KMT STREAMLINE SL-IV 50 PLUS, Operation And Service Manual

Page 1: ...STREAMLINE HIGH PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL SL IV 50 PLUS HSEC Manual No 80079650 ...

Page 2: ...ibed in this manual to be accurate and reliable Much care has been taken in its preparation however the Company cannot accept any responsibility financial or otherwise for any consequences arising out of the use of this material The information contained herein is subject to change and revisions may be issued to advise of such changes and or additions KMT WATERJET SYSTEMS Fluid Products KMT Waterj...

Page 3: ...ION 2 Installation 2 1 2 1 Installation Overview 2 1 2 1 1 Buyer Obligations 2 2 2 1 2 Seller Obligations 2 3 2 2 Installation Requirements Utilities 2 4 2 2 1 Equipment Location Environment 2 4 2 2 2 Service Connections 2 5 2 2 3 Tools and Equipment 2 6 SECTION 3 OPERATION 3 Operation 3 1 Main Menu 3 4 Run Screen 3 5 Run Screen 2 3 7 Hours 3 8 Alarm History Screen 3 9 Pressure Control Screen 3 10...

Page 4: ... 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 W...

Page 5: ...STEM 9 Hydraulic System 9 1 9 1 Features 9 1 9 1 1 Components 9 2 9 2 Operation 9 3 9 2 1 Hydraulic Pressure Adjustment 9 3 9 2 2 Hydraulic System Pressure Protection 9 4 9 3 Motor Hydraulic Service Maintenance 9 5 9 3 1 Motor Service 9 6 9 3 2 Manifold Service 9 6 SECTION 10 RECIRCULATION SYSTEM 10 Recirculation System 10 1 10 1 Components 10 1 10 2 Operation 10 3 10 3 System Pressure Protection ...

Page 6: ... Intensifier Pumps Motor Horsepower Rating Plunger Quantity and Diameter inches Hp Kw Intensifier Model HP Water Max Oper Pressure psi 7 8 0 875 22 mm 1 1 8 1 125 29 mm Frame Dim L inches Redundant Option Available 30 22 SL IV 30 2 67 75 Yes 50 37 SL IV 50 2 67 75 Yes 60 45 SL IV 60 2 77 75 Yes 75 56 SL IV 75 2 77 75 Yes 100 75 SL IV 100D 4 77 75 No 100 75 SL IV 100S 60 000 2 77 75 Yes 1 1 Physica...

Page 7: ... with 10 micron double length filter High efficiency heat exchanger in independent recirculation pump circuit Stand alone unit with built in motor starter wye delta or across the line High pressure safety dump valve Dual pressure compensator 1 or 2 liters of high pressure attenuator volume Microprocessor control with diagnostic capability Water inlet shut off valve Booster pump Integral water and ...

Page 8: ...fer to Table 1 2 for HP water performance limits for various power levels of SL IV waterjet pumps TABLE 1 2 HP WATER PERFORMANCE SL IV WATERJET INTENSIFIER PUMPS 55 000 psi 60 000 psi Horsepower Orifice Size inches Flow Rate gpm Orifice Size inches Flow Rate gpm 30 0 011 0 60 0 010 0 52 50 0 014 0 98 0 013 0 88 60 0 015 1 12 0 014 1 02 75 0 017 1 44 0 016 1 33 100 0 020 2 00 0 019 1 88 The recircu...

Page 9: ... training is also available 1 3 1 Service Department To contact the KMT Waterjet Service Department USA Customer Service Manager Europe Technical Manager KMT Waterjet Systems KMT Waterjet Systems GmbH P O Box 231 Wasserstrahl Schneidetechnik 635 West 12th Street Auf der Laukert 11 Baxter Springs KS 66713 D 61231 Bad Nauheim USA Germany Phone 620 856 2151 Phone 49 0 6032 997 117 Fax 620 856 5050 Fa...

Page 10: ...nts Yes No 2 Is the unit a convenient size Yes No 3 Controls a Are the controls user friendly b Is the unit easy to operate Comments Yes Yes No No 4 Performance a Does the unit perform smoothly and meet your expectations Does the unit run quietly Comments Yes Yes No No 5 Did installation and start up go smoothly Comments Yes No 6 What feature s do you consider the most significant with this unit Q...

Page 11: ...uantity of the photos illustrations Comments Yes No Text 1 Does the information in the manual adequately explain how to operate and service the equipment Comments Yes No 2 Are there paragraphs or procedures you feel need clarification Please identify them by page number and add your comments Comments Yes No 3 Is there anything you would add or delete from the manual to make it more useful Comments...

Page 12: ... if the caution instruction is ignored Indicates the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning instruction is ignored ISO 3021 High pressure waterjet can cause eye injury Wear eye protection when operating or working near machine Hazardous noise can cause hearing loss Wear ear protection when operating or working near machine IS...

Page 13: ...SECTION 1 INTRODUCTION Page 1 8 49831878 Rear of Waterjet Pump HP Water OUT Plant Air IN Cooling Water IN Cooling Water OUT Cutting Water IN Drain ...

Page 14: ...see if the power goes off Each device should be checked on a specified schedule Each time the device is checked it must function or be replaced before operating the system Apply High Purity Goop P N 10084440 to all threaded high pressure connections All tubing fittings and bolted connections should be torqued to recommended values Do NOT attempt to tighten or loosen a HP water fitting when the cir...

Page 15: ...sent Make sure the safety devices are operational To panic stop the pump and bleed the high pressure the EMERGENCY STOP buttons must be pushed in The system pressure dump valves must be open Do not attempt to touch or be exposed to high pressure water The high pressure water will penetrate all parts of human body without exception The liquid stream or material ejected by these extreme pressures ca...

Page 16: ... HP water present a jet of HP water will exit the nearest weep hole with possible hazardous results Use extreme caution when handling high pressure equipment Possible failure from fatigue cracking or over pressurization can result in a hazardous high pressure leak or component failure A flexible HP tube whip is frequently used on the cutting system to allow cutting nozzle movement Supports and gui...

Page 17: ... KS 66713 620 856 2151 Back Side This person has been working with water jetting at pressures to 55 000 psi 374MPa 3740 bar 3867 Kg cm2 with a jet velocity of 3 000 fps 914 mps Foreign material sand may have been injected with water Unusual infections with microaerophilic organisms occurring at lower temperatures have been reported such as gram negative pathogens as are found in sewage Bacterial s...

Page 18: ...udy of this manual to understand the system in detail 2 1 Installation Overview Read the manual and become familiar with the operation of each component and its nomenclature Understand the complete system and its function before operating it Safety procedures and safe practices must be followed during installation operation and maintenance of the SL IV Waterjet Pump ...

Page 19: ...ic drops with manual shutoff valves Provide all mounting and support brackets and hardware for high pressure tubing runs Provide and install water conditioning equipment necessary to meet water purity requirements Provide and install manual shutoff valves Provide and install necessary cooling water inlet outlet and drain water connections to the intensifier pump and or cutting equipment and manual...

Page 20: ...for water and pneumatic service Test motor rotation direction and correct if necessary Check and test electrical signal connections between intensifier pump and cutting area Power up and check out pump and cutting station if supplied by KMT Waterjet for proper operation Set boost pump discharge pressure Install and test high pressure plumbing Follow the standard test procedure to insure satisfacto...

Page 21: ... by qualified personnel and must meet national and local electrical codes 2 2 1 Equipment Location Environment Space Requirements There should be a minimum of 900mm 36 inches clearance on all sides of the pump to facilitate service Electrical Wiring Power supplied to the pump must be in accordance with national and local electrical codes See specifications or requirements Control Wiring Wiring for...

Page 22: ...ater IN Supply piping must be properly sized to handle the necessary flow and pressure Piping must meet national and local piping codes HP Water OUT Properly rated sized and well supported high pressure HP piping must be connected to the pump Drain Cutting water released in the pump is discharged from the drain port and must be piped to an appropriate location i e sewer line Piping must meet natio...

Page 23: ... in the following table Cut tubing to length and deburr High pressure piping and fittings rated for 4 138 bar 60 000 psi must be used Failure to do so may cause component failure causing equipment damage personal injury or death Tube Engagement Length and Gland Nut Torque HP Tube Diameter inch Engagement Length EL mm inch Gland Nut Torque N m ft lb 1 4 12 7 0 50 34 25 3 8 17 5 0 69 68 50 9 16 21 3...

Page 24: ...e tube per following diagram and procedure Cone and Thread Dimensions O D Size mm inch I D size mm inch D max mm inch L max mm inch Thread NF LH 6 35 1 4 2 11 0 083 3 58 0 141 14 3 0 562 1 4 28 9 52 3 8 3 18 0 125 5 56 0 219 19 1 0 750 3 8 24 14 27 9 16 4 78 0 188 7 14 0 281 23 8 0 938 9 16 18 ...

Page 25: ...Cone and Threading Tool Item Description 1 Cutter Handle 2 Cutter Support 3 Feed Nut 4 Cutting Blades 5 Collet 6 Housing 7 Gland Nut Tube Size inch 1 4 3 8 9 16 A mm inch 3 30 0 13 4 07 0 16 7 11 0 28 Coning Tool KMT Part 10079556 10097418 10079663 Threading Tool KMT Part 10079697 10097434 10097442 ...

Page 26: ...t 3 clockwise until cutting blades 4 contact end of tubing Rotate cutter handle 1 in clockwise direction while simultaneously turning the feed nut 3 in a clockwise direction at a rate to assure that the cutting blades 4 are taking a light cut at all times Continue rotating cutter handle until feed nut bottoms on housing 6 then rotate cutter handle several more revolutions to face off end of cone U...

Page 27: ...sure 1 Slip gland nut 2 on tubing 1 as shown and lubricate thread with High Purity Goop Thread collar 3 on tubing until one to two threads are exposed between collar item 3 and tube cone 2 Lubricate male threads of gland with High Purity Goop Insert tubing in fitting engage gland nut and tighten finger tight 3 Tighten gland to specified torque as given in the torque table specifications ...

Page 28: ...d on end connection to take load alone Proper piping support and guide must be provided 1 Slip gland nut 2 and collet 4 on tubing 1 thread collar 3 until one to two threads are exposed between collar and tube cone 2 Lubricate male threads of gland nut with High Purity Goop Insert tubing in fitting engage gland nut and finger tighten 3 Tighten gland nut to the specified torque according to the tabl...

Page 29: ...n the functions available in the control and how to select and use them Following is an explanation of the functions of the control logic including the start up sequence The intensifier is equipped with a booster pump output pressure switch Seven seconds after the intensifier is started the switch is monitored If the switch opens a warning is issued message and flashing red light If the condition ...

Page 30: ...ay logic along with the software revision number running on the machine are shown on the Maintenance Screen The PLC monitors the motor overload relay and displays a message when the overloads trip The overloads will now be set on automatic reset rather than manual so the enclosure does not have to be opened to reset them The display will give a message motor feedback failure if the start relay doe...

Page 31: ... screen will always default to the Run screen after being on any other screen more than 5 minutes If the intensifier is equipped with a HP transducer the displayed pressure can be shown in psi or Bar Recalibration of the transducer is automatic and does not require operator input If the intensifier is equipped with an hp transducer another level of overstroke protection is obtained by shutting dow...

Page 32: ...set function idle shutdown time Transducer and Proportional Pressure Select Redundant select Screen configures display for a particular machine Analog Also contains PSI BAR select button Stroke Rate Screens 2 Set and observe machine stroke rate stroke count Hours Screen 2 Displays total operating hours and re settable maintenance hours Alarm Screen Displays all alarm conditions Alarm History Scree...

Page 33: ...is screen After 5 minutes on any screen display will return to Run Screen Recirc Select this to toggle the recirculation mode on or off The recirc mode runs the machine without generating high pressure and is used to circulate the hydraulic oil through the heat exchanger to cool the oil following a high temperature shutdown I Indicates recirc on O Indicates recirc is off Stop Stop Recirc with this...

Page 34: ...essure indicates that cutting supply water pressure is inadequate to permit proper machine operation and shutdown is pending less than 30psi 6 Bleed High Pressure Lines Indicates that the intensifier is shut down and that high pressure is present in the discharge plumbing of the intensifier that should be bled off to avoid the possibility of injury 7 Left Right Intensifier Overstroke Warning and S...

Page 35: ...CTION 3 OPERATION p 3 7 05146410 RUN SCREEN 2 RUN SCREEN 3 REDUNDANT This screen will be displayed if REDUNDANT button on the SETUP screen is ON SELECT INT button is used to select intensifier one or two ...

Page 36: ...from this screen HOURS This screen displays total machine hours and resettable maintenance hours to 9 999 999 for intensifiers 1 and 2 TOTAL HOURS cannot be reset MAINTENANCE HOURS on intensifiers 1 and 2 can be reset by pressing the RESET MAINT HOURS display button ...

Page 37: ...6410 EXAMPLE ALARM HISTORY SCREEN The alarm list stores the last 100 triggered alarms indicating date time and type of alarm Scroll up and down to see alarm history The Alarm History Screen does not have an intensifier STOP function ...

Page 38: ...ng THIS UNIT IS NOT EQUIPPED WITH PROPORTIONAL CONTROL The PRESSURE CONTROL SCREEN that is required can be selected on the SET UP SCREEN for the appropriate pressure control used if a proportional valve a pressure transducer or both are used on machine These are the TRANSDUCER SELECT and PROPORTIONAL SELECT buttons on the SET UP SCREEN HIGH LOW pressure switch and UP DOWN arrow indicating high or ...

Page 39: ...E RATE SCREEN Set STROKE RATE 2 to 4 strokes above normal running rate to shutdown machine in case of overstroke condition RESET Press to reset intensifier stroke count STROKES MIN is actual stroke rate The bar graph illustrates strokes minute ...

Page 40: ...e transducer and or a proportional valve are installed on the machine WATER RESET FUNCTION Press on I to shut water off five 5 minutes after machine shuts down Selecting this function will insure that the inlet cutting water is shut off following a shutdown fault This can prevent water from leaking past a damaged water seal following an overstroke shutdown caused by a seal failure IDLE SHUTDOWN TI...

Page 41: ...ill stop unit Jog right will extend piston to the right giving full exposure to the right plunger once the unit is disassembled Jog left will do the same to the left plunger CAUTION Unit must be completely assembled to use Jog functions PLC and display part and revision numbers are displayed on this screen to indicate programs installed ...

Page 42: ... pressure will shut down the machine 40 seconds after alarm condition is detected HIGH BOOSTER TEMPERATURE Alarm indicates high booster pump temperature The machine will shut down 30 seconds after this alarm condition is detected PRESSURE INLET LOW alarm indicates low booster outlet water pressure The machine will be shut off if the condition persists for 30 seconds OUTLET HIGH alarm indicates exc...

Page 43: ...OPERATION p 3 15 05146410 NO PRESSURE CONTROL This screen will appear if the pressure control on main menu is selected and machine does not have PROPORTIONAL control The machine cannot be stopped from this screen ...

Page 44: ...SECTION 3 OPERATION p 3 16 05146410 LANGUAGE Scroll up and down for desired language and press ENTER to select FRENCH GERMAN ITALIAN SWEDISH or ENGLISH ...

Page 45: ...l gauge on the reservoir check for leaks Oil Temp High Check cooling water flow with a flow meter Low Booster Pressure Check the booster pressure adjustment and check booster condition Low Inlet Water Pressure Check water supply pressure at maximum flow rate Long Idle Time Shutdown May be selected for energy saving Overstroke Shutdown Check plumbing for leaks check HP orifice check for leaking HP ...

Page 46: ...ance of the five systems is necessary and is described in their respective sections Refer to the following sections for detailed information on the operator console and systems maintenance Operator Console Section 3 Low Pressure Water Section 6 High Pressure Water Section 7 Electrical System Section 8 Hydraulic System Section 9 Recirculation System Section 10 ...

Page 47: ...e back of the variable piston pump which has a through shaft Booster Pump includes a stainless steel vane type pump with pressure adjustment and high temperature switch low pressure water filter bypass relief valve and associated water tubing and fittings The booster pump is mounted to the back of the hydraulic gear pump which has a through shaft Intensifier Assembly includes one high pressure HP ...

Page 48: ...eck Valve Port Sealing Head X X Temperature Checks Cooling Water Inlet Outlet Oil Water Heat Exchanger X F Motor Bearings Lube Hydraulic Power Unit X R Lubrication Filter Checks Hydraulic Filter Hydraulic Oil Tank X X R Electric Motor F L Vibrations Rotating Equip Hydraulic Pump F Splined Shaft Service Motor Pump Connection Motor Female Spline Piston Pump Male Spline L2 Hydraulic Pump F HP Tubing ...

Page 49: ...bench in a dust and dirt free work area Use lint free material for wipe cloths When blowing off parts with compressed air use only clean dry air When flushing parts with a solvent use only clean filtered fluid Always use original KMT Waterjet replacement parts for consistent performance reliability safety and to protect equipment warranty Safety Recommendations Carefully read the Safety Guidelines...

Page 50: ...ng any high pressure components flush the high pressure water system by operating the waterjet pump for a short period with the nozzle valve open and no orifice in place Next shut down the waterjet pump install an orifice and slowly increase the discharge water pressure in stages Check all high pressure connections for leaks Unusual requirements should be referred to the Customer Services group at...

Page 51: ...separate sheets of paper Note that if there are two intensifiers on the pump redundant option then indicate which intensifier I or II in the column labeled Intensifier Note that intensifier I is located to the front when standing such that the control panel is to one s left and the plumbing connections are to the right rear of the pump Also note which HP cylinder is being serviced Cylinder A is cl...

Page 52: ...water Abrasive Operating Pressure _____________bar psi No of Orifices Orifice Size _____ each x ______ mm inch SL IV Service Log Page ____ Date Person Hours 1 2 3 4 TW CYL 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Remarks A B A B A B A B A B A B A B A B A B A B A B A B ...

Page 53: ...unger Cartridge 8 05144506 Plunger Ceramic 9 05144555 Liner HP Cylinder 10 05059712 Cylinder HP 12 05116579 Seat HP Check Valve Wear out first side then reverse and use opposite side 13 05116579 Seat HP Check Valve Wear out second side then replace 14 05147863 Spring HP Check Valve 15 05119839 Pin 16 05119680 Poppet LP Water Inlet Check Valve Wear out first side then reverse to use opposite side 1...

Page 54: ...SECTION 4 MAINTENANCE Page 4 9 49831902 ...

Page 55: ... Turned Off Reset water valve by pressing RESET on Run menu 5 1 2 Console Display and Lights Fail to Illuminate E STOP Button Depressed Pull out E STOP button Check all remote E STOP pushbuttons Push CONTROL POWER ON button white light on CONTROL POWER ON button should illuminate Main Power Disconnected Check main power Door Unlatched locked out Check that the door disconnect switch is properly en...

Page 56: ...lve Check left inlet check valve Right Overstroke Check right HP seal Check left discharge check valve Check right inlet check valve T W Overstroke Check plumbing for leaks Check HP orifice Check HP dump valve Booster Pump Pressure Check booster adjustment Check booster condition Inlet Water Pressure Check water supply Check water filter Oil Temp Verify hydraulic oil tank temperature is above 620C...

Page 57: ...r shifting of 4 way directional control valve Verify proper proximity switch operation 5 2 2 Hot Surfaces On HP Cylinder Components HP Discharge Check Leaking Inspect check valve seat poppet spring and spring guide condition and sealing head LP Inlet Check Valve Leaking Inspect check valve poppet spring o ring poppet retaining screw and sealing head Sealing Head or Plunger Check plunger and sealin...

Page 58: ... with 600 emery cloth 5 2 4 HP Check Valve Leak If there are no visible HP water leaks but there are higher temperatures on HP cylinder or sealing head this indicates a HP or LP check valve leak Use corrective action listed in 5 5 for both discharge and inlet checks 5 2 5 Normal Temperature but Check Valve Problem Follow the instructions for HP check valve leak described in 5 5 5 2 6 HP Cutting Wa...

Page 59: ...anger improve flow of cooling water or replace heat exchanger Recirculation Pump Hydraulic Pressure below 20psi Replace hydraulic oil filter If filter is new replace recirculation pump 5 4 2 Hydraulic Pressure but no High Pressure Water Pressure Proximity switch failure Verify left hand and right hand LED lights on DC alternately illuminate ON OFF If so both proximity switches are properly functio...

Page 60: ...gh the intensifier will shut down and the display will tell you where to look for the problem For instance if the display indicates a Left Stroke Warning or Shutdown the probable problem is either at Left Inlet Valve or Right Discharge Valve You can usually confirm which it is by feeling heat on one side or another NOTE The bolted flange metal to metal seal arrangement of the SL IV Plus sealing he...

Page 61: ...he oil to water heat exchanger The low pressure water system supplies the pump with the following Water of sufficient cleanliness and pressure to the inlets of the HP cylinders Cooling water of sufficient flow rate and low temperature to the oil to water heat exchanger Figure 6 1 SLIV Waterjet Pump Item Description 1 Intensifier 6 Bulkhead Frame 7 Drip Pan Frame 8 Hyd Reservoir 10 Motor Pump Ass y...

Page 62: ...SLIV Waterjet Pumps 1 Heat Exchanger Oil to Water Cooler 2 Water Modulating Valve 3 Hydraulic Pump Gear Type Recirculating 4 Hydraulic Filter Return Line 5 Main Hydraulic Pump 6 Electric Motor 7 Hydraulic Reservoir Tank 8 Temperature Bulb Reservoir Well 9 Cutting Water Booster Pump ...

Page 63: ...ter from a cooling manifold or series circuit Issues with low supply pressure or high supply temperature may arise in connection with this cooling system To raise or lower hydraulic oil operating temperature an adjustment on the water modulating valve 2 increases or decreases force on a spring Turning the screw counterclockwise causes increased water flow while DECREASING oil temperature Likewise ...

Page 64: ...amaging the pump However when the low pressure water filter gets loaded up with dirt contaminants the water pressure exiting this filter may be too low to supply the booster pump The cutting water supply circuit is automatically shut off after the motor has been off for 2 minutes To reset the water supply valve press F6 6 2 1 Normal Operating Condition During normal operation the low pressure wate...

Page 65: ...e at port B of 4 bar 58 psi The pump may require adjustment if local inlet pressure is different because discharge pressure depends on inlet pressure Inlet pressure is affected by filter condition as well as local water supply conditions The water flows through the low pressure water supply filter 2 and then enters the booster pump Booster pump 1 inlet water is monitored by pressure switch 6 Water...

Page 66: ...ly 4 Filter Assembly LP Water 5 Pressure Switch 60psig Low Booster Pump Pressure 6 Pressure Switch 30psig Low Supply Water Pressure 7 Temperature Switch High Booster Pump Out 8 Pressure Gage Cutting Water Supply Pressure 9 Pressure Gage Booster Pump Output Pressure 10 Check Valve 11 Orifice 12 Air Bleed Valve 13 Sealing Head Assembly Intensifier 14 Relief Valve Built in 15 Relief Valve Circuit ...

Page 67: ...lve pressure 6 2 4 Low Pressure System Protection System pressurization over 8 6 bar 125 psi is prevented by the relief valve 15 Note that a leaking check valve in a sealing head 13 could cause relief valve 15 to open Booster pump overheating due to lack of water or long deadheaded conditions is prevented by the temperature switch 7 which turns the waterjet pump off To reduce booster pump overheat...

Page 68: ... proper operation it is necessary to replace the water filter and or adjust the booster pump The guidelines for servicing these parts are described below Figure 6 5 Item Description 1 Booster Pump 2 Temperature Sensor 3 Relief Valve Acorn Nut 4 Pressure Gage 5 Bleed Valve 6 Filter Head 7 Pressure Gage 8 Filter Housing 9 Filter Element 10 Shut off Valve Solenoid ...

Page 69: ... unthread tool to turn housing Container to capture some water spill Rags Parts Elements for water 10 micron quantity 2 Polymer mixer 40 micron quantity 2 Water Filter Element Replacement Procedure 1 Turn off cutting water supply 2 Press bleed valve to relieve trapped pressure 3 Unscrew housing from head Remove element 4 Install new elements in housing Screw housing into head 5 Open cutting water ...

Page 70: ...ure control knob Container To capture some water spill Rags Parts None required Booster Pump Adjustment Procedure 1 Turn on cutting water supply 2 Start waterjet pump and observe booster discharge pressure 3 Stop waterjet pump and press E Stop button 4 Remove acorn nut from the side of the booster pump and turn screw clockwise to increase pressure or counter clockwise to decrease pressure 5 Replac...

Page 71: ...s include the hydraulic intensifier HP attenuator s HP dump valve HP pressure indicator optional and HP piping Maintenance on the intensifier is discussed in detail in this section In addition to HP components and assemblies the hydraulic cylinder features of the intensifier are discussed in this section See Section 12 for part number information on specific components Figure 7 1 Item Description ...

Page 72: ...attenuator is discussed but no disassembly procedures are included Note that HP attenuators are not considered to be serviceable by the customer Some special terms used in this section include 1 HSEC Hard Seal End Cap Items 7 10 and 12 Figure 7 2 2 HP Cylinder Jug High Pressure Cylinder Sealing Head Assembly and End Cap assembly treated as a unit Items 1 3 7 etc Figure 7 2 3 Hydraulic Cylinder Hyd...

Page 73: ...dr Seal Cartridge 9 Retaining Flange 10 Jackbolt 11 Cylinder Liner 12 O ring 14 Retainer Ring 15 Hydraulic Cylinder 16 Back up Ring 17 O ring 19 Proximity Switch 20 Cap Screw 21 Piston Assembly 28 Spacer Standard HP gland nut hex sizes for HP piping are as follows 3 8 HP fittings 13 16 open end wrench 9 16 HP fittings 30mm 1 3 16 wrench 7 16 Jackbolts 3 8 socket wrench ...

Page 74: ...ed the following operations can be performed HP cylinder can be removed from hydraulic cylinder head HP plunger seal can be serviced After the pump has been reassembled then the HP water piping and LP water disconnect are reinstalled as follows 5 Connect LP water hose fitting to flared fitting on HSEC 6 Install the HP water piping to the intensifier Check HP fittings for proper collar position 1 t...

Page 75: ...disassembly re assembly practices Due to the weight approx 55 lbs of the HP cylinder jug adequate support should be provided to prevent damage to the plunger or seals during disassembly re assembly See Figure 7 3 for suggested special tools to support the HP cylinder jug for this procedure Figure 7 3 Use Cradle Tool 2 to support HP Cylinder Jug 1 while removing or installing Jug 1 from Hydraulic C...

Page 76: ...r down sequence HP Cylinder Jug Re Installation 1 Verify that HP cylinder threads are adequately lubed with High Purity Goop and that the threads have been sanded dressed if galling was encountered during HP cylinder jug removal 2 Verify that the HP plunger seal assembly packing follower and plastic cylinder liner tube are correctly installed Align HP cylinder jug 1 with plunger and hydraulic cyli...

Page 77: ...r paragraph 7 2 1 above 3 Loosen jackbolts 4 Remove HSEC Note that sealing head may be removed with end cap 5 Remove sealing head Note that a white plastic spacer ring used to position the sealing head relative to the HP cylinder bore may remain in cylinder bore This ring should be removed prior to re installing a sealing head to avoid pushing the ring further into the HP cylinder bore Note that a...

Page 78: ...n screws will result in hydraulic oil spraying in general directions 6 Restart KMT Waterjet pump first operating in LOW pressure mode to flush out air in HP components and also to check for obvious leaks Switch to HIGH pressure after 5 10 minutes of LOW pressure operation watching for obvious leaks Be ready to shut off the pump if leaks appear Remedy leaks then repeat start procedure moving from L...

Page 79: ...ower to insure a good seal for hydraulic seal removal 5 Place shop rag around plunger to avoid splash back 6 Lightly drive plunger into HP cylinder using dead blow hammer until plunger seal components move outward at point A HP cylinder jug is heavy and if it is stood on top pan of IRWJ pump will present a falling object hazard Take care to properly support jug so that it will not fall 7 Slip plas...

Page 80: ... replace plunger Refer to Paragraph 7 2 6 for procedure regarding plunger removal installation Seal Installation Procedure 1 Lightly coat seal components with FML grease refer to Table 7 2 item 1 prior to installing seal parts on plunger Install new HP plunger seal assembly onto plunger refer to Figure 7 2 Detail I for proper seal component orientation Note that steel spring inside U cup if so equ...

Page 81: ...kbolt Tightening Hand Tight Torque ft lb 20 Torque N m 27 2nd Stage Tightening Sequence Crossing Pattern Note 1 Torque ft lb 35 Torque N m 48 3rd Stage Tightening Sequence Crossing Pattern Note 1 Torque ft lb 35 Torque N m 48 4th Stage Tightening Sequence Circular Pattern Note 2 Note 1 Crossing Pattern tighten pairs of opposing jackbolts for example as shown in numbered sequence in Figure A Note 2...

Page 82: ...68 Table 7 6 Lube Specs KMT Waterjet Intensifier Pumps Item No KMT P N Description Applications 1 10087385 FML Grease White Lube Parts HP Cylinder 2 10084440 High Purity Goop SS Threads SS Threads 3 49832199 Moly Disulfide Grease Non SS Threads ...

Page 83: ...ef Part No Æ 7 2 1 7 2 1 7 2 2 7 2 3 7 2 5 7 2 6 1 Outlet HP Check Valve Sealing Head Yes No No No No No 2 Inlet HP Check Valve Sealing Head Yes Yes No Yes No No 3 HP Plunger Seal HP Cylinder Yes Yes Yes No No No 4 Hydraulic Seal Cartridge Plunger Hydraulic Cylinder Head Yes Yes Yes No Yes No 5 Sealing Head Cone Seal Sealing Head Yes Yes No Yes No No 6 HP Cylinder Yes Yes No Yes No No 7 Plunger Ye...

Page 84: ...er 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 ...

Page 85: ... removed The proximity switch mounting flats provide a small lip for loosening the cylinder head 5 To remove the hydraulic piston 21 from the hydraulic cylinder 15 remove one cylinder head remove the proximity switch toward that end On the opposite end remove the HP cylinder and end cap and then remove the retainer flange and hydraulic cartridge The piston must be driven from the cylinder bore due...

Page 86: ...HIGH PRESSURE WATER p 7 16 80078868 Figure 7 8 Item Description 1 Cylinder Head 4 Bushing Retainer Flange 2 Plunger 5 Retaining Ring 6 Hydraulic Cylinder 3 Hydraulic Cartridge Plunger Seal 7 Plunger Removal Tool ...

Page 87: ... Cartridge Plunger Seal Assy 17 Backup Ring 28 Spacer 7 3 Intensifier Subassemblies Inspection and Repair The inspection and repair of the following subassemblies will be discussed Discharge HP Check Valve Section 7 3 1 Inlet Check Valve Section 7 3 2 Sealing Head Section 7 3 3 HP Cylinder Section 7 3 4 Plunger Section 7 3 5 Hydraulic Seal Cartridge Section 7 3 6 Hydraulic Piston Section 7 3 7 Hyd...

Page 88: ...removed by carefully dislodging it with a screwdriver The seat is removed with a magnet Inspect the seat for damage or cracking A cracked seat should be replaced The seat is symmetrical and can be installed with either face toward the poppet Note that a slight burr at the hole edge identifies the used side of the poppet seat When reinstalling the seat apply a thin film of High Purity Goop to both ...

Page 89: ...ds Install the gland nut into the sealing head The gland nut should be hand tightened until there is a gap of 5mm 0 20 between the gland nut and sealing head No threads should show If the gap exceeds 5mm 0 20 then the poppet has slipped out of place and the parts must be removed inspected and reassembled 6 Using a crowfoot torque wrench combination torque the gland nut to 176 Nm 130 ft lbs 7 Recon...

Page 90: ... 2 and spring 7 on poppet retainer 11 Apply small amount of Loctite 222 thread locker to thread of poppet retainer taking care not to get Loctite on poppet or other inlet check valve sealing surfaces 5 Tighten poppet retainer 11 using 1 2 in flat blade screwdriver taking care not to twist off poppet retainer If torque wrench tools are available tighten to 25 30 in lbs 6 Inspect the assembled unit ...

Page 91: ...TION 7 HIGH PRESSURE WATER p 7 21 80078868 Figure 7 11 Item Description 1 Sealing Head 2 Poppet Inlet Check 3 Gland Nut 4 HP Cylinder 5 Spacer Ring 6 Hard seal End Cap 7 Jackbolt 8 O ring 9 Cylinder Liner ...

Page 92: ...d for pits scratches or jetting erosion Refinishing the seal head inlet poppet face is mandatory when rebuilding the sealing head Using a piece of plate glass not window glass on a sturdy table place a piece of 400 grit wet dry sandpaper atop the plate of glass which provides the absolutely flat surface necessary for the polishing process Using even deliberate strokes polish the sealing head until...

Page 93: ...ingernail across it will cause it to appear as a surface flaw It is usually necessary to clean the area before performing an inspection 4 Use 600 grit wet dry sandpaper to polish HP cylinder inside diameter where the seal will locate Polish only in a circumferential motion Do not polish or drag the sandpaper along the length of the cylinder Hold the sandpaper on the end of your finger and move in ...

Page 94: ...become discolored or dull in appearance If any of these conditions become severe the plunger HP seal and possibly the hydraulic seals will leak excessively Repair of plunger surface flaws usually cannot be accomplished on site KMT Waterjet offers a plunger reconditioning service Figure 7 13 Item Description 1 Plunger Button 2 Plunger 3 Button Chamfer ...

Page 95: ...O ring 6 O Ring 7 Back Up Ring 8 U cup Seal NOTE It is important to examine the inside diameter surfaces of cartridge seal grooves for scratches especially any scratches in the axial direction that might offer a leak path Use caution during seal removal and installation to avoid scratching these surfaces Do not use metal screwdrivers wires etc to remove inside diameter seals Plastic or wood should...

Page 96: ... piston opposite side These check valves prevent hydraulic pressure from building behind the plunger button Replace Piston Seal 1 Remove bearing rings 10 and worn seal ring assembly 9 Do not scratch bottom surface of piston seal groove Scratches to the seal groove sides and or bottom can result in a hydraulic leak NOTE Use a smooth dull edged blade made from brass or similar soft relative to steel...

Page 97: ...t may show the impression of the plunger on it due to the high contact forces between piston and plunger This compression mark is normal Service Piston Internal Check Valves NOTE Check valve 4 servicing is not necessary unless there is suspicion of a problem If the check valves 2 each or piston internal passages must be serviced seal and pin servicing is also recommended 1 Check valves items 4 2 e...

Page 98: ...ton seal assembly must be compressed before the piston assembly will slide into the hydraulic cylinder A ring compression tool such as shown in the figure below is recommended 1 Check that hydraulic cylinder bore is free grit or contamination and that the proximity switches are removed to prevent interference Lubricate piston bearing and seal surfaces with FML 2 See Table 7 6 grease Lightly lubric...

Page 99: ...SECTION 7 HIGH PRESSURE WATER p 7 29 80078868 Figure 7 16 Item Description 15 Hydraulic Cylinder 20 Seal Ring Compression Tool P460 19 Proximity Switch 21 Hydraulic Piston Assy ...

Page 100: ...ic cylinder should be inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed Excessive grooving on this bore is indicative of piston seal wear Figure 7 17 Item Description 1 Hydraulic Cylinder 2 Cylinder Head 3 Proximity Switch 5 Cap Screw 8 Back up ring 9 O ring 10 Spacer ...

Page 101: ...ded in the Parts Lists Section 12 Bulkhead Piping Assy 7 5 HP Attenuator There is no servicing of the HP attenuator at the customer level The seals in the HP attenuator are tested at KMT Waterjet to high pressure in excess of operating pressure making disassembly difficult In the event of a HP water leak of a HP attenuator the attenuator should be replaced The defective attenuator should be return...

Page 102: ...SSURE WATER p 7 32 80078868 Figure 7 18 1 Plunger Removal Tool 6 Seal Removal Tool Stand 2 Vee Block Cradle 7 3 8 Plug 3 Cylinder Wrench 8 3 8 Gland Fitting 4 End Cap Wrench 6x 8x 9 Seal Removal Tool 5 End Cap Wrench 8x ...

Page 103: ...rcuit diagnostics malfunction warning and protection The electrical enclosure and the display buttons lights and electrical harnesses into and out of this enclosure can be exposed to occasional water spray and dust per NEMA 12 standards 8 1 Electrical Overview There is only one electric motor on the SL IV Waterjet Pump The control voltage of 24vdc is furnished by the built in power supply drawing ...

Page 104: ... 2 3 Phase Line Service Drop Power 11 Optical Relays 3 Enclosure Door Disconnect Circuit Breaker 12 Touch Screen Interface Panel 4 Motor Starter Contactor s 13 Modem Optional 5 Contractor Coil s 230V 14 Emergency Stop Button 6 Electric Motor 15 Proportional Control Optional 7 Transformer 230V AC Out 16 Pressure Transducer Optional 8 Power Supply 24V DC Out ...

Page 105: ...nput side of the main circuit breaker door disconnect To make the SL IV Intensifier Pump electrically safe one should switch the wall disconnect 1 OFF and observe LOCK OUT TAG OUT safety practices Note that the wall disconnect 1 should have circuit breakers or fuses but that this over current protection may be oversized for the current draw of the particular SL IV Intensifier Pump The primary over...

Page 106: ...re Motor Overload Motor Feedback Failure Oil Level Low Oil Temp High Low Booster Pressure Low Inlet Water Pressure Long Idle Time Shutdown Booster Temp High Left Overstroke Shutdown Right Overstroke Shutdown Topworks Overstroke Shutdown For more information on these conditions and recovery procedures refer to Section 3 Operation of this manual The functions listed below are available by connecting...

Page 107: ... Intensifier Shift A B Port Shifting Solenoid operated directional control valve DCV hydraulic pilot operated spool Hydr manifold assy motor pump group 5 HI LO Pressure Select Solenoid shutoff valve hydr cartridge style Hydr manifold assy motor pump group 6 Low oil level temperature Combination level temp switch immersed in hyd fluid Hydraulic reservoir 7 High Booster Pump Temp Temperature sensor ...

Page 108: ...20 seconds after motor is started after which pressure will go to high if high is selected otherwise the pump will stay in low pressure The final pressure may also be set on the PRESSURE CONTROL screen if analog control is present On the STROKE RATE screen set the STROKE RATE ALLOWED Because overstroke protection is related to stroke speed under actual pressure setting this allows you to control s...

Page 109: ...20 seconds after motor is started after which pressure will go to high if high is selected otherwise will stay in low The purpose for this is to allow entrapped air to be bled from any HP cylinder that has been maintained to avoid hot air burning the plunger seals 2 Standard machine start up after normal stop Safety dump valve will be closed pump will be held in low pressure for 20 seconds after m...

Page 110: ...otor starter in the control panel is activated and the motor starts The intensifier assembly starts operating Reversal position is sensed by proximity switches which send signals to the PLC inside the control panel The PLC activates the opposite solenoid on the pump reversing valve ...

Page 111: ...ed to two places 1 motor contactor s 5 and 2 24 volt DC power supply 8 To minimize the load requirement on the 24 volt DC power supply motor contactor coil s 5 use 230 volt AC coil s while the relay logic 11 controlling the motor contactor s 4 is powered by 24 volts DC The 24 volt DC power supply 8 receives 230 volts AC input power and regulates it to 24 volts DC 5 amps maximum output power 24 vol...

Page 112: ... on the switch Symptoms of a failed proximity switch are 1 the LED lights do not change state indicating not sensing the piston or 2 the LED lights are continuously flashing Replace the switch when failure occurs Components 1 Intensifier Assembly 2 Piston 3 Proximity Switch 4 Hydraulic Cylinder Recommended Tools Allen hex Wrench M5 Torque Wrench Rags Parts Proximity Switch Replace Proximity Switch...

Page 113: ...mm 1 8 inch Parts Optical Relay Replace Optical Relay Switch 1 Turn off waterjet pump disconnect and LOCKOUT electric power 2 Open control panel 3 Unscrew optical relay switch mounting bolts remove and replace If the motor will not start and a motor feedback fault message appears the optical relay which controls the motor starter may need replaced ...

Page 114: ...pump is directly coupled to the motor rather than a conventional standalone housing and shaft coupling assembly Reference hydraulic gage used for adjusting pressures in the HI LO relief valves Displays hydraulic pressure as well as water pressure in multiple units directly at the pressure adjustment knob Built in hydraulic oil drip pan allows for the spills to be contained within the machine Remot...

Page 115: ...nted to the motor The main pump control includes hi and lo preset pressures The operator is able to switch between pressures at the operator s console Item Description 1 HI pressure control 2 LO pressure control 3 Fixed relief valve 4 Gage 5 Manifold 6 Pump 7 Motor 8 Directional Control Valve 9 Hydraulic Cylinder 10 Hi Lo Solenoid Valve ...

Page 116: ...he programmable controller PLC This PLC in turn activates the directional control valve 8 to change flow and to reverse direction of movement of piston until activating the opposite end of stroke proximity switch Although one DCV supplies hydraulic power to two intensifier hydraulic cylinders arranged in parallel these cylinders operate at approximately the same cycle rate due to logic built into ...

Page 117: ...e Decrease Maximum Minimum High Pressure 1 Clockwise Counterclockwise 207 3 000 1 7 25 Low Pressure 2 Clockwise Counterclockwise 103 1 500 1 7 25 Main Relief 3 Fixed Fixed 234 3 400 Not applicable NOTE Do not adjust the HI pressure control to pressures greater than 207 bar 3 000 psi Doing so will cause the main relief to open limiting hydraulic pressure to 234 bar 3 400 psi Excessive opening of th...

Page 118: ...l and filter maintenance see Section 10 Recirculation System The hydraulic system components that require periodic maintenance are the motor and the manifold The motor needs to be serviced every 5000 hours of use The operating pressure settings of the manifold needs to be checked daily and adjusted if necessary Recommended Tools Manual Grease Gun Open End Wrench 14mm 9 16 Rags Parts Bearing Grease...

Page 119: ...a few minutes 9 3 2 Manifold Service 1 Check operating pressure 2 If pressure adjustment is necessary 3 Adjust high pressure control valve Turn locking nut counterclockwise then turn the knob clockwise to increase pressure counterclockwise to decrease 4 Adjust low pressure control valve Turn locking nut counterclockwise with open end wrench Turn the hex clockwise to increase pressure and countercl...

Page 120: ...nd together with the hydraulic tank removing air bubbles entrained in the oil due to agitation and turbulent flow in the main pump circuit 10 1 Components The cooling and filtration system recirculation system is equipped with the following Recirculation pump gear type which receives oil from the oil tank Heat exchanger cooling water is controlled by the water modulating valve Oil filter assembly ...

Page 121: ...RCULATION SYSTEM Page 10 2 49836026 Figure 10 1 Recirculation System Item Description 1 Recirculation Pump 2 Water Modulating Valve 3 Heat Exchanger 4 Visual Indicator 5 Oil Filter 7 Oil Fill Port 8 Hydraulic Oil Tank ...

Page 122: ... indicator 4 indicates when the filter element needs replacement It should be read when both the water jet pump is running and the oil temperature is approximately 115 F Oil fill port must be used when pumping oil into tank to assure cleanliness By filling at this point the hydraulic oil must pass through the hydraulic filter to get to the hydraulic tank guaranteeing that the oil into the tank get...

Page 123: ... the drain The operating oil temperature is factory set at 46 C 115 F based on the temperature and flow of cooling water at the factory Field adjustment may be necessary 10 3 System Pressure Protection System pressurization over 4 2 bar 60 psi is prevented by relief valve located in filter housing 5 Table 10 2 Re circulating Oil Temperature and Pressure Controls Adjustment Setting Control Valve In...

Page 124: ...il with additives such as zinc diophosphate ZDDP for anti wear are not recommended because of reaction with water Tools Open End Wrench 1 1 4 Rags Container to collect oil Oil transfer pump with hoses Inlet hose with male pipe connector and pump discharge hose with female JIC connector TABLE 10 3 Hydr Oil Filter Change Criteria SL IV Pump Models Type of Indicator Interpretation of indicator readin...

Page 125: ...riteria Components 1 Oil Filter Head 2 Element 3 Visual Indicator Parts Element Tools Filter Wrench Rags Container to collect oil spills Replace Oil Filter 1 Unscrew element from filter head with the filter wrench 2 Oil gasket of new element 3 Screw new element on head 4 Start pump and check for leaks ...

Page 126: ...e when the level rises Drain valve and Fill components The fill components consists of the Oil Filter Head Fill Port and the Fill Port Cap The breather is not a fill component and must not be used as a fill point After 3 000 hours of operation or yearly whichever happens first analyze the hydraulic oil and replace if necessary Item Description 1 Filter Assembly 2 Oil Fill Port 3 Temperature Sensor...

Page 127: ...o fill port This will assure clean filtered oil is pumped into the tank Oil must be filtered through an equivalent filter such as a 10 micron filter element Failure to do so will cause damage to the primary hydraulic components voiding the warranty 5 Check oil sight gage to assure proper fill level Remove hose cap fill port 6 Remove the plug of the main hydraulic pump case and make sure the case f...

Page 128: ...imum Operating Temp 95 95 Electrical see note 3 Motor type TEFC TEFC see note 4 200 3 50 92 150 208 3 60 88 144 240 3 60 80 130 400 3 50 46 75 415 3 50 44 72 480 3 60 40 65 Voltage Service Amps 575 3 60 32 52 Volts Phase Hertz Amps Sound Level 72 5 72 5 dB A see note 5 Note Specifications listed below apply equally to 30 hp and 50 hp models Controls Voltage 24 volts DC Power Supply 10 amps DC Safe...

Page 129: ...re must be maintained within operating specifications 2 When relative humidity is above 50 frequently check oil in tank for water content 3 Not all motor voltages are readily available check with factory for availability 4 Totally enclosed fan cooled 5 Sound level per TUV report DE1 I 9047401 ...

Page 130: ...ar psi Maximum inlet pressure 7 100 bar psi Maximum outlet pressure 8 3 120 bar psi Maximum inlet temperature 29 85 C F Optimum inlet temperature 18 65 C F Factory Booster Pump Settings Inlet Pressure 4 58 bar psi Outlet Pressure Set at 8 3 120 bar psi see Note 8 Cutting Water Out 2 4 0 63 3 8 1 0 l min gpm 55 000 Maximum flow rate 2 2 0 58 3 4 0 9 l min gpm 60 000 Note Specifications listed below...

Page 131: ... larger than 10 microns upstream of the filter for each particle per ml greater than 10 microns downstream of the filter Note 7 ISO 4406 fluid cleanliness ratings 17 1 300 particles per ml 25 microns 14 160 particles per ml 15 microns Note 8 Booster pump discharge pressure is dependent on inlet pressure ...

Page 132: ...P Fitting Gland Nuts 1 4 Nut 34 25 5 8 Crowfoot 3 8 Nut 67 50 13 16 Crowfoot 9 16 Nut 149 110 1 3 16 Crowfoot See Section 7 for complete tightening procedure NOTE Measurements are made with lubricated components and a calibrated torque wrench Inconsistencies in wrench settings lubrication and technique may not produce a leak tight seal If leakage persists increase the torque until the components s...

Page 133: ...mg l 25 25 10 Oxygen mg l 2 1 0 1 pH Value 6 5 8 5 6 5 8 5 6 5 8 5 Silica mg l 15 10 1 Sodium mg l 50 10 1 Sulfate mg l 25 25 1 Total Dissolved Solids mg l 200 100 5 Total Hardness as CaCO3 mg l 25 15 1 Turbidity NTU 5 5 1 Do not reduce beyond this amount or the water will become too aggressive 11 4 Cooling Water Specifications Depending on the type of cooling system closed recirculation once thro...

Page 134: ...quilibrium with respect to calcium carbonate 11 5 Orifice Support Capacity The SL IV Waterjet Pump supplies high pressure HP water up to 3 800 bar 55 000 psi The following table shows size ratings and maximum quantity of orifices that can be supported Qty of Orifice by size 1 Rated power kW hp Pressure Bar Psi Flow lpm gpm 14 13 11 10 9 7 5 22 30 3 800 55 000 2 4 0 63 1 2 4 22 30 4 100 60 000 2 2 ...

Page 135: ...ustomer Service Manager Europe Technical Manager KMT Waterjet Systems KMT Waterjet Systems GmbH Production Equipment Group Wasserstrahl Schneidetechnik 635 West 12th Street POB 231 Auf der Laukert 11 Baxter Springs KS 66713 0231 D 61231 Bad Nauheim USA Germany Phone 800 826 9274 Phone 49 0 6032 997 117 Fax 620 856 5050 Fax 49 0 6032 997 270 E mail wj_service kmtwaterjet com E mail order service km...

Page 136: ... 12 1 Part Description Abbreviations and Nominal Size Guide Item Description Item Description Assy Assembly mm sq Square millimeters 1 4 9 16 3 4 Nominal sizes in fractions of an inch eg 1 2 NPT 0 50 inch national pipe thread or 9 16 HP tube 0 56 inch OD HP tubing or tube fitting JIC 37 degree flared threaded Hydraulic fitting JIC standard typically used on Hydraulic hose end connections Hydr Hydr...

Page 137: ... 80078447 12 17 12 8 Hydraulic Manifold Assembly 05071766 12 19 12 9 Bulkhead Piping 80070295 S 80080500 R 12 21 12 10 Low Pressure Filter Assembly 49838378 12 23 12 11 Hydraulic Power Unit 49834229 12 25 12 12 Motor Pump Assembly 05071758 12 27 12 13 Reservoir Assembly 05141660 12 29 12 14 Top cover Assembly 49834757 12 31 12 15 Electrical Assembly 80078116 12 33 12 16 Control Panel Configuration...

Page 138: ...onal 6 1 49833262 80073711 Decal Package 7 1 05128087 Start Up Tag 9 1 80070295 80080500 Bulkhead Assembly 10 1 05143714 Frame Assembly 11 1 05041660 Reservoir Assembly 12 1 49834757 Cover Assembly 13 1 49834229 Hydraulic Power Package 14 1 05052519 Hose Connections 15 05022702 Hydraulic Fluid 16 192 05072582 Stripping 17 192 05072590 Stripping 18 4 10097657 Button Head Screw 1 4 20 x 3 4 19 4 953...

Page 139: ...SECTION 12 PARTS LISTS page 12 5 80079163 ...

Page 140: ... x 2 31 14 2 05034798 Ring Retaining 15 1 05034764 Cylinder Hydraulic 16 2 10075000 O ring 17 2 05034855 Ring Backup 18 16 05141106 Cap Screw Socket Head M14x60 19 2 05127584 Switch Proximity 20 250 VAC VDC 20 4 10183572 Cap Screw Socket Head M6x1x22mm 316 304 Stainless 21 1 05132253 Piston Assembly Hydraulic 23 2 05049812 Stem Mounting Hydraulic Cylinder 25 8 05079652 Cap Screw Socket head M10 x ...

Page 141: ...SECTION 12 PARTS LISTS page 12 7 80079163 ...

Page 142: ...o DESCRIPTION 1 1 49834039 Body Sealing Head 2 1 05144662 Poppet Inlet Cutting Water 3 1 05116777 Gland HP Sealing Head 4 1 05112768 Seat HP Sealing Head 5 1 05116561 Poppet Valve HP Check 6 1 05144670 Retainer Poppet 7 1 05147863 Spring Compression 8 1 49884562 Spring Compression 9 1 05116751 Pin Guide ...

Page 143: ...SECTION 12 PARTS LISTS page 12 9 80079163 ...

Page 144: ...Body Hydraulic Piston 2 12 05074380 Pin Clevis 3 2 05049887 Screw Set Socket with Through Hole 4 2 10148757 Valve Check Cartridge with O ring 5 49877509 Adhesive Thread Locker 6 2 05088364 Ring Snap Flat Wire 7 2 05049994 Ring Backup 8 2 05087713 O ring 9 1 05117965 Seal Assembly Hydraulic Piston 10 2 05117940 Bearing Hydraulic Piston ...

Page 145: ...SECTION 12 PARTS LISTS page 12 11 80079163 ...

Page 146: ...LY 05130091 ITEM No QTY PART No DESCRIPTION 1 1 05130109 Body Seal Cartridge 2 2 05015060 Seal U Cup with O ring 3 1 10193522 O ring 4 1 05050760 Ring Backup 5 1 05129481 O ring 6 1 05013024 O ring 7 1 05129515 Back up Ring 8 1 05027255 Seal U Cup Ref 1 0 05009048 Tool Seal Installation ...

Page 147: ...SECTION 12 PARTS LISTS page 12 13 80079163 ...

Page 148: ...ssembly Hydraulic 25 ID 4 JIC Swivel Both Ends 32 10 1 05049713 Hose Assembly Hydraulic 75 ID 12 JIC Swivel Both Ends 27 11 2 05071105 Hose Assembly Hydraulic 75 in ID 12 JIC 90 deg x 12 JIC Swivel 12 1 05071121 Hose Assembly Hydraulic 25 ID 4 JIC Swivel Both Ends 18 13 2 05052493 Elbow 45 Degree 12 JIC x 10 SAE O ring Steel 14 2 95702619 Adapter Straight 12 JIC x 12 SAE O ring Steel 15 3 10142644...

Page 149: ...SECTION 12 PARTS LISTS page 12 15 80079163 ...

Page 150: ...in 4 200 bar TUV 11 2 49830599 Tee HP 56 60ksi stainless 12 10 10083897 Ferrule 25 Hose 13 4 95413696 Washer Lock 13 14 4 05144837 Spacer Accumulator 15 4 95383790 Cap Screw Socket Head 13 x 1 in Stainless 16 2 05090717 Nut Retaining HP Accumulator 17 150 10186153 Conduit Extra Flexible 38 in ID Galvanized 18 1 49837362 Tube Bent 38 in HP 60 ksi Stainless 19 1 10105443 Tube 38 in x 4 00 HP 60 ksi ...

Page 151: ...SECTION 12 PARTS LISTS page 12 17 80079163 ...

Page 152: ...7 Gage Pressure Hydraulic O 5 000 psig 4 SAE O ring Bottom Mount 7 1 10187052 Valve Relief Hydraulic 100 3 000 psi Range Knob Adjustable 8 1 10187060 Valve Relief Hydraulic 25 800 psi Range Adjustable 9 1 10074953 O ring 10 1 49889744 Retainer Valve Cartridge 1 in 11 1 49889736 Valve Check Hydraulic Cartridge 12 1 05092523 Valve Directional Hydraulic Solenoid Operated DO 8 24 VDC 040 in Orifice 13...

Page 153: ...SECTION 12 PARTS LISTS page 12 19 80079163 ...

Page 154: ...t 15 2 05111406 Adapter Str 25 NPT x 8 JIC 16 1 10077055 Adapter Bulkhead 4 15 Brass 19 4 10069771 Washer 63 23 1 10176766 Elbow 90 deg L P NPT 24 5 10189025 Adapter Hose JIC 8 x 8 26 4 49832959 Screw Hex Head 5 8 11 x 75 27 4 49833072 Lock Washer 63 29 1 10084523 Nipple in NPT x4 in 30 10079903 Tube Polyethylene 25 in 32 1 49834310 Adapter Tube Pipe 50 33 1 49834302 Adapter Tube Pipe 50 36 2 4989...

Page 155: ...SECTION 12 PARTS LISTS page 12 21 80079163 ...

Page 156: ... 1 05140751 Pressure Switch 7 1 05142062 Pressure Switch 8 1 49868813 Temperature Sensor 9 1 05070982 Valve Relief 50 150 psi NPT 10 1 05135645 Adapter Pipe Hose Barb 8NPT x 8 Hose 11 1 05135652 Check Valve 12 2 49830714 Adapter Pipe Hose Barb 90 Degree 4 13 1 05038690 Body Filter Water NPT 14 1 49834716 Element Filter LP Water Polypropylene 10 Micron 15 4 95391322 Washer Flat 25 16 4 95838314 Was...

Page 157: ...SECTION 12 PARTS LISTS page 12 23 80079163 ...

Page 158: ...5572897 Hex Head Screw 1 4 20 x 5 8 4 3 95838314 Lock Washer 1 4 5 1 49887094 Vane Water Pump 12 1 10092302 Shaft Coupling 13 2 10116952 Cap Plug 14 2 95750394 Lock Washer 3 8 15 2 95416319 Hex Head Screw 3 8 16 x 1 16 1 10091510 Decal 18 1 05092523 Directional Control Valve 19 6 95055026 Socket Head Screw 1 2 13 x 1 3 4 20 6 95688750 High Collar Lock Washer 1 2 21 2 10069714 Washer 3 8 ...

Page 159: ...SECTION 12 PARTS LISTS page 12 25 80079163 ...

Page 160: ...1 cc rev 5 2 05037593 Socket Head Screw M10 x 1 50 x 25mm 6 2 10069714 Flat Washer 3 8 7 1 05071766 Manifold Assembly 8 1 05047451 Adapter JIC O ring 90 Degrees 12 12 9 1 05045364 Gear Pump Double Shaft 10 4 05091756 Socket Head Screw 7 16 14 x 6 11 4 05050356 High Collar Lock Washer 44 12 1 10074953 O ring 13 12 05089792 Washer Flat 7 16 14 05088083 Shaft Seal Piston Pump 15 05095997 O Ring Pump ...

Page 161: ...SECTION 12 PARTS LISTS page 12 27 80079163 ...

Page 162: ...0766 Lock Washer 31 14 6 10103232 Neoprene Nitrile 0 13 x 1 15 1 10091858 Bulb Well 16 4 95119897 Hx Hd Screw 5 16 18 x 1 2 17 2 05145974 Heat Exchanger Bracket 18 4 95716890 Lock Washer 50 19 4 10069763 Washer 50 20 1 05057559 Adptr Str 12 O rng x 3 4 NPT 21 1 49868524 Adptr Bushing 1 1 4 x 1 NPT 22 1 05006291 Diffuser Return Line 23 1 10099901 Elbow 90 Deg Pipe JIC 25 24 1 10080901 Valve Shutoff...

Page 163: ...SECTION 12 PARTS LISTS page 12 29 80079163 ...

Page 164: ...Cover 4 2 49834708 End Cover Left 5 2 49834690 End Cover Right 7 4 49837511 Bracket 8 4 49837529 Bracket 9 4 49837503 Spring 10 32 49837743 Screw Button Head 3 8 16 x 1 1 4 11 32 05091988 Nut 3 8 16 12 24 95897948 Screw Button Head 10 32 x 1 2 13 24 49832181 Nut 10 24 14 1 49837768 Gasket 15 6 95670972 Lock Washer 38 16 6 05091954 Screw Button Head 3 8 16 x 1 00 17 4 80076748 Cable ...

Page 165: ...SECTION 12 PARTS LISTS page 12 31 80079163 ...

Page 166: ...exible Conduit Connector 6 1 05081377 Conduit Bushing 7 12 10159143 8 Terminal Ring 8 4 10069763 Washer 50 9 150 10105674 4 Wire Black 10 50 10170140 6 Wire Green 11 6 95423653 Hex Head Screw 1 4 20 x 1 2 49832025 12 6 95416335 Hex Nut 1 4 20 13 6 95686721 Socket Head Screw 1 4 20 x 1 3 4 15 4 95423695 Hex Nut 1 2 13 16 1 10174357 6 Terminal Ring 18 4 95716890 Lock Washer 1 2 19 5 10125912 Cable T...

Page 167: ...SECTION 12 PARTS LISTS page 12 33 80079163 ...

Page 168: ... 10103034 Screw 10 32 x 3 4 12 1 05111448 Din Rail 13 8 10185395 Crimp Connector Ferrule 14 48 10176410 16 Wire Blue 15 48 10170165 16 Wire Green Yellow 16 2 95830766 Lock Washer 31 17 2 05095609 Ground Lug 18 2 95423620 Screw Hx Hd 5 16 18 x 3 4 19 24 05106398 3 Wire Green Yellow 20 42 10170157 10 Wire Green Yellow 21 90 05019898 14 Wire Black 22 12 05019617 Crimp Pin Connector 23 1 05140686 Circ...

Page 169: ...SECTION 12 PARTS LISTS page 12 35 80079163 ...

Page 170: ...tactor Block 21 1 49833379 Pilot Light Green 22 14 05113634 Terminal Block 23 1 5 05112826 Terminal Block 24 1 49830268 Cable Channel 26 1 05049432 Legend Plate Holder 28 1 05140504 Sub plate 29 1 10156859 I O Rack 30 4 10146363 Single Point Module 31 2 10157659 Lock Washer 25 32 1 2 05021944 Wiring Duct 33 28 10170132 Rivet 34 6 49874191 Hole Seal 35 05140926 16 Wire Orange 36 10185395 Crimp Conn...

Page 171: ...SECTION 12 PARTS LISTS page 12 37 80079163 ...

Page 172: ...pter Straight 12 SAE O ring Both Ends Steel 8 4 05073168 Elbow 45 deg 12 JIC x 12 SAE O ring Steel 9 2 10084184 Plug Connector 10 2 10067205 Cable Connector 11 2 10083012 Lock Nut 12 2 10082857 Gasket Assembly 13 1 80070303 Tube Bent 38 in HP 60 ksi Stainless 14 4 80070311 Tube Bent 38 in HP 60 ksi Stainless 15 2 10097533 Three way Valve 16 2 10078129 Gland 38 in HP Tube 60 ksi Stainless 17 2 1007...

Page 173: ...SECTION 12 PARTS LISTS page 12 39 80079163 ...

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