How to Change High-Pressure Seals on Flow Style Intensifier Using Kit #11135

Remove the high-pressure cylinder(s) from the pump.

Position the high-pressure cylinder on the seal guide tool.

Position the small (stepped) end of the installation tool into the top of the high-pressure cylinder.

Use a rubber mallet to push the internal back-up seal sleeve through the high-pressure cylinder forcing the seal and the hoop out of the other end.

Do not remove the sleeve from the high-pressure cylinder.

Turn the high-pressure cylinder over so the dynamic end is facing up.

Put the non-stepped end of the installation tool in the dynamic side of the high-pressure cylinder, push the other seal out by tapping with a rubber mallet.

Clean the high-pressure cylinder thoroughly after polishing.

Visually inspect the high-pressure cylinder bore at both ends.

If the inside bore finish is blemished, use scouring pad in both ends of the high-pressure cylinder, to smooth out blemishes, rolling back and forth.

Apply high-vacuum grease to the O-rings.

Install all 4 O-rings onto the high-pressure seals.

Be sure not to twist the O-rings when installing them onto the high-pressure seals.

Thread the seal guide tool onto the static end of the high-pressure cylinder.

It is helpful to begin with the flat end of the high-pressure cylinder side up.

Put the installation sleeve into the sleeve guide with the larger ID (tapered) end up.

Lubricate the ID of the Installation sleeve with the high-vacuum grease.

Put the high-pressure seal into the sleeve with the O-ring side down.

Use the blunt (non-stepped) end of the installation tool to hand press the high-pressure seal into the high-pressure cylinder.

Put the hoop into the sleeve with the sharp (tapered) end first.

Push the hoop down into the sleeve with the blunt end of the installation tool.

Put the hoop in place by tapping the installation tool in with a rubber mallet until the tool bottoms at the high-pressure cylinder face.

Remove the seal guide tools from the top of the high-pressure cylinder (static side).

Apply a light coat of grease to both ends of the back-up seal sleeve.

Put the sleeve into the open end of the high-pressure cylinder and repeat the high-pressure seal installation process.

Thread the seal guide tool onto the dynamic side of the high-pressure cylinder.

Put the sleeve into the seal guide tool with the tapered end facing up.

Apply a high-vacuum grease to the ID of the sleeve.

Put the seal assembly into the sleeve with the O-ring first.

Use the blunt (non-stepped) end of the installation tool to hand press the high-pressure seal into the high-pressure cylinder.

Put the hoop into the sleeve with the sharp (tapered) end first.

Push the hoop down into the sleeve with the blunt end of the installation tool.

Put the hoop in place by tapping the installation tool in with a rubber mallet until the tool bottoms out on the high-pressure cylinder face.

Remove the seal guide tools from the dynamic side of the high-pressure cylinder.

Apply Blue Goop to both threads of the high-pressure cylinder.

Remove the old bronze back-up ring from the plunger.

Apply Blue Goop to the threads on both ends of the cylinder and to the threads on the end cap.

Replace the bronze back-up with the new disc from the kit onto the plunger.

Put the high-pressure cylinder on the plunger with the dynamic side first.