Condec UPC5210 - Manual (Page 27)

24 UPC5200/UPC5210 Operation and Maintenance Manual
Reassembly of Rings and Seals:
NOTE: Clean all parts with solvent and use shop air hose to remove any dust particles from all mechanical
parts, except screws and washers. Wipe the bores of the intensifier housing with a clean cloth before installing
the piston. Replace all damaged parts with new ones.
1. Smear a medium amount of grease in O-ring cavity on piston (18). Grease both sides of the two backup
rings (20) and O-ring (21). Install into groove on piston (18).
NOTE: Split of each backup ring, item 84, must be 180 o from each other and ends overlapping properly.
2. Lightly coat edges of backup rings (20) and O-ring (21) with oil lubricant (PN 60944).
3. Lightly coat both inside diameters of housing (17).
4. Place grease on piston ring retainer (24) where piston rings (22) seat.
5. Place grease on both sides of the three piston rings (22) and install the three piston rings (beveled sides
aligned) onto piston ring retainer (24).
6. Slide piston (18) into housing (17), being careful not to damage wall areas. Slide until smaller diameter
of piston (18) is exposed from side of housing (17).
7. Thread item (24), with the three piston rings (22) into piston (18) approximately four turns.
8. Stand housing (17) on end, with piston ring retainer (24) facing upward. Push piston ring retainer (24) to
verify it will go into housing (17) fully. Top of piston ring retainer (24) must be slightly below surface of
housing (17).
9. Place housing (17) on its side. Place 3/16" hex key in item (24) and 1/4" hex key in piston (18). Rotate
1/4" hex key to tighten.
10. Remove the 3/16" hex key and verify piston (18) will rotate. If piston rotates remove 1/4" hex key. If it
doesn’t rotate, loosen piston slightly.
11. Grease both sides of O-ring (4), and end cap (3) O-ring groove. Then install O-ring (4) into groove of
end cap (3).
12. Place housing (17) sub-assembly with large I.D. upward and install end cap (3) into housing (17).
13. Place cap screw (1) through washer (2) and thread finger tight into end cap (3). Repeat for the other nine
cap screws.
14. Use torque wrench and 1/4" hex key socket to torque each bolt to 325 in/lbs.
NOTE: Torque cap screws in a side to side pattern, (do not use a circular pattern), and in small increments to
insure end cap, item 67 is seated flat to Housing surface.
15. If previously removed, place 1/4" Teflon tape, two turns, on 90
o
NPT elbow (23). Thread and tighten 90
o
NPT elbow (23) into end cap (3). Align so that 90
o
NPT elbow (23) is parallel with the small hole located
on the side of housing (17).
16. Grease both sides of O-ring (7) and O-ring seat area on end cap (19). Install O-ring (7) onto end cap (19)
and in turn place onto housing (17). Orient such that the small hole located on housing side is on your
left at the "9 o’clock" position. The inlet check valve fitting (12) placement hole located on end cap (19)
must be at the 6 o’clock position.
17. Place Cap Screw (5), thru Washer (6), end cap (19) and thread finger tight into housing (17). Repeat for
the other nine cap screws. Use torque wrench and 3/8” hex key socket to torque each bolt to 325 in/lbs.
NOTE: Torque cap screws in a side to side pattern (do not use a circular pattern) and in small increments to
ensure end cap (item 83) is seated flat to housing surface.
18. Install intensifier assembly into UPC5200/UPC5210 per Section 4.2.7 on page 20.