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Introduction

This is a how-to guide for replacement of 1-18973 Hyplex Prime Minor Repair Kit from Accustream.

  1. Refer to original equipment manufacturer's safety and maintenance instructions. Failure to do so could result in injury or death.
    • Refer to original equipment manufacturer's safety and maintenance instructions. Failure to do so could result in injury or death.

    • Always remove all stored energy and lock out equipment before beginning any work.

  2. Insert wisdom here. Insert wisdom here.
    • Insert wisdom here.

  3. Pressure Loading tool Check valve clamp tool
    • Pressure Loading tool

    • Check valve clamp tool

  4. Remove inlet water hoses from the bottom of the end cap Disconnect air line from actuator Disconnect PCV drain line
    • Remove inlet water hoses from the bottom of the end cap

    • Disconnect air line from actuator

    • Disconnect PCV drain line

  5. Remove high-pressure tube from manifold using a 13/16" open end wrench Remove high-pressure inlets from all end caps using 13/16" open end wrench while supporting the manifold
    • Remove high-pressure tube from manifold using a 13/16" open end wrench

    • Remove high-pressure inlets from all end caps using 13/16" open end wrench while supporting the manifold

  6. Ensure oil is full. Open the 3/16" hex screw located on the contact face to check/fill using ATF fluid Ensure pressure loading tool screw is fully retracted
    • Ensure oil is full. Open the 3/16" hex screw located on the contact face to check/fill using ATF fluid

    • Ensure pressure loading tool screw is fully retracted

    • Ensure piston is fully retracted

  7. Keep screw lubricated with MOLYKOTE® BR-2 Plus or similar Wipe stud threads clean and apply Loctite 8150 anti-seize (#1-18750)
    • Keep screw lubricated with MOLYKOTE® BR-2 Plus or similar

    • Wipe stud threads clean and apply Loctite 8150 anti-seize (#1-18750)

  8. Attach pressure loading tool to each set of studs, rotating each tool stud by hand until tight Once snug, back out the tool studs 1/4 turn. Place a radial line with a permanent marker to make this easier to see Use a 3/4" (19mm) ratcheting socket to pressurize the tool by rotating screw clockwise. Pressurize per manufacturers recommended gauge pressure
    • Attach pressure loading tool to each set of studs, rotating each tool stud by hand until tight

    • Once snug, back out the tool studs 1/4 turn. Place a radial line with a permanent marker to make this easier to see

    • Use a 3/4" (19mm) ratcheting socket to pressurize the tool by rotating screw clockwise. Pressurize per manufacturers recommended gauge pressure

  9. While tool is pressurized, loosen the four nuts a few turns by hand
    • While tool is pressurized, loosen the four nuts a few turns by hand

    • Turn the 3/4" socket counter-clockwise to reduce the pressure in the tool

    • Back off each of the four tool studs and remove the pressure loading tool

  10. Remove the fours nuts and washers Carefully slide the end cap off, being careful not to lose any of the high-pressure components
    • Remove the fours nuts and washers

    • Carefully slide the end cap off, being careful not to lose any of the high-pressure components

  11. HP cylinder and filler tube may come out with end cap Use a screwdriver to remove seal carrier, if necessary
    • HP cylinder and filler tube may come out with end cap

    • Use a screwdriver to remove seal carrier, if necessary

  12. Remove subplate adapter (gently pry groove if necessary) Remove snap ring and rod seal, install new rod seal (1-11993) and snap ring (1-18745). Inspect and replace spacer with bevel down
    • Remove subplate adapter (gently pry groove if necessary)

    • Remove snap ring and rod seal, install new rod seal (1-11993) and snap ring (1-18745). Inspect and replace spacer with bevel down

  13. Carefully lift the check valve assembly using two flathead screwdrivers in the groove on the check valve body
    • Carefully lift the check valve assembly using two flathead screwdrivers in the groove on the check valve body

  14. Insert check valve body clamp tool into bench vise Use a 9/16" socket to tighten the clamp onto the check valve body
    • Insert check valve body clamp tool into bench vise

    • Use a 9/16" socket to tighten the clamp onto the check valve body

    • Remove the Outlet Cage using the 9/16" socket - be careful not to lose the internal components

    • Inspect check valve body and outlet cage for excessive wear or failure

  15. Secure lapping paper to a hard, flat surface such as the glass plate that came with your system, or a granite surface plate
    • Secure lapping paper to a hard, flat surface such as the glass plate that came with your system, or a granite surface plate

    • 1-13281 Granite Surface plate, 9" x 12" x 2"

    • Wet paper and lap the check valve body on the inlet face poppet face using a figure 8 pattern.

    • After 10-12 cycles, rotate check valve body by 45 degrees and repeat process until face is smooth and free from defects.

  16. Re-use check valve body and cage, assuming they are in acceptable condition. Replace the following: 1-11679-025 O-ring
    • Re-use check valve body and cage, assuming they are in acceptable condition. Replace the following:

    • 1-11679-025 O-ring

    • 1-18867

    • 1-18868

    • 1-18869

    • 1-18752

    • Maintain alignment of internal components while hand-tightening the Outlet Cage. Torque outlet cage to 30 ft-lb (41 N-m) while clamped in the Outlet Cage Clamp tool

  17. Install new End Cap o-ring
    • Install new End Cap o-ring

    • Apply high-vac grease (1-11447) to both o-rings

    • Insert check valve assembly into end cap

  18. With manifold removed from pump, place manifold in a heavy bench vise Remove the PCV body using a 1-1/4" (32 mm) wrench Remove the PCV body using a 1-1/4" (32 mm) wrench
    • With manifold removed from pump, place manifold in a heavy bench vise

    • Remove the PCV body using a 1-1/4" (32 mm) wrench

  19. Apply blue lubricant to threads and both faces of the PCV adapter Install new PCV Ring onto new PCV Seat, and insert PCV Poppet into seat. Insert PCV assembly into PCV body Thread manifold onto PCV Adapter. Torque to 190 ft-lb (258 N-m)
    • Apply blue lubricant to threads and both faces of the PCV adapter

    • Install new PCV Ring onto new PCV Seat, and insert PCV Poppet into seat. Insert PCV assembly into PCV body

    • Thread manifold onto PCV Adapter. Torque to 190 ft-lb (258 N-m)

  20. Attach 1-18747 spring to 1-18865 Inlet Poppet
    • Attach 1-18747 spring to 1-18865 Inlet Poppet

  21. Insert dynamic seal and rod seal into new seal carrier (slight pressure is required to seat dynamic seal) Install rebuilt subplate adapter
    • Insert dynamic seal and rod seal into new seal carrier (slight pressure is required to seat dynamic seal)

    • Install rebuilt subplate adapter

    • Slide seal assembly over plunger up to subplate adapter

  22. Insert new o-ring into HP Cylinder. Apply a small amount of high-vac grease to o-ring Carefully slide HP cylinder over the seal carrier, keeping the weep hole facing down Insert 1-18748 spring into Filler Tube. Slide filler tube sleeve onto filler tube, insert poppet assembly into filler tube
    • Insert new o-ring into HP Cylinder. Apply a small amount of high-vac grease to o-ring

    • Carefully slide HP cylinder over the seal carrier, keeping the weep hole facing down

    • Insert 1-18748 spring into Filler Tube. Slide filler tube sleeve onto filler tube, insert poppet assembly into filler tube

    • Insert assembly into HP Cylinder

  23. Slide End Cap onto tie rods and align with HP Cylinder
    • Slide End Cap onto tie rods and align with HP Cylinder

    • Place washers and nuts on tie rods, hand tighten until snug

    • Attach and pressurize the pressure loading tool. Tighten nuts by hand until they are snug against the end cap

    • Remove pressure from pressure loading tool

    • Repeat for all three lines

  24. Apply blue lubricant to high-pressure fittings Torque high-pressure glands to: 40 ft-lbs (54 N-m) Attach manifold/high-pressure glands, air line, PCV drain line, and inlet lines
    • Apply blue lubricant to high-pressure fittings

    • Torque high-pressure glands to: 40 ft-lbs (54 N-m)

    • Attach manifold/high-pressure glands, air line, PCV drain line, and inlet lines

    • Check oil level and quality. Change oil per the recommendation of your specific system

    • Check belt quality and tension

    • Replace water filters as necessary

    • 1-11390 - 1 micron

    • 1-11402 - .45 micron

    • When complete, unlock system and restore energy

    • Start pump and check for any leaks

Finish Line

Kathy

Member since: 05/14/2019

3 Guides authored

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