KMT H20JET 50 Pump Manual

KMT H20JET 50 Pump Manual

KMT H2O JET

WATERJET INTENSIFIER

OPERATION AND MAINTENANCE MANUAL

K M T H 2 O J E T

WATERJET

INTENSIFIER

7 2 1 0 6 1 6 1 ( R 0 )

KMT H2O JET

WATERJET INTENSIFIER

OPERATION AND MAINTENANCE MANUAL

MANUAL 72106161(R0)

72106161

12-2011/Rev 01

NOTICE

This document contains subject matter in which KMT Waterjet Systems has proprietary rights. Recipients of this document shall not duplicate, use or disclose information contained herein, in whole or in part, for other than the purpose for which this manual was provided.

KMT Waterjet believes the information described 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 advising of such changes and/or additions.

KMT WATERJET SYSTEMS 2009

KMT Waterjet Systems

635 West 12th Street

POB 231

Baxter Springs, KS 66713-0231

Phone:

Fax:

(800) 826-9274

(620) 856-5050

TABLE OF CONTENTS

Title Page

Notice

Table of Contents

Appendix

Section Page

1 Introduction...................................................................................................... 1-1

1.1 Overview...............................................................................................1-1

Nameplate................................................................................1-1

Overview...........................................................................1-1

Low Pressure Water System .................................................................1-2

Recirculation System ............................................................................1-2

Hydraulic System..................................................................................1-2

High Pressure Water System ................................................................1-3

1.4 Safety ....................................................................................................1-3

Lockout/Tagout Procedure....................................................................1-4

Warning Labels.....................................................................................1-4

Emergency Medical Treatment.............................................................1-6

1.5 Worldwide Product Support .................................................................1-6

2

1.7 Equipment and Service Manual Questionnaire.....................................1-7

Installation ........................................................................................................ 2-1

2.1 Overview...............................................................................................2-1

Requirements .................................................................................2-2

Transporting..........................................................................................2-2

Connections..............................................................................2-3

Cooling Water.......................................................................................2-4

Cutting Water........................................................................................2-5

Drain .....................................................................................................2-5

Plant Air................................................................................................2-5

2.7 High Pressure Piping.............................................................................2-7

Measurements and Dimensions ............................................................2-8

Hand Coning .........................................................................................2-9

Power Coning........................................................................................2-10

Hand Threading ....................................................................................2-11

Power Threading...................................................................................2-11

2.8 High Pressure Connections ...................................................................2-12

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3

4

Standard Connections ...........................................................................2-12

Anti-Vibration Connections..................................................................2-13

2.9 Commissioning .....................................................................................2-14

2.10 Decommissioning .................................................................................2-16

Maintenance ..................................................................................................... 3-1

3.1 Overview...............................................................................................3-1

3.2 Maintenance..........................................................................................3-1

Daily Inspection....................................................................................3-1

Periodic Maintenance............................................................................3-1

High Pressure System Maintenance......................................................3-2

3.3 Maintenance Precautions ......................................................................3-3

Operation .......................................................................................................... 4-1

4.1 Overview...............................................................................................4-1

4.2 Startup and Stop Sequence ...................................................................4-1

Startup Following High Pressure Maintenance ....................................4-2

Emergency Stop....................................................................................4-2

5

6

7

8

9

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Low Pressure Water System ........................................................................... 5-1

5.1 Overview...............................................................................................5-1

5.2 Cutting Water Supply Quality ..............................................................5-1

5.3 Operation...............................................................................................5-1

5.4 Service and Maintenance Procedures ...................................................5-2

Filter Assembly Maintenance ...............................................................5-2

Recirculation System ....................................................................................... 6-1

6.1 Overview...............................................................................................6-1

6.2 Operation...............................................................................................6-1

6.3 Service and Maintenance Procedures ...................................................6-2

Hydraulic Oil Maintenance...................................................................6-2

Oil Filter Maintenance ..........................................................................6-4

Hydraulic System ............................................................................................. 7-1

7.1 Overview...............................................................................................7-1

7.2 Operation...............................................................................................7-1

7.3 Service and Maintenance Procedures ...................................................7-2

Hydraulic Operating Pressure ...............................................................7-3

Motor/Hydraulic Pump Maintenance ...................................................7-4

Shift Valve and Manifold Service.........................................................7-4

Solenoid and Pilot Valve Service .........................................................7-7

Electrical System .............................................................................................. 8-1

8.1 Overview...............................................................................................8-1 and

8.3 Service and Maintenance Procedures ...................................................8-4

Proximity Switch Maintenance.............................................................8-4

High Pressure Water System .......................................................................... 9-1

ii

9.1 Overview...............................................................................................9-1

9.2 Operation...............................................................................................9-1

9.3 Service and Maintenance Overview .....................................................9-3

Torque Specifications ...........................................................................9-4

9.4 High and Low Pressure Water Piping...................................................9-5

9.5 High Pressure End Caps........................................................................9-6

High Pressure End Cap Removal..........................................................9-6

High Pressure End Cap Installation ......................................................9-6

9.6 High Pressure Cylinder Assembly ........................................................9-7

High Pressure Cylinder Removal..........................................................9-7

High Pressure Cylinder Installation......................................................9-8

High Pressure Cylinder Maintenance ...................................................9-9

9.7 Sealing Head Assembly ........................................................................9-9

High Pressure Discharge Check Valve .................................................9-10

Low Pressure Inlet Check Valve...........................................................9-11

Sealing Head Maintenance ...................................................................9-13

9.8 High Pressure Seal Assembly ...............................................................9-13

Seals .....................................................................................9-17

9.10 Hydraulic Piston and Plunger Service ..................................................9-19

Hydraulic Piston and Plunger Removal................................................9-19

Plunger Installation ...............................................................................9-21

Hydraulic Piston Installation.................................................................9-21

Maintenance ............................................................................9-23

9.13 High Pressure Attenuator......................................................................9-23

9.14 High Pressure Dump Valve ..................................................................9-24

Pneumatic Control Dump Valve...........................................................9-24

Pneumatic Actuator...............................................................................9-29

10 Troubleshooting ............................................................................................... 10-1

10.1 Overview...............................................................................................10-1

11 Specifications .................................................................................................... 11-1

11.1 Overview...............................................................................................11-1

Specifications.....................................................................11-1

Environment..........................................................................................11-1

Sound Level ..........................................................................................11-1

Equipment Dimensions.........................................................................11-2

Service Connections..............................................................................11-2

Plant Air................................................................................................11-2

Specifications .............................................................................11-3

Cutting Water Supply ...........................................................................11-3

Cooling Water Supply...........................................................................11-3

Water Quality Standards .......................................................................11-4

Specifications........................................................................11-6

Electrical System ..................................................................................11-6

Ampacity and Power Voltage Requirements........................................11-6

11.5 Hydraulic and High Pressure System Specifications............................11-6

Hydraulic System..................................................................................11-6

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High Pressure Water System ................................................................11-6

Orifice Capacity....................................................................................11-7

Torque Specifications ...........................................................................11-8

12 Parts List........................................................................................................... 12-1

12.1 Overview...............................................................................................12-1

12.2 Index .....................................................................................................12-2

APPENDIX

Exhibit

Electrical Schematic

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12-2011/Rev 01 iv

SECTION 1

INTRODUCTION

1.1 Overview

The KMT H2O Jet combines all the unique capabilities and advantages of waterjet cutting with the reliability, ease of operation and service support that have made KMT Waterjet

Systems a leader in waterjet technology.

Table 1-1

KMT H2O Jet

Motor

Horsepower

Rating

HP Kw

50

Maximum

Operating

Pressure

37 60,000 psi (4,137 bar)

Maximum

Flow Rate

(at full pressure)

1.0 gpm (3.8 L/min)

Maximum Single

Orifice Diameter

(at full pressure)

0.014 inch (0..56 mm)

1.2 Product Nameplate

The product nameplate contains the pump model, serial, identification and part numbers for each individual machine.

Figure 1-1: Nameplate

1.3 Operational Overview

The following provides a brief overview of the function and primary components associated with the individual systems. A detailed discussion of each system is provided in Sections 4 through 9. Equipment specifications are provided in Section 11, Specifications.

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Section 1

Introduction

Low Pressure Water System

The low pressure water system supplies the cutting water flow to the intensifier. Major system components include the booster pump/motor assembly and the low pressure water filter assembly.

Recirculation System

The recirculation system is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system. Major system components include the recirculation pump, heat exchanger, oil filter assembly and the hydraulic oil reservoir.

Figure 1-1: System Components

A LP Water System C Recirculation System

1 Booster Pump/Motor Assembly 6 Oil Filter Assembly

2 LP Water Filter Assembly 7 Hydraulic Oil Reservoir

B Hydraulic System

3 Electric Motor

4 Hydraulic Pump

5 Hydraulic Manifold

8 Heat Exchanger

9 Recirculation Pump

Hydraulic System

The hydraulic system supplies the intensifier with the hydraulic oil required to produce high pressure water. Major system components include the electric motor, hydraulic pump, and the 4-way directional control valve mounted on the hydraulic manifold.

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Section 1

Introduction

High Pressure Water System

The high pressure water system is the heart of the waterjet system. Water is pressurized and continuously delivered to the cutting head. As water passes through a tiny hole in the orifice, water pressure is converted to water velocity capable of cutting most any material.

The major components include the high pressure cylinder assemblies, hydraulic cylinder assembly, hydraulic piston, attenuator and the safety dump valve.

Figure 1-2: High Pressure System Components

1 High Pressure Cylinder

2 Hydraulic Cylinder

3 Safety Dump Valve

4 Attenuator

1.4 Safety

The high pressure waterjet cutting system is a high energy cutting tool capable of cutting many dense or strong materials. Do not touch or be exposed to high pressure water. High pressure water will penetrate all parts of the human body. The liquid stream and the material ejected by the extreme pressure can result in severe injury.

All personnel operating, servicing or working near the waterjet cutting equipment shall adhere to the following safety precautions, as well as the applicable plant safety precautions.

Only KMT factory trained, qualified personnel shall service and maintain the equipment.

The operator shall practice and promote safety at all times to avoid potential injury and unnecessary downtime.

The operator shall ensure that the work area around the equipment is clean and free of debris and oil spills.

All protective guards, shields or covers shall be in place on the equipment at all times.

Safety glasses and ear protection shall be worn when operating or working near the equipment.

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Section 1

Introduction

Lockout/Tagout Procedure

This lockout/tagout procedure is designed to protect all employees from injuries caused by the unexpected energizing or startup of the machine, or the release of stored energy during service and maintenance.

This is accomplished with energy isolating devices that prevent the transmission or release of energy. An energy source is any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy source that could cause injury to personnel.

A lockout device utilizes a lock and key to hold an energy isolating device in the safe position and prevents the machine from being energized. A tagout device is a prominent warning device that can be securely attached to the machine warning personnel not to operate the energy isolating device. This procedure requires the combination of a lockout device and a tagout device.

The lockout/tagout procedure applies to any employee who operates and/or performs service or maintenance on the machine. Before any maintenance or repairs are performed, the machine shall be isolated, and rendered inoperative as follows.

1. Shut down the machine and open the high pressure cutting water valve to bleed the water and hydraulic pressure from the system.

2. Disconnect, lockout and tag the main, customer supplied, power source.

3. Close, lockout and tag the manual shutoff valves for all service connections: cutting water in, cooling water in and out, and air.

Warning Labels

Warning labels are posted on the machine to indicate potential hazards. The operator and service personnel shall pay particular attention to these warning labels. Table 1-2 describes the necessary precautions and provides the part number required to order replacement labels.

1

Table 1-2

Warning Label Precautions

The electrical enclosure and motor junction box can present an electrical shock hazard. Always disconnect and lockout the main power and the circuit breaker/disconnect on the electrical enclosure before performing any type of maintenance.

P/N 05114962

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Section 1

Introduction

Table 1-2

Warning Label Precautions

The surface of high pressure water and hydraulic components becomes hot during normal operation.

Failed, or failing components, can become extremely hot during operation.

2

P/N 05114970

High pressure water and/or hydraulic pressure can remain in the system even when the pump has been shut off. All pressure can be safely bled from the system by opening the high pressure cutting water valve for a few seconds after shutting off the pump. 3

4

P/N 05098017

Pressing the

EMERGENCY STOP

button turns the control power to the intensifier off, stops the pump and bleeds the high pressure water through the safety dump valve.

All personnel involved in the installation, operation and/or service of the intensifier must carefully read, understand and follow the procedures in this manual to avoid creating unsafe conditions, risking damage to the equipment, or personal injury.

P/N 20415794

Safety precautions and warnings for specific procedures are emphasized throughout this manual as illustrated in the following examples. These precautions must be reviewed and understood by operating and maintenance personnel prior to installing, operating or servicing the machine. Adherence to all Warnings, Cautions and Notes is essential to safe and efficient service and operation.

WARNING

Warnings emphasize operating or service procedures, or conditions that can result in serious personal injury or death.

CAUTION

Cautions emphasize operating or service procedures, or conditions that can result in equipment damage or impairment of system operation.

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Section 1

Introduction

NOTE

Notes provide additional information that can expedite or improve operating or service procedures.

Emergency Medical Treatment

An emergency medical card is included in the binder of this manual. This information should be used to aid in the treatment of a waterjet injury. Additional cards may be obtained by contacting KMT Waterjet Systems using the address or telephone number shown on the card.

Medical Alert

This card is to be carried by personnel working with high pressure waterjet equipment. Obtain medical treatment immediately for ANY high pressure waterjet injuries.

KMT Waterjet Systems

635 West 12th Street

Baxter Springs, KS 66713

(620) 856-2151

This person has been working with water jetting at pressures to 60,000 psi (414 MPa, 4137 bar, 4,218

Kg/cm

2

) 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 swabs and blood cultures may therefore be helpful. This injury must be treated as an acute surgical emergency and be evaluated by a qualified surgeon. Circulation may be compromised, therefore, DO NOT APPLY HEAT TO INJURED

PART. For first aid: (1) Elevate injured part (2)

Antibiotics (3) Keep injured person NPO.

1.5 Worldwide Product Support

The KMT Waterjet Customer Service Department is available to answer your questions regarding equipment installation and service. Technical assistance is available by phone and on-site support is available on request.

On-site technical assistance is available during equipment installation and startup.

Additionally, technical support for service and maintenance issues and training of operators and maintenance personnel is available. Periodic training sessions are also conducted at

KMT Waterjet and customer facilities.

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Section 1

Introduction

Contact the KMT Waterjet Customer Service Department for additional information.

USA Customer Service Manager Europe Technical Manager

KMT Waterjet Systems

PO Box 231

635 West 12th Street

Baxter Springs, KS 66713

USA

Phone: (800) 826-9274

Fax: (620) 856-2242

Email: [email protected] [email protected]

KMT Waterjet Systems GmbH

Wasserstrahl-Schneidetechnik

Auf der Laukert 11

D-61231 Bad Nauheim

Germany

Phone: +49-6032-997-117

Fax: +49-6032-997-270

Email: [email protected]

1.6 Spare Parts

KMT Waterjet maintains a well-stocked Spare Parts Department, staffed by trained, knowledgeable personnel. If required, emergency shipment is available. Contact the

Customer Service Department to order spare parts, or for additional information.

1.7 Equipment and Service Manual Questionnaire

We are interested in your impression of the KMT Waterjet System recently installed at your location. Your comments and recommendations will aid us in our continuing goal to improve our products, and make our technical information more useful to our customers.

At your convenience, please take a few minutes to complete the following questionnaire, and return it to the applicable Customer Service Department listed above.

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1-7

Equipment and Service Manual Questionnaire

Was the unit received in good condition?

Comments:

Is the unit a convenient size?

2. Controls

Are the controls user friendly?

Is the unit easy to operate?

Comments:

3. Performance

Does the unit perform smoothly and meet your expectations?

Does the unit run quietly?

Comments:

4. Did the installation and startup go smoothly?

Comments:

5. What features do you consider the most significant?

Appearance

Performance/Operation

Repair/Maintenance

Other

6. What areas could be improved?

Appearance

Performance

Serviceability

Other

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

72106161

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1-1

Equipment and Service Manual Questionnaire

Does the Table of Contents help you find topics easily?

Comments:

Is the information well organized?

Comments:

Is the page layout suitable for the material being presented?

Comments:

8. Graphics

Are the illustrations suitable for the material being presented?

Comments:

9. Text

Does the information adequately explain how to operate and service the equipment?

Comments:

Are there paragraphs or procedures you feel need clarification? Please identify them by page number and add your comments.

Comments:

Is there anything you would add or delete to make the manual more useful?

Comments:

Is there any information that should receive more emphasis?

Comments:

Name

Company

Address

Title

Date

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

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SECTION 2

INSTALLATION

2.1 Overview

Installation and commissioning requirements and procedures are detailed in this section.

These procedures require a thorough understanding of the individual components and systems, safety issues, and the overall operation of the intensifier.

All personnel involved in the installation, operation and/or service of the intensifier must carefully review this manual prior to installing and commissioning the machine.

The Technical Service Department at KMT Waterjet Systems is available to assist in the installation and commissioning process. Service and repair training for maintenance personnel is also available.

2.2 Installation Summary

The following summary lists the procedures required for the installation and commissioning of the intensifier system. Details and requirements for each item are discussed in this section.

Upon receipt, the machine must be uncrated and moved into position on a level surface.

Properly sized power drops with fused disconnects or circuit breakers, and properly sized starting components must be installed.

A pneumatic drop with a manual shutoff valve and regulator for the air connection must be installed.

Plumbing and manual shutoff valves for the inlet and outlet cooling water, and the inlet and outlet cutting water must be installed.

Incoming source water must meet specific water quality standards, flow rates and pressure requirements. It may be necessary to install water conditioning and/or pressure boosting equipment to meet these water purity and pressure requirements.

Drain water plumbing must be suitably located and installed for the proper disposal of wastewater.

High pressure tubing runs from the intensifier to the cutting station must be installed with the appropriate mountings, support brackets and hardware.

Wiring must be installed and connected between the intensifier and the cutting station control system.

The machine must be commissioned and tested.

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Section 2

Installation

2.3 Site Requirements

The intensifier must be installed indoors where air borne dust and contaminants are minimal.

The ambient temperature should be between 40

F (5 C) and 104 F (40 C), with a maximum relative humidity of 95 percent.

Refer to Table 2-1, Equipment Dimensions, to establish a suitable installation site. A minimum clearance of 36 inches (914 mm) should be provided on all sides of the machine to facilitate service.

Figure 2-1: Equipment Dimensions

Table 2-1

Equipment Dimensions and Weight

(1) Length (2) Width (3) Height Weight

58.00” (1,473 mm) 47.44” (1,205 mm) 41.64” (1,058 mm) 2,260 lbs (1,025 kg)

Transporting

The weight of the machine is not evenly distributed from one end to the other. Note the warnings stamped on the crate. The center of gravity is clearly identified on the sides of the crate. The forklift should be positioned accordingly.

When the machine has been removed from the crate, note the position of the fork pockets on the bottom of the machine. The pockets are positioned in relationship to the center of gravity to balance the weight on the forklift.

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2-2

Figure 2-2: Fork Pockets

Section 2

Installation

1 Fork Pockets

CAUTION

The machine must be lifted from the bottom. Do not attempt to lift the machine from the intensifier.

2.4 Power Requirements

Power supplied to the pump and wiring for remote control must comply with local, regional and national electrical codes. Service voltage and ampacity must meet the requirements detailed in Table 2-2. Voltage fluctuations in excess of +/- 10 percent of nominal voltage may damage the machine and void the warranty.

Power Voltage

Table 2-2

Ampacity and Power Voltage Requirements

Motor

Horsepower

Full Load

Amps

Recommended

Circuit Breaker Amps

2.5 Service Connections

Depending on the model, the intensifier requires one or two incoming water sources, cooling water and cutting water; one or two drain lines, cooling water and wastewater; a high pressure discharge line, and an air supply line. All piping must comply with local, regional and national codes.

All service connections are made on the bulkhead of the machine as shown in Figure 2-3,

Service connections. Table 2-3 lists the fittings required and the height of each interface connection.

With the exception of the wastewater drain line, manual shutoff valves should be installed for all connections. To facilitate service, the valves should be located as close as practical to the interface connection.

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Section 2

Installation

CAUTION

Thoroughly purge all supply plumbing prior to connection to remove any residue that could contaminate the system.

Figure 2-3: Service Connections

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Table 2-3

Service Connections

A Drain

B Cutting Water In

C Cooling Water Out

D Cooling Water In

E Cutting Water Out

F Plant Air In

1/2” BSPT

1/2” BSPT

1/2” BSPT

1/2” BSPT

9/16” HP

1/4” BSPT

10.26” (260 mm)

14.26” (362 mm)

18.26” (464 mm)

22.26” (565 mm)

30.26” (768 mm)

35.39” (899 mm)

Cooling Water

Inlet cooling water flows through the oil-to-water heat exchanger in the hydraulic system to control heat buildup in the hydraulic oil. The cooling water is then discharged through the cooling water out port to either the drain or routed to a customer supplied water chiller.

Cooling water supply piping must be sized to meet the flow and pressure requirements of the equipment. If municipal or well water is used for cooling, ensure the supply flow and pressure meet the requirements in Section 11, Specifications.

If a facility-wide chilled water system is used for cooling, ensure there is a minimum of 60 psi

(4.0 bar) pressure differential between the facility supply and discharge plumbing.

Installation of an in-line pressure boosting pump may be necessary to provide adequate cooling flow. Dedicated chilled water systems should be sized according to pump horsepower as illustrated in Table 2-4, Chilled Water Systems.

2-4

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Section 2

Installation

Table 2-4

Chilled Water Systems

Cooling Requirements at Full Capacity

Horsepower BTU/HR

50 22,000

Note: Coolant flow to the heat exchanger is regulated by the temperature of the contents in the hydraulic reservoir and will be shut off at times.

Cutting Water

Inlet cutting water is routed to the intensifier where it is pressurized and delivered to the cutting head. The cutting water supply must meet the minimum water quality standards outlined in Section 11, Specifications. Poor water quality will drastically shorten component life and void the warranty.

Cutting water supply piping must be sized to meet the flow and pressure requirements listed in Section 11. Only PVC, copper or rubber hose should be used between the cutting water source and the machine.

The inlet cutting water must be maintained at a minimum pressure of 35 psi (2.5 bar) at all times. If the facility water pressure is below, or can fall below 35 psi (2.5 bar), a water pressure booster pump is required.

Drain

Cutting water released through the safety dump valve when the emergency stop button is initiated is discharged from the drain port. The discharge is considered wastewater and must be piped to an appropriate location, i.e. a sewer line. The volume of water released will be minimal and does not require high pressure plumbing; however, piping must comply with local, regional and national codes.

Plant Air

The facility compressed air connection should provide clean, dry air regulated to 85 psi (5.9 bar). Air usage is minimal, normally less than 1 scf/m.

The following table provides specifications for each ISO air quality classification. KMT recommends adherence to Quality Class 4.

ISO Quality

Class

1

2

Table 2-5

ISO Air Quality Classifications

Maximum

Particle Size

(microns)

0.1

1

Maximum Pressure

Dew Point

(water @ 100 psi)

-94° F (-60° C)

-40° F (-40° C)

Maximum Oil Content

(Mg/m

3

)

0.01

0.1

2-5

Section 2

Installation

5

6

3

4

5

15

40

--

Table 2-5

ISO Air Quality Classifications

-4° F (-20° C)

+38° F (+3° C)

+45° F (+7° C)

+50° F (+10° C)

1

5

25

--

2.6 Flow Requirements

Figure 2-4, Pressure Drop Values, illustrates the pressure drop for four different pipe sizes.

The graph can be used to calculate the minimum source water pressure.

1. Enter the graph at the required GPM and note the pressure drop figures for the different pipe sizes.

2. Multiply the pressure drop (PSI/FT) by the length in feet of each pipe size used from the water source to the intensifier. Add the values together for a total pressure drop value.

3. Add 30 to the total pressure drop to determine the minimum flowing, source water pressure required to provide adequate supply to the intensifier.

Cutting water and cooling water capacity should be calculated separately. Note that the cutting water requirements represent instantaneous, not average, demand.

Figure 2-4: Pressure Drop Values

Pipe Sizing

0.45

0.4

0.35

0.3

0.25

0.2

0.15

0.1

0.05

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Required GPM

1/2" ID

3/4" ID

1" ID

1-1/4" ID

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Section 2

Installation

2.7 High Pressure Piping

High pressure piping is used to transport high pressure cutting water from the machine to the cutting station. High pressure piping and fittings must be properly rated and sized. When transporting high pressure water over long distances, tubing and fittings with an outside diameter of 9/16-inch are recommended. The large tubing size reduces vibration, strain and motion; as well as reducing pressure drop and pulsation.

WARNING

High pressure tubing and fittings must be rated for 60,000 psi (4,136 bar). Failure to use properly rated components may result in component failure causing equipment damage, personal injury or death.

High pressure tubing lengths must be coned and threaded prior to installation. KMT Waterjet provides both hand and power tools for coning and threading high pressure tubing. Tool descriptions and part numbers are provided in Table 2-6.

1/4” Coning Tool

3/8” Coning Tool

9/16” Coning Tool

1/4” Threading Tool

3/8” Threading Tool

9/16” Threading Tool

1/4” Tube Vise

3/8” Tube Vise

9/16” Tube Vise

Table 2-6

Coning and Threading Tools

Part Number

Hand Tools

05108832

05108857

05108840

05108865

05108873

05108881

05108782

05108790

05108774

Power Tools

05109897

05109889

05109871

05122742

05120258

05122759

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Section 2

Installation

Measurements and Dimensions

Tubing must be cut to the proper length, both ends of the tubing must then be coned, threaded and deburred.

To determine the tube length, measure the distance between the fittings, and add two times the engagement allowance shown in Table 2-7. Table 2-8 lists the required cone and thread dimensions illustrated in Figure 2-6.

Figure 2-5: Tube Length

LENGTH

TUBE LENGTH = LENGTH + 2(EA)

Table 2-7

Engagement Allowance (EA)

1/4” Tubing

3/8” Tubing

9/16” Tubing

0.49” (12.4 mm)

0.68” (17.3 mm)

0.86” (21.8 mm)

Figure 2-6: Cone and Thread Dimensions

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Table 2-8

Cone and Thread Dimensions

Tube OD

1/4” (6.35 mm)

3/8” (9.52 mm)

0.083” (2.11 mm)

0.125” (3.18 mm

9/16” (14.29 mm) 0.188” (4.78 mm)

Tube ID

D

(Maximum)

L

(Maximum)

0.125” (3.2 mm) 0.562” (14.3 mm)

0.219” (5.6 mm) 0.750” (19.1 mm)

1/4” - 28

3/8” - 24

0.281” (7.1 mm) 0.938” (23.8 mm) 9/16” - 18

Thread

UNF-LH

2-8

Hand Coning

Figure 2-7: Hand Coning Tool

Section 2

Installation

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1 Tubing

2 Collet

5 Handle

6 Blade

7 Body

4 Feed Nut 8 Gland Nut

1. Place the body of the coning tool in a vise allowing adequate clearance for the rotation of the cutter handle. Position the tool so the cutter handle is elevated slightly so the lubricant will flow to the cutting blades.

2. Turn the feed nut counter-clockwise to retract the cutting blades past the access window.

3. Loosen the gland nut and insert the tubing through the collet. The end of the tubing should just make contact with the cutting blades. Loosely tighten the gland nut to slightly grip the tubing.

4. Turn the feed nut counter-clockwise 1/4 turn to retract the cutting blades away from the tubing, and tighten the gland nut with a wrench.

5. Apply a liberal amount of cutting oil to the exposed end of the tubing, the cutting blades and through the lubrication channel at the cutter handle.

Apply cutting oil frequently and liberally throughout the cutting operation. A medium weight cutting oil with high sulfur content is recommended.

6. Turn the feed nut clockwise until the cutting blades contact the end of the tubing.

7. In a smooth, continuous motion, turn the cutter handle in a clockwise direction.

Simultaneously turn the feed nut in a clockwise direction to establish a constant feed.

Do not remove too much material at once; the cutting blades should make light, uninterrupted cuts.

2-9

Section 2

Installation

NOTE

Before interrupting the cut, back the cutter blades away from the tubing. Use compressed air or a small brush to remove the accumulation of chips from the blades and the tubing throughout the coning operation.

8. Continue the operation until the feed nut bottoms on the housing. Turn the cutter handle several more rotations to face-off the end of the cone.

9. Retract the cutter blades, loosen the gland nut and remove the tubing. Inspect the cone for surface finish and completeness.

NOTE

Clean the machining chips from the blade and from the collet before coning the next tube.

Power Coning

1. Secure the tubing in a tube vise. No more than the recommended length of tubing should extend beyond the face of the vice. See Table 2-9, Recommended Extension

Length.

2. Mount the coning tool in a 3/8-inch or 1/2-inch, variable speed power drill. Apply cutting oil to the end of the tube and slide the coning tool on the tubing.

3. Apply steady pressure against the end of the tubing while the cone is being cut.

Apply cutting oil frequently and liberally throughout the cutting operation. A medium weight cutting oil with high sulfur content is recommended.

4. The tool will stop cutting when the tube angle and facing is complete.

NOTE

Clean the machining chips from the blade and body of the tool before coning the next tube.

Table 2-9

Recommended Extension Length

1/4” Tubing

3/8” Tubing

9/16” Tubing

1.25-1.50” (31.8-38.1 mm)

1.25-1.50” (31.8-38.1 mm)

1.75-2.00” (44.5-50.8 mm)

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Section 2

Installation

Hand Threading

1. Secure the coned tubing in a tube vise. No more than the recommended length of tubing should extend beyond the face of the vice. See Table 2-9, Recommended

Extension Length.

2. Apply cutting oil to the end of the tube and slide the threading tool on the tubing.

3. Grip the handles of the tool firmly, apply steady pressure and turn the tool counterclockwise. Approximately every half turn, reverse direction to break off and remove the chips.

Apply cutting oil frequently and liberally throughout the cutting operation. A medium weight cutting oil with high sulfur content is recommended.

4. Continue threading until the proper thread length is reached, see Table 2-8, Column L.

Remove the tool from the end of the tubing.

NOTE

Clean the machining chips from the die and body of the tool before threading the next tube.

Power Threading

1. Secure the coned tubing in a tube vise. No more than the recommended length of tubing should extend beyond the face of the vice. See Table 2-9, Recommended

Extension Length.

2. Mount the threading tool in a 3/8-inch or 1/2-inch, variable speed power drill. Apply cutting oil to the end of the tube and slide the threading tool on the tubing.

3. Make sure the drill is set to turn counter-clockwise. Apply steady pressure against the end of the tubing while the threads are being cut.

Apply cutting oil frequently and liberally throughout the cutting operation. A medium weight cutting oil with high sulfur content is recommended.

4. Continue threading until the proper thread length is reached, see Table 2-8, Column L.

Reverse the direction of the drill and remove the threading tool.

NOTE

Clean the machining chips from the die and body of the tool before threading the next tube.

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Section 2

Installation

2.8 High Pressure Connections

When installing high pressure discharge piping it is essential that all burrs be carefully removed and the tubing sections purged with clean compressed air prior to assembly. Lightly spraying the inside of the tube with a carrier fluid, such as WD-40, before purging with air will help carry the burrs.

High pressure piping must be installed without torsional or bending stresses and proper supports and guides must be provided. Torsional stress will cause premature component failure.

Pure Goop anti-seize compound must be applied to the threads and contact surfaces of all stainless steel components prior to assembly. Failure to lubricate components with Pure

Goop will result in galling, rendering the components useless.

CAUTION

Do not use any other anti-seize compound. Apply Pure Goop only to stainless

steel components.

Standard Connections

Standard connections are used for general applications where internal pressure is the only load on the tubing.

Figure 2-8: Standard High Pressure Connections

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1 Gland Nut

2 Tubing

3 Collar

4 Exposed Threads

1. Deburr the tubing ID and thoroughly clean the tubing threads.

2. Slip the gland nut onto the tubing.

3. Apply Pure Goop to the threads on the tubing. Screw the collar onto the threaded end of the tubing leaving 1-1/2 to 2-1/2 threads exposed on the tubing between the collar and the coned tubing.

4. Apply Pure Goop to the male threads on the gland nut and insert the tubing into the connection. Engage the gland nut and tighten finger tight.

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Section 2

Installation

5. Tighten the gland nut to the torque specifications in Table 2-10.

WARNING

Proper piping supports and guides must be provided. End connections will not support the tubing load alone.

1/4” Tubing

3/8” Tubing

9/16” Tubing

Table 2-10

Torque Specifications

High Pressure Connections

25 ft-lb (34 Nm)

50 ft-lb (68 Nm)

110 ft-lb (149 Nm)

Anti-Vibration Connections

The bending stresses resulting from excessive vibration or shock on the threaded area of the tubing can cause premature failure at the back of the thread. When tubing will be subjected to vibration, rotation and movement, anti-vibration connections must be used. The antivibration collet gland transfers the stress to the unthreaded section of the tubing, and the gripping action of the collet strengthens the entire assembly.

Figure 2-9: Anti-Vibration Connections

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1 Tubing

2 Gland Nut

4 Collet

5 Exposed Threads

3 Collar

1. Deburr the tubing ID and thoroughly clean the tubing threads.

2. Slip the gland nut and the collet onto the tubing.

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Section 2

Installation

3. Apply Pure Goop to the threads on the tubing. Screw the collar onto the threaded end of the tubing leaving 1-1/2 to 2-1/2 threads exposed on the tubing between the collar and the coned tubing.

4. Apply Pure Goop to the male threads on the gland nut and insert the tubing into the connection. Engage the gland nut and tighten finger tight.

5. Tighten the gland nut to the torque specifications in Table 2-10.

When a flexible whip is used to allow cutting nozzle movement, anti-vibration fittings and proper supports and guides must be provided to prevent failures from non-water related stresses. The whip will only flex in a single plane without being subjected to torsional stress.

The use of high pressure swivels is strongly recommended.

2.9 Commissioning

When the machine has been positioned, all service connections installed, and the high pressure plumbing has been installed to the cutting area, the machine is ready to be commissioned.

The following procedure is used for the initial startup and testing of the machine.

1. Check all areas in and around the pump for foreign objects and debris. Remove all tools, parts, etc. from the area.

2. Check the hydraulic fluid level. The hydraulic system is pre-filled prior to shipping.

If the hydraulic fluid is low or empty due to leakage during transit, the system must be filled. Follow the instructions in Section 6, Recirculation System.

3. Open the shutoff valves on the service connections and check for leaks.

4. Check the connection between the customer supplied, main power disconnect and the machine. Verify the proper voltage supply.

5. Turn the control power on and use the customer supplied control to select low pressure operation.

6. To avoid a sudden increase in pressure, it is necessary to adjust the high pressure setting. The high pressure adjustment is made at the high pressure control valve on the hydraulic manifold. Refer to Section 7, Hydraulic System, for additional information.

Loosen the locking nut on the high pressure control valve by turning counterclockwise. Turn the high pressure control valve counter-clockwise, decreasing the pressure to the lowest setting.

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Section 2

Installation

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1 Hydraulic Manifold 3 High Pressure Control Valve

2 Hydraulic Pressure Gauge

7. Check the motor rotation. The correct direction of rotation is marked with an arrow on the electric motor.

CAUTION

Do not allow the motor to run backward. Incorrect motor rotation will result in damage to the hydraulic pump.

Start the motor and observe the pressure gauge on the hydraulic manifold. If the motor rotation is correct, pressure will begin to build in just a few seconds. If the rotation is not correct, the gauge will not move.

If the motor shaft is rotating in the wrong direction turn the control power off. The electrical power phase must be reversed to any two motor leads. The leads must be reversed at the electric motor, or at the main power disconnect.

8. Remove the cutting orifice and open the nozzle valve.

9. Start the motor and run the machine at a low pressure for approximately five minutes with the orifice removed to purge the system.

10. Check for any leaks in the plumbing, or around the high pressure cylinders. If leaks are detected, stop the machine and correct any problems.

11. Check the safety circuits by pushing the

EMERGENCY STOP

button in and verifying that the power goes off and high pressure water is drained from the system. If applicable, check all remote start and emergency stop functions.

12. Install a large, inexpensive orifice and start the machine.

13. Use the customer supplied control to select high pressure operation and increase the high pressure setting in gradual increments, checking for leaks at each interval.

Continue increasing the pressure until the operating pressure is reached.

The high pressure setting is increased by turning the high pressure control valve on the hydraulic manifold clockwise.

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Section 2

Installation

NOTE

It is strongly recommended that the high pressure plumbing be purged under high pressure operating conditions, using a large, inexpensive orifice. Contamination can be released when the tubing expands under pressure. Early orifice failures could be experienced if the piping is not adequately purged.

2.10 Decommissioning

All local regulations must be adhered to when the intensifier is decommissioned and taken out of service for any reason.

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2-16

SECTION 3

MAINTENANCE

3.1 Overview

The KMT H2O Jet has been designed to fail safely. Systems fail gradually; seals and connections can begin to leak slowly or suddenly through specially designed weep holes.

Water or oil dripping from a weep hole indicates internal seals or valves are beginning to fail, a warning that maintenance will be required.

3.2 Maintenance

The waterjet system has been designed for ease of maintenance and long, reliable operation.

In order to keep the equipment in optimum operating condition, routine and preventive maintenance is essential. Detailed maintenance procedures for specific systems are provided in subsequent sections of this manual.

Daily Inspection

The following inspection procedures should be performed each day. If problems are detected, they should be remedied before placing the machine in service.

Prior to startup, inspect the area around the machine, the high pressure piping and connections for indications of leaks.

Make sure there is no maintenance work in process.

Check the hydraulic oil level.

As the machine is started and water pressure increases, listen for unusual sounds.

Check for water or oil leakage.

Check the condition of the hydraulic oil filter

Periodic Maintenance

A number of factors can contribute to component failure; poor water quality, operating conditions, or improper maintenance procedures. Maintaining a service log can be a useful method of tracking component life and maintenance trends. Analyzing service intervals will assist in preparing a preventive maintenance schedule tailored to your specific application and production requirements. Periodic maintenance, at regularly scheduled intervals, will minimize unscheduled downtime and premature component failure.

Improper assembly can lead to the premature failure of components. Maintenance procedures must be followed carefully; components must be properly cleaned prior to assembly and tightened to the correct torque specifications.

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3-1

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Section 3

Maintenance

Maintain a clean, dust and dirt free work area for maintenance.

Use only clean, dry air and clean, filtered solvent when flushing parts.

Use lint free cloths for cleaning.

Use extreme care when aligning close tolerance parts for assembly. Do not force the parts together. If parts bind during assembly, they must be disassembled and realigned.

Use only original KMT Waterjet replacement parts for consistent performance and reliability; and to protect equipment warranty.

To avoid unsafe conditions and the risk of equipment damage, operating personnel and service technicians must carefully read and follow the procedures in this manual.

High Pressure System Maintenance

The high pressure system is conveniently mounted on a drip pan. All service components are readily accessible, and can be removed from the unit easily for maintenance and service.

High pressure fittings, valves and tubing must be rated for 60,000 psi (4,137 bar).

Failure to use properly rated components may result in component failure, equipment damage and personal injury.

Do not over-torque fittings to stop leakage.

Ensure all components are clean, free of burrs, metal particles, dirt and dust prior to assembly.

After servicing high pressure components the high pressure water system must be thoroughly flushed to remove any debris or contaminates.

1. Operate the intensifier for a short period with the nozzle valve open and the orifice removed.

2. Turn the intensifier off and install an orifice.

3. Turn the machine on and increase the operating pressure in gradual increments.

Check all high pressure connections for leaks.

Many components are lubricated prior to assembly. Table 3-1 lists the recommended lubricants and their applications. Substitutions are not recommended.

Table 3-1

Lubrication Specifications

Blue Goop, 2 ounce

FML-2 Grease, 14-1/2 ounce

JL-M Grease, 16 ounce

Stainless steel threads

O-rings, backup rings, bearing rings, seal components

Non-stainless steel threads

20460486

10087385

49832199

3-2

Section 3

Maintenance

3.3 Maintenance Precautions

Make sure all safety devices are operational. Each device should be checked on a specified schedule. If the device does not function, it must be replaced before operating the machine.

Before performing any maintenance on the equipment, take the system out of service and make sure the controls are properly locked and marked. Never perform any maintenance on the equipment without making sure the main control power is locked out in the

OFF

position.

Never service or maintain the equipment while it is operating.

All high pressure leaks must be repaired immediately. Turn the control power off and bleed off the high pressure water from the intensifier before performing maintenance.

Never service or maintain any high pressure component, or loosen any high pressure fitting when it is pressurized. Turn the control power off and bleed off the high pressure water from the intensifier before servicing.

If leakage occurs at a sealing surface, high pressure water is released through weep holes. If a pressurized fitting is loosened, a jet of high pressure water will exit the nearest weep hole with possible hazardous results.

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3-3

SECTION 4

OPERATION

4.1 Overview

The operator interface on the KMT H2O Jet is through the control panel or an optional, remote control panel. Figure 4-1 identifies the control panel components and functions.

Figure 4-1: Control Panel

1 Start Pump

2 Stop Pump

3 Emergency Stop

EMERGENCY STOP button turns the control power off. The electric motor, hydraulic pump and intensifier stop, the dump valve opens and high pressure is bled from the system. Pull the

EMERGENCY STOP button out to reset.

START

button starts the pump and generates high pressure. This green button is illuminated during normal operation.

STOP

button turns the electric motor and hydraulic pump off. Control power remains on. This red button flashes during abnormal operation and remains on if the pump stops due to an abnormal condition.

4.2 Startup and Stop Sequence

The following procedure is used to start and stop the pump under normal operating conditions.

1. Pull the

EMERGENCY STOP

button out.

2. Press the

START

button. The green button will illuminate, the motor will start and after a brief delay, the hydraulic pump will start.

3. To stop the pump, press the

STOP

button. The green light will go off, the pump will stop, and the red light will illuminate.

Startup Following High Pressure Maintenance

The following startup procedure should be used following maintenance on any high pressure components.

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4-1

Section 4

Operation

1. Disconnect the electrical power cable from the solenoid valve on the dump valve.

2. Press the

START

button.

The intensifier will cycle and discharge water through the dump valve, purging the air from the high pressure cylinders and filling them with water.

CAUTION

Failure to purge the air from the high pressure system following maintenance will damage the high pressure seals.

3. Connect the electrical power cable to the solenoid valve on the dump valve.

4. Check for any leaks in the plumbing, or around the high pressure cylinders.

Emergency Stop

When the

EMERGENCY STOP

button is pressed, all electrical power is immediately terminated.

The dump valve opens and high pressure is relieved in the system. The emergency stop function can be wired to a remote control panel.

4.3 Fault Conditions

Automatic shutdown will occur as a result of the faults listed in Table 4-1. The red,

STOP button will blink and the number of blinks will indicate the type of fault.

Table 4-1

Fault Conditions

Number of Blinks

4

Indication

Overstroke

A left overstroke condition has occurred

Overstroke

A right overstroke condition has occurred

Comments

Abnormally high stroke rate caused by an external or internal leak.

Shutdown will occur if condition persists.

Abnormally high stroke rate caused by an external or internal leak.

Shutdown will occur if condition persists.

An intensifier overstroke condition has occurred.

Abnormally high stroke rate in both directions caused by an external or internal leak. Shutdown will occur if condition persists.

Motor Overload Fault The motor overload relay is monitored and displayed when the overloads trip. Overloads are set on automatic reset.

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4-2

Section 4

Operation

Table 4-1

Fault Conditions

Number of Blinks Indication

Oil

High hydraulic oil temperature, in excess of 144

F (62 C)

Oil

Oil level is below 21 gallons (79 liters)

Comments

The red light will illuminate and shutdown will occur. When the temperature returns to normal, the red light will go off.

The red light will illuminate and shutdown will occur. When the fault has been corrected, the red light will go off.

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4-3

SECTION 5

LOW PRESSURE WATER SYSTEM

5.1 Overview

The low pressure water system, cutting water supply circuit, supplies the intensifier with the required cutting water flow and pressure.

5.2 Cutting Water Supply Quality

The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance. Impurities in the water create grinding and corrosive effects on all components. See Section 11, Specifications, for details regarding water quality standards.

5.3 Operation

Cutting water is introduced through the 1/2-inch BSPT connection on the bulkhead of the machine and passes through the normally closed, inlet water solenoid valve. When the control power is turned on, the solenoid valve opens and allows water to flow through the valve. The inlet water is monitored by a 30 psi pressure switch. If the pressure drops below

30 psi (2 bar) the switch activates an automatic shutdown.

Figure 5-1: Low Pressure Water System

1 Inlet Water Solenoid Valve

2 30 psi Pressure Switch

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3 Booster Pump/Motor Assembly

4 LP Water Filter Assembly

5-1

Section 5

Low Pressure Water System

Cutting water is then routed to booster pump. The booster pump increases the pressure to the relief valve setting to ensure proper supply to the intensifier assembly.

Pressurized water passes through the filter assembly where debris is removed to prevent contaminates from damaging the check valves and seals in the intensifier. The filter assembly consists of a filter head, housing and a filter element. A bleed valve on the top of filter head is used to release pressure or air inside the housing.

From the filter assembly, cutting water is routed to the inlet check valves in the sealing heads on each end of the intensifier.

5.4

Service and Maintenance Procedures

To ensure water quality and supply to the high pressure system, the filter element, strainer and booster pump will require routine servicing and maintenance. The procedures for servicing these components are detailed below.

NOTE

Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.

Filter Assembly Maintenance

The life of the filter element is directly related to the quality of the inlet water. The condition of the filter element can be monitored by observing the pressure gauge on the assembly.

Document the pressure reading when the filter element is new. The element should be replaced when the pressure drops to 15 psi (1 bar) below the original value.

The following procedure is used to replace the filter element and clean the strainer.

Figure 5-3: Filter Element

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5-2

Section 5

Low Pressure Water System

1 Pressure Gauge

2 Bleed Valve

3 Filter Element

1. Turn the cutting water supply off.

4 Filter Element

5 Filter Housing

2. Press the red bleed valve on the filter head to release any pressure trapped inside the housing.

3. Use a filter wrench to unscrew the housing and remove the old element.

4. Install the new element. Apply FML-2 grease to the o-ring in the filter housing and use the filter wrench to replace the housing.

5. Turn the cutting water supply on.

6. Press the red bleed valve to remove any air inside the filter housing.

7. Start the machine and verify satisfactory pressure readings.

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5-3

SECTION 6

RECIRCULATION SYSTEM

6.1 Overview

The oil recirculation circuit is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system. Hydraulic oil is maintained at the proper operating temperature and condition by continuous recirculation.

System components include the recirculation pump, oil-to-water heat exchanger, oil filter assembly and the hydraulic oil reservoir.

6.2 Operation

Cooling water is introduced through the 1/2-inch BSPT connection on the bulkhead and routed to the ball valve mounted on the heat exchanger. The ball valve is used to manually regulate the cooling flow to the heat exchanger. Oil temperature can be visually monitored from a dual scale level/temperature sight gauge on the side of the hydraulic oil reservoir.

Figure 6-1: Recirculation System Components

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1 Temperature/Low Level Switch

2 Hydraulic Oil Reservoir

3 Air Breather

4 Recirculation Pump

5 Level/Temperature Sight Gauge

6 Manual Ball Valve

7 Heat Exchanger

8 Pressure Gauge

9 Filter Head

10 Oil Fill Port

11 Filter Element

6-1

Section 6

Recirculation System

The recirculation pump pulls oil from the reservoir and sends it to the heat exchanger where heat buildup is controlled in the hydraulic oil.

The cooled oil then passes through the filter element and returns to the reservoir. The cooling water either is discharged to the 1/2-inch BSPT drain on the bulkhead or is routed to a customer supplied water chiller.

The hydraulic oil filter assembly consists of the filter head with a bypass relief valve and pressure gauge, a filter element and the oil fill port. The filter element should be changed when the gauge reads 30 psi (2.1 bar) at normal operating temperature.

If the element is not replaced, and fills with debris, the bypass relief in the filter head will open to prevent over pressurization. The relief valve opens at 50 psi (3.4 bar). When the valve opens, the oil bypasses the filter and unfiltered oil is allowed to return to the reservoir.

The temperature/low level switch monitors the oil temperature and level in the reservoir.

NOTE

To conserve water usage it is recommended that the cooling water be shut off at the end of the day. A sensor bulb from the modulating valve is submerged in the reservoir. Even when the control power is off, the valve will remain open, allowing water to flow until the oil is cooled.

6.3 Service and Maintenance Procedures

To ensure the supply of properly conditioned oil to the main hydraulic system, the components will require routine servicing and maintenance. The procedures for servicing these components are detailed below.

NOTE

Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.

Hydraulic Oil Maintenance

The hydraulic oil should be replaced after 3,000 hours or one year of service, whichever comes first. The oil should be replaced sooner if a fluid sample indicates contamination that cannot be rectified by filtering.

An air breather and filter are located on the reservoir. The air breather prevents dirt from being sucked into the reservoir when the oil level drops, and allows air to escape when the level rises. The air breather must not be used as a fill point. Oil must only be added at the

fill port on the filter head and removed at the drain valve.

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6-2

Section 6

Recirculation System

CAUTION

Do not attempt to fill the reservoir from the air breather. The oil will not be filtered and will not conform to the cleanliness requirements of the system.

Figure 6-2: Hydraulic Oil Reservoir

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1 Drain

2 Temperature/Low Level Switch

3 Breather

4 Level/Temperature Sight Gauge

5 Oil Fill Port

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.

2. Drain the oil reservoir by connecting the inlet hose from an oil transfer pump to the drain on the reservoir.

3. Pump the used oil out to a container and remove the inlet hose from the drain.

NOTE

Oil from a new drum does not meet the cleanliness requirements of the hydraulic system. For this reason, it is important to use an oil transfer pump that will force oil through the return filter into the reservoir.

6-3

Section 6

Recirculation System

4. Connect the discharge hose from the oil transfer pump to the fill port on the oil filter and pump the fresh oil into the reservoir.

CAUTION

To ensure cleanliness, the oil fill port must be used to pump oil into the reservoir.

Filling at this point guarantees the hydraulic oil will pass through the oil filter before entering the reservoir.

5. Check the oil sight gauge on the reservoir to ensure proper fill level.

6. Remove the hose from the case drain on the hydraulic pump to make sure the pump case fills with oil. With the hose removed, head pressure from the reservoir will force oil into the pump case.

CAUTION

Oil in the pump case provides internal lubrication for the main hydraulic pump.

Failure to the fill the pump case with oil will allow air to become trapped inside, damaging the pump.

7. Disconnect the discharge hose from the fill port.

8. Check the sight gauge again and follow the same procedure to add additional oil if necessary.

Oil Filter Maintenance

If the filter element is not properly serviced and is allowed to fill with debris, the oil will be forced through the relief valve, bypassing the filter. The bypass relief valve opens at 50 psi

(3.4 bar).

The filter element must be replaced when the pressure gauge reading is 30 psi (2.1 bar) or greater during normal operating conditions. Normal operating conditions indicate the machine is running and the oil temperature has reached 115

F (46 C).

Figure 6-3: Oil Filter Assembly

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6-4

Section 6

Recirculation System

1. Use a filter wrench to unscrew the filter element from the filter head. Ensure the old gasket is removed with the filter.

2. Lubricate the gasket on the new element with fresh oil.

3. Use the filter wrench to screw the new element onto the filter head and hand-tighten.

Do not over tighten.

4. Start the machine and check for leaks.

Section deleted – Water Modulating Valve

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6-5

SECTION 7

HYDRAULIC SYSTEM

7.1 Overview

The main hydraulic power circuit supplies the intensifier assembly with the hydraulic flow required to produce high pressure water. High pressure cutting water is generated from the oil pressure in the hydraulic cylinder.

System components include the electric motor, hydraulic pump, and the hydraulic manifold.

The manifold houses the 4-way directional control valve and the system relief valve. The relief valve monitors hydraulic oil pressure and provides system protection by limiting excess pressure.

7.2 Operation

The electric motor drives two pumps mounted in tandem; the main hydraulic pump and the recirculation pump.

Hydraulic fluid from the reservoir is drawn into the inlet, low pressure side of the hydraulic pump. Oil delivered to the pump should be maintained at 110-115

F (43-46 C). Hydraulic fluid then enters the bottom of the manifold through an internal anti-rotation check valve.

After a shutdown, the anti-rotation check valve prevents the pump from running backwards.

Figure 7-1: Hydraulic System Components

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7-1

Section 7

Hydraulic System

1 Hydraulic Pump

2 Electric Motor

3 Pressure Gauge

5 Low Pressure Control

6 High Pressure Control

7 Directional Control Valve

4 High/Low Solenoid Valve 8 System Relief Valve

The main system relief valve provides system protection by monitoring the oil pressure entering the manifold. If the hydraulic pressure exceeds 3,400 psi (234 bar), the valve opens to limit the pressure. The valve is factory calibrated and is not serviceable. A drain line from the valve prevents oil from collecting behind the relief valve to ensure a constant pressure under all operating conditions.

The hydraulic system operates at high or low pressure settings up to the maximum flow capacity of the hydraulic pump. The high and low limit compensators mounted on the pump regulate the flow of hydraulic fluid to maintain constant operating pressures. Operating pressures are set and adjusted at the high and low pressure control valves on the manifold.

CAUTION

The high and low limit compensators regulate the flow of hydraulic fluid to the system by controlling the angle of the swashplate. If the oil is not properly maintained, the compensators can become blocked with debris. As a result, pump control will be lost and you will not be able to create hydraulic oil pressure.

The normally closed, two pressure solenoid valve is controlled by the operator’s selection of high or low pressure. The valve is closed while operating in high pressure and is open during low pressure operation. A light on the solenoid connector indicates low pressure operation.

A reference gauge on the top of the hydraulic pump manifold displays hydraulic pressure to the intensifier. When the intensifier shifts, it is normal for the pressure to quickly fall and then rise again.

The directional valve consists of a spool with internal passages that direct hydraulic flow to one end of the hydraulic cylinder while returning fluid to the reservoir through the opposite end. Spool position is solenoid operated. The solenoids are alternately energized in response to the position of the hydraulic piston as the proximity switch detects the end of the stroke.

7.3 Service and Maintenance Procedures

The extreme duty cycles demanded of the hydraulic system make routine inspection and maintenance acutely important. Leaks must be detected and remedied as soon as possible.

The operating pressure setting must be checked daily, and the electric motor must be inspected at regular intervals.

NOTE

Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.

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7-2

Section 7

Hydraulic System

Hydraulic Operating Pressure

Hydraulic operating pressure settings should be checked daily and adjusted as necessary.

High and low operating pressure is adjusted at the high and low pressure control valves per the specifications in Table 7-1.

Table 7-1

Hydraulic Operating Pressure Limits

High Pressure

Low Pressure

Clockwise

Clockwise

Counter-clockwise

Counter-clockwise

Figure 7-2: High/Low Pressure Controls

290 psi (20 bar)

290 psi (20 bar)

3,000 psi (207 bar)

800 psi (55 bar)

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1 High Pressure Control 2 Low Pressure Control

1. Check the operating pressure to determine if adjustment is necessary.

2. If high pressure adjustment is required, loosen the locking thumbscrew on the high pressure control valve by turning counter-clockwise.

3. Turn the knob on the control valve clockwise to increase operating pressure. Turn the knob counter-clockwise to decrease pressure.

4. Tighten the locking nut and verify the high pressure setting.

5. If low pressure adjustment is required, loosen the locking nut on the low pressure control valve by turning counter-clockwise.

6. Turn the hex clockwise to increase operating pressure. Turn the hex counterclockwise to decrease pressure.

7. Tighten the locking nut and verify the low pressure setting.

7-3

Section 7

Hydraulic System

Motor/Hydraulic Pump Maintenance

The motor should be inspected at regular intervals, approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motor clean and the ventilation openings clear.

NOTE

Motor bearings are sealed for life and require no periodic maintenance.

The hydraulic pump is mounted to the electric motor by means of a keyed shaft, close coupling. If the pump and motor are separated, the shaft and coupling must be lubricated with anti-seize grease prior to re-assembly.

Shift Valve and Manifold Service

As oil flows in and out of the hydraulic cylinder it flows through the shift valve. The valve spool opens and closes passageways to direct pressurized oil into one end of the cylinder, and bleeds the oil from the opposite end, causing the cylinder to stroke. The spool movement is controlled hydraulically by a pilot valve mounted directly on the shift valve. The shift valve and manifold require no routine maintenance.

Figure 7-3: Shift Valve

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Problems associated with a faulty shift valve are usually limited to an uneven, slow, or noncycling intensifier. Uneven stroking can also be caused by check valve problems.

A cracked manifold or leaking o-rings are usually the result of misaligned end bells, i.e., one end bell is rotated in relation to the other.

Figure 7-4: End Bell Misalignment

7-4

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Section 7

Hydraulic System

Whenever the tie rods are removed, the intensifier assembly fixture must be used to ensure that the end bells are aligned during the assembly process.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.

2. Remove the cap screws securing the end covers on the shift valve and remove the covers.

3. Using your fingers, check the shift valve spool for freedom of movement. The spool must move with light pressure through the full stroke. If the spool is jammed, the valve must be replaced.

4. Remove the spool and check that all grooves in the spool are clean and all polished surfaces are undamaged. Check the inside of the shift valve body for any damage or foreign material. If everything is satisfactory, insert the spool into the shift valve.

5. If the shift valve and manifold are satisfactory, replace the end cap.

Shift Valve Replacement

WARNING

The shift valve is a specially modified unit designed for use in this application.

Using a substitute shift valve may create a potential safety hazard, lower performance of the pump and will void the warranty.

1. If the shift valve or port o-rings must be replaced, remove the shift cable and pilot valve and set them aside. See the Solenoid and Pilot Valve Service for the correct procedure.

2. Loosen the fasteners in one-eighth turn increments until all torque has been removed.

Remove the shift valve and discard it if faulty.

3. Check the manifold and o-rings. If they are not in need of service, proceed to Step 18.

If the manifold or o-rings need service continue with Step 4.

4. Disconnect the oil supply and return lines from the manifold; cap the lines with the plugs supplied with the pump.

5. Disconnect the water supply lines at the quick-disconnects.

6. Remove the pressure relief valve and set aside. Use a spanner wrench (20460162) to make removal easier.

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Section 7

Hydraulic System

7. Disconnect the small diameter, hydraulic high pressure line connected to the manifold.

Move the high pressure lines out of the way.

8. Loosen the screws mounting the manifold to the intensifier in one-eighth turn increments.

9. Remove the screws mounting the manifold to the frame and remove the manifold.

10. If the manifold is cracked, check that the end bells are in alignment with each other using a steel straight edge. If any misalignment is noted, mount the intensifier on the intensifier assembly fixture and loosen the tie rod nuts. Torque the four cap screws mounting the end bells to the assembly fixture to 35 ft-lbs (48 Nm), then back off oneeighth to one-quarter turn until more than finger tight. The bolts must hold the end bells tight against the fixture to prevent any misalignment but not interfere with the tightening of the tie rod nuts.

11. Using a figure-eight pattern, torque all tie rod nuts to 40 ft-lbs (54 Nm)], then 60 ft-lbs

(81 Nm)], then 80 ft-lbs (108 Nm)], then 100 ft-lbs (135 Nm), then 120 ft-lbs (163

Nm). Remove the intensifier from the intensifier assembly fixture and place it back in the pump.

12. Clean and inspect all parts to be reused.

13. Lubricate the new o-rings with Parker Super O-Lube and place in the port cavity’s end bell. If any oil is lost in the process, refill with fresh oil.

14. Align the manifold ports with the intensifier ports and thread in the fasteners.

15. Torque all cap screws to 25 ft-lbs (34 Nm) in one-eighth to one-quarter turn increments using a figure-eight pattern.

16. Install the cap screws mounting the manifold to the pump frame and torque to 110 ftlbs (149 Nm).

17. Connect the oil supply and return lines to the manifold.

18. Lubricate the o-rings with Parker Super O Lube and place the o-rings in the port grooves of the shift valve to be installed.

19. Place the shift valve onto the manifold and install the fasteners. Torque the fasteners in one-eighth turn increments in a two-step process.

Torque screws 1 and 2 to 11.5 ft-lbs (15.5 Nm). Torque the outer screws (3-6) incrementally to 55 ft-lbs (75Nm) in a crisscross pattern. Verify screws 1 and 2 are at

11.5 ft-lbs (15.5 Nm).

7-6

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Figure 7-5: Torque Sequence

Section 7

Hydraulic System

3

2

6

5

1

4

CAUTION

Failure to correctly follow torque sequence when installing the shift valve may sufficiently warp the body, preventing spool movement. Such damage is usually not reversible.

20. Using your fingers, make sure the spool moves freely.

21. Lubricate the end cover o-rings with Parker Super O-Lube and mount the end cover to the shift valve housing. Torque the cap screws to 10 ft-lbs (14Nm).

22. Install the pilot valve and the solenoid cables.

23. Attach the water supply lines at the quick-disconnect fittings. Attach the high pressure tubing at both ends, and then torque the gland nuts.

24. Check the intensifier for incomplete work, tools, parts and rags. Start the pump and operate at idle oil pressure.

25. Slowly increase the pressure to the rated output while checking for leaks.

26. Stop the pump and inspect for any leakage and correct as required.

Solenoid and Pilot Valve Service

The pilot valve spool and solenoid plunger can be checked for freedom of movement without disassembling the pilot valve.

1. With the machine turned off, depress the small center ring on the end of the solenoid with a small wooden dowel. It will initially depress about .25” (6 mm) and then the movement of the valve spool can be felt. If movement is not felt, repeat this process on the other side. The spool itself will only move .13” (3 mm). If no movement is felt the entire assembly will probably require replacement.

7-7

Figure 7-6: Solenoid

Section 7

Hydraulic System

2. While the intensifier is off, apply 24 volts across the front and rear contacts (not the side one) on the solenoid connection to check for solenoid movement.

3. The black plastic nut on each solenoid can be unscrewed and the electro-magnet portion of the solenoid removed.

4. Inside there is a silver shaft that houses the solenoid plunger and a spring to absorb shock from the movement of the pilot valve spool. This shaft has a set of notches on it to receive a wrench for removal.

5. When the assemblies are removed from each side the pilot valve spool can be manually pushed from side to side to check the movement.

6. The pilot valve spool should then be removed at this point to check for burrs and other signs of wear and leakage. If there is any wear or leakage across the valve, the entire assembly must be replaced.

Figure 7-7: Pilot Valve

1

2

3

4

5

6

7

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1 Pilot Valve

2 Pilot Valve Spool

3 Spool Stop

4 Solenoid Plunger Housing

5 Solenoid Electro Magnet

6 O-Ring

7 Plastic Nut

7-8

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Section 7

Hydraulic System

Pilot Valve Assembly Replacement

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.

2. Unplug the connections at the solenoid where the shift lights are located.

3. Remove the screws on top of the pilot valve assembly.

4. Make sure there is a slight film of oil on the o-rings and face of the new pilot.

5. Clean any debris that may be on the joining surface on the top of the shift valve and check for scratches or other marks.

6. Mount the new pilot valve assembly in place so the wire connections on the solenoids face the back of the cabinet.

7. The screws only have to be hand tight at about 15 ft- lbs (20 Nm).

8. Reconnect the cables to the solenoids. Notice they are labeled for front left (FL), front right (FR) and so on.

7-9

SECTION 8

ELECTRICAL SYSTEM

8.1 Overview

Major components of the electrical system for the KMT H2O Jet include the electric motors and the wiring harness that connects the sensors and solenoid valves to the customer supplied controller.

The 12-lead electric motor can be wired for either wye-delta or across-the-line starting. The motor includes a 9-post terminal block for the junction of motor and starter wire leads.

8.2 Sensors and Solenoids

Sensors monitor operating conditions and electronically operated solenoids provide basic intensifier shift control. The cables connected to these sensors and solenoids are bundled into a wiring harness. Table 8-1 lists the recommended shutdown settings.

Table 8-1

Recommended Shutdown Settings

Label Sensor

1

1

Low hydraulic oil level

High hydraulic oil temperature

Figure 8-1: Sensors and Solenoids

21 gal (79 L)

144

F (62 C)

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8-1

1 Oil Level/Temperature Switch (1)

2 Inlet Water Solenoid (6)

3 Safety Dump Valve (7)

4 Left Proximity Switch (2)

Component

Hydraulic Reservoir

Section 8

Electrical System

5 Right Proximity Switch (3)

6 4-Way Valve ‘A’ Solenoid (4)

7 4-Way Valve ‘B’ Solenoid (5)

8 Inlet Water Pressure Switch

Table 7-2

Sensors and Solenoids

Function

1 The temperature/low level switch monitors the oil temperature and level in the reservoir. Although the float switch and the temperature switch are combined in a single unit, the two switches function independently.

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Inlet Water Solenoid Valve

2 The normally closed, inlet water solenoid valve is located at the service bulkhead. When the control power is turned on, the valve opens and allows low pressure cutting water to enter.

Safety Dump Valve

3 When control power is removed, the safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines. The high pressure dump valve assembly includes a normally open high pressure water valve and a solenoid operated air valve.

The normally open pneumatic dump valve is held closed by air pressure. When the air supply is interrupted, the valve opens and allows water to flow through the valve. Pressure is released in the intensifier and the high pressure water stream exits through the drain.

8-2

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Component

Hydraulic Cylinder

Section 8

Electrical System

Table 7-2

Sensors and Solenoids

Function

4 As pressurized hydraulic oil is sent to one side of the hydraulic cylinder, it pushes against the piston, moving it in one direction until it activates the proximity switch at the end of the stroke. The hydraulic flow is then sent to the opposite side of the cylinder, and the piston reverses direction until it activates the proximity switch at the opposite end of the stroke.

The proximity switches are activated when the piston makes contact with the shift pin and the movement is transferred to the magnet in the actuator assembly. When the switch is activated, it sends a signal to the controller to change the flow of the directional control valve and reverse direction.

Hydraulic Manifold

5 The 4-way directional control valve shifts the hydraulics back and forth to the intensifier. A shift valve directs pressurized oil to one end of the hydraulic cylinder and returns fluid to the reservoir from the opposite end, causing the intensifier to stroke. The movement is controlled hydraulically by a pilot valve that is electronically operated by two solenoids.

Inlet Water

6 The 30 psi pressure switch monitors the inlet cutting water. If the pressure drops below 30 psi

(2 bar) the switch activates an automatic shutdown circuit, protecting the booster pump from damage due to insufficient water supply pressure.

8-3

Section 8

Electrical System

8.3 Service and Maintenance Procedures

Electrical components require minimal service. The proximity switches on the hydraulic cylinder may require replacement.

NOTE

Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.

Proximity Switch Maintenance

A proximity switch has failed and needs to be replaced if the LEDs do not change state, indicating they are not sensing the piston, or if an LED flashes continuously.

Figure 8-2: Proximity Switch

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1 Proximity Switch

2 Proximity Switch Screw

3 Firing Pin

4 Actuator Assembly

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance on the system components.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.

2. Disconnect the proximity switch cable.

3. Remove the proximity switch screws and carefully remove the proximity switch.

Some force may be required due to the resistance created by the o-rings.

8-4

Section 8

Electrical System

4. Remove the actuator assembly and inspect for ease of movement and to ensure the springs and magnet are intact.

5. To remove the firing pin, lubricate the o-ring in the firing pin tool and insert the tool into the actuator assembly bore in the end bell, o-ring end first. This creates a suction that extracts the pin.

Figure 8-3: Firing Pin Removal

1 Actuator Assembly Bore

2 Actuator Assembly Bore

3 Firing Pin Bore

4 End Bell

6. Inspect the firing pin. It should be approximately 1.150” (29.20 mm) long, with a shaft OD of approximately 0.082” (2.08 mm) and have no measurable bend.

7. Inspect the firing pin bore in the end bell. It must be polished and have no gouges, burrs or other surface disruptions. It must not be elongated or egg shaped.

8. Use the firing pin tool and a small Allen wrench to replace the firing pin. Position the firing pin in the groove of the tool with the head toward the o-ring. Insert the tool into the actuator assembly bore using the Allen wrench to apply pressure against the firing pin. Rotate the tool until the pin lines up with the firing pin bore. The pressure applied will force the firing pin into the bore. Visually inspect the pin to ensure it is correctly installed.

9. Install the actuator assembly, large end first, so the magnet faces the proximity switch.

10. Install the new proximity switch. Apply JL-M grease to the threads on the screws and tighten to 140-160 in-lbs (16-18 Nm).

CAUTION

Ensure that the proximity switch is properly installed and secured prior to starting the machine. Failure to tighten the hold down screws on each switch will result in the spray of hydraulic oil.

11. Reconnect the proximity switch cable.

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8-5

SECTION 9

HIGH PRESSURE WATER SYSTEM

9.1 Overview

The high pressure water system is supported by both the cutting water supply circuit and the hydraulic circuit. Cutting water of sufficient flow and pressure is routed from the cutting water supply circuit to the intensifier where it is pressurized up to 60,000 psi (4,137 bar) and delivered to the cutting head.

The directional control valve in the hydraulic system creates the stroking action of the intensifier by sending pressurized hydraulic oil to one side of the hydraulic cylinder or the other. As the flow is sent to one side, hydraulic fluid is returned to the reservoir from the opposite side.

System components include a double-ended hydraulic cylinder; reciprocating piston assembly; high pressure cylinders attached to each end of the hydraulic cylinder; two plungers, sealing heads and end caps; and a .41 liter capacity attenuator. Sophisticated check valves and seal assemblies ensure hydraulic oil, and the low pressure and high pressure water travel in the appropriate direction.

9.2 Operation

The directional control valve sends pressurized hydraulic oil to one side of the hydraulic cylinder. The pressurized oil pushes against the piston, moving it in one direction until it activates the proximity switch at the end of the stroke. The hydraulic flow is then sent to the opposite side of the cylinder, and the piston reverses direction until it activates the proximity switch at the opposite end of the stroke.

The green light on the proximity switch indicates there is power to the switch. The red light illuminates when the switch is activated. The proximity switches are magnetically activated by the presence of the magnet in the actuator assembly. When the switch is activated, the flow of the directional control valve is changed and the direction is reversed.

As the pressurized oil pushes the piston in one direction, the plunger on that end extends and pushes against the water in the high pressure cylinder, increasing the pressure up to 60,000 psi

(4,137 bar). When the piston reverses direction, the plunger retracts and the plunger in the opposite cylinder extends to deliver the high pressure water.

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9-1

Figure 9-1: High Pressure Cylinder

Section 9

High Pressure Water System

1 Discharge Check Valve

2 Sealing Head

3 Inlet Check Valve

4 Hydraulic Piston

5 Retracted Plunger 8 Extended Plunger

6 Hydraulic Cylinder 9 Inlet Water Passage

7 High Pressure Cylinder 10 Outlet Water Passage

Low pressure water is routed through the inlet water ports to the inlet passages in the sealing heads. When the plunger retracts, the inlet check valve opens to allow water to fill the high pressure cylinder. When the plunger extends to create high pressure water, the inlet valve closes to seal the inlet passage and the discharge check valve opens to allow the high pressure water to exit the cylinder. As the plunger retracts, the discharge check valve closes.

Figure 9-2: High Pressure Water System

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1 High Pressure Cylinder

2 Proximity Switch

3 Hydraulic Cylinder

4 End Bell

5 High Pressure End Cap

6 Safety Dump Valve

7 Attenuator

9-2

Section 9

High Pressure Water System

The intensifier is a reciprocating pump. As the piston and plungers move from one side to the other, high pressure water exits one side of the intensifier as low pressure water fills the opposite side.

The high pressure water is then routed to the attenuator. The attenuator acts as a shock absorber to dampen pressure fluctuations and ensure a steady and consistent supply of water.

From the attenuator, the high pressure water exits to the cutting head.

The high pressure dump valve releases the stored pressure in the intensifier and high pressure delivery lines. The high pressure dump valve assembly includes a normally open high pressure water valve and an electrically controlled air valve.

The normally open pneumatic dump valve is held closed by air pressure. When the air supply is interrupted and exhausted, the valve opens and allows water to flow through the valve.

Pressure is released in the intensifier and the high pressure water stream exits through the drain.

9.3 Service and Maintenance Overview

Never perform any type of maintenance on the high pressure water system while it is pressurized. Always turn the main control power off and bleed the high pressure water before servicing.

Improper assembly can lead to the premature failure of components. Maintenance procedures must be followed carefully; components must be properly cleaned prior to assembly and tightened to the correct torque specifications.

Some high pressure components are not serviceable at the customer level, others require precise refinishing. KMT Waterjet Systems offers maintenance and refinishing services for these components.

NOTE

Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.

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9-3

Section 9

High Pressure Water System

Torque Specifications

Table 9-1, Torque Specifications, details the torque specifications and tightening sequences for the high pressure components and connections.

End Bell Lock Nuts

1st Stage

2nd Stage

3rd Stage

4th Stage

5th Stage

6th Stage

Table 9-1

Torque Specifications

High Pressure Water System

Finger-tight

40 ft-lbs (27 Nm)

Crossing Pattern

60 ft-lbs (43-47 Nm)

Crossing Pattern

80 ft-lbs (43-47 Nm)

Crossing Pattern

100 ft-lbs

Crossing Pattern

120 ft-lbs

Crossing Pattern

Crossing Pattern

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Proximity Switch

Torque

Sealing Head

Discharge Gland Nut

Pneumatic Control Valve

3/8-inch HP Gland

1/4-inch HP Gland

Pneumatic Actuator

HP Adapter

140-160 in-lbs (16-18 Nm)

30-50 ft-lbs (41-67 Nm)

50 ft-lbs (68 Nm)

25 ft-lbs (34 Nm)

5 ft-lbs (7 Nm)

25 ft-lbs (34 Nm)

9-4

High Pressure Fittings

1/4” HP Gland Nut

3/8” HP Gland Nut

9/16” HP Gland Nut

Section 9

High Pressure Water System

Table 9-1

Torque Specifications

High Pressure Water System

25 ft-lbs (34 Nm)

50 ft-lbs (68 Nm)

110 ft-lbs (149 Nm)

9.4 High and Low Pressure Water Piping

Before performing any maintenance on the high pressure components, it is necessary to remove the high and low pressure water piping. The following procedure should be used to remove and install the piping.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance on the high pressure system components.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.

1. Turn the cutting water supply off.

2. Loosen and remove the high pressure gland fitting connected to the discharge high pressure check valve. Move the tubing to clear the work area.

3. Remove the low pressure water quick disconnect from the inlet water port on the end cap.

4. When the required maintenance has been completed and the components reassembled, connect the low pressure water connection to the inlet water port on the end cap.

5. Apply Pure Goop to the threads on the high pressure gland fitting. Before installing the high pressure fitting, ensure proper collar position, 1-1/2 to 2-1/2 threads should be exposed. Install and tighten the fitting to the torque specifications in Table 8-1.

6. Turn the cutting water supply on and check for low pressure leaks.

7. Remove the cutting orifice and start the machine. Operate at low pressure to flush the high pressure passages.

8. Install the orifice and operate at high pressure to check for leaks.

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9-5

9.5 High Pressure End Caps

Section 9

High Pressure Water System

High Pressure End Cap Removal

Prior to removing electrical power or any high or low pressure piping, start the machine and retract the plunger on the opposite end to be serviced to allow full exposure when the unit is disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

3. Use a pin spanner wrench (P/N 20460162) to turn the end cap counter-clockwise to break the end cap loose. It may be necessary to tap the spanner wrench with a plastic mallet. Continue to unscrew the end cap until it is removed. Removing the sealing head assembly at the same time is recommended.

Figure 9-3: High Pressure End Cap

1

2

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3

1 High Pressure Cylinder

2 High Pressure End Cap

3 Sealing Head Assembly

High Pressure End Cap Installation

1. Apply Blue Goop to the flat end of the high pressure cylinder and the shoulders on the sealing head. Apply FML-2 grease to the o-rings on the sealing head.

9-6

Section 9

High Pressure Water System

2. Install the sealing head in the high pressure cylinder and thread the end cap onto the cylinder. Turn the end cap clockwise until it bottoms out and then tighten with a spanner wrench using only your hands. Any additional torque could cause problems the next time the end bell is removed.

3. Connect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

9.6 High Pressure Cylinder Assembly

The high pressure cylinder can be removed from the end bell with the end cap and sealing head assembly installed. However, due to the combined weight of these components, removing the end cap and sealing head first is recommended.

High Pressure Cylinder Removal

Prior to removing electrical power or any high or low pressure piping, start the machine and extend the plunger on the end to be serviced to allow full exposure when the unit is disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Use a girth grip wrench to unthread the high pressure cylinder from the end bell.

Support the weight of the cylinder until it completely clears the plunger.

CAUTION

The high pressure cylinder is heavy and can damage the plunger or cause injury if it not supported correctly.

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9-7

Figure 9-4: High Pressure Cylinder Assembly Removal

2

1

Section 9

High Pressure Water System

3

1 High Pressure Cylinder

2 End Bell

3 Plunger

NOTE

If thread or metal surface galling is detected during removal, galled surfaces and threads must be filed, sanded and lubricated prior to reassembly. See the procedure, High Pressure Cylinder Maintenance.

High Pressure Cylinder Installation

1. Inspect and clean the high pressure cylinder threads and alignment surfaces.

2. Apply Pure Goop the high pressure cylinder threads and shoulder guides. Thread the cylinder into the end bell. Supporting the weight of the cylinder, use caution to not slam the cylinder against the end bell, damaging the threads.

NOTE

The shoulder guides are close fitting, smooth diameters located at either end of the cylinder threads. As the plunger goes into the cylinder, the cylinder will become difficult to rotate. If necessary, use the cylinder wrench to assist.

3. Use the cylinder wrench (P/N 20459001) to tighten the high pressure cylinder handtight. Then tap the wrench with the palm of your hand to tighten.

4. Install the end cap and sealing head assembly, following the procedure, End Cap

Installation.

5. Connect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

6. Start the machine at low pressure to flush air from the high pressure components and to check for obvious leaks. After 5-10 strokes, switch to high pressure operation and check for leaks.

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9-8

Section 9

High Pressure Water System

If leaks are detected, turn the machine off and remedy the problem. When the problem has been remedied, repeat the startup procedure, moving from low to high pressure soon after the intensifier starts pumping water. There is no further need to flush air from the system.

High Pressure Cylinder Maintenance

The plunger seal area in the high pressure cylinder bore should be inspected and cleaned each time the high pressure seal assembly is replaced.

1. Clean the sealing area on the inside diameter of the high pressure cylinder and inspect the bore for rings, scratches, pits, residue or other potential leak paths.

Seal material or residue can build up, forming a ring. Running a fingernail across the buildup will cause it to appear as a surface flaw. Grooves or ridges are typically seal debris buildup rather than marks on the inside diameter wall of the cylinder.

2. Polish the inside diameter of the cylinder where the seal will locate with 600-grit wet/dry sandpaper. Hold the sandpaper on the end of your finger and move in a cylindrical wiping motion. Polish in a circumferential motion only. Do not polish or drag the sandpaper along the length of the cylinder.

3. Clean the residue from the inside diameter of the cylinder and re-inspect for surface defects.

9.7 Sealing Head Assembly

The inlet and discharge check valves in the sealing head ensure the low pressure and high pressure water only travels in the appropriate direction.

Figure 9-5: Sealing Head

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1 Discharge Check Valve

2 End Cap

3 Sealing Head

4 High Pressure Cylinder

5 Inlet Check Valve

9-9

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Section 9

High Pressure Water System

High Pressure Discharge Check Valve

The discharge check valve can only be serviced with the end cap removed from the high pressure cylinder.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high pressure water piping, following the procedure, High and Low

Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Remove the gland nut. The poppet pin, spring and discharge poppet will normally remain in the gland nut when it is removed. Remove the components from the gland nut.

5. Use a magnet to remove the poppet seat from the sealing head.

6. Inspect the poppet pin, spring and discharge poppet for wear. If any component is worn, replace all components.

NOTE

The spring and discharge poppet should be replaced as a set. If one component requires replacement, replace all components.

7. Inspect both faces of the seat for damage or cracking. A cracked or damaged seat must be replaced. The seat is not symmetrical; the rounded side must face the sealing head body.

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Figure 9-6: High Pressure Discharge Check Valve

Section 9

High Pressure Water System

5

3

1

4

2

1 Gland Nut

2 Poppet Pin

3 Compression Spring

4 Discharge Poppet

5 Seat

8. Apply a thin film of Blue Goop to the rounded face of the seat and insert the seat into the sealing head body. Do not apply Goop to the flat face.

9. Install the poppet pin, spring and discharge poppet in the gland nut.

10. Apply Blue Goop to the threads on the gland nut and thread the gland nut into the sealing head. Do not apply Goop to the sealing face of the gland.

11. Use a torque wrench to tighten the gland nut to the torque specifications in Table 8-1.

12. Install the end cap and sealing head assembly, following the procedure, End Cap

Removal.

13. Connect the high pressure water piping, following the procedure, High and Low

Pressure Water Piping.

14. Start the pump and operate at low pressure, without a cutting orifice, to flush the high pressure passages, and then operate the pump at high pressure with orifice installed to check for leaks. Verify that the high pressure fittings do not leak, and that the high pressure water signal is normal, indicative of the normal check valve operation.

Low Pressure Inlet Check Valve

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

9-11

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Section 9

High Pressure Water System

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high pressure water piping, following the procedure, High and Low

Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Remove the poppet retainer screw and then remove the poppet retainer and inlet poppet.

Figure 9-7: Low Pressure Inlet Check Valve

3

4

2

1

1 Inlet Poppet

2 Poppet Retainer

3 Poppet Retainer Screw

4 Inlet Water Passage

5. Inspect the sealing head for pits, scratches jetting erosion on the sealing surface. If defects are detected, the surface must be refinished. See the procedure, Sealing Head

Maintenance.

6. Inspect the inlet water port in the sealing head of cracking.

7. Inspect the sealing surface of the inlet poppet. If the surface is marred it can be relapped. If the poppet will not be within the required limits after re-lapping it must be replaced. See the procedure, Sealing Head Maintenance.

8. Install the inlet poppet assembly

9. Inspect the assembled unit to ensure the poppet moves freely and the poppet retainer screw is seated.

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Section 9

High Pressure Water System

Sealing Head Maintenance

The sealing head should be inspected for scratches, excessive sealing damage or erosion marking on the contact surface, and on the inlet poppet valve contact surface. If defects are detected, the surfaces must be refinished. The sealing head can be returned to KMT Waterjet for refinishing.

Place a piece of 600-grit wet/dry abrasive strip on the granite lapping block. Make sure there are no air bubbles between the abrasive sheet and the lapping block.

1. Lap the discharge poppet and gland nut as necessary. A minimum allowable thickness of 0.350” (8.890 mm) must be maintained on the insert. The minimum allowable length of the discharge poppet is 0.607” (15.418 mm).

NOTE

The discharge poppet requires only the use of a 600 grit wet/dry abrasive strip.

Use of above 600 grit and lapping to a mirror-like surface may cause check valve sticking problems.

2. Use a figure eight pattern when lapping the inlet poppet and sealing head body. Finish with one straight pass, then rotate 90-degrees and do one more pass. This will give a crosshatch appearance.

A minimum height of 0.365” (9.271 mm) must be retained on the shoulder of the inlet poppet face. A radius of 0.035” (0.889 mm) and a minimum thickness of 0.120:

(3.048 mm) must also be maintained.

9.8 High Pressure Seal Assembly

The following procedure should be used to replace the high pressure seal assembly. The high pressure seal tool kit (P/N 20458926) will be required for this procedure.

Prior to removing electrical power or any high or low pressure piping, start the machine and extend the plunger on the end to be serviced to allow full exposure when the unit is disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

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9-13

Section 9

High Pressure Water System

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder

Removal.

5. Remove the seal buttress from the end bell. Wipe and clean surfaces, weep holes and grooves and check for cracks.

Figure 9-8: Seal Buttress Removal

1

2

3

1 Seal Buttress 3 High Pressure Seal Assembly

2 Plunger

6. Use the seal removal tool and a plastic faced mallet to remove the high pressure seal assembly and backup sleeve from both ends of the high pressure cylinder. Be careful not to scratch the cylinder bore.

Figure 9-9: High Pressure Seal Removal

4

2

1

3

2

1

1

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1 High Pressure Seal Assembly

2 Backup Sleeve

3 High Pressure Cylinder

4 Seal Removal Tool

9-14

Section 9

High Pressure Water System

7. Inspect the backup sleeve for wear. Polish is necessary.

8. Clean and inspect the cylinder bore for obvious ridges or grooves. If seal debris is present, follow the procedure, High Pressure Cylinder Maintenance.

NOTE

The ends of the high pressure cylinder often show a ‘step’ between the backup sleeve and the high pressure seal where the two overlap by a small amount. This is normal and does not indicate a flaw in the cylinder.

9. Inspect the exposed surface of the plunger for scratches, surface discoloration or unusual contact markings. Replace the plunger if necessary.

10. Screw the adapter flange onto the flat end of the high pressure cylinder and place the tapered sleeve compressor into the flange with the largest ID facing out.

Figure 9-10: High Pressure Seal Installation, Flat End

2

1

5

2

3

4

4

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1 High Pressure Seal Assembly

2 Tapered Sleeve Compressor

3 Adapter Flange

4 High Pressure Cylinder

5 Seal Removal Tool

11. Apply food grade grease to the high pressure seal assembly and insert the assembly into the tapered sleeve with the o-ring facing in.

12. Use the seal plunger tool to push the seal assembly into the high pressure cylinder until it is flush with the end of the cylinder. A rubber mallet may be required to position the seal assembly correctly.

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Section 9

High Pressure Water System

13. Unscrew the adapter flange from the high pressure cylinder, turn the cylinder over and place the flat end on the large aluminum spacer.

Figure 9-11: High Pressure Seal Installation, Opposite End

5

7

2

3

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6

1

4

1 High Pressure Seal Assembly

2 Tapered Sleeve Compressor

3 Adapter Flange

4 High Pressure Cylinder

5 Seal Removal Tool

6 Spacer

7 Backup Sleeve

14. Apply food grade grease to the backup sleeve and slide the sleeve into the high pressure cylinder.

15. Screw the adapter flange onto the end of the high pressure cylinder and place the tapered sleeve compressor into the flange with the largest ID facing out.

16. Apply food grade grease to the high pressure seal assembly and to the inside of the sleeve and insert the assembly into the tapered sleeve with the o-ring facing in.

17. Use the seal plunger tool to push the seal assembly into the high pressure cylinder until it is flush with the end of the cylinder.

18. Install the seal buttress.

19. Install the high pressure cylinder, following the procedure, High Pressure Cylinder

Assembly Installation.

20. Install the end cap and sealing head assembly, following the procedure, End Cap

Installation.

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Section 9

High Pressure Water System

21. Reconnect the high and low pressure water piping and turn the low pressure water supply on.

9.9 Hydraulic Seals

The intensifier assembly fixture is required for this procedure. The fixture is used during the reassembly process to square the end bells with each other and to minimize the possibility of o-ring damage as the cylinder is being drawn onto the end bells. When the end bells are assembled out of alignment, oil manifold leakage and breakage may occur.

Prior to removing electrical power or any high or low pressure piping, start the machine and extend the plunger on the end to be serviced to allow full exposure when the unit is disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder

Removal.

5. Remove the proximity switch on the end of the hydraulic cylinder to be serviced.

Remove the opposite proximity switch to drain hydraulic oil into the reservoir if both ends of the hydraulic cylinder are to be serviced.

6. Remove the lock nuts and then remove the tie rods retaining the end bells to the hydraulic cylinder. Remove the end bell.

NOTE

The bore of the hydraulic cylinder should be inspected for wear grooves and surface finished whenever the end bells are removed. Excessive grooving on the bore is indicative of piston seal wear.

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9-17

Figure 9-12: Hydraulic Seal Installation

1

2

Section 9

High Pressure Water System

4

3

1 Low Pressure Seal Assembly 3 Hydraulic Seal Assembly

2 Snap Ring 4 Hydraulic Seal Spacer

7. Remove the snap ring and the hydraulic seal spacer from the end bell.

8. Remove the hydraulic seal assembly from the inside of the end bell and remove the low pressure seal assembly from the outside.

9. Apply FML-2 food grade grease to the new hydraulic and low pressure seal assemblies and install.

10. Position the end bell, apply JL-M grease to the threads on the tie rods and install the tie rods and lock nuts. Torque the nuts to the specifications in Table 8-1.

11. Apply JL-M grease to the screw threads and install the proximity switch(s). Torque the screws to the specifications in Table 8-1.

CAUTION

It is recommended that the proximity switch be reinstalled as soon as practical.

Removal of the switch presents the potential of an oil spray hazard.

Ensure that the proximity switch is properly installed and secured prior to starting the machine. Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil.

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9-18

Section 9

High Pressure Water System

9.10 Hydraulic Piston and Plunger Service

The following procedures are used to remove, repair and install the hydraulic piston and plunger.

Hydraulic Piston and Plunger Removal

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

2. Disconnect the high and low pressure water piping, following the procedure, High and

Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap

Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder

Removal.

5. Remove the proximity switches on the each end of the hydraulic cylinder to drain the hydraulic oil into the reservoir.

6. Remove the lock nuts and then remove the tie rods retaining the end bells to the hydraulic cylinder. Remove both end bells.

NOTE

The bore of the hydraulic cylinder should be inspected for wear grooves and surface finished whenever the end bells are removed. Excessive grooving on the bore is indicative of piston seal wear.

7. Remove the hydraulic piston and plungers from the hydraulic cylinder. If the piston must be driven out of the cylinder due to seal squeeze and friction, us a plastic headed hammer to avoid striking the assembly with a metal object.

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9-19

Figure 9-13: Plunger Removal

Section 9

High Pressure Water System

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1 Hydraulic Piston

2 Plunger

3 Hydraulic Cylinder

5 Plunger Retainer

6 Backup Ring

7 Plunger Seal

4 Snap Ring

8. Remove the snap ring and the plunger retainer. The retainer can be loosened by blowing air into one of the four openings in the retainer. Remove the plunger by hand.

9. Repeat Step 8 to remove the other plunger.

10. Remove the backup rings from each side of the piston using a non-metallic tool to prevent scratching or scoring the piston.

11. Remove the plunger seals from each side of the piston.

12. Clean off parts of the piston assembly. Ensure all oil, dirt and burrs are removed from all surfaces.

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Section 9

High Pressure Water System

Plunger Installation

1. Apply Parker O-Lube to the backup rings and plunger seals. Install two backup rings and one plunger seal in each piston groove. The plunger seal must be positioned between the backup rings.

Figure 9-14: Plunger Seal Installation

2

1

4

5

6

3 3

1 Plunger

2 Grooves

3 Backup Ring

4 Plunger Seal

5 Correct

6 Incorrect

2. Install the plungers in the counter-bores in the piston with a turning motion. Ensure the plunger seal and backup rings do not get nicked or rolled.

3. Slide the plunger retainers over the plungers with the large end facing the piston.

Install the snap rings to secure the plungers.

Hydraulic Piston Installation

The center band on the piston consists of four parts. There are two nylon backup rings, an inner energized ring and an outer Teflon cap ring. Two bearing rings are installed in the outer band on the piston.

1. Remove the old piston seals.

CAUTION

Do not scratch the bottom surface of the piston seal groove. Scratches to the seal groove sides and/or bottom can result in hydraulic leaks.

2. Inspect the seal groove bottom for marks or scratches and residue buildup. Clean and/or repair the groove surfaces as required.

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Section 9

High Pressure Water System

3. Carefully slide inner energized ring over the piston until it rest in the center slot. Use a mandrel and finger sleeve to stretch the Teflon cap ring over the piston. The Teflon cap ring must be centered on top of the energized ring.

NOTE

Heating the Teflon cap ring in 150-200° F (65-90° C) water for 2-3 minutes will soften the ring enough to facilitate installation.

The Teflon cap ring must be resized using a ring compressor for at least three minutes so it will fit in the hydraulic cylinder.

4. Install the nylon backup rings on each side of the Teflon cap ring with the curved inside edge facing the cap.

Figure 9-15: Center Band Component Installation

3

3

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1

2

1 Energized Ring

2 Teflon Cap Ring

3 Nylon Backup Ring

5. Install the bearing rings in the outside slots in the piston. Rotate the bearing rings so the end joints do not line up.

6. Inspect the hydraulic cylinder for scratches, burrs or gouges to ensure it is suitable for use.

7. Lubricate the cylinder bore and the piston assembly with hydraulic oil.

8. Use a ring compressor to contain the bearing rings and plunger seal assemblies.

9. Push the piston assembly into the hydraulic cylinder bore.

10. Remove the ring compressor and continue to drive the piston assembly into the cylinder until it is approximately centered in the cylinder.

11. Install the plungers, following the procedure, Plunger Installation.

12. Position the end bells, apply JL-M grease to the threads on the tie rods and install the tie rods and lock nuts. Torque the nuts to the specifications in Table 8-1.

9-22

Section 9

High Pressure Water System

CAUTION

The intensifier assembly fixture must be used to ensure the end bells are aligned during the assembly process.

13. Apply JL-M grease to the screw threads and install the proximity switches. Torque the screws to the specifications in Table 8-1.

CAUTION

It is recommended that the proximity switch be reinstalled as soon as practical.

Removal of the switch presents the potential of an oil spray hazard.

Ensure that the proximity switch is properly installed and secured prior to starting the machine. Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil.

14. Install the high pressure cylinder, following the procedure, High Pressure Cylinder

Assembly Installation.

15. Install the end cap and sealing head assembly, following the procedure, End Cap

Installation.

16. Reconnect the high and low pressure water piping and turn the low pressure water supply on.

9.11 Hydraulic Cylinder Maintenance

The inside diameter surface of the hydraulic cylinder should be inspected for wear grooves and surface finish whenever the end bells are removed. Excessive grooving is indicative of piston seal wear.

9.12 Plunger Maintenance

Plunger surfaces can become streaked with longitudinal scratches or flaws, and discolored or dull in appearance; or the outboard end can become smeared with stainless steel due to contact with the backup sleeve. If any of these conditions become severe, the high pressure seal assembly and possibly the hydraulic seals will leak.

Plunger surface flaws usually cannot be repaired on site. The plunger can be returned to

KMT Waterjet for reconditioning.

9.13 High Pressure Attenuator

The high pressure attenuator is not serviceable at the customer level. KMT Waterjet Systems tests the seals in the attenuator at pressures exceeding normal operating pressure, making disassembly difficult. If the attenuator develops a high pressure water leak, it should be replaced.

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9-23

Section 9

High Pressure Water System

9.14 High Pressure Dump Valve

The high pressure dump valve assembly includes a normally open high pressure water valve and a solenoid operated air valve. The following procedures are recommended for servicing the high pressure dump valve. Failure to follow these procedures will cause damage to the stem, valve seat, or both.

WARNING

The high pressure dump valve is a safety device designed to instantly release high pressure in the system. Proper maintenance is imperative to prevent potential personal injury.

Figure 9-16, Pneumatic Valve Seal Tools, illustrates the special tools recommended for this procedure.

Figure 9-16: Pneumatic Valve Seal Tools

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1 Seal Installation Tool (20470417)

2 Seal Positioning Tool (05067350)

2-Port Dump Valve

3 Seal Positioning Tool (49833114)

3-Port Dump Valve

3 Seal Push Tool (20470413)

Seal Tool Kit (20470475)

Pneumatic Control Dump Valve

For reliable operation the valve seat, seal assembly, brass backup ring and stem shall

always be replaced at the same time. The SST backup ring can be reused.

Before proceeding, disconnect and lockout the main power supply and the electrical enclosure; and ensure that all high pressure water and hydraulic pressure has been bled from the system.

9-24

Section 9

High Pressure Water System

WARNING

Severe injury can result if the machine is not properly locked out. Observe electrical Lock Out/Tag Out procedures before proceeding.

Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding.

1. Turn the air supply off.

2. Remove the air supply hose, and the electrical connection to the solenoid valve.

Figure 9-17: High Pressure Dump Valve

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2 HP Water Out to Cutting Head

3 Out to Drain

5 Signal

6 Solenoid Valve

7 Control Air In

3. Loosen and remove the high pressure gland connections and the drain connection.

4. Remove the valve and actuator assembly from the machine.

9-25

Figure 9-18: Dump Valve Components

Section 9

High Pressure Water System

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1 Pneumatic Actuator

2 Stem

3 SST Backup Ring

4 Brass Backup Ring

5 Seal Assembly

7 Valve Seat

8 High Pressure Adapter

5. Loosen the cylinder head on the actuator. Unscrew and remove the actuator from the valve body.

6. Unscrew the high pressure adapter and remove the adapter and valve seat.

7. Remove the stem, SST backup ring and brass backup ring from the valve body.

8. Remove the seal assembly by pushing it with the seal push tool (P/N 20470413). The

assembly must be pushed out through the actuator port in the top of the valve

body.

9. Discard the stem, brass backup ring, seal assembly and valve seat.

10. Clean and inspect the valve body, being careful not to damage or scratch the bore.

9-26

Figure 9-19: Valve Seal Installation

Section 9

High Pressure Water System

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1 Pneumatic Actuator

2 Seal Push Tool

4 Seal Installation Tool

5 Valve Body

6 Seal Positioning Tool

7 High Pressure Adapter

8 O-Ring

9 Seal

10 Bronze Wedge Ring

11. Place the seal positioning tool into the opposite end of the valve body as shown in

Figure 9-19, Valve Seal Installation. Thread the high pressure adapter into the valve body until light contact is made with the positioning tool. Tighten finger-tight only.

12. Apply Pure Goop anti-seize compound to the threads on the seal installation tool.

Screw the seal installation tool into the threads of the valve body. Tighten finger-

tight only. See Figure 9-19, Valve Seal Installation.

13. Lubricate the new seal and o-ring with FML-2 food grade grease. Insert the seal, oring and bronze wedge ring into the seal installation tool, inserting the o-ring end of the seal first so the tapered end of the seal (wedge ring end) faces the actuator. The tapered end of the seal must face the actuator. See Figure 9-19, Valve Seal Installation.

14. Use the seal push tool to push the seal assembly into the bore of the valve body until the seal makes light contact with the seal positioning tool.

15. Remove the push tool and the installation tool from the valve body.

16. Install the existing SST backup ring and a new brass backup ring on a new stem. The vee groove on the SST backup ring must face toward the brass backup ring. The small

OD of the brass backup ring must face toward the seal assembly. See Figure 9-18,

Dump Valve Components.

17. Apply FML-2 grease to the tip of the stem and insert the stem with the backup rings into the top of the valve body so the stem enters the ID of the seal assembly. Insert

the stem until the chamfer on the stem is seated against the SST backup ring. See

Figure 9-20, Valve Stem Placement.

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Section 9

High Pressure Water System

CAUTION

Do not push the o-ring on the seal assembly past the inlet port on the valve body.

This will damage the seal o-ring.

Figure 9-20: Valve Stem Placement

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1 SST Backup Ring

2 Inlet Port

3 Seal Positioning Tool

4 Seal O-Ring

5 Stem Chamfer

18. Remove the high pressure adapter and the seal positioning tool.

19. Apply Pure Goop anti-seize compound to the threads of the actuator and carefully thread it into the valve body, guiding the stem head into the hole in the actuator. Turn the actuator clockwise until resistance is felt. Reverse the actuator 1/4-turn, and give it a quick spin clockwise to seat it. Hand-tighten only, 5 ft-lbs (7 Nm).

20. Apply Pure Goop anti-seize compound to all surfaces, except the ID, of a new valve seat. Install the seat into the valve body, inserting the small OD first.

21. Apply anti-seize compound to the threads on the high pressure adapter. Install the adapter and torque to 25 ft-lbs (34 Nm).

22. Replace the 1/4-inch drain gland nut and collar and torque to 25 ft-lbs (34 Nm).

23. Apply anti-seize compound to the threads on the 3/8-inch high pressure gland fittings.

Install the collar and the gland fittings and torque to 50 ft-lbs (68 Nm).

24. Install the air supply hose and the electrical connection to the solenoid valve. Turn the air pressure to the actuator on and test the valve for leaks and proper operation.

9-28

Pneumatic Actuator

The following procedure is used to service the pneumatic actuator.

Figure 9-21: Pneumatic Actuator

Section 9

High Pressure Water System

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Normally Open Actuator - Air Pressure to Close

1 Cylinder Head

2 O-Ring

3 O-Ring

4 Piston

5 O-Ring

7 Control Air 1/8 Female NPT

8 Cylinder Head

9 Piston

10 O-Ring

11 O-Ring

6 Pneumatic Cylinder 12 Pneumatic Cylinder

1. Unscrew and remove the cylinder head. Remove the piston from the cylinder.

2. Remove the o-ring on the cylinder head. Apply FML-2 grease to a new o-ring and install.

3. Remove the two o-rings on the piston. Apply FML-2 grease to two new o-rings and install.

4. Install the piston in the pneumatic cylinder. Apply anti-seize compound to the threads on the cylinder head and screw it into the pneumatic cylinder.

9-29

SECTION 10

TROUBLESHOOTING

10.1 Overview

The troubleshooting guide will help identify the probable cause of a system malfunction and assist in providing corrective action. The following symptoms are discussed in this section:

1. High temperature

2. Low level

3. Restricted or no cooling flow

4. Hydraulic pressure but no high pressure water pressure

5. No hydraulic oil pressure

6. Pump shaft will not turn

7. Pump will not start

8. Pump quits running

9. Abnormal fluctuations in high pressure water signal

10. Hot surfaces on the high pressure cylinder components

11. Low cutting water supply pressure

12. Oil pressure is satisfactory, but cutting water flow or pressure is low

13. Hydraulic oil leaking from the weep hole at the intensifier

14. Water leaking from the weep hole at the high pressure plunger seal

15. Water leaking from the weep hole at the high pressure sealing head seal

10.2 Troubleshooting Guide

Listen to the machine and observe it in operation. Learn to recognize the normal sounds and operating conditions of the system. Carefully define the symptom of the problem. Locate the symptom on the troubleshooting guide that most closely corresponds to the problem.

If the symptoms in the guide do not correspond to the malfunction, or if the problem is not resolved by the recommended corrective action, contact the KMT Customer Service

Department for assistance.

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10-1

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Section 10

Troubleshooting

Malfunction

1.

High oil temperature

2.

Low oil level

KMT H2O Jet Troubleshooting Guide

3.

Restricted or no cooling flow

4.

Hydraulic pressure but no high pressure water pressure

5.

No hydraulic oil pressure

6.

Pump shaft will not turn

Indication Comments

Cooling water flow is restricted

Check cooling water source for proper temperature and flow rate.

Water modulating valve is stuck open or closed

Replace the valve.

Scale build up in the heat exchanger has restricted the flow

The heat exchanger will need to be flushed or replaced.

Check the level gauge.

Check for hydraulic leaks.

Check cooling water flow to and from the heat exchanger

Water modulating valve is stuck or out of adjustment

Proximity switch failure

Coil failure on the directional control valve

The high and low limit compensators on the hydraulic pump are blocked with debris

Incorrect motor rotation

Hydraulic pump has seized

Check the level switch.

The water pressure differential across the heat exchanger requires a minimum of 35 psi (2.4 bar) for flow through the exchanger.

Replace the valve.

Adjust the valve.

Jog the intensifier left and right and verify that the red light comes on at both proximity switches.

Check the coils on the directional valve with a volt meter to verify if they are good or bad.

Disassemble the compensators, clean and inspect the components.

Check the motor rotation.

Replace the hydraulic pump.

10-2

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Section 10

Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction

7.

8.

Pump will not start

Pump quits running

9.

Abnormal fluctuations in high pressure water signal

Indication Comments

Emergency stop button is depressed

Check all remote buttons.

E

-

STOP

Main power is disconnected Check the main power and verify that the main power disconnect is on.

Electrical power has been interrupted

Check the power supply circuit for a tripped breaker.

Verify that power is available at the main power source.

Large, worn or damaged orifice

Make sure the orifice does not exceed the capacity of the pump.

Make sure the orifice is in good working condition.

Verify that the jewel is installed in the orifice mount.

Piping leaks

Check valve leakage

Seal leakage

Hydraulic control malfunction

Check system components for leaks, including the dump valve connection.

Inspect the discharge check valves in the sealing heads.

Inspect the inlet check valves in the sealing heads.

Inspect the high pressure seal at the plunger.

Inspect the high pressure seal at the sealing head.

Check the operation of the hydraulic relief valve.

Verify that the directional control valve is shifting properly.

Check the operation of the proximity switches.

10-3

72106161

12-2010/Rev 0

Section 10

Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction

10.

Hot surfaces on the high pressure cylinder components

Indication Comments

Leaking discharge check valve

Inspect the condition of the seat, poppet valve, spring, and guide.

Leaking inlet check valve Inspect the condition of the poppet valve and poppet retainer.

Worn plunger Check the high pressure seal at the plunger and check the plunger for wear. Replace if necessary.

11.

Low cutting water supply pressure

12.

Oil pressure is satisfactory, but cutting water flow or pressure is low

Damaged high pressure cylinder

Restricted water supply

Clogged strainer

Low hydraulic pressure setting

Check the high pressure cylinder for cracks or damage.

Check cutting water supply flow and pressure.

Check the strainer and clean if necessary.

If operating in low pressure, switch to high pressure operation and check the hydraulic pressure setting.

Restricted or no cutting water supply

Check the cutting water supply flow and pressure.

Leak in high pressure water lines

Inspect fittings for leakage and torque to the specified values.

Worn hydraulic piston seals Replace the piston seals.

Replacing all hydraulic oil seals at the same time is recommended.

Excessive demand for high pressure water

Reduce demand to rated output.

Worn check valves

Leaking high pressure seals

Repair the check valves.

Replace the seals.

10-4

72106161

12-2010/Rev 0

Section 10

Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction

13.

Hydraulic oil leaking from the weep hole at the intensifier

Indication Comments

Check the hydraulic cylinder o-ring for leakage.

Check the proximity switch area for oil leakage.

14.

Water leaking from the weep hole at the high pressure plunger seal

Worn high pressure plunger seal

Damaged plunger

Check the hydraulic oil seal and clean or replace as necessary.

Replace the high pressure seal assembly.

15.

Water leaking from the weep hole at the high pressure sealing head seal

Damaged high pressure cylinder

Worn high pressure sealing head seal

Damaged high pressure cylinder

If the leak is greater than 1 drop in 10 strokes, check the plunger.

Check for the scratches, grooves or material buildup on the inside diameter of the high pressure cylinder.

Replace if damage is detected.

Check the seal assembly

Check for the scratches, grooves or material buildup on the inside diameter of the high pressure cylinder.

Replace if damage is detected.

10-5

72106161

12-2010/Rev 0

Figure 10-1: Troubleshooting Guide

1

2

5

17

3

Section 10

Troubleshooting

16

6

7

8

9

4

10

11

15

14

13

12

5. Hydraulic oil

6. Hydraulic oil

7. Cold water

8. Hot water

9. Hydraulic oil

10. Hot water

11. Pulsing warm water

12. Hot water

13. Hot water

14. Cold water

15. Cold water

17. Hot water

Pinched or failed o-ring or incorrectly torque tie rod

Failed oil seal

Failed o-ring on high pressure plunger seal

Failed high pressure plunger seal or high pressure cylinder

Improperly torque, pinched or failed o-ring

Loose discharge gland

Leaking inlet check valve

Leaking discharge check valve

Loose gland nut or failed cone or seat

Failed inlet water o-ring

Failed o-ring on high pressure sealing head seal

Failed high pressure sealing head seal or high pressure cylinder

10-6

SECTION 11

SPECIFICATIONS

11.1 Overview

Comprehensive listings of specifications for the KMT H2O Jet are provided in this section.

Table 11-1

KMT H2O Jet

Model

KMT H2O Jet

Motor Horsepower

Rating

HP Kw

50 37

11.2 Installation Specifications

Environment

Installation location

Air borne dust/contaminants

Ambient temperature

Indoors

Minimal

36

F (2 C)

40

F (5 C)

104

F (40 C)

95% Maximum relative humidity*

(at maximum operating temperature)

*Note: When the relative humidity is above 50%, the oil in the reservoir should be checked frequently for water content.

Sound Level

Sound level with optional side panels 75.0 [dB(A)]

72106161

12-2011/Rev 01

11-1

Equipment Dimensions and Weights

Length Width Height Weight

58.00” (1,473 mm) 47.44” (205 mm) 41.64” (1,058 mm) 2,260 lbs (1,025 kg)

Section 11

Specifications

Service Connections

A Drain

B Cutting Water In

C Cooling Water Out

D Cooling Water In

E Cutting Water Out

F Plant Air In

1/2” BSPT

1/2” BSPT

1/2” BSPT

1/2” BSPT

9/16” HP

1/4” BSPT

10.26” (260 mm)

14.26” (362 mm)

18.26” (464 mm)

22.26” (565 mm)

30.26” (768 mm)

35.39” (899 mm)

Plant Air

The facility compressed air connection should provide clean, dry air regulated to 85 psi (5.9 bar). Air usage is minimal, normally less than 1 scf/m.

The following table provides specifications for each ISO air quality classification. KMT recommends adherence to Quality Class 4.

ISO Quality

Class

1

2

5

6

3

4

Table 11-2

ISO Air Quality Classifications

Maximum

Particle Size

(microns)

0.1

1

5

15

40

--

Maximum Pressure

Dew Point

(water @ 100 psi)

-94° F (-60° C)

-40° F (-40° C)

-4° F (-20° C)

+38° F (+3° C)

+45° F (+7° C)

+50° F (+10° C)

Maximum Oil Content

(Mg/m

3

)

0.01

0.1

1

5

25

--

72106161

12-2011/Rev 01

11-2

11.3 Water Specifications

Cutting Water Supply (Low Pressure Water System)

Maximum consumption

Minimum inlet water pressure

Maximum inlet water pressure

Optimum inlet water temperature

Maximum inlet water temperature

Low inlet water pressure

4.0 gpm (15.1 L/min)

35 psi (2.4 bar) flowing

100 psi (6.9 bar)

65

F (18 C)

85

F (29 C)

30 psi (2 bar)

Section 11

Specifications

Cooling Water Supply (Recirculation System)

Maximum consumption at 75

F (24 C)

Total heat rejection

Reservoir capacity

Low oil level shutdown

Minimum operating oil temperature

Optimum operating oil temperature

Hot oil shutdown (maximum operating oil temperature)

Minimum inlet cooling water pressure

Maximum inlet cooling water pressure

Oil filtration rating (Beta filtration rating)

Fluid cleanliness rating (ISO fluid cleanliness rating))

Nominal recirculation pressure

Recommended oil type

General service

Food service

3.0 gpm (11.4 L/min)

8.6 HP (6.4 kW)

30 gal (114 L)

21 gal (79 L)

60

F (15 C)

115

F (46 C)

144

F (62 C)

35 psi (2.4 bar)

100 psi (6.9 bar)

Β

7

≥1000*

17/14**

30 psi (2 bar)

Mobil DTE 26, Grade 68

Conoco Hydroclear

TM

R&O multi-purpose

Fuchs/Geralyn AW68 Food Grade Oil

* Note: For each particle per milliliter downstream of the filter greater than 7 microns, there are 1000 particles per milliliter larger than 7 microns upstream of the filter.

**Note: Indicates ISO 4406 range numbers for maximum permissible number of particles per milliliter, greater than 5 and 15 microns.

17 <1,300 particles per milliliter, >5 microns

14 <160 particles per milliliter, >15 microns

72106161

12-2011/Rev 01

11-3

Section 11

Specifications

Water Quality Standards

The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance. Water treatment requirements can be determined by a water analysis.

The cutting water supply must meet the following standards. A high concentration of dissolved solids, especially calcium, silica and chlorides will affect high pressure component life.

Constituent

(mg/l)

Table 11-3

Water Quality Standards

Minimum

Requirement Better Best

Calcium

Chloride

Free Chlorine

Magnesium as Mg

Manganese as Mn

Nitrate

Silica

25 5 0.5

100 15 1

1 1 0.05

0.5 0.1 0.1

0.1 0.1 0.1

25 25 10

15 10 1

Total Hardness 25 10 1 pH 6.5-8.5 6.5-8.5

Turbidity (NTU) 5 5 1

* Note: Total dissolved solids

**Note: Do not reduce the TDS beyond this amount or the water will be too aggressive.

72106161

12-2011/Rev 01

11-4

Section 11

Specifications

Constituent

Table 11-4

Water Impurities

Chemical Formula Comments

(HCO

Carbonate (CO

3

)

Hydrate (OH), expressed as CaCO

3

Ca

Acid neutralizing capacity of water. Foaming and carryover of solids, causes embrittlement of steel, can produce CO

2

, a source of corrosion.

Calcium

Chloride Cl

When dissolved makes water hard; contributes to the formation of scale.

Adds to solid content and increases corrosive character of water; in relative percentage presence with oxygen induces stress corrosion cracking.

Free Chlorine

Manganese as Mn

Nitrate

Silica

Sodium

Cl

Iron Fe

Magnesium as Mg

Fe

2

++

+++

Mn

(ferrous)

++

(ferric)

Oxidizing agent; can attack elastomeric seals and damage reverse osmosis (RO) membranes.

Discolors water or precipitation; source of scale and erosion.

When dissolved makes water hard; contributes to the formation of scale.

Discolors water or precipitation; source of scale and erosion.

NO

3

Adds to solid content; effect is not generally significant industrially.

SiO

2 scale

Na Found naturally; introduced to water in the ion exchange water softening process.

Sulfate SO

4

TDS

Total Hardness pH

CaCO

3

Adds to solid content; combines with calcium to form calcium sulfate scale.

Measure of the total amount of dissolved matter in water.

Sum of all hardness constituents in water; typically expressed as their equivalent concentration of calcium carbonate; primarily due to calcium and magnesium in solution, but may include small amounts of metal. Carbonate hardness is usually due to magnesium and calcium bicarbonate; non-carbonate hardness is due to sulfates and chlorides.

Intensity of the acidic or alkaline solids in water; pH scale runs from 0, highly acidic, to 14, highly alkaline; with 7 being neutral.

72106161

12-2011/Rev 01

11-5

11.4 Electrical Specifications

Section 11

Specifications

Electrical System

Motor type TEFC (Totally Enclosed Fan Cooled)

Controls

Voltage

Power supply 5 amps DC

Ampacity and Power Voltage Requirements

Power Voltage

Motor

Horsepower

Full Load

Amps

Circuit Breaker

Amps

380/3/50 50 69 100

11.5 Hydraulic and High Pressure System Specifications

Hydraulic System

Maximum operating pressure

Main system relief valve

2,750 psi (190 bar)

3,408 psi (235 bar)

High Pressure Water System

Maximum flow rate

60,000 psi (4,137 bar)

Plunger diameter

Piston diameter

Intensification ratio

Minimum outlet pressure

Maximum outlet pressure

Pneumatic Control Valve

Maximum water pressure

Regulated air pressure

Maximum flow rate

1.0 gpm (3.8 L/min)

0.875” (22 mm)

4.00” (101.64 mm)

19.9:1

10,000 psi (689 bar)

60,000 psi (4,137 bar)

60,000 psi (4,137 bar)

85 psi (5.9 bar)

1.0 cfm (0.028) m 3 /min

72106161

12-2011/Rev 01

11-6

Section 11

Specifications

Orifice Capacity

The following tables provide horsepower requirements for some of the more popular orifices.

Model

H2O Jet

Table 11-5

Single Orifice Diameter

Motor

Horsepower

Rating

HP Kw

50 37

Maximum

Operating

Pressure

Maximum Single

Orifice Diameter

(at full pressure)

60,000 psi (4,137 bar) 0.014 inch (0.36 mm)

Orifice Size inches (mm)

Table 11-6

Horsepower Requirements

45,000 psi

(3,103 bar)

50,000 psi

(3,447 bar)

55,000 psi

(3,792 bar)

60,000 psi

(4,137 bar)

0.003 (0.076)

0.004 (0.102)

0.005 (0.127)

0.006 (0.152)

0.007 (0.178)

0.008 (0.203)

0.009 (0.229)

0.010 (0.254)

0.011 (0.279)

0.012 (0.305)

0.013 (0.330)

0.014 (0.356)

0.015 (0.381)

0.016 (0.406)

0.017 (0.432)

0.018 (0.457)

22.4

26.6

31.2

36.2

41.6

47.3

53.4

59.9

9.1

11.8

15.0

18.5

1.7

3.0

4.6

6.7

26.2

31.2

36.6

42.4

48.7

55.4

62.6

70.1

10.6

13.9

17.5

21.6

2.0

3.5

5.4

7.8

30.2

36.0

42.2

48.9

56.2

63.9

72.2

80.9

12.2

16.0

20.2

25.0

2.3

4.0

6.2

9.0

The horsepower requirements for operating multiple orifices are determined by adding the requirements in Table 11-6 for each orifice. Examples are shown below.

34.4

41.0

48.1

55.8

64.0

72.8

82.2

92.2

2.6

4.6

7.1

10.2

13.9

18.2

23.0

28.5

72106161

12-2011/Rev 01

11-7

Orifice Size inches (mm)

0.005 (0.127)

0.012 (0.305)

0.009 (0.229)

Number of

Orifices

3

1

1

Operating

Pressure

55,000

Calculation

3 x 6.2

Section 11

Specifications

Total

Horsepower

18.6

Torque Specifications

Measurements are made with lubricated components and a certified calibrated torque wrench.

Inconsistencies in wrench settings, lubrication and technique may not produce a leak free seal.

If leakage occurs, the torque can be increased to seal the components. However, do not

exceed the recommended torque value by more than 15 percent. If leakage persists, there is a component problem.

WARNING

Excessive torque can cause component damage or failure, resulting in potential hazards to equipment and personnel.

Torque Specifications

End Bell Lock Nuts

1st Stage

2nd Stage

3rd Stage

4th Stage

5th Stage

6th Stage

Crossing Pattern

Finger-tight

40 ft-lbs (27 Nm)

Crossing Pattern

60 ft-lbs (43-47 Nm)

Crossing Pattern

80 ft-lbs (43-47 Nm)

Crossing Pattern

100 ft-lbs

Crossing Pattern

120 ft-lbs

Crossing Pattern

72106161

12-2011/Rev 01

11-8

Torque Specifications

Proximity Switch

Torque

Sealing Head

Discharge Gland Nut

Pneumatic Control Valve

3/8-inch HP Gland

1/4-inch Outlet to Drain

Pneumatic Actuator

HP Adapter

High Pressure Fittings

1/4” HP Gland Nut

3/8” HP Gland Nut

9/16” HP Gland Nut

140-160 in-lbs (16-18 Nm)

30-50 ft-lbs (41-67 Nm)

50 ft-lbs (68 Nm)

25 ft-lbs (34 Nm)

5 ft-lbs (7 Nm)

25 ft-lbs (34 Nm)

25 ft-lbs (34 Nm)

50 ft-lbs (68 Nm)

110 ft-lbs (149 Nm)

Section 11

Specifications

72106161

12-2011/Rev 01

11-9

SECTION 12

PARTS LIST

12.1 Overview

This section contains a comprehensive list of all parts for the KMT H2O Jet 50. To facilitate the ordering of replacement parts, item numbers in each table correspond to the identifying numbers in the accompanying figures.

Use the following information to contact the Customer Service Department at KMT Waterjet Systems.

72106161

12-2011/Rev 01

USA Europe

Customer Service Department

KMT Waterjet Systems

PO Box 231

635 West 12th Street

Baxter Springs, KS 66713-0231

USA

Spare Parts Manager

KMT Waterjet Systems GmbH

Wasserstrahl Schneidetechnik

Auf der Laukert 11

D-61231 Bad Nauheim

Germany

Phone

Fax

Email

(800) 826-9274

(620) 856-2242 [email protected] [email protected]

Phone

Fax

Email

+49-6032-997-119

+49-6032-997-271 [email protected]

12-1

12.2 Index

Part lists are arranged in the following sequence.

Table Description

12-1 KMT H2O Jet 50 Intensifier Unit

12-3 Sealing Head Assembly

12-4 High Pressure Piping

12-5 Pneumatic Valve/Actuator Assembly

12-6 Hydraulic Power Package

12-7 Hydraulic Pump Assembly

72106161

12-2011/Rev 01

Parts List Index

Part

Number Page

12-3

20458728 12-5

20458908

20497330

12-7

12-8

20427739 12-10

20497413 12-12

20498668 12-14

Table Description

12-8 Electronic Shift Assembly

12-10 Reservoir Assembly

12-11 Bulkhead Pipe Assembly

12-12 Electrical Assembly

12-13 Electrical Configuration

12-14 Cover Assembly

12-15 LP Water Filter Assembly

Part

Number Page

12-16

20497379 12-18

20498197 12-21

20497372 12-23

72102411 12-26

72102429 12-28

20498048 12-31

72110201 12-33

Section 12

Parts List

12-2

72106161

12-2011/Rev 01

Item

Part

Number

Table 12-1

KMT H2O Jet 50 Intensifier Unit

Description

7 20497413 Hydraulic Power Package

Quantity

1

1

1

1

1

1

1

1

Section 12

Parts List

12-3

72106161

12-2011/Rev 01

Figure 12-1: KMT H2O Jet 50 Intensifier Unit

Section 12

Parts List

12-4

Item

Part

Number Description

2 20457399 High Pressure Cylinder

3 20458299 End Bell, LH

4 20458302 End Bell, RH

9 20458773 Rebuild Kit, High Pressure Seal Assembly

10 20458797 Rebuild Kit, Hydraulic Seal Assembly

11 20457912 Plunger

20458113 High Pressure Seal

20457393 Seal Hoop

Table 12-2

Intensifier Assembly

20458728

Quantity

1

2

1

1

2

2

2

1

1

4

8

Item

Part

Number Description

13 20458869 Hydraulic Piston Assembly

20457966

20458821

Hydraulic Piston

Rebuild Kit, Piston Rings

20460216 Seal

17 05202930 Snap Ring

20457159 Adapter, Quick Disconnect

20459025 O-Ring, Quick Disconnect

72106161

12-2011/Rev 01

Section 12

Parts List

Quantity

2

2

2

2

2

1

2

12-5

72106161

12-2011/Rev 01

Figure 12-2: Intensifier Assembly

Section 12

Parts List

12-6

Item

Part

Number Description

2 20457381 Gland

3 20458140 Seat

4 20458089 Poppet Retainer Screw

5 20457948 Inlet

6 20460048 Discharge

7 05116751 Poppet

8 20458896 Poppet

9 80077241 O-Ring

10 20460033 Compression

20458830 Repair Kit

Includes items 3, 4, 5, 6, 8, 9 and 10

72106161

12-2011/Rev 01

Table 12-3

Sealing Head Assembly

20458908

Quantity

1

1

2

1

1

1

1

1

1

1

Figure 12-3: Sealing Head Assembly

Section 12

Parts List

12-7

Item

Part

Number Description

2 20498314 Attenuator Assembly, .96L

3 49830581 Coupling, HP Bulkhead, .56 x .38

4 10094704 HP Tube, .38 x 3.0

5 10078715 HP Collar .38

6 10078129 HP Gland, .38

7 20427739 Pneumatic Valve/Actuator Assembly

8 20498577 HP Tube, Bent, .38

9 10078426 HP Collar, .25

11 20498652 HP Tube, Bent, .25

12 10079531 Coupling, HP/HP, .56 x .38

Section 12

Parts List

Quantity

1

1

1

1

2

4

1

1

4

1

1

Table 12-4

High Pressure Piping

20497330

Item

Part

Number Description

13 20498280 U-Bolt, 3.50

14 49883499 Lock Washer, M12

15 49898729 Flat Washer, M12

16 10078780 Elbow, HP, .38 x .38

17 20498585 HP Tube, Bent, .38

18 20499594 Socket Head Screw, M14 x 2 x 20MM

19 20499610 Lock Washer, M14

20 05045497 Pressure Gauge, 0-5000 psi

22 20498618 HP Tube, Bent, .38

23 10078590 Tee, HP, .38

Quantity

3

1

1

1

1

2

3

4

1

2

4

72106161

12-2011/Rev 01

12-8

72106161

12-2011/Rev 01

Figure 12-4: High Pressure Piping

Section 12

Parts List

12-9

Item

Part

Number Description

1 20427648 Valve Body

3 49830904 Adapter, HP Water Valve

5 10188233 Backup Ring, Brass

6 20428052 Seal Assembly

Table 12-5

Pneumatic Valve/Actuator Assembly, Normally Open

20427739

Quantity

1

1

1

1

1

Item

Part

Number Description

10189553 Actuator Assembly, Normally Open

7 BV401184 Pneumatic

8 BV601184 Cylinder Head

9 BV501184 Piston

10 10187250 Backup Ring, SST

11 10074714 O-Ring, 2.44 x 2.63 x .09

12 10074565 O-Ring, 2.25 x 2.38 x .06

Section 12

Parts List

Quantity

2

1

1

1

1

1

72106161

12-2011/Rev 01

12-10

72106161

12-2011/Rev 01

Figure 12-5: Pneumatic Valve/Actuator Assembly, Normally Open

Section 12

Parts List

12-11

72106161

12-2011/Rev 01

Item

1

Part

Number

20498147

Table 12-6

Hydraulic Power Package

20497413

Description

Electric Motor, 50HP

9

10

11

12

13

Ref 1

4

5

6

7

20477284

49892375

49892359

49892342

20498660

20477807

20477803

20477800

20477758

10091510

Vibration Isolation Mount

Hex Head Screw, M16 x 2 x 60MM

Lock Washer, M16

Flat Washer, M16

Socket Head Screw, M16 x 2 x 25MM

Hex Nut, M18

Lock Washer, M18

Flat Washer, M18

Hex Head Screw, M18

Arrow Decal

Quantity

1

1

6

6

1

2

8

8

--

4

8

6

4

8

Section 12

Parts List

12-12

72106161

12-2011/Rev 01

Figure 12-6: Hydraulic Power Package

Section 12

Parts List

12-13

Item

Part

Number

Table 12-7

Hydraulic Pump Assembly

20498668

Description

5

6

3

4

7

8

05139720

49883580

10064715

05037593

05048780

05048806

O-Ring, 85MM x 3MM

Flat Washer, M10

Lock Washer, M10

Socket Head Screw, M10 x 1.50 x 25MM

Split Flange Kit, 2.0

Adapter, Flange/Hose, 2.0 x 2.0

Quantity

2

2

1

2

1

1

1

1

Section 12

Parts List

72106161

12-2011/Rev 01

12-14

72106161

12-2011/Rev 01

Figure 12-7: Hydraulic Pump Assembly

Section 12

Parts List

12-15

Item

Part

Number Description

1 20457897 Firing Pin

2 72106179 Hydraulic Manifold Assembly

2.1 20499180 Manifold

2.3 10187060 LP Relief Valve

2.4 10185585 Solenoid Valve

2.5 05122650 Plug, ORB, #8

2.6 05104559 Plug, ORB, #4

2.7 80085756 Check Valve

2.9 72104336 Ring Spacer

3 20457264 Actuator Assembly, Shift Sensor

20458050

20457372

20457501

Magnet Retainer

Plunger, Spring Guide

Nut, Spring Guide

72106161

12-2011/Rev 01

Section 12

Parts List

Quantity

1

2

3

1

1

1

2

1

1

1

1

Table 12-8

Electronic Shift Assembly

Item

Part

Number Description

4 20458290 Shift Sensor Housing and Cable Assembly

20457402 Housing

05202782 O-Ring

05202873 O-Ring

20459037

20493669

Socket Head Screw, 10-24 x 1

Cable, Electronic Sensor

20493677 Cord Connector

5 20458941 Pilot Shift and Main Valve Assembly

20458173 Hydraulic Spool

6 20493396 Adapter, JIC/SAE, 1.0 x 1.0

7 95159513 Socket Head Screw, 1/4-20 x 2

8 95119038 Socket Head Screw, 3/8-16 x 2-1/4

9 95308508 Hex Head Screw, 3/8-16 x 2-1/4

10 95277109 Flat Washer, .38

Quantity

4

4

2

2

4

1

2

12-16

72106161

12-2011/Rev 01

Figure 12-8: Electronic Shift Assembly

Section 12

Parts List

12-17

Item

Part

Number Description

1 10142644 Adapter, JIC/ORB, .25 x .25

2 20497437 Hydraulic Hose Assembly, .75 x 20.50

3 10083517 Hose Clamp

4 10179018 Radiator Hose, 2.0

5 20499618 Hydraulic Hose Assembly, 1.0 x 16.50

6 80086192 Adapter, JIC/ORB, 1.0 x 1.0

7 05052493 Adapter, JIC/ORB, .75 x .63

8 20499652 Hydraulic Hose Assembly, .75 x 14.0

9 05073168 Adapter, JIC/ORB, .75 x .75

10 20497421 Hose, 1.0 x 1.0 x 33.0,FLANG/JIC,90D

Table 12-9

Hydraulic Hose Connections

20497379

Quantity

3

1

2

8.0"

1

1

1

1

1

1

Item

Part

Number Description

11 20499576 Hydraulic Hose Assembly, .25 x 27.0

12 20499644 Hydraulic Hose Assembly, .25 x 15.50

13 20497429 Hydraulic Hose Assembly, .75 x 28.50

14 20426972 Adapter, ORB/JIC, 1.0 x .75

15 05122650 Plug, ORB, .63

16 05104559 Plug, ORB, .38

17 05045497 Pressure Gauge, 0-5000 psi

18 20499626 Hydraulic Hose Assembly, .75 x 10.0

19 86300018 Split Flange Kit, 1.0

20 10142594 Adapter, ORB/JIC, 1.0 x .75

Section 12

Parts List

Quantity

3

1

1

1

1

1

1

1

1

1

72106161

12-2011/Rev 01

12-18

72106161

12-2011/Rev 01

Figure 12-9A: Hydraulic Hose Connections

Section 12

Parts List

12-19

72106161

12-2011/Rev 01

Figure 12-9B: Hydraulic Hose Connections

Section 12

Parts List

12-20

Item

Part

Number Description

1 20498181 Reservoir Weldment

2 20498272 Gasket, Reservoir

3 20498189 Lid, Reservoir

4 61149739 Pipe Plug, 2.0

5 20468736 Air Breather

6 10191484 Pan Head Screw, M5 x 10MM

7 72118248 Temperature/Level Switch

8 49892466 Flat Washer, M10

9 49891948 Lock Washer, 10MM

10 80089410 Hex Head Screw, M10 x 1.50 x 30MM

11 20468655 Temperature/Level Gauge

12 20468728 Adapter, BSPT/JIC, .75 x .75

13 20468740 Bushing, BSPT, 1.25 x .75

Quantity

1

9

10

10

1

2

2

1

1

1

1

3

1

1

1

1

Table 12-10

Reservoir Assembly

20498197

Item

Part

Number Description

17 20470406 Hose Barb, .50 x .50

18 10070191 Hex Nut, M8

19 10069672 Lock Washer, M8

20 20477570 Adapter, JIC/BSPT, .75 x .50

21 20499717 Adapter, JIC/BSPT, .75 x .50

22 20499743 Plug, BSPT, .75

23 20468704 Adapter, BSPT/JIC, 1.0 x 1.0

24 20498264 Hex Head Screw, M12 x 1.75 x 20MM

25 49883499 Lock Washer, M12

26 49898729 Flat Washer, M12

27 20479720 Adapter, BSPT/JIC, .25 x .25

28 20468695 Plug, BSPT, .50

29 20499725 Adapter, BSPT/JIC, .75 x .75

31 20499750 Magnet

32 20468732 Heat Exchanger 16 20476941 Adapter, BSPT/ORB, .75 x .75

72106161

12-2011/Rev 01

Section 12

Parts List

Quantity

1

1

2

1

2

4

4

4

1

4

1

1

1

1

2

1

1

12-21

72106161

12-2011/Rev 01

Figure 12-10: Reservoir Assembly

Section 12

Parts List

12-22

Item

Part

Number Description

1 20469497 Coupling, Bulkhead, BSPT, .94 x .25

2 20469488 Coupling, Bulkhead, BSPT, 1.50 x .50

3 20469985 Jam Nut, 3/4-16

4 10070092 Jam Nut, 1-14

5 20468995 Elbow, BSPT, .12 x .25

6 20469007 Check Valve

7 20469989 Nipple, BSPT, .12 x .12

8 20469016 Solenoid Valve

9 20469020 Coupling, Tube, 6MM x .12

10 20469023 Poly Tube, 6MM

11 20469027 Adapter, Tube/Pipe, 6MM x .13

12 20469031 Tee, BSPT,.50

13 86200011 Pressure Switch, 30 psi

72106161

12-2011/Rev 01

Table 12-11

Bulkhead Pipe Assembly

20497372

Quantity

1

1

1

12.0"

1

1

1

1

1

1

4

1

4

Item

Part

Number Description

14 20469066 Adapter, BSPT/JIC, .50 x .50

15 20468724 Hose Barb, .50 x .50

16 20470406 Hose Barb, .50 x .50

17 20469070 Nipple, BSPT, .50 x 3.0

18 20469074 Solenoid Valve

19 20469031 Tee, BSPT, .50 x .50

20 20498644 Adapter, BSPT/Pipe, .50 x .50

21 49834328 Adapter, Pipe/Tube, .50 x .25

22 20498569 Adapter, ORB/ipe, .50 x .38

23 10079036 Hose Barb, .50 x .38

24 20498603 Adapter, ORB/Pipe, .50 x .38

25 20498676 Adapter, Hose/Pipe, .50 x .38

26 20421272 Hose, Push-on, .50

86200015 Assembly

28 10078152 Bushing Pipe, .75 x .50

29 72110201 LP Water Filter Subassembly

30 05013313 Hex Head Screw, M6 x 1 x 20MM

Section 12

Parts List

Quantity

1

1

4

1

1

1

1

200.0"

1

2

1

2

1

1

1

1

1

12-23

72106161

12-2011/Rev 01

Figure 12-11A: Bulkhead Pipe Assembly

Section 12

Parts List

12-24

72106161

12-2011/Rev 01

Figure 12-11B: Bulkhead Pipe Assembly

Section 12

Parts List

12-25

Item

Part

Number Description

1 20498230 Enclosure

2 72102429 Electrical Configuration

3 49898729 Flat Washer, M12

4 49891922 Lock Washer, M12

5 20499784 Hex Nut, M12

7 10125912 Cable Tie, .87

8 10115830 Connector, Flexible Conduit, 1.50

9 05141700 Ring Terminal, #8

10 20469132 Flexible Conduit, 1.50

11 20468875 Wire, 10MM, Black

12 20477288 Cable, 9MM, Green/Yellow

13 20468427 Connector, Crimp Ferrule, #8

Quantity

10

1

2

30.0"

300.0"

100.0"

18

1

1

4

4

4

1

Table 12-12

Electrical Assembly

72102411

Item

Part

Number Description

14 10085520 Connector, Flexible Conduit, 1.50

15 20470325 Terminal Lug, #14-2/0

16 72109623 Pushbutton Switch, Red

17 72109615 Pushbutton Switch, Green

18 20468378 Legend Plate, Yellow

20 10124279 Connector, Cable, .50

21 80079775 Cable, #18

22 10122646 Connector, Cable, .50

23 10082857 Gasket Assembly

24 10083012 Lock Nut, .50

25 49874191 Hole Seal, .50

26 72109649 Contact Block

Section 12

Parts List

Quantity

1

6

1

1

1

1

1

50.0"

1

2

2

4

1

1

72106161

12-2011/Rev 01

12-26

72106161

12-2011/Rev 01

Figure 12-12: Electrical Assembly

Section 12

Parts List

12-27

Item

Part

Number Description

1 20477059 Circuit Breaker

2 05081955 Socket Head Screw, 8-32 x 2

3 20468452 Rotary Drive, Circuit Breaker

4 20468448 Breaker, Terminal Cover

6 20468420 Ground Lug

7 10167070 Pan Head Screw, 8-32 x 1

8 10069607 Lock Washer, #8

9 95146429 Hex Nut, #8-32

10 20477288 Cable, 9MM, Green/Yellow

11 05141700 Ring Terminal, #8

12 20468313 Terminal Block

13 20468440 DIN Rail

14 10073492 Pan Head Screw, 8-32 x 1/2

15 10114627 Flat Washer, #8

17 20468892 Wire, 2.5MM, Black

72106161

12-2011/Rev 01

Table 12-13

Electrical Configuration

72102429

Quantity Item

Part

Number Description

1

4

1

2

4

2

18

19

20

21

20468416

20468235

20468875

20468427

Connector, Crimp Ferrule, #14

Circuit Breaker

Wire, 10MM, Black

Connector, Crimp Ferrule, #8

8

8

4

110.0"

4

1

60.0"

33

33

23 72102288 Overload Relay

24

25

26

27

28

80078223

20468239

20468900

20468424

20469108

End Block

Transformer

Wire, 1.5MM, Red

Connector, Crimp Ferrule, #16

Circuit Breaker

29 20468403 Power Supply

30 20468896 Wire, 1.5MM, Blue

31 20468904 Wire, 1.5MM, Blue/White

32 20468883 Wire, 1MM, Green/Yellow

150.0" 33 80078207 Terminal

60.0" 34 20468395 Circuit Breaker

Section 12

Parts List

Quantity

8

1

72.0"

6

1

1

11

1

160.0"

250

1

1

1,040.0"

240.0"

80.0"

5

1

12-28

Item

Part

Number Description

35 20468375 Terminal Block

37 20468367 Jumper, Terminal Block

38 20468358 Marker, Terminal Block

Table 12-13

Electrical Configuration

72102429

Quantity

32

2

2

16

Item

Part

Number Description

39 20468305 Terminal Block

40 20498694 Subplate

41 20468288 PLC, S7200

42 20468342 Battery, PLC

20468248 Base

44 20468256 Tube Base Relay

Section 12

Parts List

Quantity

7

1

1

1

3

3

72106161

12-2011/Rev 01

12-29

72106161

12-2011/Rev 01

Figure 12-13: Electrical Configuration

Section 12

Parts List

12-30

Item

Part

Number Description

Table 12-14

Cover Assembly

20498048

7

8

9

10

4

5

6

12

10122067 Flat Washer, M8

10069672 Lock Washer, M8

10070191 Hex Nut, M8

05080841 Button Head Screw, M6 x 1 x 22MM

10107118 Flat Washer, M6

49892011 Lock Washer, M6

10070183 Hex Nut, M6

05014584 Hex Head Screw, M8 x 1.25 x 16MM

72106161

12-2011/Rev 01

Quantity

1

1

5

2

2

5

8

8

8

8

2

3

Section 12

Parts List

12-31

72106161

12-2011/Rev 01

Figure 12-14: Cover Assembly

Section 12

Parts List

12-32

72106161

12-2011/Rev 01

Table 12-15

LP Water Filter Assembly

72110201

Item

Part

Number Description

2

5

6

3

4

8

9

86800001 Filter Element, 10 Micron

72110219 Bushing, BSPT, .75 x .50

20470406 Hose Barb, .50 x .50

20469031 Tee, BSPT, .50 x .50

72110226 Bushing, BSPT, .50 x .25

20469066 Adpater, BSPT/JIC, .50 x .50

20468724 Hose Barb, .50 x .50

Quantity

2

1

2

2

1

1

1

1

Section 12

Parts List

12-33

72106161

12-2011/Rev 01

Figure 12-15: LP Water Filter Assembly

Section 12

Parts List

12-34

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