© Flow International Corporation M-416 | 3
INTRODUCTION
HyPlex Prime Pump
Chapter 1. Equipment Description
Features 5
Specifications 6
Interface illustrations 7
Interface labels 10
Water requirements 11
Air requirements 12
Environment requirements 12
High-pressure tubing 12
Anti-vibration mat 13
Startup procedure 14
Temperature input offset adjustment routine 16
Calibrating the pump control system 16
Preparing the HyPlex Prime pump for
shipping or storage 17
Chapter 2. Safety
Safety precautions 19
Warnings, cautions, and notes 19
Safety tips 20
Protective clothing 21
Emergency medical information 22
Chapter 3. Maintenance & Troubleshooting
Periodic maintenance 23
General precautions 23
Inspection & maintenance schedules 25
Routine daily checks 25
Mandatory maintenance schedules 26
30 hp HyPlex Prime pump maintenance schedule 27
50 hp HyPlex Prime pump maintenance schedule 28
Troubleshooting the HyPlex Prime Premium pump
using FlowSENSE 29
FlowSENSE diagnostic codes 30
Troubleshooting the high-pressure components 32
Additional troubleshooting tips 32
Weep holes 32
Visual troubleshooting guide for
the high-pressure components 33
Troubleshooting table 34
Chapter 4. Service
Servicing the high-pressure pump 41
Service tips & notes 41
High-pressure components illustration 42
Using the pressure loading tool 43
Installing the Dynamic Seal Maintenance kit 45
Installing the Minor Maintenance kit 55
Installing the Major Maintenance kit 67
Installing the pressure control valve (PCV)
Maintenance kit 79
Changing the filter elements 83
Replacing the dynamic seal and plunger 84
Tensioning and aligning the belt drive 91
Servicing the belt 91
Servicing the crankcase 93
Chapter 5. Engineering Drawings
Drawing lists 95
Maintenance kits 97
Tools 99
Recommended spares 99
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