaks.
CAUTION
Operating the pump without an adequate supply
of inlet water will cause damage.

Do not tighten any loose or leaking connections while the

pump is operating or while the line is pressurized.

6. Make sure the belt guard is attached.

7. Place the main electrical disconnect in the ON
position.
8. Release the E-stop button(s).

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 CHAPTER 1
Equipment Description

Starting the Basic and Standard package Starting the Plus and Premium package
pumps pumps
These are the steps to be performed at the initial startup These are the steps to be performed at the initial startup
of a shift. of a shift.
1. Check all connections for leaks. 1. Check all connections for leaks.
2. Turn the manual air pressure regulator all the way 2. Depress the red pressure relief buttons on both of
counter-clockwise. the inlet water filters to release any air.
3. Depress the red pressure relief buttons on both of 3. Run the HyPlex Prime pump Temperature Input Off-
the inlet water filters to release any air. set Adjustment routine on Page 16.
4. Start FlowCUT and open a part file. Click the Run 4. Run the Calibrating the pump control system routine
Machine button. The screen will display the pump on Page 16.
on/off control. 5. Click on the low-pressure selection in the sidebar.
5. Reduce the air pressure to the PCV to zero. 6. Turn the pump on for 5-10 minutes while checking
6. Click on the high-pressure selection in the sidebar. for leaks. Correct as required.
7. Turn the pump on by clicking the pump ON button. CAUTION
When the pump is spinning at full rpm, turn the Do not tighten any loose or leaking connections while the
manual air pressure regulator clockwise until the pump is operating or while the line is pressurized.
pressure display reads 55,000 psi of pressure.
The pump is now ready for use.
Pressure is indicated on either the analog gauge (Ba-
sic) or on the digital display in FlowMaster (Stan-
dard). Operate the pump at this pressure for 5-10
minutes while checking for leaks. Correct as re-
quired.
CAUTION
Do not tighten any loose or leaking connections while the
pump is operating or while the line is pressurized.

The pump is now ready for use.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

HyPlex Prime pump temperature input Calibrating the pump control system
offset adjustment routine This applies to the Plus and Premium packages.
This routine applies to the Plus and Premium packages. This software routine must be run each time the PCV
This software routine must be run each time the pump is poppet is replaced, and whenever the pump output
started at the beginning of a shift, and any time a pressure is significantly off the commanded pressure set-
high-pressure pump component is replaced. ting.
The routine reads the temperature inputs from the three The routine commands the pump to create pressure at
thermistors and calculates the relative value of each to increasing set intervals and then adjusts the controls to
the lowest among the three. These relative values are match each interval.
used in the calculation for continuous monitoring of the
cylinder temperature when the pump is running.
1. Start FlowCUT, open a part file,
and go to the Run Machine screen.
1. Make sure the pump is at room temperature. This is 2. Position the cutting head away
important to get a uniform reading from each of the from any material or tooling.
thermistors.
3. Click on the Option Component
2. Start FlowCUT, open a part file, and button in the sidebar. In the Option
go to the Run Machine screen. Component dialog box that appears,
3. Click on the Option Component scroll through the selections to find
button in the sidebar. In the Option the "Pressure Calibration" routine.
Component dialog box that ap- 4. Enable the routine by clicking the numbered button.
pears, scroll through the selections Click Close to close the Option Component dialog
to find the "Enable Temperature Sensor Offset Ad- box.
justment" option.
4. Enable the routine by clicking the numbered button. WARNING
Click Close to close the Option Component dialog Waterjet nozzle will automatically open when finishing the
box. calibration routine. The cutting head must be positioned
away from any material or tooling.
5. Select low-pressure mode and click the Pump ON
button. 5. Select low-pressure mode and click the Pump ON
The pump will run at idle for about 45 seconds, button.
then go to low pressure. Pump pressure is indicated The pump will run at idle for about 45 seconds,
in the status bar at the bottom of the FlowCUT Run then go to low pressure (as specified by user settings
Machine screen. in Jet Setup). Pump pressure is indicated in the sta-
6. When the pump goes to low tus bar at the bottom of the FlowCUT Run Machine
pressure, stop the pump, click screen.
the Previous Screen button, then 6. When the pump goes to low
click the Run Machine button to pressure, stop the pump, click
make the routine adjustments ef- the Previous Screen button, then
fective. click the Run Machine button to
make the routine adjustments effective.

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 CHAPTER 1
Equipment Description

Preparing the pump

for shipping or storage
Whenever a Flow pump is moved, put into storage, Crating
or shipped, the following guidelines will help prevent
12. The pump must be shipped on a framed and rein-
damage caused by movement or environmental condi-
forced wooden pallet designed to isolate and sup-
tions. These instructions comply with transportation
port its weight and load characteristics.
regulations.
13. Secure the user interface console and motor starter
Note: U.S. Department of Transportation regulations re-
box so it cannot vibrate.
quire that crankcase oil be transported only in sealed
containers. Before shipping, remove all crankcase oil 14. Wrap a plastic band around the horizontal circum-
from the reservoir. ference of the pump, protecting all corners with
cardboard between the strap and the cover corner.
Wrap an additional plastic band around the top and
Service steps under the frame, also protecting corners with card-
1. Disconnect power, turn off inlet water, and turn off board.
air.
2. Disconnect main motor lead terminals from the mo-
tor starter in the machine power enclosure. DO NOT
CUT LEADS. (Motor leads are terminated with eye
lugs and bolted to terminals from the motor starter
primary conductors.)
3. Disconnect the HP interface at the utilities bulk-
head.
4. Remove both filter canisters and empty out any wa-
ter.
5. Reattach the water filter canisters to the filter heads.
6. Remove the hose from the 1 micron filter outlet.
7. Apply compressed air to the 1 micron filter outlet
hose. Expelled water will be visible at the HP inter-
face connection at the utilities bulkhead. This should
expel most remaining water from the HP and LP cir-
cuits.
8. Reattach the hose to the 1 micron filter outlet.
9. Drain the water from the inlet water pressure gauge
lines at the end opposite the gauge. Reattach when
all water is expelled.
10. Drain the water from the inlet water line between
the utilities bulkhead and the inlet water shut-off so-
lenoid valve. Reattach after draining.

Plug fittings
11. Tie wrap the inlet water, drain, and air lines.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Notes

18 | M-416 © Flow International Corporation

 CHAPTER 2
Safety
This chapter contains a comprehensive list of safety pre- Warnings, cautions, and notes
cautions that must be followed to ensure safe operation
Service procedures in the waterjet manuals include
of the equipment. These precautions must be read and
safety warnings, cautions, and notes that must be read,
understood by everyone operating and maintaining the
understood, and adhered to. These are specific catego-
equipment—before they start working with the equip-
ries of safety notices, and are defined as follows:
ment. Note that OSHA and state safety agency rules
must be complied with in addition to those given in this
chapter and elsewhere in this manual. Applicable plant WARNING
An operating condition or service
general safety precautions must also be followed.
procedure that can result in death or
serious injury to personnel.

Safety precautions
CAUTION
FLOW designed your high-pressure waterjet cutting sys- Highlights an operating condition or service
procedure that can lead to impaired system
tem and related equipment with safety in mind.
operation or equipment damage.
Throughout the manual, safety precautions and warnings
for specific operations are highlighted. Safety precautions Note: Highlights an operating or service procedure or
are also posted on the equipment. The operator and ser- condition that is considered essential for efficient opera-
vice personnel shall pay particular attention to these pre- tion and service.
cautions at all times.
Operators of a high-pressure waterjet cutting system
must treat the system as they would treat any high-speed
cutting tool. Although the waterjet may appear harmless,
Replacement label
it is a high-energy cutting tool capable of cutting many • Part number 006317-1
non-metallic materials such as composites, plastics, and 3.75 x 6 in.
wood products. Misuse of this equipment or carelessness
• Part number 009837-1
in its application can be extremely hazardous to operat-
1.8 x 3 in.
ing personnel. Always treat the waterjet cutting system
with respect.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Safety tips • Clear all tools, parts, and rags from moving parts af-
ter servicing the equipment.
• Do not allow the waterjet stream to touch any part
of your body—it will cause serious injury. Do not
point the waterjet at anyone. Electrical system
• During equipment maintenance, take the system out • Only a certified electrician shall perform electrical
of service. The controls must be properly locked and and/or electronic troubleshooting and servicing of
marked with a warning sign. electrical devices.
• All personnel required to perform any system oper- • Always assume that power is ON in all electrical sys-
ating or service function must pay particular atten- tems. Always check and lock out the main power
tion to all warning signs and notices posted in the switches before servicing the equipment. Post a sign,
plant and on the equipment. “Maintenance in Progress—Do Not Energize.”
• All protective guards, shields, and covers must be in • Be aware that live electrical circuits are present in
place on the equipment at all times. the control console whenever the master disconnect
• First aid facilities shall be provided in convenient lo- is on, regardless of whether the E-Stop is engaged.
cations throughout the plant. These locations must • Disconnect circuit breakers and lock them in the
be known by all personnel. OFF position before servicing the electrical system. If
• Always keep the work area around the equipment this isn’t possible, have someone stand by to prevent
clean and free of debris. Oil spillage results in slip- someone from powering up the system.
pery floors and must be cleaned up immediately. • Take extra precautions when servicing the power sys-
• Any unfavorable conditions that may result in inju- tem in a damp environment.
ries shall be reported to the plant supervisor • Never alter or bypass protective interlocks or devices
immediately. unless specifically instructed to do so, and only if all
• As a general practice, it is recommended that safety precautions are followed.
shoes, glasses, and hearing protection be worn by all • You must give capacitors sufficient time for dis-
personnel working around the equipment. Do not charge. If this is not possible, discharging should be
wear rings, watches, or necklaces when working done manually and with care.
around any equipment that has moving parts. • Do not use jumper wires across fuses, fuse holders,
or breakers.
Mechanical system • Make sure all tools are properly insulated for the job.
Use only proper test apparatus; check regularly to
• Don’t start the system unless you know how to stop
make sure it is working correctly. Use caution when
it.
connecting a test probe to test points.
• Never maintain, service, or clean around the equip-
• All replacement wires shall conform to the manufac-
ment while it is operating.
turer’s specifications, including color coding, wire
• Do not use incorrect tools—it can cause injury or numbers, and size.
costly damage to equipment.
• Close the control panel doors or junction box covers
• Never climb on or around the equipment on make- after servicing.
shift devices. Use only approved catwalks, ladders,
or platforms.
Waterjet system
• Do not exceed specified pressure setting limits for
pneumatic or hydraulic components. Exceeding • High-pressure water can remain in the system for an
these limits may result in serious injury to personnel extended time after shutting down the water source.
or damage to the equipment. Always bleed-down system pressure before servicing
• Shield and bundle equipment hoses and cables so any part of the system.
they do not obstruct the operator’s freedom of • Do not touch weep holes with your bare hands or
movement. try to stop water by plugging the holes.
• Always be alert when working around the • Remember that the waterjet stream is a knife. Do
equipment. not introduce anything into its path that you do not
intend to cut.

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 CHAPTER 2
Safety

• Wear a face shield when required by operating Eye protection

instructions.
• At a minimum, operators must wear
• Do not remove protective shields from high-pressure safety glasses with side shields and a vi-
tubing. If shields are removed for servicing, they sor, or goggles and a visor, to gaurd
must be replaced before starting the system. against spray and flying debris.
• Torque all fittings to the manufacturer’s torque • All eye protection shall meet
specifications. appropriate ANSI requirements for that
• Stepping or leaning on high-pressure tubing can type of eye protection.
break connections, causing leakage. • Some states and countries have their
• Use only high-pressure fittings, valves, and tubing own eye protection rules that must be
certified for 60,000 psi (4138 bar) when making al- followed.
terations or additions to the high-pressure water sys-
tem. Head protection
• Do not alter or eliminate stress relief tubing coils.
• Helmets must be worn at all times by all
• Follow the tubing manufacturer’s recommendations
personnel within the work area. Helmet
for high-pressure tube bending radii.
material must withstand mechanical
• Do not exceed specified operating pressures for shock to 10 G in 8 ms without
high-pressure water system components. fracturing.
• Do not over-torque fittings or bend swivels
excessively. Hand protection
• Follow the manufacturer’s recommendations for ser-
vicing the equipment, and use only original manu- • The operator must wear gloves at all
facturer replacement parts. times. Leather gloves are preferred.

• Follow the manufacturer’s system startup procedure

to ensure safe operation. Foot protection
• Use care when lifting equipment covers during • Safety footwear with steel toe-caps at
operation. least 0.02 in. (5 mm) thick must be
worn. The toe cap must cover at least
30% of the footwear length.
WARNING • For some applications, footwear must
NEVER point a waterjet cutting or cleaning tool be equipped with metatarsal guards to
at yourself or at any person. Do not aim any provide instep protection.
waterjet tool at anything you do not want to cut.

Hearing protection
• Operators and other personnel exposed
to noise levels of more than 90 dBa for
Protective clothing more than 1 hour must wear suitable
ear protection. Ear plugs and muffs are
Personnel operating hand-held, high-pressure water cut-
usually adequate.
ting or cleaning equipment and those working nearby
should wear the protective clothing and safety devices
described in this chapter. Body protection
FLOW recommends that work-site safety personnel ap- • Waterproof garments only protect the
prove all safety equipment and clothing for everyone operator from spray and flying debris.
working around waterjet equipment. They do NOT deflect direct jet
impact.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Emergency medical information

Anyone who receives equipment-related injuries while
operating high-pressure water equipment should be
given immediate hospital attention. It is vital that medical
personnel have information about this type of injury.
Therefore, all waterjet operating personnel should carry
a waterproof emergency medical tag or card that de-
scribes their work and the nature of injuries inherent in
using waterjet cutting devices. The card illustrated below
can be purchased from Flow International (A-8466).
The tag or card should contain the following standard
information:

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 CHAPTER 3
Maintenance & Troubleshooting

Periodic maintenance • Do not use metal rulers, flashlights, pencils, or tools

that have exposed conducting material.
Periodic maintenance is service to be performed on the
• De-energize all equipment before connecting or dis-
equipment at regular intervals, designed to help mini-
connecting meters or test leads.
mize unscheduled production down time and premature
parts failure. FLOW recommends that you keep detailed • When connecting the volt meter to terminals for
service records to help you prepare a maintenance measurement, use a range higher than the expected
schedule that is compatible with your application and voltage.
production requirements. • Replacement wires must conform to the manufac-
turer’s specifications, including proper color coding
and wire numbers.
General precautions
Observe the following general precautions at all times. Mechanical
Review the safety information in Chapter 2 before per-
forming any maintenance or service, and pay attention to • Use only high-pressure fittings, valves, and tubing
the safety messages in the maintenance and service pro- certified for 60,000 psi (4140 bar) when making
cedures. Do not make any unauthorized changes to changes to the high-pressure water system.
equipment or components. • Immediately repair any leaks in fittings or connec-
tions. Torque all fittings to the manufacturer’s
Electrical specifications.
• When pressurizing any new, rebuilt, or recently ser-
• Maintain all electrical components, protective guards, viced high-pressure component, clear all personnel
and shutdown devices according to approved prac- from the immediate area until system pressure has
tices. been applied for three minutes and cycled on and
• Make sure power cannot be applied to equipment off at least three times. At first startup, run the pump
during maintenance work by turning off the main at low pressure. Then, if no leaks or problems occur,
electrical disconnect and locking it out. increase the pressure to the full operating pressure
• Before servicing, use a volt meter to make sure the and continue.
system is not energized. Take extra precautions when • Do not touch high-pressure leaks.
servicing the electrical system in a damp • Bleed down the system pressure before servicing
environment. any part of the system. Never tighten pressurized fit-
• Never use jumper wires across fuses, fuse holders, or tings.
breakers. • Follow the manufacturer’s recommendations for ser-
vicing the equipment, and use only original manu-
facturer replacement parts.

© Flow International Corporation M-416 | 23

HYPLEX PRIME PUMP
Maintenance & Service Manual

• Use cleaning solvents only in well-ventilated areas. Torque specifications

Avoid prolonged breathing fumes and contact with
skin or eyes. Refer to the following table when specific torque re-
quirements are not listed in a service procedure.
• Inspect the entire system before operating it.
Correct any fault or malfunction. CAUTION
Never torque mounting bolts and machine screws
beyond the manufacturer’s recommended limits.
Tools
The torque values for high-pressure water assemblies
• Use only approved test equipment, and check it reg- and fittings are listed in U.S. Customary System foot-
ularly for correct operation and calibration. pounds (ft-lb) and Systéme International (SI) Newton-
• Use the correct tools—the incorrect tool can result in meters (N-m).
injury to personnel or costly damage to the equip-
ment. High-pressure U.S. SI
• Clear all tools and rags from around the machine af- gland nuts ft-lb N-m
ter service and before starting the equipment. 1
4 in. 15–25 20–34
• Use only approved work platforms. Never climb on 3
8 in. 35–45 47–60
or around the equipment using makeshift devices.
9
16 in. 60–75 80–100
Protective clothing
• Do not wear loose clothing or jewelry while working
around rotating parts of machinery.
• Pressurized air can drive particles into eyes and skin
if handled improperly. To prevent injury, use appro-
priate protective equipment and clothing and exer-
cise extreme caution.

24 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

Inspection & maintenance

schedules
Flow equipment has been designed for long service life.
However, maximizing the life, safety, and efficiency of
the equipment depends on daily inspections and regular
maintenance. Periodic maintenance can take the form of
regularly scheduled preventive maintenance, such as the
items listed below. It also includes replacing worn parts
that have reached the end of their service life.
In addition, the HyPlex Prime pump has four mandatory
maintenance kits that are installed at fixed intervals.
These are described in Chapter 4.

Routine daily checks

Before startup
• Inspect pump, high-pressure tubing, connections,
and valves for leakage. Correct any problems before
starting the pump.
• Check the oil level in the pump.
• Check the main electrical disconnect for “Out of Ser-
vice” tags and check all around the equipment for in-
dications of maintenance work in process.

After startup
• Listen for unusual sounds as the pump starts and wa-
ter pressure increases. Inspect for leaks.
• Check the inlet water pressure gauges. If the pressure
differential between the pre-filter and post-filter inlet
water (shown on the pressure gauges) exceeds 30 psi
(2.1 bar) the filters are clogging and the filter ele-
ments must be changed.

End of shift
• Inspect and clean machine work area

© Flow International Corporation M-416 | 25

HYPLEX PRIME PUMP
Maintenance & Service Manual

Mandatory maintenance schedules

At fixed intervals for the life of the pump, you must per-
form a mandatory maintenance kit installation.
For all HyPlex Prime pumps (except the standalone ver-
sion), the Service information feature in FlowCUT is fac-
tory-set to remind the operator 10 hours before the next
required maintenance hour mark (these are listed below).

Maintenance periods by pump hours

Every 500 hours for a 30 hp pump and every 300 hours
for a 50 hp pump you must install a maintenance kit.
• Complete kit bills of material are in Chapter 5
• Complete kit installation procedures are in Chapter 4

26 | M-416 © Flow International Corporation

 30 hp HyPlex Prime maintenance schedule
Hourly
Interval Kit Service procedures

500 Dynamic Seal Replace UHP Lap inlet check

© Flow International Corporation

seal & rod seal valve components

1000 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
components

1500 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
seal & rod seal valve components cylinder seal carrier adapter poppet & seat

2000 Dynamic Seal Replace UHP Lap inlet check

seal & rod seal valve components

2500 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
components

3000 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
seal & rod seal valve components cylinder seal carrier adapter poppet & seat

PCV Replace PCV Replace bearing

plunger assembly & seals

3500 Dynamic Seal Replace UHP Lap inlet check

seal & rod seal valve components

4000 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
components

4500 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
seal & rod seal valve components cylinder seal carrier adapter poppet & seat

At fixed intervals for the life of the pump, you must perform a mandatory maintenance kit installation.

For all HyPlex Prime pumps (except the standalone version), the Service information feature in FlowCUT is factory-set to remind the operator
10 hours before the next required maintenance hour mark.

M-416 | 27
CHAPTER 3
Maintenance & Troubleshooting
 © Flow International Corporation
50 hp HyPlex Prime maintenance schedule
Hourly
Interval Kit Service procedures
300 Dynamic Seal Replace UHP Lap inlet check
seal & rod seal valve components
600 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
components
900 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
seal & rod seal valve components cylinder seal carrier adapter poppet & seat
1200 Dynamic Seal Replace UHP Lap inlet check
seal & rod seal valve components
1500 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
components
1800 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
seal & rod seal valve components cylinder seal carrier adapter poppet & seat
PCV Replace PCV Replace bearing
plunger assembly & seals
2100 Dynamic Seal Replace UHP Lap inlet check
seal & rod seal valve components
2400 Minor Maintenance Replace UHP Lap inlet check Replace outlet Replace filler Service subplate Change PCV
seal & rod seal valve components check valve tube sleeve adapter poppet & seat
Maintenance & Service Manual

components
2700 Major Maintenance Replace UHP Replace all check Replace UHP Replace UHP Service subplate Change PCV
HYPLEX PRIME PUMP

seal & rod seal valve components cylinder seal carrier adapter poppet & seat

28 | M-416
At fixed intervals for the life of the pump, you must perform a mandatory maintenance kit installation.
For all HyPlex Prime pumps (except the standalone version), the Service information feature in FlowCUT is factory-set to remind the operator
10 hours before the next required maintenance hour mark.
HYPLEX PRIME
Maintenance & Service Manual

Troubleshooting the HyPlex Prime

Premium pump using FlowSENSE
FlowSENSE is only available for the Premium package.
HyPlex Prime Premium pumps are continuously monitored
by FlowSENSE, a diagnostic program that monitors a num-
ber of system conditions, some of which are specific to
pump conditions. Sensors located on the pump enable
FlowSENSE to alert the operator of pump conditions that
will require attention. To indicate a warning, the positional
indicator on the FlowCUT Run Machine screen will blink. If
a shutdown condition exists, a dialog box will appear on
the machine console display.
To investigate the cause for the of the fault, and how it can
be corrected, select Advanced | FlowSENSE diagnostic in
the FlowCUT menu bar. Errors and warnings are indicated
in the window.
More information about using the FlowSENSE Diagnostic
functionality can be found in FlowCUT integrated help.

© Flow International Corporation M-416 | 29

HYPLEX PRIME PUMP
Maintenance & Service Manual

FlowSENSE diagnostic codes

FlowSENSE is only available for the Premium package.
The tables below list all shutdown and warning codes for the HyPlex Prime that may appear on the system display (or
console display if a standalone pump). Likely causes and possible solutions to those causes are included after each
code description.

FlowSENSE shutdown codes

27203 Low inlet water pressure shutdown

• Water supply valve(s) closed Check the water supply cut off, and make sure the water supply valve (when
• Inlet water pressure low (< 15 psi [1.03 bar]) supplied) is in the correct position. Remove and check the water filter car-
• Dirty water filters tridges; replace if dirty.

Faulty cable coming from the multi-port box Inspect the cable assembly at the multi-port box. Replace if necessary.

27206 Motor overload shutdown

Overload setting is lower than specified in the Call Flow Technical Service.
electrical schematic drawing.

27201 Pump is in E-Stop condition shutdown

Machine (M4c or M2c) is in E-stop condition Follow proper E-stop reset procedure (M4c or M2c).

Problem with safety network Call Flow Technical Service.

27202 Motor starter shutdown

Main circuit breaker has tripped Reset circuit breaker.

• Faulty soft starter Call Flow Technical Service.

• Faulty isolation contactor

FlowSense warning codes

27255 Inlet water high temperature warning

• Water inlet above 70°F (21°C) Check inlet water temperature to make sure it is below 70°F.
• Dynamic seal(s) may be damaged
Install a Minor Maintenance Kit.

Faulty cable coming from the multi-port box Inspect the cable assembly at the multi-port box. Refer to electrical sche-
matic. Replace if necessary.

27257 Analog input out of range warning

Thermistor cables disconnected Make sure the cables are connected.

Faulty thermistor(s) Run the Temperature Input Offset Adjustment Routine. If warning persists,
replace thermistors if suspected.

Faulty analog input module Call Flow Technical Service.

Faulty pump health board

30 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

27253 Cylinder overtemp warning

• Dynamic seal starting to fail • Check pump hours, and install the appropriate required maintenance
• Cracked dynamic seal carrier kit.
• Damaged plunger • Disassemble pump and inspect all components as per maintenance
procedures in this manual. Repair/replace as required.
• Debris under or failed inlet poppet
• Cracked check body
• Cracked UHP cylinder

Temperature sensor offset adjustment routine has not Run Temperature Input Offset Adjustment Routine.
been run on new pump.

Faulty thermistors or poor cable connection. Inspect sensors and cables. Replace if necessary.

27258 Crankcase overtemp warning

Low oil level Add oil to crankcase.

Problems in crankshaft/rotating group Contact Flow Technical Service.

Faulty cable coming from the multi-port box Inspect the cable assembly (A-26009-1) at the multi-port box. Replace if
necessary.

27251 Overpressure warning

Debris in PCV poppet seat Remove PCV and clean poppet/seat to remove debris. Replace pop-
pet/seat if required.
Note: Debris in the seal can also cause an underpressure problem.

Control air pressure to PCV set too high Run the Pump Pressure Control System calibration routine.
Note: Max. pressure for PCV is 70 psi (4.82 bar).

Damaged PCV piston Repair/replace piston and/or piston seals.

UHP transmitter-related problem Inspect the UHP sensor cable assembly at the multi-port box. Replace if
necessary.

27254 Pump health warning

One of the high-pressure cylinders is no Immediate service is required (dynamic seals and/or check valves).
longer producing pressure

Debris under or failed outlet poppet/seat in check Disassemble pump and inspect all components, paying special attention to
valve assembly the check valve outlet poppet area. Follow the maintenance procedures in
this manual to repair or replace parts as required.

27252 Pressure calbration is in process

• Pressure calibration routine has been initiated by operator

27256 Temperature sensor calibration is in process.

• Temperature sensor offset adjustment routine has been initiated either

by operator
• Pump has not been started for more than 2 hours (automatic temp.
sensor cal. routine)

© Flow International Corporation M-416 | 31

HYPLEX PRIME PUMP
Maintenance & Service Manual

Troubleshooting the high-pressure Weep holes

components Weep holes provide an outlet for high-pressure water in
You may experience conditions that are explained in the case of seal problems, and thus can help you identify
troubleshooting table that begins on the next page. To problems with the pump.
supplement the table, also refer to the color troubleshoot-
ing illustration in this chapter.
Unless otherwise specified, service procedures are located
in Installing the minor maintenance kit or Installing the
major maintenance kit, located in this chapter.

Additional troubleshooting tips

The following tips have been helpful in isolating less com-
mon system malfunctions and in correcting problems
quickly.
• Listen to the machine and watch it operate. Learn to
recognize the normal noises, temperature, and oper-
ating conditions. This will increase your ability to no-
tice any unusual machine behavior.
• Keep a record of all service performed on the equip-
ment. This will provide valuable information to help
you stock spare parts and schedule maintenance.

32 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

© Flow International Corporation M-416 | 33

HYPLEX PRIME PUMP
Maintenance & Service Manual

Troubleshooting table
Refer to the illustrated HyPlex Prime troubleshooting guide. If you have questions about anything on the troubleshoot-
ing table, contact Flow Technical Service.

My pump is leaking oil.

Note: Some degree of oil leakage is normal. If oil leakage appears to be excessive:

Seals are worn and require replacement. Install a Major Maintenance Kit.

Seals were installed without proper assembly

tools.

Piston rod seals are worn. Replace piston rod seal assembly.

My pump is leaking water.

CAUTION: Make sure the system is turned off and bled-down before servicing.

High-pressure water leaks. Refer to the illustrated troubleshooting guide

located at the beginning of this section.

Low-pressure water leaks. Tighten fittings or replace o-rings.

My pump is vibrating and/or noisy.

By nature, pumps vibrate and make noise. If you think the vibration/noise is excessive, check the following:

No anti-vibration mat. Use or replace anti-vibration mat.

Improper belt tension or failed belt(s). Adjust or replace belts to proper tension (see
section Tensioning and aligning the belt drive).

UHP seal or check valve failure. Replace components as necessary.

Crankcase failure. Replace crankcase.

Loss of electrical power leg; or the motor is Call a certified electrician.

spinning backwards.

My pump does not build the pressure I expect.

My pump does not cut The maximum cutting pressure of the pump is 55,000 psi. The maximum output pressure has
at 60 ksi. the potential to reach 60,000 psi.

My pump does not Belts are slipping or failed (broken/stretched). • Replace failed set of belts (4)
produce the pressure • Check or adjust belt tension using the
requested from supplied tension gauge
FlowMaster. • Check and/or replace pulley
• Check torque on pulley bolts

UHP orifice is incorrectly sized or damaged Replace with correctly-sized orifice(s)

(or too many orifices of a smaller size are be- (see Specifications).
ing used).

Insufficient operator-supplied air pressure. • Check air source (compressor)

• Check hoses and fittings for leaks

34 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

My pump does not Insufficient water pressure or volume from • Check water source (flow rate and pres-
produce the pressure operator supply. sure; filtration system)
requested from • Check hoses and fittings for leaks/kinks
FlowMaster
(continued). Failed inlet check valve (damaged surfaces, • Rebuild per service procedure
erosion, debris, etc.). • Replace check valve assembly

Failed outlet check valve (damaged surfaces, • Rebuild per service procedure
erosion, debris, etc.). • Replace check valve assembly

Failed check valve body (damaged seating Replace check valve body.
surface, cracked indentations from debris).

Failed UHP seal. May be an indication of a failed plunger, im-

proper tie rod loading, elevated inlet water
temperature, or lack of cooling water (clogged
cooling ports).
• Inspect seal carrier and plungers (replace as
necessary)
• Replace dynamic seal and rod seal

Leaking UHP cylinder. • Inspect for cracks

• Inspect seal carrier and check valve body
contact surfaces for spalling, erosion, or
damage. Replace as necessary.
• Replace the cylinder

Failed UHP tubing and connections. • Check gland for proper torque
• Check collar position
• Check tubing or fitting for cracks. Replace
as necessary.
• Check for deformed cone on tubing (may
indicate over-torque). Replace tubing as
necessary.

Failed on/off valve. • Install on/off valve service kit

• Replace on/off valve body

Clogged inlet water filters. Replace filters (see section Changing the filter
elements).

Mis-installed subplate adapter rod seal. Re-install rod seal properly.

Loose wiring connection to the air propor- Check and tighten connections.
tional control valve.

Failed or loose connection on the UHP trans-

mitter.

Failed or improperly calibrated UHP pressure Replace gauge or transmitter (the gauge trans-
gauge. mitter cannot be re-calibrated).

Excessive length of tubing between pump and Call Flow Technical Service.
pressure gauge.

Failed air proportional control valve. Replace air proportional control valve.

© Flow International Corporation M-416 | 35

HYPLEX PRIME PUMP
Maintenance & Service Manual

My pump does not Failed or improperly set air relief valve. Replace air relief valve.
produce the pressure
requested from Loose fittings or failed hose for low-pressure Tighten fittings or replace hose.
FlowMaster water.
(continued).
Improper pulley ratio for power frequency. Verify required pulley sizes for input power
(see Interface illustrations for part numbers).

Missing 3-phase power leg. Call a certified electrician.

Incorrect version of computer code (specifi- Call Flow Technical Service for correct revision
cally FlowMaster). number and install correct version.

Worn PCV poppet and seat. Install PCV maintenance kit (see section In-
stalling the pressure control valve maintenance
kit).

Debris in PCV poppet and seat. • Clean or remove debris, check for damage
of poppet and seat
• Ensure proper plumbing of the PCV drain
line

Incorrect motor rotation. • Verify and ensure proper rotation

• Call a certified electrician to swap polarity
on motor

Inlet water supply valve or solenoid failure (or • Replace valve

loose wires). • Tighten wire fittings
• Check breaker inside electrical control box
2-way air valve failure or loose wiring.

2-way air valve override switch is improperly Position the override switch to "automatic"
positioned. mode.

My UHP pressure display is not stable.

A signal fluctuation greater than 5000 psi indicates:

Install PCV maintenance kit (see section In-

Slow movement PCV poppet/seat damaged. stalling the pressure control valve maintenance
kit).

• Rebuild per service procedure

Rapid movement Check valve is damaged or debris is present.
• Replace check valve assembly

Cutting orifice is too large or damaged. Replace with correctly-sized orifice (see sec-
tion Changing the orifice in your cutting head
manual).

UHP check valve components are damaged Install a Minor or Major Maintenance Kit.
or require maintenance.

36 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

My UHP pressure seems to change depending on the state of the on/off valve (whether it's on or off).
Some degree of pressure change (2000-3000 psi [138-207 bar]) with the switching of the on/off valve is normal.

My pump does not start.

Pump not wired. • Check that operator-supplied service dis-
connect is on and all fuses are properly
sized and functional
• Check that the motor starter disconnect is
turned on
• Check for loose wiring. Call a certified
electrician.

Tripped circuit breaker in control box. Call Flow Technical Service.

My pump starts but immediately shuts down.

Crankcase oil temperature too high (can be • Ensure proper oil level
validated through FlowMaster Advanced • Verify electrical sensor is functioning prop-
Diagnostics). erly and replace if necessary
• Replace crankcase if all other options have
been exhausted

Low inlet water pressure. • Validate proper operation of inlet solenoid,

pressure gauges and switches; replace if
necessary
• Verify adequate operator-supplied water
source
• Check fuses

Motor overload shutdown has been tripped. Check with a certified electrician.

My inlet water gauges are not reading pressure.

Operator-supplied water not on, or supply Turn water on, inspect water supply pressure.
pressure is insufficient.

Failed inlet pressure gauges or gauge snubbing Replace gauges or clean snubbing orifices.
orifices are clogged.

Inlet solenoid valve not opening. • Verify that an open signal is sent to the
valve
• Check wiring and tighten or replace
• Check fuses

Kinked or obstructed gauge line. Re-position the line or replace if damaged.

© Flow International Corporation M-416 | 37

HYPLEX PRIME PUMP
Maintenance & Service Manual

My pump's inlet water filters are clogging too quickly.

Missing (or clogged) operator-supplied Install or replace the pre-filter.
5 micron inlet water pre-filter.

Improper inlet water plumbing material (use Call Flow Technical Service.
of iron or galvanized steel).

Use of alternate filter vendor (non-Flow). Flow recommends purchasing components

from Flow International Corporation to ensure
part quality and safety.

Recent upstream water supply maintenance Call Flow Technical Service.

or change of municipal supply.

Filter element order is reversed. Correct the order of the filters. The correct fil-
ter element order is indicated by labels on the
pump frame.

My pump seems to be running hotter than previously

Failed inlet check valve. Install a Minor or Major Maintenance Kit.

Failed outlet check valve.

Failed UHP seal.

Low oil level in crankcase. Add or replace oil with correct oil
(see Specifications section).
Bad or old oil in crankcase.

Blocked or kinked cooling water hose. Re-position hose or replace if damaged.

Air temperature is above specified limit. Call Flow Technical Service.

My pump's UHP tubing is failing quickly

Note: Tubing failures occur more frequently with age.

Use of alternate tubing vendor (non-Flow). Flow recommends purchasing components

from Flow International Corporation to ensure
Use of incorrect pressure-rated tubing. part quality and safety.

Frequency of low-pressure pierces will shorten Call Flow Technical Service.

tubing life.

UHP tubing length is causing "standing pres-

sure spikes."

38 | M-416 © Flow International Corporation

 CHAPTER 3
Maintenance & Troubleshooting

My UHP component life is excessively short.

CAUTION: It is expected that you have followed all recommended service and maintenance procedures. All parts
of kits should be installed at the same time - do not replace components/positions individually.

It is expected that all utility and installation requirements have been met.
Common causes for prematurely short component life include:
• Poor inlet water quality
• Low inlet water pressure
• Improperly plumbed PCV drain line
• Improperly loaded tie rod

UHP seal Worn or damaged UHP plungers. Install a Minor or Major Maintenance Kit.

Worn or damaged check valve assembly.

Worn or damaged seal carrier.

Inlet water temperature too high or too low. Call Flow Technical Service.

Incorrect seal installation. Re-install seals (refer to drawings at the end of

the manual).

UHP seal carrier Worn or damaged UHP plungers. Install a Minor or Major Maintenance Kit.

Incorrect seal installation.

Cooling ports clogged; insufficient cooling wa- Clean cooling ports. Inspect water filters and
ter flow. user-supplied water pressure.

Inlet check valve Improperly lapped components. Lap components (see Lap the inlet face of the
inlet check valve).

Inlet poppet pinched. Install a Minor or Major Maintenance Kit.

Broken spring.

Filler tube or sleeve worn out.

Improper use of lubricants on check valve sur- Clean and re-install the check valve with the
faces. proper amount of lubrication (see section As-
semble the check valve).

Debris/dirt between poppet and seat. Clean out debris; inspect poppet and seat for
damage. Install Minor or Major Maintenance
Kit if necessary.

Outlet check valve Broken spring. Clean out debris; inspect poppet and seat for
damage. Install Minor or Major Maintenance
Debris/dirt between poppet and seat. Kit if necessary.

UHP plunger Worn or damaged seal carrier. Install Major Maintenance Kit.

Incorrect seal installation (seal reversed).

Cooling ports clogged; insufficient cooling wa- Clean cooling ports, inspect water filters and
ter flow in subplate adapter and seal carrier. operator-supplied water pressure.

© Flow International Corporation M-416 | 39

HYPLEX PRIME PUMP
Maintenance & Service Manual

Notes

40 | M-416 © Flow International Corporation

 CHAPTER 4
Service

Servicing the high-pressure pump • All parts that contain high-pressure water (cylinder,
check valve housing, tubing) are susceptible to stress
The step-by-step instructions and illustrations in the ser- fatigue accelerated by nicks, scratches, or other sur-
vice procedures will help you service the equipment. face disruptions. Replace the damaged components.
There are required service procedures that must be done
• Life expectancy of high-pressure water seals and
at specific intervals; these and other procedures for re-
other high-pressure parts is related to stress on the
placing parts are located in this chapter.
parts, and is a function of stroke rate, water pressure,
and inlet water temperature. Exceeding pump rat-
Service tips & notes ings can lead to increased costs and downtime.

Review the safety precautions in Chapter 2 and the

Clean environment
maintenance tips in this chapter before starting any
work. If you have questions about any service, contact • Keeping components clean is critical. Make every ef-
Flow Technical Service. fort to find a clean area to service the compo-
• Inspect the equipment every day before operating it. nents—do not tear down parts in the same area
where cleaning is taking place. Airborne dirt and
• Read and thoroughly understand each service proce-
abrasive have serious detrimental effects on part life.
dure before starting the work.
• Carefully clean and blow compressed air on parts
• Maintain records of service performed. This will pro-
being reassembled. Do not use paper towels. Do not
vide valuable information to help you stock spare
create airborne dust.
parts and avoid suprise repairs.
• Clean all parts with fresh, clean solvent that does not
• Do not use a substitute for the fluids, sealants, and
leave a residue, such as Citra-safe® or isopropyl al-
lubricants recommended by FLOW. All threaded
cohol. FLOW recommends that you set up a dedi-
high-pressure connections require an even coating of
cated solvent tank for these critical parts.
Blue Lubricant (A-2185).
Contamination from other industrial parts will seri-
• Routinely check for loose bolts or wire connections. ously reduce part life.
• Handle critical parts with care and avoid scratching
or denting the high-pressure water system
components.
• Protect all machined and lapped mating surfaces
against nicks, scratches, and burrs.
• Monitor water seepage from end cap weep holes.

© Flow International Corporation M-416 | 41

HYPLEX PRIME PUMP
Maintenance & Service Manual

High-pressure components

42 | M-416 © Flow International Corporation

 CHAPTER 4
Service

Using the pressure loading tool

The pressure loading tool is used to accurately load and 3. Use a 19 mm (3/4 in.) socket and ratchet to rotate the
unload the tie rods on the HyPlex Prime pump. Follow tool plunger clockwise until a value of 1500 bar
these instructions to prevent damage to the tie rods, gauge pressure is reached.
high-pressure seals, or cylinders.
CAUTION
Do not use a torque wrench to attempt to
tighten the tie rod nuts. No methods other than those de-
scribed in this section may be used to load the tie rods.

Unloading the tie rods

1. Rotate the threaded pressure loading tool plunger
counter-clockwise until it stops to ensure it is fully re-
tracted. Install the pressure loading tool onto the tie
rods by running the tool studs onto the exposed
threads of the tie rods.
When tightening, alternate between opposite studs to
avoid binding. Tighten the tool studs firmly in order
to seat the tool piston fully into the tool body, and 4. Loosen the four primary hex nuts two full turns. Use a
against the end cap as shown below. 24 mm (15/16 in.) combination wrench if needed.

Note: The threaded plunger of the pressure loading 5. Use a 19 mm (3/4 in.) socket and ratchet to rotate the
tool must be backed to the stop in order to fully seat tool plunger counter-clockwise until the gauge pres-
the piston within the cylinder. sure reads 0 bar. Rotate the threaded tool plunger un-
til it is fully retracted.
2. Back out the four tool studs 1/4 turn. This allows for 6. Back out all four of the tool studs to remove the tool
easy removal of the loading tool after unloading is from the tie rods.
complete.
Note: Alternate between opposite studs to avoid
binding. Use a 22 mm (7/8 in.) combination wrench
if needed.
7. Repeat Steps 1–6 for the remaining pump positions.

© Flow International Corporation M-416 | 43

HYPLEX PRIME PUMP
Maintenance & Service Manual

Loading the tie rods

1. Rotate the threaded pressure loading tool plunger 3. Run the primary nuts of the pump down by hand
counter-clockwise until it stops to ensure it is fully re- until firmly seated against the end caps. These nuts
tracted. Install the pressure loading tool onto the tie must be fully bottomed-out against the wash-
rods by running down the tool studs onto the exposed ers/end caps.
threads of the tie rods.
When tightening, alternate between opposite studs to
avoid binding. Tighten the tool studs firmly in order to
seat the tool piston fully into the tool body, and against
the end cap as shown below.

Note: Do not use wrenches when running the pri-

mary nuts down.

4. Use the socket wrench to remove pressure from

the tool. The gauge will read 0 bar when pressure
has been removed.
5. Back out all four of the tool studs to remove the
tool from the tie rods.

Note: The plunger of the pressure loading tool must Note: When loosening, alternate between oppo-
be backed to the stop in order to fully seat the piston site studs to avoid binding.
within the cylinder.
6. Repeat steps 1 through 5 for the remaining pump
2. Use a 19 mm (3/4 in.) socket and ratchet to rotate the positions.
tool plunger clockwise until a value of 1500 bar gauge
pressure is reached.

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 CHAPTER 4
Service

Installing the Dynamic Seal Maintenance kit

Use this procedure when installing the Dynamic Seal Maintenance kit on your HyPlex Prime pump.

Tools Service notes

• Pressure loading tool assembly, 049512-1 • All parts of the kit should be installed at the same
• Combination wrenches (14-32 mm) time - do not replace components individually.

• ½ in. drive socket set (14-32 mm) • All components should be clean and free of debris
prior to assembly. Keeping the work area clean is im-
• ½ in. torque wrench (0-100 ft-lb) portant while working on the equipment.
• Screwdriver set • Read the entire procedure before beginning service,
paying particular attention to safety instructions.
Maintenance kit CAUTION
Failure to follow these step-by-step instructions and
• Dynamic Seal Maintenance kit, 050626-1 the procedures in your service manual could result in
premature failure or damage to the equipment.

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HYPLEX PRIME
Maintenance & Service Manual

Disassembly
1. Push in the E-stop. For each of the three high-pressure cylinders
4. Remove the end cap, high-pressure cylinder, inlet
WARNING
Place the main electrical disconnect OFF and bleed down
poppet, springs, filler tube, and sleeve.
all high-pressure lines. Place an “Out of Service” tag on the 5. Slide the dynamic seal carrier off the plunger if it did
main electrical disconnect and lock it out. Failure to do so not come out with the high-pressure cylinder. Re-
may result in equipment damage or injury to personnel.
move and discard the dynamic seal and rod seal.

2. Disconnect all high-pressure and low-pressure inter- CAUTION

face connections to access the tie rods. Place the Use care when removing the dynamic seal and rod seal.
Do not scratch or nick the seal carrier bores.
manifold and PCV assembly combination aside.
3. Use the pressure loading tool to unload the tie rods 6. Place the end cap vertically on a work bench with
(see Unloading the tie rods on Page 43). the check valve end up.
7. Remove the check valve assembly from the end caps
by using two flat screwdrivers in the circumferential
groove in the OD of the check valve body. Take care
not to damage the body or end cap. Remove the
o-ring from the check valve assembly.
8. Place the check valve body in the provided rebuild
clamp.
Note: Do not cover the holes on the outer circum-
ference of the check valve body to prevent metal
from being introduced into the opening.

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 CHAPTER 4
Service

9. Loosen and remove the outlet cage.

10. Remove the outlet poppet, outlet poppet spring, outlet
poppet guide, and outlet poppet seat. Place these items to
the side.

Note: It is important to lap the check valve body with the

outlet poppet and seat removed to prevent contamination
when lapping.

Lap inlet face of check valve body

and inlet poppet
11. Use the glass lapping plate from the tool kit and
320 grit lapping paper from the repair kit.
12. Lightly wet the paper with water. Place the inlet face of the
check valve body against the lapping paper. With a light
downward pressure, lap the body in a figure 8 pattern.
CAUTION
Be very careful not to rock the check valve body
while lapping the surface—flatness is very critical.

After 10-12 laps, rotate the check valve body 45° and re-
peat until the surface has a smooth matte finish free of de-
formation from the inlet poppet.
13. Lap the inlet check valve poppet in same method.
14. Thoroughly clean the check valve body openings and inlet
poppet to remove particles from the lapping process.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Installation and reassembly

Assemble the check valve Assemble the end cap
1. Insert the new outlet poppet into the new outlet
poppet guide.
Note: Install poppet into the outlet poppet guide as
shown, with the radiused back of the outlet poppet
going in first. The counterbore in the outlet poppet
is visible after installation
2. Place the new outlet poppet spring around the
guide. The spring should be loose on the guide.
3. Place the assembly into the outlet cage along with
the outlet poppet seat.
4. Hold the outlet cage assembly (threaded end of the
outlet cage facing up), so that the installed compo-
nents will not fall out. Apply a thin film of Blue Lu-
bricant to the threads of the outlet cage.
1. Lightly lubricate the check valve o-ring with o-ring
5. Carefully thread the check valve body onto the lube and install it into the groove on the check valve
outlet cage assembly. body
6. Secure the check valve body in the rebuild clamp 2. Lightly lubricate the end cap o-ring with o-ring lube
with the inlet face downward. and install it into the groove on the inner diameter
7. Secure the rebuild clamp in a vise. Torque the outlet of the end cap.
cage to 30 ft-lb (41 N-m). 3. With the outlet cage facing the end cap, insert the
Repeat Steps 1–7 for the remaining check valves. check valve body into the end cap.

Repeat for the remaining end caps.

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 CHAPTER 5
Service

Assemble and install the dynamic seal carrier

1. Inspect the dynamic seal carrier for cleanliness.
Make sure the guide bearing of the seal carrier is
flush with the face of the carrier and is in good con-
dition (the presence of cracked or loose pieces is
reason for replacement).
Replace the dynamic seal carrier if necessary. Clean
as necessary.

2. Install the new rod seal as shown, with the v-shape

groove facing up, away from the dynamic seal
carrier.

3. Install the new dynamic seal into the inner diameter

of the rod seal, making sure the dynamic seal is fully
seated against the dynamic seal carrier.
Note: Make sure the plungers are clean and free of
any damage or scratches before installing the dy-
namic seal carriers. The subplate adapter/seal carrier
interface must be clean and free of debris.
4. Slide the dynamic seal carrier onto the plungers until
seated against the register of the subplate adapter.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Install the high-pressure cylinder Assemble the inlet poppet

1. Lubricate the o-ring with o-ring lube and place it in 1. Place the inlet poppet spring over the shouldered
the groove of the high-pressure cylinder. side of the inlet poppet.

2. Apply pressure to the spring and rotate counter-

clockwise until it snaps into place. Be sure the spring
is firmly attached.

Repeat for remaining inlet poppets.

2. Slide the high-pressure cylinder over the plunger as-
sembly and seat it against the seal carrier. Position
the cylinders with weep holes facing downward.
Note: A small amount of force may be needed to
seat the cylinder against the seal carrier.

Repeat for the remaining high-pressure cylinders.

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 CHAPTER 4
Service

Assemble the filler tube

1. Place the dynamic seal compression spring into the
tapered end of the filler tube.
2. Insert the inlet poppet assembly into the filler tube,
spring end first.
3. Partially install the filler tube sleeve so that it sur-
rounds the inlet poppet and spring.
Note: The filler tube sleeve helps align the poppet
with the check valve body and prevents pinching of
the poppet between the check valve and the filler
tube during assembly.

4. Insert the filler tube, spring end first, into the

high-pressure cylinder, making sure to engage the
spring into the dynamic seal.
Repeat for the remaining filler tubes.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Install the end cap

CAUTION 4. Apply anti-seize compound to both sides of the
It is important to install the end cap in one fluid motion to- washers and to the tie rod threads.
wards the crankcase. Do not let the end cap move away
from the high-pressure cylinder while installing. If it does, 5. Install washers and hex nuts hand tight.
the inlet poppet can be pinched, causing damage. 6. Remove the temporarily installed hex nuts. Apply
1. Align the end cap so it will slide over the tie rods, anti-seize to both sides of the washers and threads,
then carefully slide the end cap towards the crank- then reinstall the nuts.
case until the check valve makes contact with the in- 7. Use the pressure loading tool to load the tie rods
let poppet. (see Loading the tie rods on Page 44).
2. Slide the end cap towards the crankcase until the
high-pressure cylinder engages the o-ring against the
high-pressure cylinder.
3. Install one of the hex nuts, hand tight, to prevent the
end cap from springing back from the HP cylinder.
Follow Steps 1-3 to install the other two end caps in the
same way, then continue with Step 4.

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Service

Install the manifold assembly

1. Apply a thin coat of Blue Lubricant to each of the 6. Loosely thread the other end of each of the three
threads on the 3/8 in. high-pressure glands. tubes into the end cap ports.
2. Slide tube shielding over the tube length.
3. On each end of the tube: slide a gland on to the
tube, then thread a collet and a collar on the
threaded end of the tube.

7. Once in place, tighten all six gland nuts. Torque to

40 ft-lb (54 N-m).
8. Reconnect all high- and low-pressure interface con-
nections.

4. Repeat Steps 1-3 for the remaining high-pressure

tubes.
5. Insert one end of the tube into the high-pressure
port on the manifold and loosely thread the glands
in place. Repeat for the other two high-pressure
tubes.

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Maintenance & Service Manual

Complete the kit installation

1. Remove the oil temperature sensor (or plug) from
the crankcase drain and completely drain the oil.
2. Reinstall the oil temperature sensor (or plug) and fill
the crankcase with oil to the level indicated on the
dipstick. Recommended oils are listed in Chapter 1.

Return the pump to service

Follow the startup procedure on Page 14 before return-
ing the HyPlex Prime pump to service.

54 | M-416 © Flow International Corporation

 CHAPTER 5
Service

Installing the Minor Maintenance kit

This service is performed at specified intervals for the life of the equipment. The complete service schedule for the mi-
nor maintenance kit (and the major maintenance kit) is described on Page 26.

Tools Maintenance kit

• Pressure loading tool, 049512-1 • Minor Maintenance Kit, 050624-1
• Combination wrenches (14-32 mm)
• ½ in. drive socket set (14-32 mm) Service notes
• ½ in. torque wrench (0-100 ft-lb) • All parts of the kit should be installed at the same
• Screwdriver set time - do not replace components individually.
• Snap-ring pliers • All components should be clean and free of debris
• Rebuild clamp or 6 in. soft jaw vise prior to assembly. Keeping the work area clean is im-
portant while working on the equipment.
• Read the entire procedure before beginning service,
paying particular attention to safety instructions.
CAUTION
Failure to follow these step-by step instructions
could cause premature parts failure and/or
damage to the equipment.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Disassembly

1. Push in the E-stop. For each of the three high-pressure cylinders

4. Remove the end cap, high-pressure cylinder, inlet
WARNING
Place the main electrical disconnect OFF and bleed down
poppet, springs, filler tube, and sleeve. Discard the
all high-pressure lines. Place an “Out of Service” tag on the inlet poppet and spring.
main electrical disconnect and lock it out. Failure to do so 5. Remove and discard the o-ring from the ID of the
may result in equipment damage or injury to personnel.
high-pressure cylinder.

2. Disconnect all high-pressure and low-pressure inter- 6. Slide the dynamic seal carrier off the plunger if it did
face connections to access the tie rods. Place the not come out with the cylinder. Remove and discard
manifold and PCV assembly combination aside. dynamic seal and rod seal.

3. Use the pressure loading tool to unload the tie rods CAUTION
(see Unloading the tie rods on Page 43). Use care when removing dynamic seal and rod
seal. Do not scratch or nick seal carrier bores.

7. Remove the subplate adapter. If necessary, use pry

bars or screwdrivers to remove the adapter. Remove
the snap ring from the subplate adapter using snap
ring pliers. Remove the spacer and seal. Remove the
two o-rings from the outer diameter of the adapter.

Discard the seal, o-rings, and snap ring. Keep the

spacer for reuse.

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Service

8. Place the end cap vertically on a work bench with

the check valve end up.
9. Remove the check valve assembly from the end caps
by using two screwdrivers in the circumferential
groove in the OD of the check valve body. Be care-
ful not to damage the body or the end cap. Remove
the o-ring from the check valve assembly.

10. Place the check valve body in the provided rebuild

clamp.
Note: Do not cover the holes on the outer circum-
ference of the check valve body to prevent metal
from being introduced into the opening.
11. Loosen the outlet cage.
12. Remove the outlet poppet and guide, outlet poppet
spring, and outlet poppet seat. Discard the poppet,
seat, guide, and spring.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Lap inlet face of check valve body Installation and reassembly

13. Use the glass lapping plate from the tool kit and Assemble the check valve
320 grit lapping paper from the repair kit. Lightly
wet the paper with water. 1. Insert the new outlet poppet into the new outlet
poppet guide.
14. Place the check valve body with the inlet face
against the lapping paper. With a light downward Note: Install poppet into the outlet poppet guide as
pressure, lap the body in a figure-8 pattern. shown, with the radiused back of the outlet poppet
going in first. The counterbore in the outlet poppet
CAUTION is visible after installation
Be very careful not to rock the check valve body
while lapping the surface—flatness is very critical. 2. Place the new outlet poppet spring around the
guide. The spring should be loose on the guide.
After 10-12 laps, rotate the check valve body 45° 3. Place the assembly into the outlet cage along with
and continue lapping until the surface has a smooth the outlet poppet seat.
matte finish free of any deep scratches or signs of
deformation from the inlet poppet. Re-wet the pa- 4. Hold the outlet cage assembly (threaded end of the
per as needed. outlet cage facing up), so that the installed compo-
nents will not fall out. Apply a thin film of Blue Lu-
15. Thoroughly clean the check valve body openings to bricant to the threads of the outlet cage.
remove particles from the lapping process.
5. Carefully thread the check valve body onto the
outlet cage assembly.
6. Secure the check valve body in the rebuild clamp
with the inlet face downward.
7. Secure the rebuild clamp in a vise. Torque the outlet
cage to 30 ft-lb (41 N-m).
Repeat Steps 1–7 for the remaining check valves.

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Service

Assemble the end cap Rebuild the subplate adapter

1. Lightly lubricate the new check valve o-ring with 1. Make sure the tie rods are firmly seated in the
o-ring lube and install it into the grooves on the subplate.
check valve body. Note: Hand tight is sufficient.

2. With the v-shaped face toward the subplate adapter,

install the new rod seal in the counterbore of the
subplate adapter.

2. Lightly lubricate the end cap o-ring with o-ring lube

and install it in the groove in the inner diameter of
the end cap.
3. With the outlet cage facing the end cap, insert the
3. Place the new spacer in the counterbore with the
check valve body into the end cap.
chamfered side down (toward the newly-installed
Repeat for the remaining end caps. seal).
4. Secure the rod seal and spacer with the new
snap ring.
Check plunger torque
5. Lubricate and install the two new o-rings onto the
1. Install the plunger nut tool over the plunger and adapter, and slide the adapter over the plunger until
plunger nut. Use a torque wrench to torque the it engages the counterbore of the subplate.
plunger nut to 20 ft-lb (27 N-m).
Repeat Steps 1-5 for the remaining subplate adapters
2. Rotate the pulley to fully extend the next plunger to
be checked.
Repeat steps for the remaining plungers. When finished,
wipe off dirt and grease from all three plungers.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Assemble and install the dynamic seal carrier

1. Inspect the dynamic seal carrier for cleanliness.
Make sure the guide bearing of the seal carrier is
flush with the face of the carrier and is in good con-
dition (the presence of cracked or loose pieces is
reason for replacement).
Replace the dynamic seal carrier if necessary. Clean
as necessary.

2. Install the new rod seal as shown, with the v-shaped

face pointing out of the dynamic seal carrier.

3. Install the new dynamic seal into the inner diameter

of the rod seal, making sure the dynamic seal is fully
seated against the dynamic seal carrier.
Note: Make sure the plungers are clean and free of
any damage or scratches before installing the dyna-
mic seal carriers. The subplate adapter/seal carrier
interface must be clean and free of debris.
4. Slide the dynamic seal carrier into the plungers until
seated against the register of the subplate adapter.
Repeat for the remaining dynamic seal carriers.

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Service

Install the high-pressure cylinder Assemble the inlet poppet

1. Lubricate the new o-ring with o-ring lube and place
it in the groove of the high-pressure cylinder.

1. Place the new inlet poppet spring over the shoul-

dered side of the new inlet poppet.
2. Apply pressure to the spring and rotate counter-
clockwise until it snaps into place. Be sure the spring
is firmly attached.
Repeat for the remaining inlet poppets.

2. Slide the high-pressure cylinder over the plunger as-

sembly and seat it against the seal carrier. Position
the cylinders with weep holes facing downward.
Note: A small amount of force will be needed to
seat the cylinder against the seal carrier.

Repeat for the remaining high-pressure cylinders.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Assemble the filler tube assembly

1. Place the dynamic seal compression spring into the
tapered end of the filler tube.
2. Insert the inlet poppet assembly into the filler tube,
spring end first.
3. Install the filler tube sleeve so that it
surrounds the inlet poppet and spring.
Note: The filler tube sleeve helps align the poppet
with the check valve body and prevents pinching of
the poppet between the check valve and filler tube
during assembly.

4. Insert the filler tube-spring end first-into the

high-pressure cylinder, making sure to engage the
spring into the dynamic seal.

Repeat for the remaining filler tubes.

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Service

Install the end cap Replace the PCV poppet and seat
CAUTION 1. Remove the air supply line from the PCV actuator,
It is important to install the end cap in one fluid motion and the drain line from the outlet adapter.
toward the crankcase. Do not let the end cap move away
from the high-pressure cylinder while installing. If it does, 2. Remove all high-pressure lines from the manifold.
the inlet poppet can be pinched, causing damage.
3. Place the manifold in a soft-jaw vise
1. Align the end cap so it will slide over the tie rods, 4. Use a 1-1/4 in. wrench to remove the PCV from the
then carefully slide the end cap towards the HP cyl- manifold. remove the outlet adapter from the PCV
inder until the check valve body makes contact with body.
the inlet poppet. 5. Remove and discard the poppet, seat, and seal ring
2. Continue to slide the end cap until the high-pressure from the PCV body.
cylinder engages the o-ring in the end cap and the Note: Needle nose pliers may be needed to remove
check valve body seats against the high-pressure the poppet from the assembly.
cylinder.
6. Lube the outlet adapter o-rings and slide onto the
3. Temporarily install one of the hex nuts, hand tight, PCV body.
to prevent the end cap from springing back.
7. Make sure the static seal ring is installed on the seat
Follow Steps 1–3 to install the other two end caps in the and loosely install the new poppet into the seat.
same way, then continue with Step 4. Note: Do not press poppet into the seat.
4. Apply a thin coat of anti-seize compound to both 8. Place poppet and seat assembly into the end of the
sides of the washers and to the tie rod threads. valve body.
5. Install washers and hex nuts hand tight. Lubricate the PCV body threads with Blue Lube and
thread the PCV assembly into the high-pressure
6. Remove the temporarily installed hex nuts. Apply manifold. Tighten to 190 ft-lb (258 N-m).
anti-seize to both sides of the washers and threads,
then reinstall the nuts. 9. Remove the manifold assembly from the vise.
7. Use the pressure loading tool to load the tie rods
(see Loading the tie rods on Page 44).

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Maintenance & Service Manual

Install the manifold assembly 6. Loosely thread the other end of each of the three
tubes into the end cap ports.
1. Apply a thin coat of Blue Lubricant to each of the
threads on the 3/8 in. high-pressure glands.
2. Slide tube shielding over the tube length.
3. On each end of the tube: slide a gland on to the
tube, then thread a collet and a collar on the
threaded end of the tube.

7. Once in place, tighten all six gland nuts. Torque to

40 ft-lb (54 N-m).
8. Reconnect all high- and low-pressure interface con-
nections

4. Repeat Steps 1-3 for the remaining two high-pres-

sure tubes.
5. Insert one end of the tube into the high-pressure
port on the manifold and loosely thread the glands
in place. Repeat for the other high-pressure tubes.

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Service

Complete the kit installation

1. Remove the oil temperature sensor (or plug) from
the crankcase drain and completely drain the oil.
2. Reinstall the oil temperature sensor (or plug) and fill
the crankcase with oil to the level indicated on the
dipstick. Recommended oils are listed in Chapter 1.

Return the pump to service

Follow the startup procedure on Page 14 before return-
ing the HyPlex Prime pump to service.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Notes

66 | M-416 © Flow International Corporation

 CHAPTER 4
Service

Installing the Major Maintenance kit

Use this procedure when installing the Major Maintenance kit on your HyPlex Prime pump. This service is performed
at every required maintenance interval for the life of the equipment. The complete service schedule for the major
maintenance kit (and the minor maintenance kit) is described on Page 26.

Tools Maintenance kit

• Pressure loading tool, 049512-1 • Major maintenance kit, 050624-2
• Combination wrenches (14-32 mm)
• ½ in. drive socket set (14-32 mm) Service notes
• ½ in. torque wrench (0-100 ft-lb) • All parts of the kit should be installed at the same
• Feeler gauge set time - do not replace components individually.
• Screwdriver set • All components should be clean and free of debris
• Snap-ring pliers prior to assembly. Keeping the work area clean is im-
portant while working on the equipment.
• 3/8 in. hex bit
• Read the entire procedure through before beginning
• ½ in. hex bit
service, paying particular attention to safety instruc-
• Rebuild clamp or 6 in. soft jaw vise tions.
CAUTION
Failure to follow these step-by step instructions
could cause premature parts failure
and/or damage to the equipment.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Disassembly
1. Push in the E-stop. For each of the three high-pressure cylinders
4. Remove the end cap, high-pressure cylinder, inlet
WARNING
Place the main electrical disconnect OFF and bleed down
poppet, springs, filler tube, and sleeve.
all high-pressure lines. Place an “Out of Service” tag on the 5. Discard the spring and poppet, filler tube sleeve,
main electrical disconnect and lock it out. Failure to do so and high-pressure cylinder.
may result in equipment damage or injury to personnel.
6. Slide the dynamic seal carrier off the plunger if it did
2. Disconnect all high-pressure and low-pressure inter- not come out with the cylinder. Remove and discard
face connections to access the tie rods. Place the the dynamic seal and rod seal.
manifold and PCV assembly combination aside. CAUTION
3. Use the pressure loading tool to unload the tie rods Use care when removing dynamic seal and rod
seal. Do not scratch or nick seal carrier bores
(see Unloading the tie rods on Page 43).
7. Remove the subplate adapter. If necessary, use pry
bars or screwdrivers to remove the adapter. Remove
the snap ring from the subplate adapter using snap
ring pliers. Remove the spacer and seal. Remove the
two o-rings from the outer diameter of the adapter.

Discard the seal, o-rings, and snap ring. Keep the

spacer for reuse.

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Service

8. Place the end cap vertically on a work bench with

the check valve end up.
9. Remove the check valve assembly from the end cap
by using two screwdrivers in the circumferential
groove in the OD of the check valve body. Be care-
ful not to damage the body or the end cap. Remove
the o-ring from the check valve assembly.

10. Place the check valve body in the provided

rebuild clamp.
Note: Do not cover the holes on the outer circum-
ference of the check valve body to prevent metal
from being introduced into the opening.
11. Loosen the outlet cage.
12. Remove the outlet poppet and guide, outlet poppet
spring, and outlet poppet seat from the outlet cage.
Retain the cage. Discard the outlet poppet and
guide, outlet poppet spring, outlet poppet seat, and
check valve body.

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Installation and reassembly

Assemble the check valve
1. Insert the new outlet poppet into the new outlet
poppet guide.
Note: Install poppet into the outlet poppet guide as
shown, with the radiused back of the outlet poppet
going in first. The counterbore in the outlet poppet
is visible after installation.

2. Place the new outlet poppet spring around the

guide. The spring should be loose on the guide.
3. Place the assembly into the outlet cage along with
the outlet poppet seat.
4. Hold the outlet cage assembly upright (threaded end
of the outlet cage facing up) so that the installed
components will not fall out. Apply a thin film of
Blue Lubricant to the threads of the outlet cage.
5. Carefully thread the new check valve body onto the
outlet cage assembly.
6. Secure the check valve body in the rebuild clamp
with the inlet face downward.
7. Secure the rebuild clamp in a vise. Torque the outlet
cage to 30 ft-lb (41 N-m).
Repeat Steps 1–7 for the remaining check valves.

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Service

Assemble the end cap Rebuild the subplate adapter

1. Lightly lubricate the new check valve o-ring with 1. Make sure the tie rods are firmly seated in the
o-ring lube and install it into the grooves on the subplate.
check valve body. Note: Hand tight is sufficient.

2. With the v-shaped face towards the subplate

adapter, install the new rod seal in the counterbore
of the subplate adapter.

2. Lightly lubricate the end cap o-ring with o-ring lube

and install it in the groove in the inner diameter of
the end cap.
3. With the outlet cage facing the end cap, insert the
check valve body into the end cap. 3. Place the new spacer in the counterbore with the
chamfered side down (toward the newly-installed
Repeat for the remaining end caps seal).
4. Secure the rod seal and spacer with the new snap
Check plunger torque ring.

1. Install the plunger nut tool over the plunger and 5. Lubricate and install the two new o-rings onto the
plunger nut. Use a torque wrench to torque the adapter, and slide the adapter over the plunger until
plunger nut to 20 ft-lb (27 N-m). it engages the counterbore of the subplate.

2. Rotate the pulley to fully extend the next plunger to Repeat Steps 1–5 for the remaining subplate adapters.
be checked.
Repeat steps for the remaining plungers. When finished,
wipe off dirt and grease from all plungers.

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Maintenance & Service Manual

Assemble and install the dynamic seal carrier

1. Inspect the dynamic seal carrier for cleanliness.
Make sure the guide bearing of the seal carrier is
flush with the face of the carrier and is in good con-
dition (the presence of cracked or loose pieces is
reason for replacement).
Replace the dynamic seal carrier if necessary. Clean
as necessary.

2. Install the new rod seal as shown, with the v-shape

face pointing out of the dynamic seal carrier.

3. Install the new dynamic seal into the inner diameter

of the rod seal, making sure the dynamic seal is fully
seated against the dynamic seal carrier.
Note: Make sure the plungers are clean and free of
any damage or scratches before installing the dy-
namic seal carriers. The subplate adapter/seal carrier
interface must be clean and free of debris.
4. Slide the dynamic seal carrier onto the plungers until
seated against the register of the subplate adapter.
Repeat for the remaining dynamic seal carriers.

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Service

Install the high-pressure cylinder Assemble the inlet poppet

1. Lubricate the bew o-ring with o-ring lube and place 1. Place the new inlet poppet spring over the shoul-
it in the groove of the new high-pressure cylinder. dered side of the new inlet poppet.

2. Apply pressure to the spring and rotate counter-

clockwise until it snaps into place. Be sure the spring
is firmly attached.
Repeat for the remaining inlet poppets.

2. Slide the new high-pressure cylinder over the

plunger assembly and seat it against the seal carrier.
Position the cylinders with weep holes facing down-
ward.
Note: A small amount of force will be needed to
seat the cylinder against the seal carrier.

Repeat for the remaining high-pressure cylinders.

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Assemble the filler tube assembly

1. Place the dynamic seal compression spring into the
tapered end of the filler tube.
2. Insert the inlet poppet assembly into the filler tube,
spring end first.
3. Install the filler tube sleeve so that it surrounds the
inlet poppet and spring.
Note: The filler tube sleeve helps align the poppet
with the check valve body and prevents pinching of
the poppet between the check valve and filler tube
during assembly

.
4. Insert the filler tube – spring end first – into the
high-pressure cylinder, making sure to engage the
spring into the dynamic seal.

Repeat for the remaining filler tubes.

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 CHAPTER 4
Service

Install the end cap

CAUTION Replace the PCV poppet and seat
It is important to install the end cap in one fluid motion
towards the crankcase. Do not let the end cap move away 1. Remove the air supply line from the PCV actuator,
from the high-pressure cylinder while installing. If it does, and the drain line from the outlet adapter.
the inlet poppet can be pinched, causing damage.
2. Remove all high-pressure lines from the manifold.
1. Align the end cap so it will slide over the tie rods, 3. Place the manifold in a soft-jaw vise
then carefully slide the end cap towards the HP cyl-
inder until the check valve body makes contact with 4. Use a 1-1/4 in. wrench to remove the PCV from the
the inlet poppet. manifold. remove the outlet adapter from the PCV
body.
2. Continue sliding the end cap until the high-pressure
cylinder engages the o-ring in the end cap and the 5. Remove and discard the poppet, seat, and seal ring
check valve body seats against the high-pressure cyl- from the PCV body.
inder. Note: Needle nose pliers may be needed to remove
3. Temporarily install one of the hex nuts, hand tight, the poppet from the assembly.
to prevent the end cap from springing back from the 6. Lube the outlet adapter o-rings and slide onto the
HP cylinder. PCV body.
Follow Steps 1–3 to install the other two end caps, then 7. Make sure the static seal ring is installed on the seat
continue with Step 4. and loosely install the new poppet into the seat.
4. Apply a thin coat of anti-seize compound to both Note: Do not press poppet into the seat.
sides of the washers and to the tie rod threads. 8. Place poppet and seat assembly into the end of the
5. Install washers and hex nuts hand tight. valve body.

6. Remove the temporarily installed hex nuts. Apply Lubricate the PCV body threads with Blue Lube and
anti-seize to both sides of the washers and threads, thread the PCV assembly into the high-pressure
then reinstall the nuts. manifold. Tighten to 190 ft-lb (258 N-m).

7. Use the pressure loading tool to load the tie rods 9. Remove the manifold assembly from the vise..
(see Loading the tie rods on page 44).

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Install the manifold assembly 6. Loosely thread the other end of each of the three
tubes into the end cap ports.
1. Apply a thin coat of Blue Lubricant to each of the
threads on the 3/8 in. high-pressure glands.
2. Slide tube shielding over the tube length.
3. On each end of the tube: slide a gland on to the
tube, then thread a collet and a collar on the
threaded end of the tube.

7. Once in place, tighten all six gland nuts. Torque to

40 ft-lb (54 N-m).
8. Reconnect all high- and low-pressure interface con-
nections.

4. Repeat Steps 1–3 for the remaining two high-pres-

sure tubes.
5. Insert one end of the tube into the high-pressure
port on the manifold and loosely thread the glands
in place. Repeat for the other two high-pressure
tubes.

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Service

Complete the kit installation

1. Remove the oil temperature sensor (or plug) from
the crankcase drain and completely drain the oil.
2. Reinstall the oil temperature sensor (or plug) and fill
the crankcase with oil to the level indicated on the
dipstick. Recommended oils are listed in Chapter 1.

Return the pump to service

Follow the startup procedure on Page 14 before return-
ing the HyPlex Prime pump to service.

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Maintenance & Service Manual

Notes

78 | M-416 © Flow International Corporation

 CHAPTER 4
Service

Installing the pressure control valve (PCV) maintenance kit

Use this procedure when installing the HyPlex Prime pressure control valve maintenance kit. The complete service
schedule for the PCV is located on Page 26.
Every other time you install a Major Maintenance kit, you should also install the PCV Maintenance kit. The poppet,
seat, and static seal described in this procedure are included in the Major Maintenance kit.

Tools Service notes

• Combination wrenches (11–32 mm) • All parts of the kit should be installed at the same
• 1/2-in. torque wrench (0–100 ft-lb) time - do not replace components individually.
• Screwdriver set • All components should be clean and free of debris
prior to assembly. Keeping the work area clean is im-
• Allen wrench set
portant while working on the equipment.
• Needle nose pliers
• Read the entire procedure through before beginning
• 6 in. soft jaw vise service, paying particular attention to safety instruc-
tions.

Maintenance kit CAUTION

Failure to follow these step-by step instructions could cause
• PCV maintenance kit, 050625-1 premature parts failure or damage to the equipment.

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Maintenance & Service Manual

Disassembly
The poppet, seat, seal ring, bearing, plunger, piston seal, 8. Push the bearing from the bore of the PCV body us-
plunger seal, and o-rings are replaced in this procedure. ing the bearing removal/installation tool (011172-1).
Remove the plunger seal and o-ring. Discard the
1. Shut down the system. plunger seal, o-ring, and bearing assembly.

WARNING
Place the main electrical disconnect OFF 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.

2. Reduce air pressure to 0 psi and remove the air and

drain lines from the PCV.
3. Remove the PCV from the manifold.
4. Remove the poppet, seat, and seal ring from the
PCV body.
Note: Needle nose pliers may be needed to remove
the poppet from the assembly.

5. Remove the PCV adapter from the valve body. Re-

move and discard the o-rings from the valve body.
6. Place the air cylinder in a soft jaw vise. Use a 1-1/4
in. (32 mm) combination wrench to remove the PCV
body from the air cylinder.
7. Use a hex wrench to remove the four cap screws
from the air cylinder. Separate the mounting block
to access the plunger. Discard the plunger.

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Service

Installation and reassembly

1. Slide the new plunger through the bore of the cylin- 7. Clean out any debris that remains in the high-pres-
der mounting block. sure port of the manifold.
2. Reinstall cap onto housing and tighten the four cap 8. Lubricate the two new o-rings with food-grade
screws. grease. Place new o-rings on the outer diameter of
3. Inspect the other non-wear components for any the valve body.
signs of deterioration; repair or replace as necessary.
4. Use the bearing removal/installation tool to push the
new bearing assembly into the bore of the PCV
body.

9. Install the PCV adapter on the valve body.

10. Make sure the static seal ring is installed on the seat
and loosely install the poppet into the seat.
5. Lubricate the plunger seal with the provided Note: Do not press poppet into the seat.
food-grade grease. Install the o-ring onto the plunger
seal. Install the combination–with the o-ring side to- 11. Place poppet and seat assembly into the end of the
wards the valve body–into the valve body. valve body, then thread the PCV assembly into the
high-pressure manifold. Tighten to 190 ft-lb (258
N-m).
12. Reconnect the air supply and drain lines.

Follow the startup procedure on Page 14 before return-

ing the HyPlex Prime pump to service.

6. With the air cylinder in a soft jaw vise, slide the

body over the plunger and thread into the mounting
block until the PCV body is firmly seated. No ex-
treme torque is needed.

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Notes

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 CHAPTER 4
Service

Changing the filter elements

Change the filter elements if the post-filter pressure is roughly less than 18 psi when the pump is running. The pump
will automatically shut down when pressure is below 15 psi.when the pump is running.

Note: Check filter pressure gauges only when pump is CAUTION

running at full speed and operating at full UHP output The 0.5m and 1.0m cartridges must be installed
in the correct position as labeled on the
pressures. When the pump is stopped, the pressures will pump—failure to do so could shorten pump life.
increase substantially, even with a dirty filter.
7. Re-assemble the filter canisters to the filter housing
using a strap wrench.
Service steps
8. Open the water inlet source valve. Check for leaks.
1. Shut down the system.
CAUTION
2. Close the water inlet source valve. You must open the water inlet source valve before
3. Remove the filter canisters using a strap wrench. starting the pump—failure to do so could
severely damage the pump.
4. Remove the filters from the canisters and discard.
9. When the filter canisters are pressurized, it is neces-
CAUTION sary to remove air from the system by pressing the
Using dirty or incorrect filter
elements can shorten pump life. red pressure-relief buttons located on top of the fil-
ter housings.
5. Inspect the contents of the canister. 10. Enter the date and/or hours of operation from the
Note: This inspection can provide early warning of a hour meter into the service log.
change in inlet water quality. Filter life and inlet wa-
ter quality are directly related.
6. Clean the canisters and install new filter cartridges.

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Replacing the dynamic seals and For example, suppose you have a 50 hp pump. The Dy-
plungers namic Seal maintenance interval is every 300 hours. The
dynamic seal fails at 250 hours, 50 hours short of a
Use this procedure if service is required outside of the scheduled maintenance period. Install the Dynamic Seal
preventive maintenance schedule. It is important that maintenance kit, but the next scheduled maintenance
you continue to maintain the pump according to the would take place at 550 hours, not 600 hours.
procedures specified in the required maintenance kit
instructions. Premature failure midway between
Remember, different horsepower pumps have different scheduled service
maintenance intervals. See the interval listing on
If the dynamic seal fails somewhere midway between
Page 26, and refer to drawing 049656.
two scheduled service periods (for example, a dynamic
In the event of premature failure, you will need to inte- seal on a 50 hp pump that fails at 150 hours since last
grate dynamic seal repair with the preventive mainte- service), FLOW recommends replacing all components
nance described in this manual. FLOW suggests the to prevent unexpected down time.
following strategy.

Premature failure close to the scheduled time

If the dynamic seal fails within 50 hours of a scheduled
service, perform a complete service procedure. Record
the actual hour meter reading when you install the main-
tenance kit—the next scheduled maintenance should
take place at the specified number of hours from this
reading.

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 CHAPTER 4
Service

Tools 5. Slide the dynamic seal carrier off the plunger if it did
not come out with the high-pressure cylinder. Re-
Plunger nut installation tool, 011153-1 move and discard the dynamic seal and rod seal.
CAUTION
Service steps Use care when removing the dynamic seal and rod seal.
Do not scratch or nick the seal carrier bores.
1. Push in the E-stop.
6. Inspect the seal carrier and plunger for damage.
WARNING Keep and reuse the seal carrier if undamaged. The
Place the main electrical disconnect OFF and bleed down plunger should not have touched the bore of the
all high-pressure lines. Place an "Out of Service" tag on the seal carrier.
main electrical disconnect and lock it out.
Failure to do so may result in equipment damage or injury • If there are contact marks on either compo-
to personnel. nent, replace both components.
• If both components are OK, skip to Step 3 of
2. Disconnect all high-pressure and low-pressure inter- Installation and reassembly on Page 86.
face connections to access the tie rods. Place the
manifold and PCV assembly combination aside. 7. Remove the subplate adapter.
3. Use the pressure loading tool to unload the tie rods Note: If the plunger is damaged, replace the rod
(see Unloading the tie rods on Page 43). seal in the subplate adapter by removing the snap
ring with snap ring pliers. Discard the rod seal. Keep
the snap ring and spacer for reuse.
For each of the three cylinders
4. Remove the end cap, high-pressure cylinder, inlet 8. Rotate the crankshaft to place the damaged plunger
poppet, springs, filler tube, and sleeve. in its fully extended position. Using the plunger nut
tool, remove and retain the plunger nut and spring.
Slide the plunger assembly from the crosshead bore
and discard.

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Installation and reassembly

1. With the crosshead in its fully extended position, ap- Assemble and install the dynamic seal carrier
ply anti-seize to the nut, and place spring into the
counterbore of the plunger nut. Slip the nut and 1. Inspect the dynamic seal carrier for cleanliness.
spring over the new plunger, engage the threads of Make sure the guide bearing of the seal carrier is
the crosshead, and tighten to 20 ft-lb (27 N-m) using flush with the face of the carrier and is in good con-
the plunger nut tool. dition (the presence of cracked or loose pieces is
reason for replacement).
2. With the v-shaped face of the rod seal towards the
subplate adapter, install the new seal in the Replace the dynamic seal carrier if necessary. Clean
counterbore of the subplate adapter. as necessary.

3. Place the spacer in the counterbore with the

chamfered side down (toward the newly-installed
seal).
4. Secure the rod seal and spacer with the snap ring.
5. Lubricate and install the o-rings onto the adapter,
and slide over the plunger until it engages the coun-
ter-bore of the subplate.
Repeat for the remaining subplate adapters.

2. Install the rod seal as shown with the v-shaped face

facing up, away from the dynamic seal carrier.

3. Install the new dynamic seal into the inner diameter

of the rod seal, making sure the dynamic seal is fully
seated against the dynamic seal carrier.
Note: Make sure the plungers are clean and free of
any damage or scratches before installing the dy-
namic seal carriers. The subplate adapter/seal carrier
interface must be clean and free of debris.
4. Slide the seal carrier onto the plunger until seated
against the register of the adapter.
Repeat for the remaining dynamic seal carriers.

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Service

Install the high-pressure cylinder

1. Lubricate the o-ring with o-ring lube and place it in
the appropriate grooves of the high-pressure
cylinder.

2. Slide the high-pressure cylinder over the plunger as-

sembly and seat it against the seal carrier. Position
the cylinders with weep holes facing downward.

Note: A small amount of force may be needed to

seat the cylinder against the seal carrier.
Repeat for the remaining high-pressure cylinders.

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 CHAPTER 5
Service

Install the filler tube assembly Install the end cap

1. Place the dynamic seal compression spring into the CAUTION
tapered end of the filler tube. It is important to install the end cap in one fluid
motion toward the crankcase. Do not let the
2. Insert the inlet poppet assembly into the filler tube, end cap move away from the high-pressure cylinder
spring end first. while installing. If it does, the inlet poppet can be
pinched, causing damage.
3. Install the filler tube sleeve so that it surrounds the
inlet poppet and spring. 1. Align the end cap so it will slide over the tie rods.
Note: The filler tube sleeve helps align the poppet Carefully slide the end cap towards the HP cylinder
with the check valve body and prevents pinching of until the check valve body makes contact with the
the poppet between the check valve and filler tube inlet poppet.
during assembly. 2. Continue to slide the end cap until the high-pres-
sure cylinder engages the o-ring in the end cap and
the check valve body seats itself against the
high-pressure cylinder.

4. Insert the filler tube–spring end first–into the

high-pressure cylinder, making sure to engage the 3. Temporarily install one of the hex nuts, hand tight,
spring into the dynamic seal. to prevent the end cap from springing back from
the HP cylinder.
Repeat for the remaining filler tubes.
Follow Steps 1–3 to install the other two end caps in the
same way, then continue with Step 4.
4. Apply a thin coat of anti-seize compound to both
sides of the washers and threads of the tie rods.
5. Install washers and hex nuts hand tight.
6. Remove the temporarily installed hex nuts. Apply
anti-seize to both sides of the washers and threads,
then reinstall the nuts.
7. Use the pressure loading tool to load the tie rods
(see Loading the tie rods on Page 44).

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 CHAPTER 4
Service

Install the manifold assembly

1. Apply a thin coat of Blue Lubricant to each of the 6. Loosely thread the other end of each of the three
threads on the 3/8 in. high-pressure glands. tubes into the end cap ports.
2. Slide tube shielding over the tube length.
3. On each end of the tube: slide a gland on to the
tube, then thread a collet and a collar on the
threaded ends of the tube.

7. Once in place, tighten all six gland nuts. Torque to

40 ft-lb (54 N-m).
8. Reconnect all high- and low-pressure interface con-
nections.

4. Repeat Steps 1–3 for the remaining two high-pres-

sure tubes.
5. Insert one end of the tube into the high-pressure
port on the manifold and loosely thread the glands
in place. Repeat for the other two high-pressure
tubes.

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 CHAPTER 5
Service

Complete the kit installation

1. Remove the oil temperature sensor (or plug) from
the crankcase drain and completely drain the oil.
2. Reinstall the oil temperature sensor (or plug) and fill
the crankcase with oil to the level indicated on the
dipstick. Recommended oils are listed in Chapter 1.

Return the pump to service

Follow the start-up procedure on Page 14 before return-
ing the HyPlex Prime pump to service.

© Flow International Corporation M-397 | 90

 CHAPTER 4
Service

Tensioning and aligning the belt drive

Service the pulleys and belts during scheduled Major Maintenance service interval or if belts fail.

For optimum belt performance, the V-belt drive must be Servicing the belts
tensioned and aligned properly. Follow these general
rules when tensioning a drive:
WARNING
• The ideal tension for the belt drive is the lowest ten- Place the main electrical disconnect in the
sion at which the belt will not slip under the highest OFF position and bleed down all high-pressure lines. Place
an “Out of Service” tag on the main electrical disconnect
load condition. and lock it out. Failure to do so can result in equipment
• Check tension on a new drive belt frequently during damage or injury to personnel.
the first day of operation and periodically thereafter.
• Excessive tension shortens belt and bearing life. 1. Shut down the system.
• Keep the belt and pulleys free from oil, grease, cut- 2. Remove the belt guard.
ting lubricants, or belt dressing—any of these can 3. Loosen the four hex nuts that attach the transmission
cause the belt to slip. housing to the electric motor. Turn the nut on the
• If a V-belt slips, it is not at proper tension and needs tension bar CCW. This allows the weldment to rotate
to be tightened. so you can remove the belts.
• Do not use subsititute hardware. 4. Install the four new belts.
Note: It is important to replace all four belts at the
same time to maintain consistent performance of the
drive system.

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5. Turn the nut on the tension bar CW until there is When the tension is correct:
tension on the belts.
8. Use a 3/4 in. socket to torque the three flanged nuts
6. Use the belt tension gauge to determine correct ten- not attached to the tension bar to the appropriate
sion on one of the belts. torque value in the table below. Do not tighten the
Note: This step is for verifying tension only. Perform flanged nut that attaches the tension rod end to the
this step before loosening any hex nuts. housing.
a. Place the gauge in the center of the belt midway
30 hp 50 hp
between pulleys, and align the sides of the
gauge parallel to the edges of the belt. 75 ft-lb (102 N-m) 125 ft-lb (170 N-m)
b. Push slowly on the colored pad with a force
perpendicular to the belt to get an accurate
reading. When you hear a click, immediately
stop pressing and carefully remove the gauge.
Note: Only the pad of the tool must be touched
during measurement.
c. Turn the gauge sideways to see the exact spot
where the top of the indicator arm intersects the
scale.
d. Take more than one reading to assure repeat-
able measurements.

7. Turn the nut on the tension bar CW to increase ten-

sion or CCW to decrease tension. Tension should be
set between 100 and 110 lbs (445-489 N). Refer to
drawing 049785.
9. Remove tension from the tension bar nut. Torque
the final (the fourth) flanged nut to the appropriate
torque value.
10. Tighten the nut on the tension bar to 15 ft-lb
(20 N-m).
11. Reinstall the belt guard.

Remove the “Out of Service” tag from the main electrical

disconnect and make final inspection to remove tools,
parts, and rags from the equipment. The pump is ready
for operation.

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 CHAPTER 4
Service

Servicing the crankcase

The only service required for the HyPlex Prime crank- Replacing the piston rod seal assembly
case is to maintain adequate levels of clean oil and to re-
The piston rod seal assembly contains three oil seals in-
place worn piston rod seal assemblies.
stalled in seal carrier and an o-ring on the outer diame-
Rebuilding the crankcase is not recommended. ter. The oil seals cannot be replaced individually; the
entire assembly must be replaced.
Lubricating the pump To access and replace the seal assembly, the subplate
must be removed
Use of Shell Morlina 100 Hydraulic Oil (ISO 100) is rec-
ommended, but other manufacturer's equivalents can be Use the assembly thimble (015624-1) on the end of the
used. crosshead adapter; this will expand the sealing edge as
the housing slides back to engage the crankcase bore.
When operating the pump in an environment with an Use care to ensure that the oil seal carrier (044099-1) is
ambient temperature greater than 86°F (30°C) a heavier oriented correctly with the OD o-ring toward the
oil is recommended to be used. Contact Flow Technical crankcase).
Services for additional information.
FLOW recommends replacing all three piston rod seal
Maintain oil level between the high and low level marks assemblies at the same time to prevent unexpected
on the dipstick inserted through the crankcase cover. down time.
• Check oil levels regularly
• Change the oil every Dynamic Seal kit interval
• Change oil immediately if water droplets are found
on the dipstick

Crankcase replacement parts

Part number Qty. Description
015445-1 3 Piston rod seal carrier
assembly
A-0275-036 3 Seal carrier o-ring
A-12498 1 Gasket

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Maintenance & Service Manual

Notes

94 | M-416 © Flow International Corporation

 CHAPTER 5
Engineering Drawings

The following drawings are provided with this manual. Please note that drawings are provided for reference only. Drawings
and part numbers can become obsolete as a part of Flow's ongoing product improvement. If part numbers are replaced by
new numbers, Flow Customer Service will inform you when you order new parts.

30/50 hp HyPlex Prime

050051-X-X-X-X-X HyPlex Prime 050242-X Application package
Base unit
Hardware kit
Control package
Cable package
Application package

-1 Basic package, no covers

-2 Extended package, covers

-3, -7 With gauge, no covers

-4, -8 With gauge, covers

049785-X Base unit -5 With transmitter, no covers

-1 30 hp 230V/460V 60Hz -6 With transmitter, covers

-2 30 hp 380V 50Hz

-6 50 hp 230V/460V 60Hz

-7 50 hp 380V 50Hz

049657-X Hardware kit

-1 Basic package

-2 Standard package

-3 Basic (dual pressure)

-4 Standard (dual pressure)

-5 Plus package

-6 Premium package

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HYPLEX PRIME PUMP
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Electrical
Elementary electrical drawings are located in the system manual.

049886-X Control package

-1 No control package

-2 30 hp Standard 460V 60Hz, 380V 50Hz

-3 30 hp Plus, Premium 460V 60Hz, 380V 50Hz

-4 30 hp Standard 230V 60Hz

-5 30 hp Plus, Premium 230V 60Hz

-10 50 hp Standard 460V 60Hz, 380V 50Hz

-11 50 hp Plus, Premium 460V 60Hz, 380V 50Hz

-12 50 hp Standard 230V 60Hz

-13 50 hp Plus, Premium 230V 60Hz

-50 30 hp or 50 hp Plus (non-B&R-controlled)

-51 30 hp or 50 hp Premium (non-B&R-controlled)

049893-X Cable package

-1 Basic:
30 hp 230V 60Hz, 30 hp 460V 60Hz, 50 hp 460V 60Hz, 50 hp 380V 50Hz
30 hp 380V 50Hz, 30 hp 575V 60Hz, 50 hp 575V 60Hz

-2 On-board:
30 hp 230V 60Hz, 30 hp 460V 60Hz, 50 hp 460V 60Hz, 50 hp 380V 50Hz
30 hp 380V 50Hz, 30 hp 575V 60Hz, 50 hp 575V 60Hz

-3 Remote:
30 hp 230V 60Hz, 30 hp 460V 60Hz, 50 hp 460V 60Hz, 50 hp 380V 50Hz
30 hp 380V 50Hz, 30 hp 575V 60Hz, 50 hp 575V 60Hz

-6 On-board:
50 hp 230V 60Hz

-7 Remote:
50 hp 230V 60Hz

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 CHAPTER 5
Engineering Drawings

Maintenance kits
050625-1 Rev A 050624-1 Rev. A
PCV maintenance kit Minor maintenance kit
30/50 hp pump
# Qty Part # Description
1 1 012906-1 Bearing assembly # Qty Part # Description
2 1 049494-1 Plunger 1 3 011051-1 Dynamic seal
3 1 013033-1 Plunger seal 2 3 A-00621-33 Rod seal
4 1 A-0275-206 O-ring 3 3 011042-1 Inlet poppet
5 1 A-0275-119 O-ring 4 3 011040-1 Outlet poppet guide
6 1 A-0275-120 O-ring 5 3 011039-1 Outlet poppet
7 1 A-4689 Food-grade grease 6 3 011041-1 Outlet poppet seat
8 1 049492-DWG PCV drawing 8 6 A-0275-033 O-ring
9 1 SB-0260 PCV maintenance bulletin 9 3 A-0275-025 O-ring
10 1 A-4689 Food-grade grease
11 3 A-9223 Compression spring
050626-1 Rev A 12 3 A-12219 Spring
Dynamic seal maintenance kit 13 3 011350-1 Filler tube sleeve
14 2 A-20386-1 Anti-seize lubricant
# Qty Part # Description 15 3 A-00720-31 Rod seal
1 3 011051-1 Dynamic seal 16 1 049656-DWG HP assembly drawing
2 3 A-00621-33 Rod seal 17 1 A-1903 320 grit paper
3 1 A-1903 Grinding paper 27 3 A-0265-062 Internal snap ring
4 1 049656-DWG HP assembly drawing 30 1 A-0275-029 HP o-ring
5 2 A-20386-1 Anti-seize lubricant 31 1 SB-0258 Minor maintenance bulle-
6 1 SB-0261 Dynamic seal maintenance tin
bulletin 34 1 042145-2 PCV poppet/seat assembly

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HYPLEX PRIME PUMP
Maintenance & Service Manual

050624-2 Rev. A
Major maintenance
30/50 hp pump

# Qty Part # Description

1 3 011051-1 Dynamic seal
2 3 A-00621-33 Rod seal
3 3 011042-1 Inlet poppet
4 3 011040-1 Outlet poppet guide
5 3 011039-1 Outlet poppet
6 3 011041-1 Outlet poppet seat
9 6 A-0275-025 O-ring
10 1 A-4689 Food-grade grease
11 3 A-9223 Compression spring
12 3 A-12219 Compression spring
13 3 011350-1 Filler tube sleeve
14 2 A-20386-1 Anti-seize lubricant
15 3 A-00720-31 Rod seal
16 1 049656-DWG HP assembly drawing
19 3 044099-1 Seal carrier
21 3 049584-1 High-pressure cylinder
22 3 049578-1 Check valve body
27 3 A-0265-062 Internal snap ring
30 3 A-0275-029 HP o-ring
32 1 SB-0259 Major maintenance bulle-
tin
33 6 A-0275-033 O-ring
34 1 042145-2 PCV poppet/seat assembly

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 CHAPTER 5
Engineering Drawings

Tools Recommended spares

These parts are not contained in a spares kit, but FLOW recom-
012068-3 Rev. K mends that you keep them on hand.
Tool kit
Water filters
# Qty Part # Description
1 1 011153-1 Plunger nut tool A-25216-1 0.5 micron filter
3 1 A-1904 Glass plate A-25216-2 1 micron filter
5 1 012324-1 Rebuild clamp (for
check valve body) PCV spares
8 1 A-8466 Medical alert card 042145-2 PCV poppet/seat assembly
9 1 A-2185 Blue Lubricant
11 1 A-25403-1 Belt tension gauge
050469-1 Rev. A
Pressure loading tool spares kit
049512-1 Rev. A # Qty Part # Description
Pressure loading tool 1 1 049515-1 Oil seal backup ring
2 1 049518-1 Hydraulic oil seal
3 1 A-0275-116 O-ring
4 1 A-0275-033 O-ring
5 1 A-0276-033 Backup ring
6 1 A-0274-3 O-ring

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HYPLEX PRIME PUMP
Maintenance & Service Manual

Notes

100 | M-416 © Flow International Corporation