SECTION 7
HIGH PRESSURE WATER
May 2003
p. 7-10
49831951
7.2.5 Plunger and Hydraulic Cartridge Removal and Installation
1. Remove HP and LP piping/ hose, then remove HP cylinder jug following
procedure 7.2.2 above.
2. Remove the proximity switch on the intensifier side nearest HP cylinder
to be serviced. This procedure will allow hydraulic oil to drain to tank
and will minimize oil spillage. Draining takes about 5 minutes. Remove
cartridge retainer flange from hydraulic cylinder head by first removing
retaining ring using a flat blade screwdriver. Wipe and clean surfaces,
weep holes, and grooves in cartridge retainer flange. Check retainer
flange for cracks.
3. Using cartridge/plunger removal tool threaded to the seal cartridge, pull
the cartridge outward over the plunger. Seals in the hydraulic cartridge
can be removed and replaced, or the entire cartridge can be replaced. It
is recommended that at least one spare cartridge be kept on hand, ready
to install. See Section 7.3.6 for servicing hydraulic seal cartridge.
4. With the cartridge removed, the plunger can be removed with the
cylinder head in place. Slide the cartridge/plunger removal tool over the
plunger, with the hex-shaped smaller end toward the plunger button.
Note orientation of plunger button retainer pins (6 each), then align hex
flats of tool with pins. Force tool by hand under pins, then rotate tool
slightly to cause pins to retract enough to release plunger. Plunger can
now be extracted from hydraulic piston. See Section 7.3.5 for servicing
the plunger.
5. To install new plunger, slip cartridge/plunger removal tool over plunger,
hex end toward plunger button, to help center plunger in cylinder head.
Position plunger in mating pocket of piston, then force into place by
hand. Using a flashlight, verify that all 6 pins are equally extended to
grip plunger button.
6. Lubricate exposed surfaces of seals in hydraulic seal cartridge with food
grade grease and slide cartridge over plunger into cylinder head cavity.
7. Thoroughly clean cartridge retainer flange, including cross-drilled weep
holes. Install flange and internal retaining ring, making sure that the
retaining ring seats fully inside its groove. Note that hydraulic cartridge
O-rings may take up clearance. To install retaining ring, first tap lightly
on retainer flange using plunger removal tool. This will compress
cartridge O-rings enough to get retaining ring started in groove. Push on
outer edge of retainer flange with a flat bladed screwdriver while working
one end of retaining ring into groove. Retainer flange should tilt or tip
enough to allow retaining ring to move into its groove. Continue working
ring into groove while tilting flange until retaining ring is fully installed.
8. Install HP cylinder jug to hydraulic cylinder head per paragraph 7.2.2.
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