SECTION 5 TROUBLESHOOTING
5 Troubleshooting
5.1 Troubleshooting - Electrical 5-1
5.1.1 Pump Will Not Start 5-1
5.1.2 Console Display and Lights Fail to Illuminate 5-1
5.1.3 Pump Quit Running 5-1
5.1.4 No Control Power (24vdc) 5-1
5.1.5 Red Light, Message on Operator’s Console 5-2
5.2 Troubleshooting – HP Water 5-3
5.2.1 HP Water Signal Abnormal Fluctuation 5-3
5.2.2 Hot Surfaces on HP Cylinder Components 5-3
5.2.3 Oil or Water Leaks from HP Intensifier 5-3
5.2.4 HP Check Valve Leak 5-4
5.2.5 Normal Temperature, but Check Valve Problem 5-4
5.2.6 HP Cutting Water Too Low 5-4
5.3 Troubleshooting – LP Water 5-4
5.3.1 Low Booster Pump Pressure 5-4
5.4 Troubleshooting – Hydraulic 5-5
5.4.1 Hot Hydraulic Oil 5-5
5.4.2 Hydraulic Pressure But No High Pressure Water Pressure 5-5
5.5 Special Procedure—HP Water Check Valve 5-6
5.5.1 HP Check Valve Troubleshooting 5-6
SECTION 6 LOW PRESSURE WATER SYSTEM
6 Low Pressure Water System 6-1
6.1 Oil Cooling Water Supply 6-3
6.2 Cutting Water Supply 6-4
6.2.1 Normal Operating Condition 6-4
6.2.2 Operation 6-5
6.2.3 Booster Pump Pressure Adjustment 6-7
6.2.4 Low Pressure System Protection 6-7
6.3 Maintenance Overview 6-8
6.3.1 Water Filter Service 6-9
6.3.2 Boost Pump 6-10
SECTION 7 HIGH PRESSURE WATER SYSTEM
7 High Pressure (HP) Water 7-1
7.1 Components 7-1
7.2 Intensifier Disassembly and Reassembly 7-2
7.2.1 HP & LP Water Piping 7-4
7.2.2 HP Cylinder 7-5
7.2.3 Hard Seal End Cap 7-7
7.2.4 HP Plunger Seal Service 7-8
7.2.5 Plunger and Hydraulic Cartridge 7-13
7.2.6 Hydraulic Cylinder Head and Piston 7-14
7.3 Intensifier Subassemblies Inspection & Repair 7-16
7.3.1 Discharge HP Check Valve 7-17
7.3.2 Inlet Check Valve 7-19
7.3.3 Sealing Head 7-21
7.3.4 HP Cylinder 7-22
REV 01 49836208.doc
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