Troubleshooting the intensifier pump
Follow this troubleshooting table if you experience any of the following conditions. Required minor and major
maintenance procedures and other service procedures are located in this chapter.
1. Intensifier
Note: Verify that the intensifier is operating correctly by looking for seal leakage and checking for high temperatures. Refer to
manual M-376, Hyperpressure™ Intensifier.
2. Intensifier overspeeding
Intensifier problem Check intensifier for leaks and high temperatures.
Orifice problem Check orifice(s) for correct size and condition.
High-pressure water leak Check entire installation for evidence of leaks.
Low inlet water pressure Clogged inlet water filters or other inlet water line restriction. Check filters and lines;
replace as needed. Check filter differential pressure indicator and inlet water pressure
switch; replace as needed.
Leaking auto bleed-down valve The valve is hot to the touch; rework or replace the valve.
3. Oil pressure and high-pressure water pressure are satisfactory, but water flow though the nozzle is low
Flow restriction in the downstream
high-pressure plumbing or
components
1. Inspect the high-pressure inline filter, if installed.
2. Check for blockage of tubing and components; remove any blockage.
3. Check for correct operation of on/off valve.
Replace components as required.
4. Supply oil pressure is OK, but high-pressure water pressure is low at the pump and nozzle
Oil return pressure is too high There may be a restriction in the return line from the intensifier to the hydraulic pump.
Cold oil at startup. Not a significant problem.
5. Supply oil pressure and high-pressure water pressure are low at the pump
Intensifier problem Check intensifier for leaks and high temperatures. Refer to manual M-376.
Orifice problem Check orifice(s) for correct size and condition.
High-pressure water leak Check entire installation for evidence of leaks.
Leaking auto bleed-down valve The valve is hot to the touch; rework or replace the valve.
Pressure control problem The pressure control system has malfunctioned. Check the system and adjust or replace
parts as required.
6. No supply oil pressure or high-pressure water pressure
No hydraulic oil in the system Turn the intensifier pump off. Examine all suction and delivery lines for leaks; check the
oil level in the reservoir. Remove oil spillage.
Broken motor shaft, pump shaft, or
coupling
Examine the motor and pump shafts and coupling. Replace as required.
Defective pressure control valve Check the pressure control system and adjust or replace parts as required.
Defective hydraulic pump Replace the hydraulic pump. See Replacing the hydraulic pump.
© Flow International Corporation M-390 | 35
CHAPTER 4
Maintenance & Troubleshooting
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