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O R I G I N A L I N S T R U C T I O N
6.6 INTENSIFIER 07531-02200 - MAINTENANCE
Dismantling Instructions
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When dismantling the Intensifi er Assembly, fi rst disconnect the air supply hose to intensifi er inlet Connector 152.
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Using an Allen Key* undo four Screws 157 and remove Protection Plate 154.
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Disconnect the trigger hose (item 177 on page 20) from Intensifi er Valve 173 or 178 by depressing the outer collet and withdrawing the hose.
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Remove Cover Plate 134 and Gasket 165 by removing Screws 167 and Washers 166 using Allen Key*.
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Ensure gasket is not damaged to ensure a proper seal on reassembly.
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Invert intensifi er assembly and drain oil from reservoir into a suitable container.
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Remove Quick Release Connector 162 together with Connector 161 and Seals 163 with a suitable spanner*.
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Remove Intensifi er Valve 173 or 178 by removing the fi xing screws with a suitable spanner taking care to retain 'O' Ring 151 located in the Intensifi er
Body Casting.
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Remove Screw 149 using a suitable Allen key* and remove Silencer Cover 146, Foam Silencer 145, Spacer 148 and Retaining Plate 150.
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Pull off the 6mm Plastic Tube 182 from Vacuum Connectors 172.
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From the base of the intensifi er insert a 3mm Allen Key * through the two holes and unscrew the Vacuum Connectors 172. 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 diffi cult to remove, the vacuum connectors can be drilled out using a
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To reassemble the Vacuum Connectors 172, 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 intensifi er threaded hole.
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From the base of the intensifi er 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 intensifi er, ensuring that there is suffi cient Loctite 574 at the base of the fi tting such that the thread is not
visible.
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Using a screwdriver, carefully remove internal Retaining Ring 144. Clean and inspect groove for signs of damage.
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Using Extractor*, insert male threaded end into End Cover 142 and withdraw it, along with intensifi er Sleeve 158 and 'O' Rings 140 and 143.
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Insert Rod* through the connector orifi ce at the front of the intensifi er body and tap out Piston Rod 139 and Piston Assembly.
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Using a suitable Allen Key*, unscrew two Screws 155 and remove End Cover 142 from intensifi er Sleeve 158.
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Remove Seal Plug 137 with a spanner*.
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Insert rod* through connector orifi ce at the front of the intensifi er body and push out Seal Housing 135 and associated 'O' rings and lip seals.
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Remove Valve Housing Assembly 164 from the main body with a suitable spanner*. Clean by blowing through with a low pressure air jet.
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Remove Piston Rod 139 from intensifi er Air Piston 141 by gripping the fi rst 20mm (
damage or mark the working surface.
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Unscrew locking Nut 147 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.
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Valve Housing Assembly 164 must be refi tted using a thread sealing adhesive.
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Assemble the Piston Assembly using a new Nut 147.
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End Cover 142 must be fi tted correctly inside internal Retaining Ring 144. The tool must not be operated if the end cover has been omitted.
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
* Refers to items included in the 07535 Mkll service kit. For complete list see page 12.
Item numbers in bold refer to the illustration and parts list opposite.
3
/
" or 4.7mm diameter drill.
16
3
/
") of the rod in a vice fi tted with soft jaws, taking care not to
4
IMPORTANT
E N G L I S H
19
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