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Equipment and Service Manual Questionnaire 

 

20425553 
5-2005/Rev 0 

2 

 

 

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Summary of Contents for STREAMLINE S30

Page 1: ...MANUAL 20425545 R01 STREAMLINE S30 WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL ...

Page 2: ...s 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 200...

Page 3: ...ical Treatment 1 7 1 5 Worldwide Product Support 1 7 1 6 Spare Parts 1 8 1 7 Manual Organization 1 8 1 8 Equipment and Service Manual Questionnaire 1 8 2 Installation 2 1 2 1 Overview 2 1 2 2 Installation Summary 2 1 2 3 Site Requirements 2 2 Transporting 2 3 2 4 Power Requirements 2 3 2 5 Service Connections 2 4 Cooling Water 2 5 Cutting Water 2 6 Optional Drain 2 6 Optional Plant Air 2 6 2 6 Flo...

Page 4: ...cedures 4 3 Filter Assembly Maintenance 4 3 Booster Pump Adjustment 4 4 5 Recirculation System 5 1 5 1 Overview 5 1 5 2 Operation 5 1 5 3 Service and Maintenance Procedures 5 2 Hydraulic Oil Maintenance 5 2 Oil Filter Maintenance 5 5 Operating Temperature Adjustment 5 6 6 Hydraulic System 6 1 6 1 Overview 6 1 6 2 Operation 6 1 6 3 Service and Maintenance Procedures 6 4 Hydraulic Operating Pressure...

Page 5: ...ge Check Valve 8 17 Low Pressure Inlet Check Valve 8 18 Sealing Head Maintenance 8 19 8 10 High Pressure Seal Assembly 8 20 8 11 Hydraulic Cartridge Seal and Plunger Removal 8 22 Plunger Maintenance 8 24 Plunger Installation 8 25 Hydraulic Cartridge Seal 8 25 8 12 Hydraulic Piston 8 27 Hydraulic Piston Removal 8 27 Bearing Rings and Seal Assembly 8 29 Plunger Button Sockets Seals and Retainer Pins...

Page 6: ...ions 10 6 Electrical System 10 6 Ampacity and Power Voltage Requirements 10 6 10 5 Hydraulic and High Pressure System Specifications 10 6 Hydraulic System 10 6 High Pressure Water System 10 7 Orifice Capacity 10 7 Torque Specifications 10 8 11 Parts List 11 1 11 1 Overview 11 1 11 2 Part Nomenclature 11 2 11 3 Index 11 3 APPENDIX Exhibit Electrical Schematics Material Safety Data Sheets ...

Page 7: ...single or redundant intensifier The redundant unit allows operation to continue if a problem is detected on the active intensifier Operation can be switched to the secondary intensifier until the next convenient shutdown when service can be performed on the primary intensifier 1 2 Performance Features and Options The S30 is designed with the same convenience and ease of access for maintenance and ...

Page 8: ...blocks inside the optional junction box Proportional pressure control provides remote control of hydraulic operating pressure 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 8 Equipment specifications are provided in Section 10 Specif...

Page 9: ...water Major system components include the electric motor hydraulic pump and the 4 way directional control valve mounted on the hydraulic manifold 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 velo...

Page 10: ...rocedure 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 chemica...

Page 11: ...able 1 2 Warning Label Precautions 1 P N 05114962 The electric motor and optional junction box can present an electrical shock hazard Always disconnect and lockout the main power before performing any type of maintenance 2 P N 05114970 The surface of high pressure water and hydraulic components becomes hot during normal operation Failed or failing components can become extremely hot during operati...

Page 12: ...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 Warnings emphasize operating or service procedures or conditions that can result in serious personal injury or de...

Page 13: ...t 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 Techni...

Page 14: ...ments Precautions associated with high pressure cutting equipment are also reviewed Sections 4 through 8 are specific to each individual system Each section contains a detailed description of the principles of operation and the function of each system Routine maintenance procedures associated with the system are also detailed Section 9 Troubleshooting is a comprehensive guide containing the inform...

Page 15: ... Is the unit easy to operate Yes No Comments 3 Performance Does the unit perform smoothly and meet your expectations Yes No Does the unit run quietly Yes No Comments 4 Did the installation and startup go smoothly Yes No Comments 5 What features do you consider the most significant Quiet operation Appearance Performance Operation Repair Maintenance Other 6 What areas could be improved Appearance Pe...

Page 16: ...illustrations suitable for the material being presented Yes No Comments 9 Text Does the information adequately explain how to operate and service the equipment Yes No Comments Are there paragraphs or procedures you feel need clarification Please identify them by page number and add your comments Yes No Comments Is there anything you would add or delete to make the manual more useful Yes No Comment...

Page 17: ... power drops with fused disconnects or circuit breakers and properly sized starting components 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 ...

Page 18: ...f 95 percent Refer to Table 2 1 Equipment Dimensions and Weight 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 Total Length Base Length Width Height Weight 53 50 1 359 mm 44 00 1 117 mm 32 39 823 mm 37 00 940 mm 1 750 lbs ...

Page 19: ...n the bottom of the machine The pockets are positioned in relationship to the center of gravity to balance the weight on the forklift Figure 2 2 Fork Pockets 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 S...

Page 20: ...in line for cooling water and a high pressure discharge line A drain line for wastewater is required for units equipped with an optional dump valve or booster pump The optional dump valve also requires an air supply line All piping must comply with local regional and national codes With the exception of the wastewater drain line manual shutoff valves should be installed for all connections To faci...

Page 21: ...mp or dump valve Supplied with optional dump valve 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 an...

Page 22: ...times If the facility water pressure is below or can fall below 60 psi 4 bar a water pressure booster pump is required NOTE If the machine is equipped with the optional booster pump and water filter the inlet water must be maintained at a minimum pressure of 35 psi 2 4 bar at all times Optional Drain Cutting water released through the optional safety dump valve or the relief valve on the booster p...

Page 23: ... FT 1 2 ID 3 4 ID 1 ID 1 1 4 ID 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 vibr...

Page 24: ... Tools Power Tools 1 4 Coning Tool 05108832 05109897 3 8 Coning Tool 05108857 05109889 9 16 Coning Tool 05108840 05109871 1 4 Threading Tool 05108865 05122742 3 8 Threading Tool 05108873 05120258 9 16 Threading Tool 05108881 05122759 1 4 Tube Vise 05108782 3 8 Tube Vise 05108790 9 16 Tube Vise 05108774 ...

Page 25: ...he required cone and thread dimensions illustrated in Figure 2 6 Figure 2 5 Tube Length Table 2 5 Engagement Allowance EA 1 4 Tubing 0 49 12 4 mm 3 8 Tubing 0 68 17 3 mm 9 16 Tubing 0 86 21 8 mm Figure 2 6 Cone and Thread Dimensions Table 2 6 Cone and Thread Dimensions Tube OD Tube ID D Maximum L Maximum Thread UNF LH 1 4 6 35 mm 0 083 2 11 mm 0 125 3 2 mm 0 562 14 3 mm 1 4 28 3 8 9 52 mm 0 125 3 ...

Page 26: ...e 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 ...

Page 27: ... 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 7 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...

Page 28: ...edium weight cutting oil with high sulfur content is recommended 4 Continue threading until the proper thread length is reached see Table 2 6 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 ...

Page 29: ...ing 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...

Page 30: ...ts and guides must be provided End connections will not support the tubing load alone Table 2 8 Torque Specifications High Pressure Connections 1 4 Tubing 25 ft lb 34 Nm 3 8 Tubing 50 ft lb 68 Nm 9 16 Tubing 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 t...

Page 31: ... the high pressure plumbing has been installed to the cutting area the machine is ready to be commissioned If normal operating pressure will not exceed 50 000 psi 3 447 bar the alternate inlet poppet valve must be installed before proceeding Follow the procedure Low Pressure Inlet Check Valve Section 8 High Pressure Water System Refer to Table 11 4 Section 11 Parts List The following procedure is ...

Page 32: ...rect 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 can be reversed at the electric motor or at the main power disconnect Do not allow the motor to run backward Incorrect motor rotation will result in damage to the hydraulic pump 8 Remove the cutting orifice and op...

Page 33: ...e 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 or from the controller if equipped with proportional pressure 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...

Page 34: ... 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 o...

Page 35: ...ce 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 comp...

Page 36: ...uipment 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...

Page 37: ... and allows water to flow through the valve and then to the sealing head check valves on each end of the intensifier Inlet cutting water pressure should be a minimum of 60 psi 4 bar flowing 4 4 Optional System Components An optional low pressure water filter removes debris from the inlet cutting water to prevent contaminates from damaging the check valves and seals in the intensifier The optional ...

Page 38: ...ll continue to be released through the drain Discharge pressure is displayed on the pressure gauge mounted on the outlet manifold The gauge should read approximately 120 psi 8 bar while the machine is idling When it strokes the pressure drop should be no greater than 30 psi 2 bar The water pressure range should remain between 90 120 psi 6 8 bar during operation NOTE While the intensifier assembly ...

Page 39: ...booster pump and low pressure water filter the filter element and booster pump will require routine servicing and maintenance NOTE Refer to Section 11 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 observin...

Page 40: ...ng water supply on 2 Start the machine and observe the discharge pressure from the booster pump 3 Remove the acorn nut on the side of the pump to access the adjustment screw It is normal for water to leak out when the acorn nut is removed 4 Use a flat screwdriver and turn the adjustment screw clockwise to increase the discharge pressure or counter clockwise to decrease the pressure Adjust the pres...

Page 41: ...e recirculation pump heat exchanger oil filter assembly and the hydraulic oil reservoir 5 2 Operation Cooling water is introduced through the 1 2 inch NPT connection on the bulkhead of the machine where the water modulating valve regulates the cooling flow to the heat exchanger The valve is factory set but may require adjustment to maintain the operating oil temperature at 115 F 46 C Oil temperatu...

Page 42: ...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 5 3 Service and Maintenance Procedures To en...

Page 43: ...the air breather The oil will not be filtered and will not conform to the cleanliness requirements of the system Figure 5 2 Hydraulic Oil Reservoir Single Intensifier Figure 5 3 Hydraulic Oil Reservoir Redundant Intensifier 1 Turn the machine off and observe the appropriate Lockout Tagout procedures ...

Page 44: ...et hose from the drain valve 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 5 Remove the cap from the fill port on the oil filter 6 Connect the discharge hose from the oil transfer pump to the fill port and pump the fresh oil into...

Page 45: ...k 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 ...

Page 46: ...ghten Do not over tighten 4 Start the machine and check for leaks Operating Temperature Adjustment The cooling water flow to the heat exchanger is regulated by the water modulating valve a manually adjusted thermostatic control valve The valve is factory set to maintain the operating oil temperature at 115 F 46 C In most cases adjustment will be required at commissioning and with seasonal changes ...

Page 47: ...e to compress the spring slowing water flow and increasing temperature Or turn clockwise to reduce spring tension increasing water flow and decreasing the temperature 3 Monitor the sight gauge on the side of the reservoir until the adjusted temperature can be determined It will take some time for the temperature in the oil reservoir to change 4 Repeat steps 2 and 3 if necessary ...

Page 48: ...e The system relief valve monitors hydraulic oil pressure and provides system protection by limiting excess pressure 6 2 Operation The electric motor drives three pumps mounted in tandem the main hydraulic pump the recirculation pump and the optional booster pump The motor drives the variable displacement pressure compensated hydraulic pump by means of a flexible coupling Hydraulic fluid from the ...

Page 49: ...Section 6 Hydraulic System 20425603 5 2005 Rev 0 6 2 Figure 6 1 Hydraulic System Components Single Intensifier Figure 6 2 Hydraulic System Components Redundant Intensifier ...

Page 50: ...rolled 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 manifold displays hydraulic pressure to the intensifier When the intensifier shifts it is normal for the pressure to quickly fall and then rise...

Page 51: ...c 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 6 1 If the machine is equipped with proportional pressure control high pressure adjustments are made from the controller The following procedure is used for low pressure a...

Page 52: ...ntrol valve by turning counter clockwise 3 Turn the knob on the control valve clockwise to increase operating pressure or 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 increas...

Page 53: ...is mounted on the hydraulic pump and must be removed to replace the flexible coupling as described in the following procedure 1 Turn the machine off and observe the appropriate Lockout Tagout procedures 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 h...

Page 54: ...old and remove the manifold and o ring from the hydraulic pump 4 Remove all electrical leads to the motor 5 Remove the bolts attaching the motor vibration mounts to the frame base plate 6 Remove the motor and pump assembly from the frame NOTE If the unit is equipped with an optional booster pump disconnect the water lines and remove the booster pump with the motor and pump assembly 7 Remove the bo...

Page 55: ...e motor shaft aligning the splines Push the flexible coupling on as far as it will go The internal band keeps the coupling centered between the motor and pump shafts 13 Move the motor and pump assembly together to engage the flexible coupling with the coupling half on the pump shaft You may need to turn the motor shaft to align the splines with the pump shaft When the motor and pump are rejoined t...

Page 56: ...e removed and replaced at the fill port on the filter head 1 Remove the cap from the fill port on the oil filter 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 2 Connect the discharge hose from an oil transfer pump to the fill port and pump the fres...

Page 57: ...ensators regulate the flow of hydraulic fluid to the system The compensators can become blocked with debris resulting in loss of pump control Figure 6 7 Hydraulic Compensator Components 1 Turn the machine off and observe the appropriate Lockout Tagout procedures Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing mainten...

Page 58: ...prings spring cup and spool 8 Clean the housing and all components with clean fluid and carefully dry with air 9 Check and clean the small internal passages in the spools 10 Check and clean the orifices in both spools 11 Assemble in the reverse order ensuring that the screw slot on the orifice is aligned with the long axis of the body When the compensators are removed the machine loses adjustment ...

Page 59: ...oller 17 Turn the adjusting screw on the high limit compensator clockwise until the hydraulic reference gauge reads 2 600 psi 179 bar 18 Select low pressure operating mode and turn the adjusting screw on the low limit compensator clockwise until the reference gauge reads 290 psi 20 bar Lock the adjustment screw in place 19 Select high pressure operating mode and turn the knob on the high pressure ...

Page 60: ...cribed in the following procedures Hydraulic Pump Replacement 1 Turn the machine off and observe the appropriate Lockout Tagout procedures 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 Drain the hydraulic re...

Page 61: ...onnect the water lines and remove the adapter and the booster pump with the recirculation pump 5 Remove the bolts that attach the hydraulic pump to the electric motor 6 Support the pump and slide it away from the motor disengaging the flexible coupling 7 Inspect the flexible coupling for damage If the flexible coupling is damaged it must be replaced 8 Inspect the metal splines on the motor couplin...

Page 62: ...ting face to the outer face of the coupling teeth dimension B in Figure 6 9 Set the position of the pump coupling half using the formula B A 0 313 12 Tighten the pinch bolt and torque to 36 ft lbs 49 Nm 13 Position the hydraulic pump on the motor ensuring the coupling teeth mesh into the flexible coupling Force should not be required 14 Verify that the mating surfaces of the motor and pump meet wi...

Page 63: ...ment procedure 19 Start the motor and apply full high pressure water pressure Inspect for hydraulic leaks and note any unusual sounds from the motor or pump assembly Electric Motor Replacement 1 Complete Steps 1 7 in the previous procedure 2 Remove all electrical leads from the motor 3 Remove the bolts attaching the vibration isolation mounts to the frame base plate and remove the old motor from t...

Page 64: ...e motor and pump meet without resistance from the coupling 9 Replace the pump mounting bolts and torque to 55 ft lbs 75 Nm 10 Position the motor and pump in the frame aligning the vibration isolation mounts with the mounting holes in the frame base plate Attach the vibration isolation mounts to the frame base plate 11 Reconnect the electrical leads 12 Complete steps 16 18 in the previous procedure...

Page 65: ...ndividual cables in the wiring harness are connected to terminals blocks inside the optional junction box Proportional pressure control allows the operator to select or vary the high pressure hydraulic operating pressure from the controller 7 3 Sensors and Solenoids Sensors monitor operating conditions and electronically operated solenoids provide basic intensifier shift control The cables connect...

Page 66: ...Section 7 Electrical System 20425610 5 2005 Rev 0 7 2 Figure 7 1 Sensors and Solenoids ...

Page 67: ...ndently Hydraulic Manifold 3 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 As pow...

Page 68: ...he metallic surface of the piston When the switch is activated it sends a signal to the controller to change the flow of the directional control valve and reverse direction High Pressure Safety Dump Valve 6 When control power is removed the optional safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines The high pressure dump valve assembly includes a no...

Page 69: ...nal Pressure Control 8 When the unit is equipped with optional proportional pressure control an electronically controlled hydraulic cartridge valve mounted on the hydraulic manifold allows the operator to select or vary the high pressure hydraulic operating pressure from the controller Figure 7 2 Electrical Harness ...

Page 70: ...nge state indicating they are not sensing the piston or if an LED flashes continuously Figure 7 3 Proximity Switch 1 Turn the machine off and observe the appropriate Lockout Tagout procedures 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 blocke...

Page 71: ...d the switch Ensure the o ring is correctly oriented 5 Apply JL M grease to the threads on the screws and tighten to 140 160 in lbs 16 18 Nm Ensure that the proximity switch is properly installed and secured prior to starting the machine Failure to tighten the two hold down screws will result in the spray of hydraulic oil ...

Page 72: ...ponents The optional high pressure dump valve instantly releases high pressure from the system and is available at the time of purchase or as upgrade kit for existing equipment 8 3 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 swi...

Page 73: ...ads 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 8 2 High Pressure Water System ...

Page 74: ...he drain Redundant Models On redundant models the cutting water supply lines are manually connected to the inlet water ports on the active intensifier Manual hydraulic valves are opened or closed to direct the hydraulic flow to the active intensifier Manual high pressure water valves are also opened or closed to direct the high pressure water flow from the active intensifier When a machine is equi...

Page 75: ...es on intensifier 1 Connect the cables to the proximity switches on intensifier 2 7 Ensure all cooling water water supply and cutting water valves are open 8 Ensure all hydraulic and high pressure fittings and the proximity switches are properly tightened on intensifier 2 9 Start the machine in low pressure mode and inspect the hydraulic high pressure fittings valves and hoses for leaks 8 4 System...

Page 76: ...Section 8 High Pressure Water System 20425618 5 2005 Rev 0 8 5 Figure 8 4 Hydraulic Cylinder Assembly Figure 8 5 Hydraulic Piston ...

Page 77: ...sembly 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 componen...

Page 78: ...e Specifications High Pressure Water System Hard Seal End Cap Jackbolts 6 7 16 each 1st Stage Hand Tight 2nd Stage 20 ft lbs 27 Nm Crossing Pattern 3rd Stage 32 35 ft lbs 43 47 Nm Crossing Pattern 4th Stage 32 35 ft lbs 43 47 Nm Clockwise Pattern From Bolt 1 Socket Wrench Size 3 8 inch 6 Bolt Crossing Pattern Note Crossing Pattern 1 2 3 4 5 6 Hydraulic Cylinder Head Socket Head Screws 8 14M each T...

Page 79: ... Socket Head Screws 2 M6 each Torque 140 160 in lbs 16 18 Nm Hex Key M5 Sealing Head Discharge Gland Nut 130 ft lbs 176 Nm Poppet Retainer 25 30 in lbs 2 8 3 4 Nm Optional Pneumatic Control Valve 3 8 HP Inlet Gland Nut 50 ft lbs 68 Nm 1 4 Outlet to Drain 25 ft lbs 34 Nm Pneumatic Actuator 5 ft lbs 7 Nm 9 16 1 4 HP Adapter 50 ft lbs 68 Nm ...

Page 80: ...ated in Figure 8 6 Specialized Maintenance Tools and part numbers are provided in Table 8 2 Figure 8 6 Specialized Maintenance Tools Table 8 2 Specialized Maintenance Tools High Pressure Water System Part Number Plunger Removal Tool 05004924 Vee Block Cradle 05149877 Plug 10079523 3 8 Gland Fitting 10078129 3 8 Seal Removal Tool 10148674 End Cap Wrench 6x8x 80079239 Cylinder Wrench 05066139 Seal R...

Page 81: ... on the hard seal end cap 4 When the required maintenance has been completed and the components reassembled connect the low pressure water piping to the inlet water port on the hard seal 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 th...

Page 82: ...ng 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 Due to the weight of the cylinder assembly adequate support must be provided to prevent damage to the plunger or seals during removal and installation See Figure 8 6 Specialized M...

Page 83: ...n 1 Verify that the high pressure cylinder threads and alignment surfaces are adequately cleaned and lubricated with Pure Goop and that the threads have been sanded and dressed if galling was encountered during removal 2 Verify that the high pressure seal assembly and cylinder liner are correctly installed Align the cylinder assembly with the plunger and the hydraulic cylinder head using the cradl...

Page 84: ...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 r...

Page 85: ...oval 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 Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before...

Page 86: ...aling head 3 Place the sealing head and the spacer in the end of the high pressure cylinder and press the sealing head into the cylinder by hand 4 Apply JL M grease to the threads on the jackbolts Ensure the jackbolts are slightly less than flush with the inner face of the end cap 5 Slide the end cap over the sealing head until it makes contact with the sealing head Fully engage the threads on the...

Page 87: ...ensifier starts pumping water There is no further need to flush air from the system 8 9 Sealing Head The sealing head is sealed to the outboard end of the high pressure cylinder by a 45 degree metal to metal compression seal The pre loading jackbolts in the hard seal end cap hold the sealing head against the end of the cylinder The inlet and discharge check valves in the sealing head ensure the lo...

Page 88: ...ure water piping following the procedure High and Low Pressure Water Piping 3 Use two 1 3 16 wrenches to remove the gland nut The poppet pin spring and poppet check valve will normally remain in the gland nut when it is removed Remove the components from the gland nut 4 Use a magnet to remove the seat from the sealing head 5 Inspect the poppet pin for wear and replace the pin if worn 6 Inspect bot...

Page 89: ...hould show If the gap exceeds 0 20 inch 5 mm the poppet or seat has slipped out of position The parts must be removed inspected and re assembled 10 Use a crowfoot torque wrench combination and tighten the gland nut to the torque specifications in Table 8 1 Low Pressure Inlet Check Valve The inlet check valves should be serviced on a regular preventive maintenance schedule Service is recommended ev...

Page 90: ...ing is fully guided on the poppet retainer The spring end is 90 degrees from the screwdriver slot on the retainer The poppet retainer is seated against the sealing head Sealing Head Maintenance The sealing head should be inspected for scratches excessive sealing damage or erosion marking on the cone ring contact surface and on the inlet poppet valve contact surface If defects are detected the surf...

Page 91: ...gh Pressure Seal Assembly 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 Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout proced...

Page 92: ...f a tool stand is not available position the cylinder on a platform of wooden blocks with the jackbolts resting on the platform Do not stand the cylinder assembly on the top pan of the machine The assembly is heavy and must be properly supported to prevent it from falling 6 Fill the cylinder with water and slide the seal removal tool or a used plunger into the bronze packing follower to ensure a g...

Page 93: ...r orientation of the backup rings as illustrated in Figure 8 12 High Pressure Seal Assembly The cantilever spring inside the u cup seal is easily distorted Verify that the spring lips and cavity appear uniform prior to installation 12 Slide the cylinder liner over the plunger 13 Install the high pressure cylinder assembly into the hydraulic cylinder head following the procedure High Pressure Cylin...

Page 94: ...lowing the torque specifications in Table 8 1 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 the switch will result in the spray of hydraulic oil 8 Thread ...

Page 95: ...The plunger can now be removed from the hydraulic piston Figure 8 15 Plunger Retainer Pins Plunger Maintenance Plunger surfaces can become streaked with longitudinal scratches or flaws and discolored or dull in appearance If any of these conditions become severe the high pressure seal assembly and possibly the hydraulic cartridge seal will leak Accumulation of debris on the surface of the plunger ...

Page 96: ...seal removal tool a plastic or wooden dowel or similar object can be used for seal removal Do not use screwdrivers wires or other metal objects that could damage the cartridge To avoid damaging the new seals the seal installation tool can be used for installation Figure 8 17 Hydraulic Cartridge Seal 1 Carefully remove the worn seals and o rings from the cartridge by pushing them with a plastic or ...

Page 97: ...ss drilled weep holes Install the retainer flange over the plunger 9 Install the retaining ring ensuring the retaining ring fully seats inside the groove in the hydraulic cylinder head The o rings on the hydraulic cartridge will take up clearance Tap lightly on the bushing retainer flange with the plunger removal tool to compress the o rings enough to start the retaining ring in the groove Use a f...

Page 98: ...plunger in position The plunger retainer pins are held in place by a flat snap ring Two internal check valves vent unwanted hydraulic pressure from one side of the piston to the other preventing pressure from building behind the plunger button Figure 8 18 Hydraulic Piston Components Hydraulic Piston Removal The following procedure is used to remove the hydraulic piston 1 Turn the machine off and o...

Page 99: ...nds of the intensifier following the procedure High and Low Pressure Water Piping 3 Remove the high pressure cylinder assembly on each end of the intensifier following the procedure High Pressure Cylinder Assembly Removal Figure 8 19 Hydraulic Piston Removal 4 Remove both of the proximity switches to prevent interference 5 Remove the retaining ring bushing retainer flange and the hydraulic cartrid...

Page 100: ... assembly NOTE Do not scratch the surfaces of the piston seal groove Scratches on the sides or bottom of the groove can result in hydraulic leaks 3 Inspect the bottom of the seal grooves for marks scratches and residue buildup Clean and or repair the groove surfaces as required 4 Apply FML 2 grease to the new bearing rings and install the rings 5 The piston seal assembly consists of an inner and a...

Page 101: ... the internal groove in the plunger socket If the backup ring is not installed the plunger can be forced out of the plunger socket 7 Install the retainer pins verifying that each pin moves freely without excess side play in the pin holes 8 Install the flat snap rings over the pins 9 Install the plungers and check the snap in feature of the plunger attachment Use the plunger removal tool to ensure ...

Page 102: ...e the pins retract to release the plunger and close to retain the plunger in a uniform manner 5 Verify that the o ring and backup ring are properly positioned in the groove on both hydraulic cylinder heads and that they are sufficiently lubricated with FML 2 grease 6 Position the cylinder heads in the ends of the hydraulic cylinder Apply JL M grease to the threads on the socket head screws Install...

Page 103: ...inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed Excessive grooving is indicative of piston seal wear 8 14 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 ...

Page 104: ...enoid operated air valve The following procedure is recommended for servicing the high pressure dump valve Failure to follow this procedure will cause damage to the stem valve seat or both The high pressure dump valve is a safety device designed to instantly release high pressure from the system Proper maintenance is imperative to prevent potential personal injury Figure 8 21 High Pressure Dump Va...

Page 105: ...e replaced at the same time The SST backup ring can be reused 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 1 Turn the air supply off 2 Remove the air supply hose and the electrical connection to the solenoid ...

Page 106: ... adapter adapter cone 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 a dowel rod made of wood plastic or brass The seal push tool can also be used to remove the seal assembly The assembly must be pushed out through the actuator port in the top of the valve body 9 Clean the valve body being careful not to dama...

Page 107: ...lightly onto the seal with the tip of your finger 15 Install the existing SST backup ring and a new brass backup ring on a new stem The vee groove on the SST backup ring should face toward the brass backup ring The small OD of the brass backup ring should face toward the seal assembly See Figure 8 23 Pneumatic Control Valve Components 16 Insert the assembly into the top of the valve body so the st...

Page 108: ...the valve for leaks and proper operation Pneumatic Actuator The following procedure is used to service the pneumatic actuator Figure 8 26 Pneumatic Actuator 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...

Page 109: ...draulic cartridge seal Replace the cartridge seal If the leak persists check the plunger for linear scratches or scoring Failed high pressure seal assembly Replace the high pressure seal assembly Damaged plunger Check the plunger for longitudinal scratches or flaws If detected replace the plunger or return to KMT for evaluation and rework Seal material buildup on plunger Polish the plunger surface...

Page 110: ...e proper torque specification Water leaking from the weep hole in the sealing head Erosion or scratches on the contact surface of the sealing head or on the gland nut where the seat makes contact Polish the surfaces following the procedure Sealing Head Maintenance High pressure piping gland nut is not tight and is not sealing properly Tighten the gland nut to the proper torque specification Check ...

Page 111: ... High Pressure Cylinder Maintenance Damaged high pressure cylinder Replace the high pressure cylinder External crack in sealing head Replace the sealing head Damaged sealing head Check for scratches or grooves on the 45 degree surface of the sealing head If detected polish the surface following the procedure Sealing Head Maintenance Water leaking from the weep holes in the hard seal end cap Improp...

Page 112: ...mponents 11 Low cutting water supply pressure 12 Low cutting water pressure 13 Hydraulic oil leaking from the weep hole in the hydraulic cylinder head 14 Water leaking from the weep hole on the hydraulic cylinder head flange 15 Water leaking from the weep hole in the sealing head 16 Water leaking from the weep hole in the sealing head gland nut 17 Water leaking from the weep holes in the hard seal...

Page 113: ...lating valve is stuck open or closed Replace the valve 1 High oil temperature 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 2 Low oil level Check the level switch 3 Restricted or no cooling flow Check cooling water flow to and from the heat exchanger The water pressure differential...

Page 114: ...ydraulic oil pressure Incorrect motor rotation Check the motor rotation 6 Pump shaft will not turn The flexible coupling has failed Replace the flexible coupling Hydraulic pump has seized Replace the hydraulic pump Emergency stop button is depressed Check all remote E STOP buttons 7 Pump will not start Main power is disconnected Check the main power and verify that the main power disconnect is on ...

Page 115: ...orifice mount Inspect the discharge check valves in the sealing heads Check valve leakage Inspect the inlet check valves in the sealing heads Inspect the high pressure seal on the plunger Seal leakage Inspect the sealing head to cylinder sealing surfaces Check the operation of the hydraulic relief valve Verify that the directional control valve is shifting properly 9 Abnormal fluctuations in high ...

Page 116: ...the high pressure cylinder for cracks Restricted water supply Check cutting water supply flow and pressure Clogged water filter Not applicable for base units Check the condition of the low pressure water filter and replace the filter element if necessary 11 Low cutting water supply pressure Trapped air Not applicable for base units Bleed the air from the cutting water plumbing If operating in low ...

Page 117: ... the plunger surface following the procedure Plunger Maintenance detailed in Section 8 High Pressure Water System Check for scratches grooves or material buildup on the inside diameter of the cylinder If detected polish the bore following the procedure High Pressure Cylinder Maintenance detailed in Section 8 High Pressure Water System 14 Water leaking from the weep hole on the hydraulic cylinder h...

Page 118: ...the weep hole in the sealing head Internal crack in sealing head Replace the sealing head A cracked sealing head can result in water leaking from the high pressure outlet passage to the low pressure inlet passages The sealing head body can become extremely hot High pressure piping gland nut is not tight and is not sealing properly Tighten the gland nut to the proper torque specification Check the ...

Page 119: ...e surface following the procedure Sealing Head Maintenance detailed in Section 8 High Pressure Water System 17 Water leaking from the weep holes in the hard seal end cap Improper torque on jackbolts Torque the jackbolts to the proper torque specification Optional Booster Pump and Low Pressure Water Filter Orifice is blocked with debris Long deadhead condition Insufficient water supply 18 High boos...

Page 120: ...justed to 120 psi 8 bar when deadheaded 21 Inlet water flow is poor and the filter housing is not filling completely Pipe sizing for inlet cutting water should be checked for pressure and flow Cutting water supply will be lacking capacity or flow 22 Water is leaking around the bleed valve on the filter head O ring that closes the passage has deteriorated A small o ring under the valve can deterior...

Page 121: ...Model HP Kw S30 30 22 10 2 Installation Specifications Environment Installation location Indoors Air borne dust contaminants Minimal Ambient temperature Minimum storage 36 F 2 C Minimum operating 40 F 5 C Maximum operating 104 F 40 C Maximum relative humidity at maximum operating temperature 95 Note When the relative humidity is above 50 the oil in the reservoir should be checked frequently for wa...

Page 122: ...n 1 2 NPT Connection Drain optional 1 2 NPT Connection 10 3 Water Specifications Cutting Water Supply Low Pressure Water System Minimum inlet flow 2 5 gpm 9 5 L min Minimum inlet water pressure 35 psi 2 4 bar flowing with optional booster pump 60 psi 4 bar flowing without booster pump Maximum inlet water pressure 100 psi 6 9 bar Maximum booster outlet water pressure 120 psi 8 3 bar Booster pump fa...

Page 123: ...l service Mobil DTE Heavy Medium No 021029 Conoco Hydroclear TM multi purpose R O Food service Anderol PQ AA 20 Food Grade Oil Note For each particle per milliliter downstream of the filer greater than 10 microns there are 100 particles per milliliter larger than 10 microns upstream of the filter Note Indicates ISO 4406 range numbers for maximum permissible number of particles per milliliter great...

Page 124: ... 0 0 Chloride 100 15 1 Free Chlorine 1 1 0 05 Iron 0 2 0 1 0 01 Magnesium as Mg 0 5 0 1 0 1 Manganese as Mn 0 1 0 1 0 1 Nitrate 25 25 10 Oxygen 2 1 0 1 Silica 15 10 1 Sodium 50 10 1 Sulfate 25 25 1 TDS 200 100 5 Total Hardness 25 10 1 pH 6 5 8 5 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 ...

Page 125: ...hen dissolved makes water hard contributes to the formation of scale Manganese as Mn Mn Discolors water or precipitation source of scale and erosion Nitrate NO3 Adds to solid content effect is not generally significant industrially Oxygen O2 Causes corrosion Silica SiO2 Causes scale Sodium Na Found naturally introduced to water in the ion exchange water softening process Sulfate SO4 Adds to solid ...

Page 126: ...e Requirements Power Voltage Motor Horsepower Full Load Amps Recommended Circuit Breaker Amps 208 3 50 60 30 86 125 230 3 60 30 76 100 400 3 50 30 43 60 415 3 50 30 43 60 460 3 60 30 38 50 575 3 60 30 32 40 10 5 Hydraulic and High Pressure Water System Specifications Hydraulic System Maximum operating pressure 3 000 psi 207 bar Main system relief valve 3 400 psi 234 bar ...

Page 127: ...i 4 137 bar Pneumatic Control Valve Maximum water pressure 60 000 psi 4 137 bar Minimum air pressure 85 psi 5 9 bar Maximum air pressure 100 psi 6 9 bar Maximum air flow rate 1 0 cfm 0 028 m3 min Orifice Capacity The following tables provide horsepower requirements for some of the more popular orifices Table 10 4 Single Orifice Diameter Motor Horsepower Rating Model HP Kw Maximum Operating Pressur...

Page 128: ...ned by adding the requirements in Table 10 5 for each orifice Examples are shown below Orifice Size inches mm Number of Orifices Operating Pressure Calculation Total Horsepower 0 008 0 203 2 50 000 2 x 13 9 27 8 0 005 0 127 0 008 0 203 1 1 60 000 7 1 18 2 25 3 Torque Specifications Measurements are made with lubricated components and a certified calibrated torque wrench Inconsistencies in wrench s...

Page 129: ...3rd Stage 32 35 ft lbs 43 47 Nm Crossing Pattern 4th Stage 32 35 ft lbs 43 47 Nm Clockwise Pattern From Bolt 1 Socket Wrench Size 3 8 inch 6 Bolt Crossing Pattern Note Crossing Pattern 1 2 3 4 5 6 Hydraulic Cylinder Head Socket Head Screws 8 14M each Torque 75 80 ft lbs 102 108 Nm Hex Key M12 Proximity Switch Socket Head Screws 2 M6 each Torque 140 160 in lbs 16 18 Nm Hex Key M5 ...

Page 130: ...etainer 25 30 in lbs 2 8 3 4 Nm Pneumatic Control Valve 3 8 inch HP Inlet Gland Nut 50 ft lbs 68 Nm 1 4 inch Outlet to Drain 25 ft lbs 34 Nm Pneumatic Actuator 5 ft lbs 7 Nm 9 16 1 4 HP Adapter 50 ft lbs 68 Nm High Pressure Fittings 1 4 inch Gland Nut 25 ft lb 34 Nm 3 8 inch Gland Nut 50 ft lb 68 Nm 9 16 inch Gland Nut 110 ft lb 149 Nm ...

Page 131: ...mbers in the accompanying figures Use the following information to contact the Spare Parts Department at KMT Waterjet Systems USA Europe Parts Department KMT Waterjet Systems Production Equipment Group 635 West 12th Street Baxter Springs KS 66713 0231 Spare Parts Manager KMT Waterjet Systems GmbH Wasserstrahl Schneidetechnik Auf der Laukert 11 D 61231 Bad Nauheim Germany Phone Fax Email 800 826 92...

Page 132: ...s of an inch D Degree HP or LP High pressure or low pressure ID or OD Inside diameter or outside diameter JIC 37 degree flared threaded hydraulic fitting NO or NC Normally open or normally closed NPT National Pipe Thread pipe thread and pressure vessel standard psi or ksi Pounds per square inch or thousands of pounds per square inch SAE O Ring O ring threaded port style Society of Automotive Engin...

Page 133: ...ing Head Assembly 80072349 11 11 11 16 Electrical Interface Option 49833874 11 34 11 5 Hydraulic Piston Assembly 05132253 11 12 11 17 Dump Valve Kit Option 05142518 11 36 11 6 High Pressure Piping 05142500 11 14 11 18 Pneumatic Control Dump Valve Option 10184760 11 38 11 7 Hydraulic Power Package 05141981 11 16 11 19 Booster Pump LP Water Filter Assembly Option 49833866 11 40 11 8 Motor Pump Assem...

Page 134: ...ox Configuration 05086889 11 64 11 3 Hydraulic Cartridge Seal 05130091 11 9 11 32 Redundant Kit 80080062 11 66 11 4 Sealing Head Assembly 80072349 11 10 11 5 Hydraulic Piston Assembly 05132253 11 11 11 24 High Pressure Piping 80080039 11 50 11 25 Hydraulic Power Package 05110614 11 52 11 26 Motor Pump Assembly 80082407 11 54 11 27 Hydraulic Manifold Assembly 05071766 11 56 11 28 Hydraulic Hose Con...

Page 135: ... 44 AutolineTM Abrasive Nozzle Assembly 05078530 11 90 11 36 Focusing Tubes 11 73 11 45 AutolineTM Diamond Orifice 11 91 11 37 Standard Orifice Assemblies 11 75 11 46 AutolineTM Sapphire Orifice 11 91 11 38 Diamond Orifice Mounts 11 75 11 47 Pneumatic Control Valve NC 10138824 11 92 11 39 High Pressure Fittings 11 76 11 48 Pneumatic Cylinder Assembly NC 10177855 11 93 11 40 Bulk High Pressure Tubi...

Page 136: ...05142500 High Pressure Piping 1 6 05141981 Hydraulic Power Package 1 7 05141585 Hydraulic Hose Connections 1 8 05143862 Attenuator Installation 1 9 10150464 Decal Cutting Water In 1 10 10150472 Decal Cooling Water In 1 11 10150480 Decal Cooling Water Out 1 12 05041009 Socket Head Screw 1 2 13 x 1 00 4 13 95688750 Lock Washer 0 50 x 0 172 4 14 10150456 Decal Cutting Water Out 1 15 05128087 Startup ...

Page 137: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 7 Figure 11 1 Streamline S30 Single Intensifier Unit ...

Page 138: ...ulic Cylinder Head 2 17 05141106 Socket Head Screw M14 x 60 16 5 05149703 HP Seal Assembly 0 875 2 18 05127584 Proximity Switch 20 250V AC DC 2 6 05144696 Spacer Sealing Head 2 19 10183572 Socket Head Screw M6 x 1 00 x 22 MM 4 7 80073646 HP Cylinder Nut HSEC 2 20 05132253 Piston Assembly 4 03 Diameter 1 8 05130091 Hydraulic Cartridge Seal Assembly 2 21 10074409 O Ring 1 x 1 1 4 x 1 8 2 9 05007786 ...

Page 139: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 9 Figure 11 2 Intensifier Assembly ...

Page 140: ...9 1 Figure 11 3 Hydraulic Cartridge Seal 2 05015060 Packing Ring W O Ring 1 125 x 0 875 2 3 10193522 O Ring 1 3 16 x 1 3 8 x 3 32 1 4 05050760 Backup Ring 1 188 x 1 375 1 5 05129481 O Ring 1 x 1 1 8 x 1 16 1 6 05013024 O Ring 1 1 4 x 1 3 8 x 1 16 1 7 05129515 Backup Ring 1 127 x 0 891 1 8 05027255 Packing Seal U Cup W O Ring 1 80084759 Rebuild Kit Includes Items 2 8 ...

Page 141: ...d Body 1 Figure 11 4 Sealing Head Assembly 2 05144662 Inlet Poppet Valve 1 10107894 Alternate Inlet Poppet Valve 3 05116777 Gland Nut 1 4 05112768 Seat 1 5 05116561 Discharge Poppet Valve 1 6 05144670 Poppet Retainer 1 7 05147863 Compression Spring 1 8 49884562 Compression Spring 1 9 05116751 Poppet Pin 1 05133335 Rebuild Kit Includes Items 4 5 7 and 9 ...

Page 142: ...evis 0 25 x 0 43 12 3 05049887 Set Screw Socket 3 8 16 x 3 8 2 4 10148757 Check Valve Cartridge W O Ring 2 5 49877509 Adhesive Thread Locker 6 05088364 Flat Snap Ring 0 032 x 0 375 x 2 010 2 7 05049994 Backup Ring 1 50 x 1 25 2 8 05087713 O Ring 1 1 4 x 1 1 2 x 1 8 2 9 05117965 Seal Assembly Hydraulic Piston 1 10 05117940 Bearing Ring Hydraulic Piston 2 05115951 Rebuild Kit Includes Items 4 6 7 8 ...

Page 143: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 13 Figure 11 5 Hydraulic Piston Assembly ...

Page 144: ...ee 0 38 2 4 05142187 Manifold Assembly 1 5 05141882 HP Tube Bent 0 38 x 0 125 Cone Thread 1 6 10078129 HP Gland 0 38 2 7 10078715 HP Collar 0 38 2 8 80079999 Intensifier Assembly 1 9 10079523 HP Plug 0 38 17 4 1 10 10083897 Ferrule 0 25 Hose 8 11 05028030 HP Tube 0 38 x 0 125 x 6 75 Cone Thread 1 12 95413696 Lock Washer 0 50 x 0 125 5 13 10186153 Conduit Extra Flexible 0 38 ID 70 0 14 95738514 Hex...

Page 145: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 15 Figure 11 6 High Pressure Piping ...

Page 146: ...bow Split Flange Hose Barb 4 50 x 2 00 1 3 80076441 Motor Pump Assembly S30 1 4 10118065 Split Flange Kit 1 00 1 5 10151470 Adapter JIC O Ring 90D 12 16 1 6 05047451 Adapter JIC O Ring 90D 12 12 1 7 05050331 Elbow JIC O Ring 90D 12 10 1 8 05092697 Hose Clamp 1 9 05050687 Cap Recirculation Pump Shaft 1 10 10142644 Adapter JIC O Ring 90D 4 4 1 Ref 1 05149166 Hose Assembly Hydraulic ...

Page 147: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 17 Figure 11 7 Hydraulic Power Package ...

Page 148: ...HP 1 5 80077019 Flange Motor Pump Adapter 1 6 95716882 Hex Head Screw 1 2 13 x 1 1 4 2 7 05083258 Piston Pump 3100 psi 45 cc 1 8 05037593 Socket Head Screw M10 x 1 50 x 25 MM 2 9 10069714 Flat Washer 0 38 x 0 078 2 10 10069763 Flat Washer 0 50 x 0 109 2 11 05073168 Elbow JIC O Ring 45D 1 12 05045364 Gear Pump Double Shaft 1 13 80077027 Coupling Flexible Drive Spline 1 14 05114087 Socket Head Screw...

Page 149: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 19 Figure 11 8 Motor Pump Assembly ...

Page 150: ... Valve Cartridge 1 15 95838314 Lock Washer 0 25 x 0 063 2 5 05122650 Plug Hex Socket 0 63 O Ring 6 16 05140942 Socket Head Screw 1 4 20 x 3 1 4 2 6 10192813 Plug O Ring 0 25 1 17 05142302 Adapter O Ring Pipe 6 4 1 7 05140397 Hydraulic Check Valve Cartridge 1 18 05142393 Socket Head Screw M10 x 1 50 x 75 MM 8 8 05140819 Flat Washer M14 x 5 1 19 05061486 Lock Washer M10 8 9 05140520 Hi Lo Solenoid V...

Page 151: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 21 Figure 11 9 Hydraulic Manifold Assembly ...

Page 152: ... Assembly LP 0 25 4 JIC 1 3 05141395 Hydraulic Hose Assembly LP 0 75 0 75 JIC 1 4 05149166 Hydraulic Hose Assembly MP 0 75 12 JIC 1 5 05141387 Hydraulic Hose Assembly LP 0 75 0 75 JIC 1 6 05141361 Hydraulic Hose Assembly LP 0 75 0 75 JIC 1 7 10179018 Radiator Hose 2 0 9 0 8 10083517 Hose Clamp 1 81 2 75 2 9 10117083 Hydraulic Hose Assembly LP 0 75 0 75F JIC 1 10 05060751 Hydraulic Hose Assembly MP...

Page 153: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 23 Figure 11 10 Hydraulic Hose Connections ...

Page 154: ...eat Exchanger Water Oil 1 17 05006291 Diffuser Return Line 1 25 NPT 1 6 10168862 Level Temperature Gauge Dual Scale 1 18 10100188 Adapter Pipe JIC 16 12 1 7 05049697 Hydraulic Filter Head W Gauge 1 19 10079713 Hose Barb 0 50 x 0 50 NPT 2 05103817 Pressure Gauge only 20 95830766 Lock Washer 0 31 x 0 078 2 8 05071063 Tee Straight Thread Branch O Ring JIC 1 21 10070191 Hex Nut M8 x 1 25 MM 4 9 050575...

Page 155: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 25 Figure 11 11 Reservoir Assembly ...

Page 156: ... NPT x 0 50 JIC 2 4 10079713 Hose Barb 0 50 x 0 50 NPT 2 14 49834302 Adapter Tube Pipe 0 50 x 0 50 1 5 49890239 Solenoid Valve 24V DC 2 Way 1 15 49834310 Adapter Tube Pipe 0 50 x 0 50 1 6 49886922 Adapter Bulkhead 8 24 3 16 10069763 Flat Washer 0 50 x 0 109 8 7 10127348 Hose Push On 0 50 250 psi 120 0 17 10066199 Hex Head Screw 1 2 13 x 3 4 4 8 10144368 Socket Head Screw 1 2 13 x 1 1 4 4 18 101738...

Page 157: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 27 Figure 11 12 Bulkhead Pipe Assembly ...

Page 158: ...0125912 Cable Tie 0 87 5 9 95077012 Hex Head Screw 5 16 18 x 1 3 4 2 3 05044029 Adapter Block Motor Junction Box 1 10 10094712 Terminal Ring 14 10 12 4 05062344 Lock Nut 1 4 20 2 11 05142542 Electrical Support Bracket 1 5 10069755 Flat Washer 0 31 x 0 078 2 12 10066967 Socket Head Screw 6 32 x 5 8 4 6 10120921 Cable Tie Mount 1 00 x 1 00 5 13 10069888 Lock Washer 6 x 0 031 4 7 95686721 Socket Head...

Page 159: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 29 Figure 11 13 Electrical Assembly ...

Page 160: ...0125912 Cable Tie 0 87 5 9 95077012 Hex Head Screw 5 16 18 x 1 3 4 2 3 05044029 Adapter Block Motor Junction Box 1 10 10094712 Terminal Ring 14 10 12 4 05062344 Lock Nut 1 4 20 2 11 49839277 Configuration Junction Box 1 5 10069755 Flat Washer 0 31 x 0 078 2 12 10097657 Button Head Screw 1 4 20 x 3 4 4 6 10120921 Cable Tie Mount 1 00 x 1 00 5 13 95838314 Lock Washer 0 25 x 0 063 4 7 95686721 Socket...

Page 161: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 31 Figure 11 14 Electrical Assembly with Junction Box ...

Page 162: ...el Insert 1 3 10103034 DIN Rail 5 0 4 10073492 Pan Head Screw 8 32 x 1 2 3 5 05032362 End Anchor Terminal Block 2 6 05115704 Terminal Block Ground 1 7 05113634 Terminal Block 3 Level 10 8 05112826 Terminal Block Jumper 10 Pole 1 4 9 05112818 Terminal Block Marker 0 5 10 05117601 End Barrier 3 Level Terminal Block 1 13 10170165 Wire 16 Green Yellow 6 0 14 10181873 Ring Terminal 16 14 1 ...

Page 163: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 33 Figure 11 15 Junction Box Configuration ...

Page 164: ...s List 20425652 5 2005 Rev 0 11 34 Table 11 16 Electrical Interface 49833874 Item Part Number Description Quantity 1 49833171 Plug Connector 37 Pin 1 2 05141973 Environmental Adapter Kit 1 3 49832983 Shrink Tube 0 125 ...

Page 165: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 35 Figure 11 16 Electrical Interface ...

Page 166: ...5141874 HP Tube 0 38 x 0 125 x 12 93 Cone Thread 1 18 10086999 Plug Hex Socket 1 2 14 1 6 10078715 HP Collar 0 38 2 19 10150449 Decal Drain 1 7 95391322 Flat Washer 0 25 x 0 063 2 20 10070092 Jam Nut 1 14 1 8 05142534 Bracket Valve Assembly 1 21 10078335 Reducing Nipple 0 25 x 0 125 1 9 10186153 Flexible Conduit 0 38 ID 30 0 22 49888035 Solenoid Valve 1 10 10077055 Bulkhead Adapter 1 23 10077030 E...

Page 167: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 37 Figure 11 17 Dump Valve Kit ...

Page 168: ... Seat 0 50 x 0 040 1 9 BV601184 Pneumatic Cylinder Head 2 425 1 3 BV701184 HP Gland Fitting 1 10 BV501184 Piston Pneumatic Control Valve 2 374 1 4 BV901184 Valve Stem 0 080 1 11 10187250 Backup Ring SST 0 475 x 0 125 x 0 105 1 5 10188233 Brass Backup Ring 0 480 x 0 082 x 0 170 1 12 10074714 O Ring 2 7 16 x 2 5 8 x 3 32 1 6 10178978 Seal Assembly 0 25 1 13 10074565 O Ring 2 1 4 x 2 3 8 x 1 16 2 7 1...

Page 169: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 39 Figure 11 18 Pneumatic Control Dump Valve Normally Open ...

Page 170: ...50 x 0 50 1 3 49833841 Bracket Filter Mount 1 13 10198190 Plug Hex Socket 1 2 14 1 4 95572897 Hex Head Screw 1 4 20 x 5 8 3 14 10189025 Adapter Hose JIC 0 50 x 0 50 2 5 95838314 Lock Washer 0 25 x 0 063 3 15 95750394 Lock Washer 0 38 x 0 094 2 6 49887094 Water Pump Vane 1 16 10069714 Flat Washer 0 38 x 0 078 2 7 10150449 Decal Drain 1 17 95416319 Hex Head Screw 3 8 16 x 1 00 2 8 49886989 Adapter P...

Page 171: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 41 Figure 11 19 Booster Pump Low Pressure Water Filter Kit ...

Page 172: ...C 0 50 x 0 50 4 4 05074067 Pipe Nipple 0 50 x 3 00 2 16 10114023 U Bolt 0 50 2 5 10078111 Pipe Bushing M F 0 75 x 0 50 2 17 10113983 Tee F 1 6 49836729 Low Pressure Manifold 1 18 05135637 Square Head Plug 0 25 NPTM 2 7 05135629 Low Pressure Manifold 1 19 95416335 Hex Nut 1 4 20 4 8 05135660 Elbow JIC O Ring 90D W Jamb Nut 4 20 95838314 Lock Washer 0 25 x 0 063 4 9 49835804 Adapter Pipe Hose Barb 1...

Page 173: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 43 Figure 11 20 Low Pressure Water Filter ...

Page 174: ...e Control 80075732 Item Part Number Description Quantity 1 80071087 Hydraulic Solenoid Valve 24V Cartridge 1 2 49867104 Cable 18 4 Conductor 96 0 3 10067205 Cable Connector 0 50 1 4 10176410 Wire 16 Blue 100 0 5 10185395 Connector Crimp Ferrule 16 10 6 80088560 End Cap 4 Way Valve 1 ...

Page 175: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 45 Figure 11 21 Proportional Pressure Control ...

Page 176: ... 10150464 Decal Cutting Water In 1 4 05086038 Base Assembly 1 15 10150472 Decal Cooling Water In 1 5 05041660 Reservoir Assembly 1 16 10150480 Decal Cooling Water Out 1 6 80080039 High Pressure Piping 1 17 05041009 Socket Head Screw 1 2 13 x 1 00 4 7 05110614 Hydraulic Power Package 1 18 95688750 Lock Washer 0 50 x 0 172 4 8 05141585 Hydraulic Hose Connections 1 19 10150456 Decal Cutting Water Out...

Page 177: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 47 Figure 11 22 Streamline S30 Redundant Intensifier Unit ...

Page 178: ...P Seal Assembly 0 875 2 18 05127584 Proximity Switch 20 250V AC DC 2 6 05144696 Spacer Sealing Head 2 19 10183572 Socket Head Screw M6 x 1 00 x 22 MM 4 7 80073646 HP Cylinder Nut HSEC 2 20 05132253 Piston Assembly 4 03 Diameter 1 8 05130091 Hydraulic Cartridge Seal Assembly 2 21 10074409 O Ring 1 x 1 1 4 x 1 8 2 9 05007786 Bushing Retainer Flange 2 22 05144183 Spacer Proximity Switch 2 10 20418805...

Page 179: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 49 Figure 11 23 Intensifier Assembly ...

Page 180: ... 0 125 1 2 05070644 HP Tube Bent 0 38 x 0 125 1 3 10078590 HP Tee 0 38 1 4 10186153 Conduit Extra Flexible 0 38 ID 120 0 5 05089735 HP Tube Bent 0 38 x 0 125 1 6 10078129 HP Gland 0 38 2 7 10078715 HP Collar 0 38 2 8 80072333 Intensifier Assembly 1 9 95383790 Socket Head Screw 1 2 13 x 1 4 10 95413696 Lock Washer 0 50 x 0 125 4 11 10083897 Ferrule 0 25 Hose 6 ...

Page 181: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 51 Figure 11 24 High Pressure Piping ...

Page 182: ...14 Item Part Number Description Quantity 1 80082407 Motor Pump Assembly 1 2 05050687 Cap Recirculation Pump Shaft 1 3 10091510 Decal Arrow 2 4 95688750 Lock Washer 0 50 x 0 172 6 5 95055026 Socket Head Screw 1 2 13 x 1 3 4 6 6 05092523 Directional Control Valve 24V DC 1 7 05092697 Hose Clamp 1 ...

Page 183: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 53 Figure 11 25 Hydraulic Power Package ...

Page 184: ...ad Screw 3 8 16 x 1 38 3 4 80076599 Electric Motor 30 HP 1 15 05085063 Socket Head Screw 3 8 16 x 6 4 5 80077019 Flange Motor Pump Adapter 1 16 05050356 Lock Washer 0 43 x 0 140 4 6 95716882 Hex Head Screw 1 2 13 x 1 1 4 2 17 10074953 O Ring 1 1 2 x 1 3 4 x 1 8 1 7 05083258 Piston Pump 3100 psi 45 cc 1 18 10069763 Flat Washer 0 50 x 0 109 2 8 05037593 Socket Head Screw M10 x 1 50 x 25 MM 2 19 1013...

Page 185: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 55 Figure 11 26 Motor Pump Assembly ...

Page 186: ...3 3 05071717 Relief Valve Cartridge 1 4 05055017 Plug O Ring 0 125 2 5 10185585 Solenoid Valve 24V DC NC 2 Way 2 Position 1 6 05045497 Pressure Gauge 0 5000 psi 1 7 10187052 Relief Valve Knob 100 3000 psi 1 8 10187060 Relief Valve 25 800 psi 1 9 49889744 Retainer Valve Cartridge 1 10 49889736 Hydraulic Check Valve Cartridge 1 11 49889769 Plug O Ring 0 25 1 Ref 1 05092523 Directional Control Valve ...

Page 187: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 57 Figure 11 27 Hydraulic Manifold Assembly ...

Page 188: ...1 50 1 7 05086210 Elbow Split Flange Hose Barb 1 8 05051214 Hydraulic Hose Assembly MP 0 25 0 25F JIC Swivel 1 9 05060751 Hydraulic Hose Assembly MP 0 25 0 25F JIC Swivel 1 10 05049713 Hydraulic Hose Assembly LP 0 75 0 75F JIC Swivel 1 11 05089875 Hydraulic Hose Assembly HP 0 50 0 50 JIC 2 12 05071121 Hydraulic Hose Assembly MP 0 25 0 25F JIC Swivel 1 13 05052493 Elbow JIC O Ring 45D 2 14 05089867...

Page 189: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 59 Figure 11 28 Hydraulic Hose Connections ...

Page 190: ...D 1 05103817 Pressure Gauge only 23 10080901 Ball Valve 1 7 05049689 Oil Filter Element 6 Micron Absolute 1 24 95033619 Plug Square Head 0 50 1 8 20421954 Elbow JIC O Ring 90D 3 25 95897948 Button Head Screw 10 24 x 1 2 4 9 05069976 Hex Pipe Cap 0 75 1 26 95367728 Lock Washer 10 x 0 047 4 10 05071063 Tee Straight Thread Branch O Ring JIC 1 27 20423993 Adapter JIC O Ring Straight 1 11 05145958 Heat...

Page 191: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 61 Figure 11 29 Reservoir Assembly ...

Page 192: ...olenoid Cable 1 2 10125912 Cable Tie 0 87 5 3 05044029 Adapter Block Motor Junction Box 1 4 05062344 Lock Nut 1 4 20 2 5 10069755 Flat Washer 0 31 x 0 078 2 6 10120921 Cable Tie Mount 1 00 x 1 00 5 7 95686721 Socket Head Screw 1 4 20 x 1 3 4 2 8 05043161 Terminal Block 9 Post 1 9 95077012 Hex Head Screw 5 16 18 x 1 3 4 2 10 10094712 Terminal Ring 14 10 12 ...

Page 193: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 63 Figure 11 30 Electrical Assembly ...

Page 194: ...0073492 Pan Head Screw 8 32 x 1 2 3 5 05032362 End Anchor Terminal Block 2 6 05046214 Terminal Block IEC 3 7 05113634 Terminal Block 3 Level 10 8 05112826 Terminal Block Jumper 10 Pole 1 4 9 05112818 Terminal Block Marker 0 5 10 05117601 End Barrier 3 Level Terminal Block 1 11 05032370 End Barrier IEC 1 12 05032396 Terminal Block Marker 0 6 13 10170165 Wire 16 Green Yellow 6 0 14 10181873 Ring Ter...

Page 195: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 65 Figure 11 31 Control Box Configuration ...

Page 196: ...P Collar 0 38 2 24 5069703 Valve Assembly Pneumatic 1 8 80072333 Intensifier Assembly 1 25 10077055 Adapter Bulkhead 1 9 95413696 Lock Washer 0 50 x 0 125 4 26 10176766 Elbow 90D 0 25 x 0 25 1 10 95383790 Socket Head Screw 1 2 13 x 1 00 4 27 10079903 Tube 0 25 Clear 60 0 11 10186153 Conduit Extra Flexible 0 38 ID 120 0 28 49834328 Adapter Tube Pipe M 0 25 x 0 50 1 12 5137781 Tube Bent 0 38 x 0 25 ...

Page 197: ...Kit with Optional Dump Valve 80080062 Item Part Number Description Quantity Item Part Number Description Quantity 35 10150449 Decal Drain 1 38 5112271 Muffler 0 125 NPT 1 36 10070092 Jam Nut 1 14 1 39 5092390 Tube Bent 0 25 x 0 083 1 37 5137831 Tube Bent 0 38 x 0 125 90D 1 ...

Page 198: ...Section 11 Parts List 20425652 5 2005 Rev 0 11 68 Figure 11 32 Redundant Kit with Optional Dump Valve ...

Page 199: ...ning Tool Assembly 05108840 9 16 Hand Coning Tool Assembly 1 05108972 1 4 Coning Tool Collet 05108964 3 8 Coning Tool Collet 05108956 9 16 Coning Tool Collet 2 05108808 1 4 Coning Tool Blade 05108824 3 8 Coning Tool Blade 05108816 9 16 Coning Tool Blade 05109897 1 4 Power Coning Tool Assembly 05109889 3 8 Power Coning Tool Assembly 05109871 9 16 Power Coning Tool Assembly 05120472 Cone and Thread ...

Page 200: ...bly 05108881 9 16 Hand Threading Tool Assembly 1 05108899 1 4 28 HP Threading Die LH 05108915 3 8 24 HP Threading Die LH 10078301 9 16 18 HP Threading Die LH 2 05108741 1 4 Guide Bushing 05108758 3 8 Guide Bushing 05108766 9 16 Guide Bushing 05122742 1 4 Power Threading Tool Assembly 05120258 3 8 Power Threading Tool Assembly 05122759 9 16 Power Threading Tool Assembly 05108782 1 4 Tube Vise 05108...

Page 201: ...ol 1 1 8 Plunger 2 05149877 Vee Block Cradle 7 8 Plunger 49830946 Vee Block Cradle 1 1 8 Plunger 3 05066139 Cylinder Wrench 4 80079239 End Cap Wrench HSEC 6x 8x 5 80079247 End Cap Wrench HSEC 8x 6 80078330 Seal Removal Tool Stand 7 10079523 HP Plug 3 8 10078772 HP Plug 9 16 8 10078129 HP Gland Fitting 3 8 10078608 HP Gland Fitting 9 16 9 10148674 Seal Removal Tool 7 8 Plunger 05146618 Seal Removal...

Page 202: ...141759 Seal Tool Kit Figure 11 35B Seal Tools 1 05103882 Seal Installation Tool 2 05067350 Seal Positioning Tool 3 05103890 Seal Push Tool Lubricants 10084440 Pure Goop 10087385 FML 2 Grease 14 5 oz 49832199 JL M Grease 16 oz 80082191 JL M Grease 15 ML 49877509 Threadlocker Adhesive 10184802 Optimol Anti Seize Grease 05135033 ...

Page 203: ...0 030 0 762 mm x 3 13 79 4 mm 80075252 R 100 0 036 0 914 mm x 3 13 79 4 mm 49833593 R 100 0 039 0 991 mm x 3 13 79 4 mm 49835390 R 100 0 040 1 016 mm x 3 13 79 4 mm 10126928 R 100 0 043 1 092 mm x 3 13 79 4 mm 10186799 R 100 0 050 1 321 mm x 3 13 79 4 mm 05117528 R 100 0 052 1 321 mm x 3 13 79 4 mm 05051891 R 100 0 058 1 473 mm x 3 13 79 4 mm 10126936 R 100 0 063 1 600 mm x 3 13 79 4 mm 10139418 R...

Page 204: ...ing Tube 05105366 R 500 0 043 1 092 mm x 2 75 69 9 mm 05097944 R 500 0 030 0 762 mm x 3 13 79 4 mm 05116652 R 500 0 036 0 914 mm x 3 13 79 4 mm 05097936 R 500 0 043 1 092 mm x 3 13 79 4 mm 05130919 R 500 0 063 1 600 mm x 3 13 79 4 mm 05130927 R 500 0 093 2 632 mm x 3 13 79 4 mm Figure 11 36C R 500 Special Focusing Tube 05105366 R 500 Special 0 043 1 092 mm x 2 75 69 9 mm ...

Page 205: ...81 mm A2260023 0 023 0 584 mm A2260008 0 008 0 203 mm A2260016 0 016 0 406 mm A2260024 0 024 0 610 mm A2260009 0 009 0 229 mm A2260017 0 017 0 432 mm A2260010 0 010 0 254 mm A2260018 0 018 0 457 mm Table 11 38 Long Life Diamond Orifice Mounts Part Number Description Part Number Description Part Number Description 49888852 0 003 0 076 mm 49888910 0 009 0 229 mm 49888969 0 016 0 406 mm Figure 11 38 ...

Page 206: ...g 3 8 x 9 16 10078426 Collar 1 4 HP Collar 10079051 Coupling 90 Degree Elbow 1 4 HP Elbow Coupling 10078715 Collar 3 8 10078780 Coupling 90 Degree Elbow 3 8 10079119 Collar 9 16 10078525 Coupling 90 Degree Elbow 9 16 10079473 Adapter 1 4 M x 3 8 F HP M F Adapter 10079424 Adapter 1 4 M x 9 16 F 10097228 Cross 1 4 HP Cross 10079432 Adapter 3 8 M x 1 4 F 10078038 Cross 3 8 10079655 Adapter 3 8 M x 9 ...

Page 207: ... 10078459 HP Gland Nut 1 4 HP Gland Nut 10078699 Anti Vibration Collet 1 4 HP Anti Vibration Collet 10078129 HP Gland Nut 3 8 10078913 Anti Vibration Collet 3 8 10078608 HP Gland Nut 9 16 10093573 Anti Vibration Collet 9 16 10079259 Hand Valve Straight 1 4 2 Way Straight Valve 10079002 Hand Valve 90 Degree 1 4 2 Way Angle Valve 10078863 Hand Valve Straight 3 8 10078749 Hand Valve 90 Degree 3 8 100...

Page 208: ...e Tubing Part Number Description 10064376 20 ft 6 10 m 1 4 10184810 Up to 40 ft 12 19 m 1 4 10064665 20 ft 6 10 m 3 8 10061190 20 ft 6 10 m 9 16 Figure 11 40 Bulk High Pressure Tubing Coned Threaded Both Ends High Pressure Tubing also available coned threaded and or autofrettaged ...

Page 209: ... 1 05114129 Filter Body 1 2 05114145 HP Gland 1 3 05114152 Filter Cover 1 4 05110531 Filter Element 0 25 1 CJ200988 HP Line Filter 0 38 Figure 11 41B 3 8 High Pressure Line Filter 1 10078715 HP Collar 0 38 2 2 10078129 HP Gland 0 38 2 3 CJ300988 Filter Body 0 38 1 4 CJ400988 HP Gland Filter 0 38 1 5 SKJA266 Filter Element 20 Micron 1 6 SKJA286 Bayonet Filter 1 7 SKJA287 Bayonet Nipple 1 B 3030 CJ2...

Page 210: ...ity BF103473 HP Line Filter 0 56 Figure 11 41C 9 16 High Pressure Line Filter 1 AF413972 HP Gland 0 562 1 2 AF303473 Seal Head 0 56 Outlet 1 3 AF503473 Filter Element 20 Micron 1 4 BF203473 Filter Body 0 5625 Connection 1 5 AF913972 HP Gland 0 656 1 6 10074599 O Ring 3 8 x 1 2 x 1 16 1 7 AF403473 Seal Head 0 56 Inlet 1 BF103473 ...

Page 211: ...ivel Joint Straight M F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 CJ311388 Swivel Body Straight 0 56 1 5 CJ401288 Swivel Bushing 1 6 CJ501288 Spindle 0 25 1 7 BJ701288 Cap Assembly 1 8 BJ201388 Seal Assembly Swivel 1 BJ701288 Cap Assembly 1 CJ801288 Cap 1 2 10144442 Swivel Bushing 0 502 x 0 344 1 C...

Page 212: ...M F Figure 11 42B 1 4 High Pressure Swivel Joint Straight M F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 CJ311388 Swivel Body Straight 0 56 1 5 CJ401288 Swivel Bushing 90D 1 6 CJ501288 Spindle 0 25 1 7 BJ701288 Cap Assembly 1 8 BJ201388 Seal Assembly Swivel 1 CJ211388 ...

Page 213: ... Swivel Joint Straight M F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 10134716 Swivel Body Straight 0 75 1 5 CJ401288 Swivel Bushing 90D 1 6 49899602 Spindle 0 38 1 7 BJ701288 Cap Assembly 1 8 BJ201388 Seal Assembly Swivel 1 9 10078913 HP Gland Anti Vibration 0 38 2 10 10078715 HP Collar 0 38 2 1013...

Page 214: ...2D 1 4 High Pressure Swivel Joint Straight F F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 10154680 Clamp Collar 0 688 x 0 313 1 5 CJ318088 Spindle 0 56 1 6 CJ418088 Cap 0 25 1 7 CJ311388 Swivel Body Straight 0 56 1 8 CJ401288 Swivel Bushing 1 9 BJ201388 Seal Assembly Swivel 1 CJ21808 ...

Page 215: ...25 M F Figure 11 42E 1 4 High Pressure Swivel Joint 90D M F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 DJ301288 Swivel Body 90D 0 56 1 5 CJ401288 Swivel Bushing 90D 1 6 CJ501288 Spindle 0 25 1 7 BJ701288 Cap Assembly 1 8 BJ201388 Seal Assembly Swivel 1 CJ201288 ...

Page 216: ...ure Swivel Joint 90D M F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 10134690 Swivel Body 90D 0 75 1 5 CJ401288 Swivel Bushing 90D 1 6 49899602 Spindle 0 38 1 7 BJ701288 Cap Assembly 1 8 BJ201388 Seal Assembly Swivel 1 9 10078913 HP Gland Anti Vibration 0 38 2 10 10078715 HP Collar 0 38 2 1013468 ...

Page 217: ...2G 1 4 High Pressure Swivel Joint 90D F F Connection 1 10084713 Thrust Needle Bearing 0 812 x 0 375 1 2 10094647 Thrust Washer 0 81 x 0 38 x 0 095 2 3 10103505 Set Screw 6 32 x 1 8 1 4 10154680 Clamp Collar 0 688 x 0 313 1 5 CJ318088 Spindle 0 56 1 6 CJ418088 Cap 0 25 1 7 DJ301288 Swivel Body 90D 0 56 1 8 CJ401288 Swivel Bushing 90D 1 9 BJ201388 Seal Assembly Swivel 1 CJ218188 ...

Page 218: ...0138410 4 65 118 11 5 00 127 0 10138469 9 65 245 11 10 00 254 0 10138428 5 65 143 51 6 00 152 40 05106224 10 65 270 51 11 00 279 40 05131784 5 91 150 11 6 25 158 75 05013735 11 65 295 91 12 00 304 80 10138436 6 65 168 91 7 00 177 80 05086913 14 65 372 11 15 00 381 0 Figure 11 43B 3 8 Nozzle Tube HP Connection 10138584 3 64 92 46 4 00 101 60 10138618 6 64 168 66 7 00 177 80 10183051 4 53 115 06 4 8...

Page 219: ...118 11 5 00 127 0 10181105 9 65 245 11 10 00 254 0 10138501 5 65 143 51 6 00 152 40 10193100 11 65 295 91 12 00 304 80 10138519 6 65 168 91 7 00 177 80 Figure 11 43D 9 16 Nozzle Tube HP Connection 10138667 3 65 92 91 4 00 101 60 10138709 7 65 194 31 8 00 203 20 10138675 4 65 118 11 5 00 127 0 10138717 8 65 219 71 9 00 228 60 10138683 5 65 143 51 6 00 152 40 10138725 9 65 245 11 10 00 254 0 1013869...

Page 220: ...mbly 1 05076971 Cap Assembly Body 1 2 05073820 Body 1 3 05076955 Abrasive Insert 0 370 0 372 0 030 x 0 156 1 05135827 Abrasive Insert 0 370 0 372 0 043 x 0 156 4 05076989 Feed Tube Adapter 1 5 05077292 Set Screw 1 4 28 1 6 05081518 O Ring 3 8 x 1 2 x 1 16 1 7 05104930 O Ring 1 2 x 5 8 x 1 16 2 8 05092887 O Ring 3 4 x 5 8 x 1 16 1 9 05078712 Retainer Knob 1 10 05087168 Guard 1 Ref 1 49885361 Poly T...

Page 221: ...4 mm 05114905 0 018 0 457 mm 05101753 0 011 0 279 mm 80086663 0 019 0 482 mm 05077300 0 012 0 305 mm 05114897 0 020 0 508 mm 05136098 0 013 0 330 mm Table 11 46 AutolineTM Sapphire Orifice Part Number Description Part Number Description 05109079 0 007 0 178 mm 20412569 0 013 0 330 mm Figure 11 46 AutolineTM Sapphire Orifice 05109087 0 008 0 203 mm 05109137 0 014 0 356 mm 05109095 0 009 0 229 mm 05...

Page 222: ...5 Cylinder Assembly Pneumatic Control Valve 1 Figure 11 47 Pneumatic Control Valve NC 2 10189181 Valve Body 1 3 BV701184 HP Gland Fitting 0 5938 1 4 10188233 Brass Backup Ring 0 048 x 0 082 x 0 170 1 5 10178978 Seal Assembly HP Valve 0 25 1 6 BV901184 Valve Stem 0 080 1 7 10178697 Valve Seat 0 50 x 0 04 1 See Maintenance Tools Table 11 35 Page 11 71 10138824 ...

Page 223: ...6 1 Figure 11 48 Pneumatic Cylinder Assembly NC 2 20411554 Cylinder Cap 1 3 10177780 Wiper Seal 0 625 1 4 10177772 Retaining Ring 2 75 1 5 10176543 Pneumatic Cylinder 2 750 ID 1 6 10177806 O Ring 2 5 8 x 2 3 4 x 1 16 3 7 05054119 Compression Spring 0 72 x 0 105 x 1 50 6 8 49895584 O Ring 5 64 x 13 64 x 1 16 1 9 10187250 Backup Ring 0 475 x 0 125 x 0 105 1 10 0080028 Cover 1 ...

Page 224: ... Cylinder Assembly Pneumatic Control Valve 1 Figure 11 49 Pneumatic Control Valve NO 2 10189181 Valve Body 1 3 BV701184 HP Gland Fitting 0 5938 1 4 10188233 Brass Backup Ring 0 048 x 0 082 x 0 170 1 5 10178978 Seal Assembly HP Valve 0 25 1 6 BV901184 Valve Stem 0 080 1 7 10178697 Valve Seat 0 50 x 0 04 1 See Maintenance Tools Table 11 35 Page 11 71 10101301 ...

Page 225: ...em Part Number Description Quantity 1 BV401184 Pneumatic Cylinder 2 375 ID 1 Figure 11 50 Pneumatic Cylinder Assembly NO 2 BV601184 Cylinder Head 1 3 BV501184 Piston 2 374 1 4 10187250 Backup Ring SST 0 475 x 0 125 x 0 105 1 5 10074714 O Ring 2 7 16 x 2 5 8 x 3 32 1 6 10074565 O Ring 2 1 4 x 2 3 8 x 1 16 2 101895530 ...

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Page 232: ...nment None LD50 LC50 Not Available Routes of Entry Skin Contact Skin Absorption Eye Contact Inhalation Ingestion No No Yes Yes Yes 4 FIRST AID MEASURES If inhaled Overexposure If person is affected by fumes remove person to fresh air Seek medical attention After contact with skin Overexposure Wash thoroughly with soap and water If severe irritation develops seek medical attention After contact wit...

Page 233: ...rotective equipment Eye and hand protection as needed Measures for protection of the environment None required Cleaning measures Use absorbent material and suitable cleaner Additional information None 7 HANDLING AND STORAGE Safety information None Information on protection from fire May decompose above 500 F 260 C to produce organo chlorine or explosion compounds organo fluorine compounds hydrogen...

Page 234: ...minum threaded connections where galling and seizure may initiate a reaction Reacts with amines liquid fluorine and liquid chlorine trifluoride Hazardous decomposition products See Sections 4 and 5 11 TOXICOLOGICAL INFORMATION Acute toxic properties None known Health effects See Sections 4 and 5 Additional health effects None known Sensitization Teratogenicity Reproductive Toxicity Mutagenicity Sy...

Page 235: ... Canadian regulation listings SARA 313 NO TSCA YES Canada s Controlled Products NO EC Relevant risk None EC Relevant safety S 37 39 Wear suitable gloves and eye face protection S 20 When using do not eat or drink Additional information Consult country codes for specific requirements 16 OTHER INFORMATION Further information contact Your Swagelok Distributor or the contacts listed in Section 1 of th...

Page 236: ...ol 1 3 57 55 6 N N Dialkyltoluidines 0 1 1 613 48 9 TITANIUM DIOXIDE 0 1 1 13463 67 7 III PHYSICAL DATA Physical State Appearance Purple liquid Odour Odour Threshold Mild Specific Gravity 1 08 at 68 F Vapour Pressure Less than 5mm at 80 F Vapour Density Not Available Evaporation Rate Ether 1 Not Available Boiling Point Greater than 300 F Freezing Point Not Available Volatile Organic Compound EPA M...

Page 237: ...ting Conditions Aggravated by Exposure None Known Toxicity Information See Effects of Acute Exposure to Product Effects of Acute Exposure to Product Mild eye irritant Estimated oral LD50 more than 5000 mg kg Estimated dermal LD50 more than 2000 mg kg Effects of Chronic Exposure to Product Literature Referenced Carcinogen Ingredients Target Organ and Other Health Effects NTP IARC OSHA Polyglycol di...

Page 238: ...s on prolonged contact Carcinogenicity See Effects of Chronic Exposure to Product Reproductive Toxicity See Effects of Chronic Exposure to Product Teratogenicity See Effects of Chronic Exposure to Product Mutagenicity See Effects of Chronic Exposure to Product Name of Toxicologically Synergistic Products Not Available WHMIS Hazard Class D 2 A D 2 B VII PREVENTATIVE MEASURES Personal Protection Eye...

Page 239: ...cable Skin Contact Wash with soap and water Eye Contact Flush at least 15 minutes with water Obtain medical attention IX SHIPPING INFORMATION Canadian Transportation of Dangerous Goods Shipping Name NOT REGULATED Classification NOT REGULATED Product ID Number NONE ICAO IATA Proper Shipping Name Unrestricted Class or Division Unrestricted UN or ID Number None X PREPARATION INFORMATION Prepared By S...

Page 240: ... and Nitrogen Oxides Hazardous Decomposition Thermal decomposition may yield methacrylate monomers Handling Precautions Use good personal hygiene practices Clean contaminated clothing and protective equipment before reuse Storage Precautions Store in a cool dry location Keep container tightly closed when not in use and during transport Keep away from open sparks or flames SECTION 7 HEALTH HAZARDS ...

Page 241: ...This product has a low order of acute oral toxicity but minute amounts aspirated into the lungs during ingestion may cause mild to severe pulmonary injury Carcinogenicity NTP No IARC Monographs No OSHA Regulated No Section 4 Emergency and First Aid Procedures EYE CONTACT Flush with clear water for 15 minutes or until irritation subsides If irritation persists consult a physician SKIN CONTACT Remov...

Page 242: ...thod Assure conformity with applicable disposal regulations Dispose of absorbed material at an approved waste disposal facility or site SARA TITLE III Section 313 Status Zinc Compounds 6 Section 9 Special Protection Information Respiratory Protection Specify type Normally not needed Ventilation Local Exhaust Used to capture fumes and vapors Special N A Mechanical General Other N A Protective Glove...

Page 243: ...ATION Under normal conditions of use this product is not considered hazardous according to regulatory guidelines See section 15 EMERGENCY OVERVIEW Amber Liquid DOT ERG No NA POTENTIAL HEALTH EFFECTS Under normal conditions of intended use this product does not pose a risk to health Excessive exposure may result in eye skin or respiratory irritation For further health effects toxicological data see...

Page 244: ... spill release to Coast Guard National Response Center toll free number 800 424 8802 In case of accident or road spill notify CHEMTREC 800 424 9300 PROCEDURES IF MATERIAL IS RELEASED OR SPILLED LAND SPILL Shut off source taking normal safety precautions Take measures to minimize the effects on ground water Recover by pumping or contain spilled material with sand or other suitable absorbent and rem...

Page 245: ...mit STEL 5 mg m3 as oil mist OSHA Permissible Exposure Limit PEL VENTILATION If mists are generated use adequate ventilation local exhaust or enclosures to control below exposure limits RESPIRATORY PROTECTION If mists are generated and or when ventilation is not adequate wear approved respirator EYE PROTECTION If eye contact is likely safety glasses with side shields or chemical type goggles shoul...

Page 246: ...or the components SKIN IRRITATION RABBITS Practically non irritating Primary Irritation Index greater than 0 5 but less than 3 Based on testing of similar products and or the components OTHER ACUTE TOXICITY DATA Although an acute inhalation study was not performed with this product a variety of mineral and synthetic oils such as those in this product have been tested These samples had virtually no...

Page 247: ...cted from this product MOBILITY When released into the environment adsorption to sediment and soil will be the predominant behavior PERSISTENCE AND DEGRADABILITY This product is expected to be inherently biodegradable BIOACCUMULATIVE POTENTIAL Bioaccumulation is unlikely due to the very low water solubility of this product therefore bioavailability to aquatic organisms is minimal 13 DISPOSAL CONSI...

Page 248: ... lists below CHEMICAL NAME CAS NUMBER LIST CITATIONS ZINC ELEMENTAL ANALYSIS 0 01 7440 66 6 22 PHOSPHORODITHOIC ACID O O DI 68649 42 3 22 C1 14 ALKYL ESTERS ZINC SALTS 2 1 ZDDP 0 09 REGULATORY LISTS SEARCHED 1 ACGIH ALL 6 IARC 1 11 TSCA 4 16 CA P65 CARC 21 LA RTK 2 ACGIH A1 7 IARC 2A 12 TSCA 5a2 17 CA P65 REPRO 22 MI 293 3 ACGIH A2 8 IARC 2B 13 TSCA 5e 18 CA RTK 23 MN RTK 4 NTP CARC 9 OSHA CARC 14...

Page 249: ...ith as accurate but without guarantee Conditions of use and suitability of the product for particular uses are beyond our control all risks of use of the product are therefore assumed by the user and WE EXPRESSLY DISCLAIM ALL WARRANTIES OF EVERY KIND AND NATURE INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN RESPECT TO THE USE OR SUITABILITY OF THE PRODUCT Nothing i...

Page 250: ...call collect Medical Emergency 1 800 342 5119 or 1 281 293 5119 WEB SITE www conoco com 2 COMPOSITION INFORMATION ON INGREDIENTS COMPONENTS CAS NUMBER Highly refined base oils 64742 54 7 0 99 5 64742 01 4 0 99 5 Proprietary additives 5 If oil mist is generated exposure limits apply See Section 8 3 HAZARDS IDENTIFICATION EMERGENCY OVERVIEW APPEARANCE ODOR Clear and bright liquid mild petroleum hydr...

Page 251: ...develops and persists consult a physician If injected under the skin necrosis could occur See physician Eye Contact In case of contact immediately flush eyes with plenty of water for at least 15 minutes Call a physician Ingestion Material poses an aspiration hazard If swallowed do not induce vomiting Immediately give 2 glasses of water Never give anything by mouth to an unconscious person Call a p...

Page 252: ...quipment including respiratory protection 6 ACCIDENTAL RELEASE MEASURES Safeguards Personnel NOTE Review FIRE FIGHTING MEASURES and HANDLING PERSONNEL sections before proceeding with clean up Use appropriate PERSONAL PROTECTIVE EQUIPMENT during clean up Remove source of heat sparks and flame Initial Containment Dike spill Prevent material from entering sewers waterways or low areas Spill Clean Up ...

Page 253: ...ial exposure and published respirator protection factors PROTECTIVE GLOVES Should be worn when the potential exists for prolonged or repeated skin contact NBR or neoprene recommended EYE PROTECTION Safety glasses with side shields OTHER PROTECTIVE EQUIPMENT Coveralls with long sleeves if splashing is probable Applicable Exposure Limits If oil mist is generated exposure limits apply PEL OSHA 5 mg m...

Page 254: ...ON Ecotoxicological Information No specific aquatic data available for this product 13 DISPOSAL CONSIDERATIONS Waste Disposal Treatment storage transportation and disposal must be in accordance with applicable Federal State Provincial and Local regulations Do not flush to surface water or sanitary sewer system Container Disposal Empty drums should be completely drained properly bunged and promptly...

Page 255: ...ntains the following ingredient s which is considered hazardous if spilled into navigable waters and therefore reportable to the National Response Center 1 800 424 8802 Ingredient Petroleum Hydrocarbons Reportable Quantity Film or sheen upon or discoloration of any water surface State Regulations U S CALIFORNIA PROP 65 Ingredients subject to the Act None PENNSYLVANIA WORKER COMMUNITY RIGHT TO KNOW...

Page 256: ...Responsibility for MSDS DNA SHE Address Conoco Inc PO Box 2197 Houston TX 77252 Telephone 1 281 293 5550 Web Site www conoco com Indicates updated section End of MSDS ...

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