Introduction
This is a how-to guide for replacement of 1-18976 Hyplex Prime Major Repair Kit from Accustream.
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Refer to original equipment manufacturer's safety and maintenance instructions. Failure to do so could result in injury or death.
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Always remove all stored energy and lock out equipment before beginning any work.
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Exploded view with BOM
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Pressure Loading tool
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Check valve clamp tool
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Plunger removal socket
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Remove inlet water hoses from the bottom of the end cap
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Disconnect air line from actuator
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Disconnect PCV drain line
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Remove high-pressure tube from manifold using a 13/16" open end wrench
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Remove high-pressure inlets from all end caps using 13/16" open end wrench while supporting the manifold
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Ensure oil is full. Open the 3/16" hex screw located on the contact face to check/fill using ATF fluid
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Ensure pressure loading tool screw is fully retracted
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Ensure piston is fully retracted
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Keep screw lubricated with MOLYKOTE® BR-2 Plus or similar
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Wipe stud threads clean and apply Loctite 8150 anti-seize (#1-18750)
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Attach pressure loading tool to each set of studs, rotating each tool stud by hand until tight
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Once snug, back out the tool studs 1/4 turn. Place a radial line with a permanent marker to make this easier to see
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Use a 3/4" (19mm) ratcheting socket to pressurize the tool by rotating screw clockwise. Pressurize per manufacturers recommended gauge pressure
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While tool is pressurized, loosen the four nuts a few turns by hand
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Turn the 3/4" socket counter-clockwise to reduce the pressure in the tool
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Back off each of the four tool studs and remove the pressure loading tool
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Remove the fours nuts and washers
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Carefully slide the end cap off, being careful not to lose any of the high-pressure components
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HP cylinder and filler tube may come out with end cap
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Use a screwdriver to remove seal carrier, if necessary
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Remove subplate adapter (gently pry groove if necessary)
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Remove snap ring and rod seal, install new rod seal (1-11993) and snap ring (1-18745). Inspect and replace spacer with bevel down
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Use plunger removal socket and ratchet to remove the plunger retaining nut
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Rotate belt/crank to extend plunger, if necessary
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Replace with new plunger and spring. Torque plunger nut to 20 ft-lb (27 N-m).Be careful not to contact the plunger
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Carefully lift the check valve assembly using two flathead screwdrivers in the groove on the check valve body
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Insert check valve body clamp tool into bench vise
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Use a 9/16" socket to tighten the clamp onto the check valve body
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Remove the Outlet Cage using the 9/16" socket
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Inspect outlet cage. Replace all other items
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Re-install outlet cage:
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Apply blue lubricant to outlet cage threads and insert new internal components
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Carefully thread cage into check valve while maintaining alignment of internal components
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Torque outlet cage to 30 ft-lb (41 N-m)
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Install new End Cap o-ring
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Apply high-vac grease (1-11447) to both o-rings
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Insert check valve assembly into end cap
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With manifold removed from pump, place manifold in a heavy bench vise
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Remove the PCV body using a 1-1/4" (32 mm) wrench
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Apply blue lubricant to threads and both faces of the PCV adapter
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Install new PCV Ring onto new PCV Seat, and insert PCV Poppet into seat. Insert PCV assembly into PCV body
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Thread manifold onto PCV Adapter. Torque to 190 ft-lb (258 N-m)
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Attach 1-18747 spring to 1-18865 Inlet Poppet
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Insert dynamic seal and rod seal into new seal carrier (slight pressure is required to seat dynamic seal)
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Install rebuilt subplate adapter
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Slide seal assembly over plunger up to subplate adapter
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Insert new o-ring into HP Cylinder. Apply a small amount of high-vac grease to o-ring
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Carefully slide HP cylinder over the seal carrier, keeping the weep hole facing down
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Insert 1-18748 spring into Filler Tube. Slide filler tube sleeve onto filler tube, insert poppet assembly into filler tube
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Insert assembly into HP Cylinder
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Slide End Cap onto tie rods and align with HP Cylinder
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Place washers and nuts on tie rods, hand tighten until snug
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Attach and pressurize the pressure loading tool. Tighten nuts by hand until they are snug against the end cap
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Remove pressure from pressure loading tool
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Repeat for all three lines
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Apply blue lubricant to high-pressure fittings
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Torque high-pressure glands to: 40 ft-lbs (54 N-m)
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Attach manifold/high-pressure glands, air line, PCV drain line, and inlet lines
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When complete, unlock system and restore energy
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Start pump and check for any leaks
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