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O R I G I N A L I N S T R U C T I O N
11. INTENSIFIER 07531-02200 - MAINTENANCE
11.1 DISMANTLING INSTRUCTIONS
When dismantling the intensifier assembly, first disconnect the air supply hose to intensifier inlet Connector 22.
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Using an Allen Key* undo four Screws 27 and remove Protection Plate 24.
Disconnect the trigger hose from the Intensifier Valve 48 by depressing the Bulkhead Connector 44 and withdrawing
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the hose.
Remove Cover Plate 4 and Gasket 35 by removing Screws 37 and Washers 36 using Allen Key*.
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Ensure that gasket is not damaged to ensure a proper seal on assembly.
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Invert intensifier assembly and drain oil from reservoir into a suitable container.
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Remove Quick Release Connector 32 together with Connector 31 and Seals 33 with suitable spanner*.
Remove Intensifier Valve 48 by removing the fixing screws with a suitable spanner taking care to retain 'O' Ring 21
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located in the Intensifier Body Casting.
Remove Screw 19 using a suitable Allen Key* and remove Silencer Cover 16, Foam Silencer 15, Spacer 18 and Retaining
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Plate 20.
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Pull off the 6mm Plastic Tube 41 from Vacuum Connectors 42.
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From the base of the intensifier insert a 3mm Allen Key * through the two holes and unscrew the Vacuum Connectors
42. Note:
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Care must be taken as the vacuum connectors are locked and sealed in place using Loctite 574.
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If difficult to remove, the vacuum connectors can be drilled out using a 3/16" or 4.7mm diameter drill.
To reassemble the Vacuum Connectors 42, the following procedure must be followed: -
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Soak the vacuum connectors in a suitable primer, i.e. Perma Bond A905
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Place a drop of Loctite 574 in the intensifier threaded hole.
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From the base of the intensifier insert the Allen Key * through the hole. Ensure that the Allen Key * is free from
Loctite 574 before inserting into the vacuum connector.
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Rotate the Allen Key while applying Loctite 574 to the base of the vacuum connector.
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Screw the Vacuum connector into the intensifier, ensuring that there is sufficient Loctite 574 at the base of the
fitting such the thread is not visible.
Using a screwdriver, carefully remove internal Retaining Ring 14. Clean and inspect groove for sign of damage.
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Using Extractor*, insert male threaded end into End Cover 12 and withdraw it along with intensifier Sleeve 28 and 'O'
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Rings 10 and 13.
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Insert Rod* through the connector orifice at the front of the intensifier body and tap out Piston Rod 9 and Piston
Assembly.
Using a suitable Allen Key*, unscrew two Screws 25 and remove End Cover 12 from intensifier Sleeve 28.
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Remove Seal Plug 7 with spanner*.
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Insert rod* through connector orifice at the front of the intensifier body and push out Seal Housing 5 and associated 'O'
rings and lip seals.
Remove Valve Housing Assembly 34 from the main body with a suitable spanner*. Clean by blowing through with a
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low-pressure air jet.
Remove Piston Rod 9 from intensifier Air Piston 11 by gripping the first 20 mm (3/4") of the rod in a vice fitted with soft
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jaws, taking care not to damage or mark the working surface.
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Unscrew locking Nut 17 with a suitable spanner*.
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Assemble in the reverse order of dismantling, observing the following:
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Clean all parts and renew all 'O' rings.
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Lubricate all seals using Moly Lithium grease.
Valve Housing Assembly 34 must be refitted using a thread sealing adhesive.
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* Refers to items included in the service kit, see page 16.
Item numbers in bold refer to the illustration and parts list opposite.
E N G L I S H
25
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