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KMT STREAMLINE SL-V SRP 100, Operation And Maintenance Manual

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KMT STREAMLINE SL-V SRP 100 Operation And Maintenance Manual Download Page 48

Section 3 

 

Maintenance 

 

20428697 
7-2005/Rev 0 

3-3 

 

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

Table 3-1 

Lubrication Specifications 

Description Application Part 

Number 

Pure Goop 

Stainless steel threads 

10084440 

FML-2 Grease 

O-rings, backup rings, bearing rings, seal 

components 

10087385 

JL-M Grease 

Non-stainless steel threads 

49832199 

 

 

 

3.3

 

Maintenance Precautions 

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

Check the 

EMERGENCY STOP

 button.  The normal operating position is pulled out.  Turn the 

power on and activate the emergency stop button by pushing it in to verify the power goes off and 
the safety dump valve opens to bleed the high pressure from the system. 

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

OFF

 position. 

•

 

Never

 service or maintain the equipment while it is operating. 

•

 

Steam or fog inside the top cover is an indication of a high pressure leak.  All high 
pressure leaks must be repaired immediately.  Press the 

EMERGENCY STOP

 button to turn 

the control power off and bleed off the high pressure water from the intensifier 

before

 

lifting the cover. 

•

 

Never service or maintain any high pressure component, or loosen any high pressure 
fitting when it is pressurized.  Press the 

EMERGENCY STOP

 button to turn the control power 

off and bleed off the high pressure water from the intensifier before servicing. 

•

 

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

possible hazardous results

. 

 

Summary of Contents for STREAMLINE SL-V SRP 100

Page 1: ...MANUAL 20428408 R08 STREAMLINE SL V SRP 100 WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL ...

Page 2: ...es 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 20...

Page 3: ...rocedure 1 5 Warning Labels 1 6 Emergency Medical Treatment 1 8 1 5 Worldwide Product Support 1 9 1 6 Spare Parts 1 9 1 7 Manual Organization 1 9 1 8 Equipment and Service Manual Questionnaire 1 10 Terms and Conditions of Sale Terms and Conditions Part Sales Terms LD 146 Domestic Service Supervisor Terms LD 147 International Service Supervisor 2 Installation 2 1 2 1 Overview 2 1 2 2 Installation S...

Page 4: ...intenance 3 1 High Pressure System Maintenance 3 2 3 3 Maintenance Precautions 3 3 4 Operation 4 1 4 1 Overview 4 1 4 2 Startup Sequence 4 2 Startup after Motor Stop 4 2 Startup after Emergency Stop 4 2 4 3 Display Controls 4 3 4 4 Main Menu 4 4 4 5 Run Screens 4 4 4 6 Pressure Control Screen 4 5 4 7 Setup Screens 4 6 4 8 Stroke Rate Screen 4 8 4 9 Hours Screen 4 9 4 10 Run Screen Alarms 4 10 4 11...

Page 5: ... and Maintenance Procedures 7 4 Hydraulic Operating Pressure 7 4 Motor Maintenance 7 6 Flexible Coupling Replacement 7 6 Hydraulic Compensator Maintenance 7 8 Hydraulic Pump or Electric Motor Replacement 7 11 Hydraulic Oil Replacement 7 17 8 Electrical System 8 1 8 1 Overview 8 1 8 2 Optional System Components 8 1 8 3 Operation 8 2 Sensors and Solenoids 8 4 8 4 Service and Maintenance Procedures 8...

Page 6: ...l 9 27 Bearing Rings and Seal Assembly 9 29 Plunger Button Sockets Seals and Retainer Pins 9 30 Internal Check Valves 9 30 Hydraulic Piston Installation 9 31 9 12 Hydraulic Cylinder Maintenance 9 32 9 13 High Pressure Attenuator 9 32 9 14 High Pressure Dump Valve 9 33 Pneumatic Control Valve 9 34 Pneumatic Actuator 9 38 9 15 Weep Holes 9 39 10 Troubleshooting 10 1 10 1 Overview 10 1 10 2 Troublesh...

Page 7: ...ations 11 6 Hydraulic System 11 6 High Pressure Water System 11 7 Orifice Capacity 11 7 Torque Specifications 11 9 12 Parts List 12 1 12 1 Overview 12 1 12 2 Part Nomenclature 12 2 12 3 Index 12 3 APPENDIX Exhibit System Schematic Electrical Schematics Material Safety Data Sheets ...

Page 8: ...aulic cylinder head simply bolts to the hydraulic cylinder each high pressure assembly can be removed and serviced independently and the hydraulic seal cartridge can be quickly replaced as a single unit The robust performance and standard features are the result of aggressive development and decades of experience Continuous operation at 35 000 psi 2 413 bar The innovative hard seal end cap provide...

Page 9: ...vide real time diagnostics troubleshooting and data analysis through a modem interface for remote monitoring of the programmable logic controller PLC Proportional pressure control allows the operator to select or vary the operating pressure from the control display or remote console The current operating pressure can be viewed from the control display with an optional pressure transducer ...

Page 10: ...on system is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system Major system components include the recirculation pump heat exchanger oil filter assembly and the hydraulic oil reservoir Hydraulic System The hydraulic system supplies the intensifier with the hydraulic oil required to produce high pressure water Major system components include the ele...

Page 11: ...de the high pressure cylinder assemblies hydraulic cylinder assembly hydraulic piston attenuator and the safety dump valve Figure 1 2 High Pressure System Components Operating System A programmable logic controller PLC provides basic intensifier shift control and monitors out of limit conditions Operator interface is through the control panel display where operating parameters are set and monitore...

Page 12: ...ut procedure is designed to protect all employees from injuries caused by the unexpected energizing or startup of the machine or the release of stored energy during service and maintenance This is accomplished with energy isolating devices that prevent the transmission or release of energy An energy source is any source of electrical mechanical hydraulic pneumatic chemical thermal or other energy ...

Page 13: ...er replacement labels Table 1 2 Warning Label Precautions 1 P N 05114962 The electrical enclosure and motor junction box can present an electrical shock hazard Always disconnect and lockout the main power before opening the enclosure Always disconnect and lockout the main power and the circuit breaker disconnect on the electrical enclosure door before performing any type of maintenance 2 P N 05114...

Page 14: ...ll personnel involved in the installation operation and or service of the intensifier must carefully read understand and follow the procedures in this manual to avoid creating unsafe conditions risking damage to the equipment or personal injury Safety precautions and warnings for specific procedures are emphasized throughout this manual as illustrated in the following examples These precautions mu...

Page 15: ... for ANY high pressure waterjet injuries KMT Waterjet Systems 635 West 12th Street Baxter Springs KS 66713 620 856 2151 This person has been working with water jetting at pressures to 60 000 psi 374MPa 4 137 bar 3867 Kg cm2 with a jet velocity of 3 000 fps 914 mps Foreign material sand may have been injected with water Unusual infections with microaerophilic organisms occurring at lower temperatur...

Page 16: ...kmtgroup com KMT Waterjet Systems GmbH Wasserstrahl Schneidetechnik Auf der Laukert 11 D 61231 Bad Nauheim Germany Phone 49 6032 997 117 Fax 49 6032 997 270 Email order service kmt waterjet com 1 6 Spare Parts KMT Waterjet maintains a well stocked Spare Parts Department staffed by trained knowledgeable personnel If required emergency shipment is available Contact the Customer Service Department to...

Page 17: ...ions contains a comprehensive list of equipment specifications a detailed discussion of water quality standards and treatment guidelines as well as flow requirements for various orifice sizes Section 12 Parts List contains part numbers descriptions and drawings to facilitate the ordering of replacement parts 1 8 Equipment and Service Manual Questionnaire We are interested in your impression of the...

Page 18: ...o 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 P...

Page 19: ...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 20: ... covered by such exemption certificate which the Company is required to pay 6 Set Offs Neither Purchaser nor any affiliated company or assignee shall have the right to claim compensation or to set off against any amounts which become payable to the Company under this contract or otherwise 7 Patents The Company shall defend any Suit or proceeding brought against the Purchaser and shall pay any adve...

Page 21: ...USE LOST PROFITS OR REVENUE INTEREST LOST GOODWILL WORK STOPPAGE IMPAIRMENT OF OTHER GOODS LOSS BY REASON OF SHUTDOWN OR NON OPERATION INCREASED EXPENSES OF OPERATION COST OF PURCHASE OF REPLACEMENT POWER OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION WHETHER OR NOT SUCH LOSS OR DAMAGE IS BASED ON CONTRACT WARRANTY NEGLIGENCE INDEMNITY STRICT LIABILITY OR OTHERWISE 10 Nu...

Page 22: ...any such defect promptly upon discovery but in no event later than six 6 months from the date of shipment of such part by the Company Warranties applicable to material and equipment supplied by the Company but wholly manufactured by others shall be limited to the warranties extended to the Company by the manufacturer which are able to be conveyed to the Purchaser The Company makes no performance w...

Page 23: ......

Page 24: ... to the Company at the completion of the services 6 The Company agrees that the Supervisor will provide Best Efforts in effecting repairs to equipment supplied by the Company but provides no guarantee that such Best Efforts will result in restoration of proper operation of equipment the Supervisor is contracted to repair 7 The Supervisor shall be suitably covered with insurance in the areas of Wor...

Page 25: ......

Page 26: ... for transport by the Supervisor the Purchaser shall assist in arranging for their return to a location designated by the Company at the completion of the services 6 The Purchaser shall provide suitable office facilities convenient to the jobsite for work assignments exceeding thirty 30 days facilities to include heat light desk chair telephone and safe storage space for drawings and tools 7 The S...

Page 27: ...tem are discussed in this section Upon receipt the machine must be uncrated and moved into position on a level surface Properly sized power drops with fused disconnects must be installed A pneumatic drop with a manual shutoff valve and regulator for the air connection must be installed Plumbing and manual shutoff valves for the inlet and outlet cooling water and the inlet and outlet cutting water ...

Page 28: ...le 2 1 Equipment Dimensions and Weight Horsepower Length Width Height Weight 100 HP 77 75 1 975 mm 36 00 914 mm 57 19 1 453 mm 4 200 lbs 1 905 kg Transporting The weight of the machine is not evenly distributed from one end to the other particularly on the larger horsepower models Do not attempt to lift the machine from either end Note the warnings stamped on the crate The center of gravity is cle...

Page 29: ...ill be installed in an overhead location a forklift or crane can be used to position the pump Heavy straps or chains properly rated for the weight requirements should be placed through each fork pocket and wrapped around the sides of the machine so they meet on the top The straps can then be attached to a crane or forklift to lift the machine The machine must be lifted from the bottom Do not attem...

Page 30: ...0 218 300 380 3 60 100 130 175 400 3 50 100 124 175 415 3 50 100 121 175 460 3 50 100 114 175 480 3 60 100 106 175 575 3 60 100 91 125 2 5 Service Connections The intensifier requires two incoming water sources cooling water and cutting water three drain lines cooling water wastewater and contaminated waste a high pressure discharge line and an air supply line All piping must comply with local reg...

Page 31: ... 267 mm C Cooling Water Out 1 2 NPT 13 50 343 mm D Cooling Water In 1 2 NPT 16 50 419 mm E Plant Air In 1 4 NPT 32 00 813 mm F Cutting Water Out 9 16 HP 36 00 914 mm G Contaminated Waste Drain 1 2 NPT 41 00 1 041 mm Cooling Water Inlet cooling water flows through the oil to water heat exchanger in the hydraulic system to control heat build up in the hydraulic oil The cooling water is then discharg...

Page 32: ...er source and the machine The inlet water must be maintained at a minimum pressure of 35 psi 2 4 bar at all times If the facility water pressure is below or can fall below 35 psi 2 4 bar a water pressure booster pump is required NOTE The machine will not start if inlet cutting water pressure is below 30 psi 2 bar Drain Cutting water released through the safety dump valve when the emergency stop bu...

Page 33: ...ifier Add the values together for a total pressure drop value 3 Add 30 to the total pressure drop to determine the minimum flowing source water pressure required to provide adequate supply to the intensifier Cutting water and cooling water capacity should be calculated separately Note that the cutting water requirements represent instantaneous not average demand The machine will not start if the i...

Page 34: ...d for 60 000 psi 4 136 bar Failure to use properly rated components may result in component failure causing equipment damage personal injury or death High pressure tubing lengths must be coned and threaded prior to installation KMT Waterjet provides both hand and power tools for coning and threading high pressure tubing Tool descriptions and part numbers are provided in Table 2 5 Table 2 5 Coning ...

Page 35: ...the required cone and thread dimensions illustrated in Figure 2 6 Figure 2 5 Tube Length Table 2 6 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 7 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 36: ...he tubing 4 Turn the feed nut counter clockwise 1 4 turn to retract the cutting blade 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 blade and through the lubrication channel at the cutter handle Apply cutting oil frequently and liberally throughout the cutting operation A medium weight cutting oil w...

Page 37: ... 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 8 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 38: ...edium weight cutting oil with high sulfur content is recommended 4 Continue threading until the proper thread length is reached see Table 2 7 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 39: ...0 before purging with air will help carry the burrs High pressure piping must be installed without torsional or bending stresses and proper supports and guides must be provided Torsional stress will cause premature component failure Pure Goop anti seize compound must be applied to the threads and contact surfaces of all stainless steel components prior to assembly Failure to lubricate components w...

Page 40: ...ue specifications in Table 2 9 Proper piping supports and guides must be provided End connections will not support the tubing load alone Table 2 9 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 tubi...

Page 41: ...ilures from non water related stresses The whip will only flex in a single plane without being subjected to torsional stress The use of high pressure swivels is strongly recommended 2 9 Commissioning When the machine has been positioned all service connections installed and the high pressure plumbing has been installed to the cutting area the machine is ready to be commissioned The following proce...

Page 42: ...ion regarding control panel functions 6 On the Run Screen select the arrow on the PRESSURE switch to select low pressure operation 7 To avoid a sudden increase in pressure it is necessary to adjust the high pressure setting On standard machines the high pressure adjustment is made at the high pressure control valve on the hydraulic manifold Refer to Section 7 Hydraulic System for additional inform...

Page 43: ...he START button on the Run Screen and observe the pressure gauge on the hydraulic manifold If the motor rotation is correct pressure will begin to build in just a few seconds If the rotation is not correct the gauge will not move If the motor shaft is rotating in the wrong direction press the STOP button and turn the control power off by pressing the EMERGENCY STOP button The electrical power phas...

Page 44: ... to increase the pressure or counter clockwise to decrease the pressure 13 Check the safety circuits by pushing the EMERGENCY STOP button in and verifying that the power goes off and high pressure water is drained from the system If applicable check all remote start and emergency stop functions 14 Install a large inexpensive orifice and start the machine 15 On the Run Screen select the arrow on th...

Page 45: ...Section 2 Installation 20428689 10 2007 Rev 04 2 19 2 10 Decommissioning All local regulations must be adhered to when the intensifier is decommissioned and taken out of service for any reason ...

Page 46: ...Detailed maintenance and troubleshooting procedures for specific systems are provided in subsequent sections of this manual Daily Inspection The following inspection procedures should be performed each day If problems are detected they should be remedied before placing the machine in service Prior to startup inspect the area around the machine the high pressure piping and connections for indicatio...

Page 47: ...onditions and the risk of equipment damage operating personnel and service technicians must carefully read and follow the procedures in this manual High Pressure System Maintenance The high pressure system is conveniently mounted on a drip pan All service components are readily accessible and can be removed from the unit easily for maintenance and service High pressure fittings valves and tubing m...

Page 48: ...om the system Before performing any maintenance on the equipment take the system out of service and make sure the controls are properly locked and marked Never perform any maintenance on the equipment without making sure the main control power is locked out in the OFF position Never service or maintain the equipment while it is operating Steam or fog inside the top cover is an indication of a high...

Page 49: ...d software updates The operator interface is through a touch sensitive control display where operating parameters are set and monitored Optional proportional pressure control allows the operator to select or vary the operating pressure from the control display or from a remote console When the machine is equipped with an optional pressure transducer the operating pressure can be viewed from the di...

Page 50: ...ed to bleed the startup sequence is the same as above If the machine is equipped with a pressure transducer and pressure is allowed to bleed through the orifice to below 1 000 psi 69 bar the dump valve will open In this case the startup sequence is as described below Startup after Emergency Stop After an emergency stop the safety dump valve will be open and high pressure released in the intensifie...

Page 51: ...re the machine can be started to create pressure The machine must be started from the Maintenance Screen to access maintenance functions The machine will start in recirculation mode STOP The STOP button displays on all screens except the Alarm History and Language Screens Motor stop only the control power remains on Return to Main Menu Return to Run Screen ON position for controls on the Set Up Sc...

Page 52: ...ation where the machine can be started to create pressure After five minutes on any other screen the display will default to the Run Screen Run screens are configured according to equipment options If machines are connected to a header system that is controlled by the KMT Waterjet Balancing System a number displays in the black box on the top of the Run Screen to indicate the machine s position wi...

Page 53: ...ed by the operator it will go to high pressure or remain in low pressure depending on the previous high low pressure setting RECIRCULATION switch select the ON position to recirculate the machine The machine will recirculate for 10 minutes before the switch shuts off Recirculation can be manually stopped by pressing the STOP button Recirculation time is indicated below the switch The Run Screen in...

Page 54: ...w pressure PROPORTIONAL PRESSURE CONTROL increment decrement pressure allows the pressure to be set in 1 increments press the or arrow to set the pressure from 0 to 100 4 7 Setup Screens Setup screens are configured for the specific machine displaying only the available functions Figure 4 6 Setup Screen Standard Machine The Setup Screen for a standard machine displays the following functions WATER...

Page 55: ...s not require operator input PROPORTIONAL PRESSURE allows the output pressure to be set from the Pressure Control Screen press the control to turn it ON or OFF PRESSURE TRANSDUCER displays the output pressure on the Run Screen and the Pressure Control Screen if applicable press the control to turn it ON or OFF WATER RESET FUNCTION automatically shuts the inlet water solenoid valve five minutes aft...

Page 56: ...eases the allowed stroke rate press the or arrow to select the rate Stroke rate should be set slightly higher than the desired operating rate to shutdown the machine quickly in the event of an overstroke condition The upper limit stroke rate for the SL V SRP 100 is preset at 61 strokes per minute Table 4 2 Overstroke Set Points shows the number of strokes per minute above the setting that will res...

Page 57: ...ing will be issued after 15 seconds The warning will continue until the rate returns to normal or exceeds the overstroke shutdown point If the stroke rate reaches 46 an overstroke shutdown pending will be issued If the condition exists for 30 seconds an automatic shutdown will occur 4 9 Hours Screen The Hours Screen displays total machine operating hours and maintenance hours Operating hours canno...

Page 58: ...gh Pressure Lines Intensifier is shut down high pressure is present in the discharge plumbing and should be bled off to avoid possible injury Applies only when equipped with optional pressure transducer Booster Temperature High Booster pump water temperature is high in excess of 128 F 53 C Shutdown will occur if condition persists High Oil Temperature High hydraulic oil temperature in excess of 14...

Page 59: ...own at the warning level if the pressure is less than 3 000 psi 207 bar Low Battery Battery is low After the alarm occurs the battery will last for approximately seven days Replace with backup replacement battery Low Booster Pressure Booster pump output pressure is less than 30 psi 2 bar Shutdown is pending Seven seconds after the machine is started the booster pump output pressure switch is monit...

Page 60: ...will appear on the Alarm History Screen Alarm banner shutdowns are listed in Table 4 3 Table 4 3 Alarm Banner Shutdowns Alarm Indication Possible Remedies Check bleed orifice in low pressure water manifold Check for long idle times Booster Temp High High booster water temperature Check the inlet water switch Check left HP seal Check right discharge Left Overstroke Shutdown A left overstroke condit...

Page 61: ...uge Check for hydraulic leaks Check the oil level switch Oil Level Low Low oil level Check inlet and discharge check valves Check right high pressure seal Check left discharge Right Overstroke Shutdown A right overstroke condition has occurred Check right inlet check valve Check plumbing for leaks Check high pressure orifice Check incoming water pressure T W Overstroke Shutdown An intensifier over...

Page 62: ...n excess of 128 F 53 C Shutdown will occur 30 seconds after detection Booster Press Low Low water pressure from booster pump less than 30 psi 2 bar Shutdown will occur 20 seconds after detection Battery Low Battery is low and needs to be replaced The battery will last approximately seven days after the alarm occurs Inlet Low Low inlet water pressure less than 30 psi 2 bar Shutdown will occur if co...

Page 63: ... not attempt to remove the permanent battery 1 Insert the new battery into the replacement battery pocket with the wires facing up 2 Insert the wire connector for the replacement battery into the connector port 3 Secure the battery wires under the wire latch as shown in Figure 4 12 Battery Replacement Figure 4 13 Battery Replacement 49837867 ...

Page 64: ...lay Ten seconds later the number 32 will replace the number 24 and a small blinking square will display on the bottom right of the screen 4 Press the blinking square to initialize the Configuration Screen used to set the parameters for the panel display 5 Select Date Time and press ENTER Set the year month day hour minutes and seconds Press EXIT to return to the previous screen 6 Select Run Mode a...

Page 65: ...on to reset and open the valve STARTUP PRESSURE TIMER press the or arrow to select a startup time from 5 60 seconds This will determine the startup time between low and high pressure operation RIGHT arrow will open the dump valve and extend the piston to the right allowing full exposure to the right plunger when the unit is disassembled The unit must be completely assembled to use this jog functio...

Page 66: ...ation II Screen is a password protected screen used to change the stroke count or the operating hours The password to access the Configuration II Screen is 111320 Figure 4 17 Configuration II Screen STROKE COUNT press the or arrow to increase or decrease the stroke reading in increments of 100 strokes The stroke count can not be changed if the pump is running CHANGE OPERATING HOURS press the or ar...

Page 67: ...er flow and pressure System components include the inlet water solenoid valve strainer booster pump and the low pressure filter assembly Pressure and temperature switches connected to the PLC monitor out of tolerance conditions in the cutting water circuit and provide automatic shutdown protection Figure 5 1 Cutting Water Supply Circuit TO BOOSTER PRESSURE GAUGE TO CUTTING WATER SUPPLY GAUGE CUTTI...

Page 68: ...Supply Gauge on the front of the machine Figure 5 2 Low Pressure Water System Cutting water enters through the normally closed inlet water solenoid valve When the control power is turned on the solenoid valve opens and allows water to flow through the valve The inlet water is monitored by a 30 psi pressure switch mounted on the inlet manifold If the pressure drops below 30 psi 2 bar the switch act...

Page 69: ...water to exit through the 1 2 inch drain connection on the rear bulkhead It is still possible to operate the machine however excess water will continue to be released through the drain Discharge pressure is displayed on the Booster Pressure Gauge on the front of the machine The gauge should read approximately 120 psi 8 bar while the machine is idling NOTE While the intensifier assembly reverses di...

Page 70: ... the inlet water The condition of the filter element can be monitored by observing the Booster Pressure Gauge on the front of the machine Document the pressure reading when the filter element is new The element should be replaced when the pressure drops to 15 psi 1 bar below the original value When the filter element is replaced the strainer should also be cleaned The following procedure is used t...

Page 71: ...screw the strainer body into the strainer head hand tighten 7 Turn the cutting water supply on 8 Press the red bleed valve to remove any air inside the housing 9 Start the machine and verify satisfactory pressure readings Booster Pump Adjustment If the discharge pressure from the booster pump stays below 90 psi 6 bar while the intensifier is shifting the relief valve on the booster pump should be ...

Page 72: ...ent screw clockwise to increase the discharge pressure or counter clockwise to decrease the pressure Adjust the pressure to the highest desired pressure within normal booster pump range If the adjustment screw is turned too far out counter clockwise an internal spring and relief will fall down inside the pump If this occurs the pump must be removed and the parts must be reinstalled to avoid compon...

Page 73: ... include the water modulating valve recirculation pump heat exchanger oil filter assembly and the hydraulic oil reservoir A temperature low level switch connected to the PLC monitors temperature and oil level conditions in the hydraulic oil reservoir and provides automatic shutdown protection Figure 6 1 Oil Recirculation Circuit BYPASS RELIEF VALVE OIL FILL PORT OIL FILTER ASSEMBLY PRESSURE INDICA...

Page 74: ...ger controls heat build up in the hydraulic oil The plate style design allows cooling water and oil to flow side by side through alternating plates The cooled oil then passes through the filter element and returns to the reservoir The cooling water either is discharged to the 1 2 inch NPT drain on the rear bulkhead or is routed to a customer supplied water chiller The hydraulic oil filter assembly...

Page 75: ...ower is off the valve will remain open allowing water to flow until the oil is cooled 6 3 Service and Maintenance Procedures To ensure the supply of properly conditioned oil to the main hydraulic system the components will require routine servicing and maintenance The procedures for servicing these components are detailed below NOTE Refer to Section 12 Parts List for a complete listing of replacem...

Page 76: ...ssure has been bled from the system Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance 1 Drain the oil reservoir by connecting the inlet hose from an oil transfer pump to the drain valve on ...

Page 77: ...ds are required install the adapter located on the inside of the frame When filling is complete remove the adapter and install the fill port cap 6 Check the oil sight gauge on the reservoir to ensure proper fill level 7 Remove the hose from the case drain on the main hydraulic pump to make sure the pump case fills with oil With the hose removed head pressure from the reservoir will force oil into ...

Page 78: ...low zone or entering the red zone during normal operating conditions Note Normal operating conditions indicate the machine is running and the oil temperature has reached 115 F 46 C Figure 6 4 Oil Filter Assembly 1 Use a filter wrench to unscrew the filter element from the filter head Make sure the old gasket is removed with the element 2 Lubricate the gasket on the new element with fresh oil 3 Use...

Page 79: ...be required during commissioning and with seasonal changes to the cooling water temperature Figure 6 5 Water Modulating Valve 1 Locate the adjusting knob a screwdriver slot on the top of the valve 2 Use a flat screwdriver and turn counter clockwise to compress the spring slowing water flow and increasing temperature Or turn clockwise to reduce spring tension increasing water flow and decreasing th...

Page 80: ... way directional control valve and the hydraulic manifold The manifold houses the high and low pressure control valves hydraulic gauge two pressure solenoid valve and the main system relief valve The system relief valve monitors hydraulic oil pressure and provides system protection by limiting excess pressure Figure 7 1 Main Hydraulic Power Circuit HYDRAULIC GAUGE HYDRAULIC MANIFOLD MAIN RELIEF VA...

Page 81: ...eration The electric motor drives three pumps mounted in tandem the main hydraulic pump the recirculation pump and the booster pump The motor drives the variable displacement pressure compensated hydraulic pump by means of a flexible coupling Hydraulic fluid from the reservoir is drawn into the inlet low pressure side of the hydraulic pump Oil delivered to the pump should be maintained at 110 115 ...

Page 82: ...to create hydraulic oil pressure The normally closed two pressure solenoid valve is controlled by the operator s selection of high or low pressure The valve is closed while operating in high pressure and is open during low pressure operation A light on the solenoid connector indicates low pressure operation At startup hydraulic pressure is automatically switched to low limiting torque demand After...

Page 83: ...ulic operating pressure settings should be checked daily and adjusted as necessary High and low operating pressure on standard machines is adjusted at the high and low pressure control valves per the specifications in Table 7 2 For machines equipped with proportional pressure control high pressure adjustments are made from the Pressure Control Screen on the control panel The following specificatio...

Page 84: ...kwise 3 Turn the knob on the control valve clockwise to increase operating pressure Turn the knob counter clockwise to decrease pressure 4 Tighten the locking nut and verify the high pressure setting Figure 7 4 Low Pressure Control Valve 1 Check the operating pressure to determine if adjustment is necessary 2 If low pressure adjustment is required loosen the locking nut on the low pressure control...

Page 85: ...lation openings clear Flexible Coupling Replacement When the flexible coupling fails the pump shaft will not turn and pressure will not be created Typically failure will be sudden without any warning signs Figure 7 5 Flexible Coupling Replacement Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance on the syst...

Page 86: ...ol harness to the top pan will need to be removed in order to move the electrical panel 5 Remove the failed flexible coupling 6 Wipe any residue dirt or oil from the coupling halves on both the motor shaft and the pump shaft Avoid damaging the shaft seal on the pump NOTE Additional clearance and access to the motor and pump coupling can be achieved by moving the pump and manifold assembly to the r...

Page 87: ...pply full high pressure water pressure Note any unusual sounds from the motor or pump assembly Hydraulic Compensator Maintenance The high and low limit compensators regulate the flow of hydraulic fluid to the system The compensators can become blocked with debris resulting in loss of pump control Figure 7 6 Hydraulic Compensator Components Severe injury can result if the machine is not properly lo...

Page 88: ...g and all components with clean fluid and carefully dry with air 8 Check and clean the small internal passages in the spools 9 Check and clean the orifices in both spools 10 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 The compensators must be reset before operation...

Page 89: ...e control adjust the high pressure setting on the Pressure Control Screen 16 Turn the adjusting screw on the high limit compensator clockwise until the hydraulic reference gauge reads 2 900 psi 200 bar 17 Select low pressure operating mode on the display panel and turn the adjusting screw on the low limit compensator clockwise until the reference gauge reads 290 psi 20 bar Lock the adjustment scre...

Page 90: ...ppropriate 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 Loosen the hold down screws on the proximity switches to allow the hydraulic oil in the cylinders and hoses to drain back to...

Page 91: ...aulic gauge and turn it out of the way Remove all electrical sensors and connections to the hydraulic manifold 6 Remove the four bolts on the top of the hydraulic manifold and remove the manifold and o ring 7 Remove the booster pump adapter and recirculation pump These components can be removed individually or as a unit by removing the two bolts that attach the recirculation pump to the hydraulic ...

Page 92: ...t be replaced 11 Inspect the metal splines on the motor coupling half Wipe any residue dirt or oil from the motor coupling and the flexible coupling Place the flexible coupling on the motor coupling half pushing it on as far as it will go 12 Take a measurement from the front face of the electric motor the pump mounting interface to the outer face of the snap ring or solid band on the flexible coup...

Page 93: ... dimension B On 100 horsepower models B A 0 250 15 Tighten the pinch bolt and torque to 218 ft lbs 295 Nm 16 Place the hydraulic pump on the motor ensuring the coupling teeth mesh into the flexible coupling Force should not be required 17 Verify that the mating surfaces of the motor and pump meet without resistance from the coupling 18 Replace the pump mounting bolts and torque to the specificatio...

Page 94: ...ssure water pressure Inspect for hydraulic leaks and note any unusual sounds from the motor or pump assembly Table 7 3 Torque Specifications Pump mounting bolts 200 ft lb 271 Nm Manifold mounting bolts 45 ft lb 61 Nm Motor coupling half bolts 85 ft lb 115 Nm Electric Motor Replacement 1 Complete Steps 1 10 in the previous procedure 2 Open the junction box on the motor and remove all electrical lea...

Page 95: ...e position of the pump coupling half 7 Place the hydraulic pump on the motor ensuring the coupling teeth mesh into the flexible coupling Force should not be required 8 Verify that the mating surfaces of the motor and pump meet without resistance from the coupling 9 Replace the pump mounting bolts and torque to the specifications in Table 7 3 10 Position the motor and hydraulic pump in the frame At...

Page 96: ...eason it is important to use an oil transfer pump that will force oil through the return filter into the reservoir 3 Check the oil sight gauge on the reservoir to ensure proper fill level 4 Remove the hose from the case drain on the main hydraulic pump to make sure the pump case fills with oil With the hose removed head pressure from the reservoir will force oil into the pump case Oil in the pump ...

Page 97: ...ge and control components and the wiring harness that connects the sensors and solenoid valves to the PLC 8 2 Optional System Components The following system options are available at the time of purchase or as upgrade kits for existing equipment A pressure transducer allows the operating pressure to be viewed from the display panel Proportional pressure control allows the operator to select or var...

Page 98: ...ly The power supply then provides 24 volt direct current to the control circuits including the emergency stop logic the programmable logic controller PLC optical relays display screen and optional control functions When the START button is pressed on the control panel the motor control relay closes and 230 volt AC power is sent to the contactor coils The coils close sending the incoming power to t...

Page 99: ...achine All power is automatically disconnected from the machine when the main disconnect on the enclosure door is opened However power is still present on the input side of the circuit breaker door disconnect The only way to isolate all power to the machine is to turn the customer installed main power disconnect off Figure 8 3 Electrical Enclosure Door CIRCUIT BREAKER DISCONNECT ...

Page 100: ...installed main power disconnect Sensors and Solenoids Warning and shutdown sensors monitor operating conditions and electronically operated solenoids provide basic intensifier shift control The harness cable connects these sensors and solenoids to the PLC see Figure 8 5 Electrical Harness Figure 8 4 Sensors and Solenoids 49831498 ...

Page 101: ...open whenever the control power is on Low Pressure Water Filter Assembly 2 The 30 psi pressure switch mounted on the inlet manifold monitors the inlet cutting water If the pressure drops below 30 psi 2 bar the switch activates an automatic shutdown circuit protecting the booster pump from damage due to insufficient water supply pressure 3 A temperature switch monitors the temperature of the cuttin...

Page 102: ...he 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 energized by the PLC As power is dir...

Page 103: ... flow of the directional control valve and reverse direction High Pressure Safety Dump Valve 9 When control power is removed the safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines The high pressure dump valve assembly includes a normally open high pressure water valve and a solenoid operated air valve The normally open pneumatic dump valve is held cl...

Page 104: ...ponent Function Pressure Transducer 11 The optional pressure transducer reads the output pressure from the attenuator in the high pressure system A signal is sent to the PLC module that allows the operating pressure to be viewed from the control panel Figure 8 5 Electrical Harness 80080500_1 ...

Page 105: ... the piston if an LED flashes continuously or if the appropriate input is not noted on the PLC processor annunciator light panel in the electrical enclosure Figure 8 6 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 maintena...

Page 106: ...nance The four optical relays identified in Table 8 2 change the state of the associated solenoid valves If the relay or the fuse for the relay fails the state will not change For example if the relay controlling the two pressure solenoid valve fails the machine will not switch between low and high pressure operation Table 8 2 Optical Relays Label Component Function 4K1 Directional Control Valve S...

Page 107: ...ckout Tagout procedures before performing maintenance on the system components Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance 2 Open the control panel and locate the appropriate optical relay 3 Remove the screws and the relay 4 Remove and test the fuse If the fuse has failed replace it and re install the existing optical relay...

Page 108: ... 9 1 High Pressure Water System Circuit System components include a double ended hydraulic cylinder reciprocating piston assembly high pressure cylinders attached to each end of the hydraulic cylinder two plungers sealing heads and hard seal end caps two liter capacity attenuator and a safety dump valve Sophisticated check valves and seal assemblies ensure hydraulic oil and the low pressure and hi...

Page 109: ...he pressurized oil pushes the piston in one direction the plunger on that end extends and pushes against the water in the high pressure cylinder increasing the pressure up to 35 000 psi 2 413 bar When the piston reverses direction the plunger retracts and the plunger in the opposite cylinder extends to deliver the high pressure water Figure 9 2 High Pressure Cylinder Low pressure water is routed t...

Page 110: ...er exits to the cutting head The safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines The high pressure dump valve assembly includes a normally open high pressure water valve and an electrically controlled air valve The normally open pneumatic dump valve is held closed by air pressure When the air supply is interrupted and exhausted from an emergency s...

Page 111: ... Cylinder Assembly Figure 9 5 Hydraulic Cylinder Assembly JACKBOLT O RING HARD SEAL END CAP SEALING HEAD GUIDE BUSHING CYLINDER LINER HIGH PRESSURE CYLINDER HIGH PRESSURE SEAL ASSEMBLY RETAINING RING BACKUP RING O RING O RING SPACER PROXIMITY SWITCH SOCKET HEAD SCREWS STEM MOUNT HYDRAULIC CYLINDER BUSHING RETAINER FLANGE SOCKET HEAD SCREW HYDRAULIC SEAL CARTRIDGE HYDRAULIC CYLINDER HEAD 05148077 ...

Page 112: ...re water through the dump valve Improper assembly can lead to the premature failure of components Maintenance procedures must be followed carefully components must be properly cleaned prior to assembly and tightened to the correct torque specifications Some high pressure components are not serviceable at the customer level others require precise refinishing KMT Waterjet Systems offers maintenance ...

Page 113: ...t 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 8 Bolt Crossing Pattern Note Crossing Pattern 1 2 3 4 5 6 or 1 2 3 4 5 6 7 8 Note A maximum torque of 38 ft lbs 51 Nm is etched on the hard seal end cap This represents the maximum allowable torque n...

Page 114: ...60 in lbs 16 18 Nm Hex Key 3 16 inch Stem Mount Socket Head Screws 4 3 8 each Torque 35 40 ft lbs 47 54 Nm Hex Key 5 16 inch Sealing Head Discharge Gland Nut 200 ft lbs 271 Nm Poppet Retainer 25 30 in lbs 2 8 3 4 Nm 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 115: ...e 9 3 Figure 9 7 Specialized Maintenance Tools Table 9 3 Specialized Maintenance Tools High Pressure Water System Part Number Cartridge Removal Tool 20430104 Vee Block Cradle 49830946 Plug 10078772 9 16 Gland Fitting 10078608 9 16 Seal Removal Tool 20430112 End Cap Wrench 80079247 8x 80079239 6x 8x Cylinder Wrench 05066139 Seal Removal Tool Stand 80078330 SEAL REMOVAL TOOL STAND PLUG GLAND FITTING...

Page 116: ... 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 117: ...nsure 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 NOTE Prior to removal verify that the alignment marks on the high pressure cylinder and on the hydraulic cylinder head are aligned If not check the condition of the retaining ring and...

Page 118: ...reads 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 packing follower and cylinder liner are correctly installed Align the cylinder assembly with the plunger and the hydraulic cylinder head using the cradle tool to support the weight...

Page 119: ...e machine off and remedy the problem When the problem has been remedied repeat the start up procedure moving from low to high pressure soon after the intensifier starts pumping water There is no further need to flush air from the system High Pressure Cylinder Maintenance The plunger seal area in the high pressure cylinder bore should be inspected and cleaned each time the high pressure seal assemb...

Page 120: ... 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 Disconnect the high and low pressure water piping following the procedure High and Low Pressure Water ...

Page 121: ...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 end cap with the high pressure cylinder The cone seal on the sealing head should be in contact ...

Page 122: ...der 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 low pressure and high pressure water only travels in the appropriate direction Figure 9 10 Sealing Head High Pressure Discharge Check Valve The high pressure discharge check va...

Page 123: ... 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 both faces of the seat for damage or cracking A cracked or damaged seat must be replaced The seat can be installed with either face toward the poppet valve If one face is worn but the opposite is not the seat can be reversed placing the new surface toward the poppet ...

Page 124: ...et check valves should be serviced on a regular preventive maintenance schedule The hard seal end cap must be removed to service the inlet check valve Follow the procedure Hard Seal End Cap Removal When the end cap has been removed proceed with Step 1 below Figure 9 12 Low Pressure Inlet Check Valve 1 Use a 1 2 inch flat blade screwdriver to remove the poppet retainer from the sealing head 2 Inspe...

Page 125: ...rjet for refinishing 1 Clean the 45 degree surface on the cone ring with 600 grit wet dry sandpaper using a radial motion It will not be possible to fully remove the main sealing marks 2 Inspect the inlet poppet valve sealing surface for pits scratches or jetting erosion If necessary refinish the surface Place a piece of 1 4 1 2 thick plate glass not window glass on a sturdy table to provide an ab...

Page 126: ... to extend the plunger on the end to be serviced The plunger will extend in the selected direction allowing 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 proceeding Ensure all pressure is relieved or blocke...

Page 127: ...o the discharge gland nut on the sealing head and hand tighten 5 Position the cylinder assembly upright in the seal removal tool stand If 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...

Page 128: ...ved with the removed seal assembly make a judgment regarding plunger and or cylinder replacement If seal debris is present on the plunger polish with 600 grit wet dry sandpaper using a radial motion 11 Lightly coat the new seal components with FML 2 grease and install the new components on the plunger Ensure the proper orientation of the backup rings as illustrated in Figure 9 13 High Pressure Sea...

Page 129: ...h Pressure Cylinder Assembly Removal 5 Use a flat screwdriver to remove the retaining ring from the hydraulic cylinder head 6 Remove the bushing retainer flange and clean the surfaces weep holes and grooves Check the retainer flange for cracks 7 Replace the proximity switch by positioning the o ring spacer and the switch Apply JL M grease to the threads on the socket head screws and tighten follow...

Page 130: ... the socket head screws in one of the hydraulic cylinder heads 11 Remove the hydraulic cylinder head with the o ring and backup ring The mounting flat for the proximity switch provides a small lip for loosening the cylinder head 12 Place a clean shop towel in the hydraulic port in the stem mount to prevent the retainer pins from falling into the port 13 Remove the flat snap ring and the plunger re...

Page 131: ... the hydraulic cartridge seal will leak Accumulation of debris on the surface of the plunger can be removed by polishing in a radial direction with 600 grit sandpaper However plunger surface flaws usually cannot be repaired on site The plunger can be returned to KMT Waterjet for reconditioning Figure 9 17 Plunger Plunger Installation Use the following procedure to install the plunger 1 Push the pl...

Page 132: ...rews in the cylinder head and tighten following the torque specifications in Table 9 2 Hydraulic Cartridge Seal Seals in the hydraulic cartridge can be removed and replaced or the complete cartridge can be replaced Seal components differ slightly depending on the plunger diameter See Figure 9 18 Hydraulic Cartridge Seal Use caution during the removal and installation of the seal components to avoi...

Page 133: ...e hydraulic cartridge seal over the plunger into the cavity of the hydraulic cylinder head 8 Thoroughly clean the bushing retainer flange including the cross 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 clearanc...

Page 134: ...the hydraulic piston 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 SET SCREW O RING CHECK VALVE PLUNGER RETAINER PIN PISTON SEAL ASS...

Page 135: ...ake approximately five minutes for the oil to drain 5 Remove the retaining ring bushing retainer flange and the hydraulic cartridge seal from both hydraulic cylinder heads It is not necessary to remove the plunger 6 Loosen and remove the socket head screws in one of the hydraulic cylinder heads 7 Remove the hydraulic cylinder head with the o ring and backup ring The mounting flat for the proximity...

Page 136: ...es 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 an outer seal ring Apply FML 2 grease to both rings Use the smooth dull edged blade to install the inner ring ensuring the ring is not twisted after installation Slide the outer seal ring over the metal ed...

Page 137: ...gs and o rings Install the rings in 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 plungers and the retainer pins verifying that each pin moves freely without excess side play in the pin holes 8 Install the flat snap ring over the pins Internal Check Valves It is not necessary to service the internal c...

Page 138: ...astic head hammer to drive the piston into position between the holes for the proximity switches 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 Inst...

Page 139: ...igh and low pressure water piping And turn the low pressure water supply on 9 12 Hydraulic Cylinder Maintenance The inside diameter surface of the hydraulic cylinder should be inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed Excessive grooving is indicative of piston seal wear 9 13 High Pressure Attenuator The high pressure attenuator is not serviceab...

Page 140: ...re 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 9 23 High Pressure Dump Valve CONE INSERT WATER IN HIGH PRESSURE GLAND AND COLLAR SIGNAL FROM PLC SOLENOID VALVE PNEUMATIC CONTROL ACTUATO...

Page 141: ... 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 valve 3 Loosen and remove the high pressure gland conn...

Page 142: ... 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 and inspect the valve body being careful not to damage or scratch the bore Figure 9 26 Valve Seal Installation STE...

Page 143: ...ng thick end first onto the seal push tool and use it as a guide to position the wedge ring onto the seal Remove the push tool and ease the wedge ring 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 must face toward the brass backup ring The small OD of the brass backup ring mu...

Page 144: ...nd torque to 50 ft lbs 68 Nm 21 Replace the 1 4 inch drain gland nut and collar and torque to 25 ft lbs 34 Nm 22 Apply anti seize compound to the threads on the 3 8 inch high pressure gland fitting Install the collar and the gland fitting and torque to 50 ft lbs 68 Nm 23 Install the air supply hose and the electrical connection to the solenoid valve Turn the air pressure to the actuator on and tes...

Page 145: ...tort the body and seize the piston preventing proper operation 2 Remove the o ring on the cylinder head Apply FML 2 grease to a new o ring and install 3 Remove the two o rings on the piston Apply FML 2 grease to two new o rings and install 4 Install the piston in the pneumatic cylinder Apply anti seize compound to the threads on the cylinder head and screw it into the pneumatic cylinder NORMALLY O...

Page 146: ...led hydraulic 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 Seal material buildup on plunger Polish the plunger surface foll...

Page 147: ...orque 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 the number...

Page 148: ... If detected polish to remove following the procedure Sealing Head Maintenance 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 Improper torque on jackbolts ...

Page 149: ...g flow 8 Hydraulic pressure but no high pressure water pressure 9 No hydraulic oil pressure 10 Pump shaft will not turn 11 Pump will not start 12 Console display and lights do not illuminate 13 Pump quits running 14 No control power 15 Red light on operator s console is flashing 16 Abnormal fluctuations in high pressure water signal 17 Hot surfaces on the high pressure cylinder components 18 Low c...

Page 150: ...dhead condition Insufficient water supply 1 High boosted water temperature Booster pump temperature switch malfunction Inlet water pressure is low Filter element is dirty and needs to be replaced 2 Outlet booster pump pressure is falling below 30 psi 2 bar Booster pump needs to be adjusted or replaced Booster pump should be adjusted to 120 psi 8 bar when deadheaded 3 Inlet water flow is poor and t...

Page 151: ... 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 6 Low oil level resulting in shutdown Check the level switch 7 Restricted or no cooling flow Check cooling water flow to and from the heat exchanger The water pressure differential across the heat exchanger requires a minimum of 35 psi...

Page 152: ...alve with a volt meter to verify if they are good or bad 8 Hydraulic pressure but no high pressure water pressure PLC failure If there are inputs from the proximity switches but no outputs contact the KMT Customer Service Department for a logic review and verification of PLC failure The high and low limit compensators on the hydraulic pump are blocked with debris and are not controlling the swashp...

Page 153: ...been activated Check the display panel for fault messages Motor overload relay has been tripped Identify the source of the overload and remedy the problem Reset the overload relay 11 Pump will not start Inlet water valve is turned off Press the RESET button on the Run Screen to reset the water valve Pull the E STOP button out Emergency stop button is depressed Check all remote E STOP buttons Main ...

Page 154: ...unning Motor overload relay has been tripped Identify the source of the overload and remedy the problem Reset the overload relay Circuit breaker has been tripped Check the input and output of all circuit breakers Power supply fault Check the input and output voltages at the power supply Pull the E STOP button out Emergency stop button is depressed Check all remote E STOP buttons Master control rel...

Page 155: ...p Large worn or damaged orifice Make sure the orifice is in good working condition Verify that the jewel is installed in the 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 ...

Page 156: ...components Damaged high pressure cylinder Check the high pressure cylinder for cracks Restricted water supply Check cutting water supply flow and pressure Clogged water filter Check the condition of the low pressure water filter and replace the filter element if necessary 18 Low cutting water supply pressure Trapped air Bleed the air from the cutting water plumbing If operating in low pressure swi...

Page 157: ...lace the plunger or return to KMT Waterjet for evaluation and rework Seal material buildup on plunger Polish the plunger surface following the procedure Plunger Maintenance detailed in Section 9 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 deta...

Page 158: ...d nut where the seat makes contact Polish the surfaces following the procedure Sealing Head Maintenance detailed in Section 9 High Pressure Water System High pressure piping gland nut is not tight and is not sealing properly Tighten the gland nut to the proper torque specification Check the number of exposed threads past the collar on the high pressure piping Only 1 1 2 to 2 1 2 threads should be ...

Page 159: ...sure Water System 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 detailed in Section 9 High Pressure Water System 24 Water leaking from the weep hol...

Page 160: ...5 11 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 water content Sound Le...

Page 161: ...Drain 1 2 NPT Connection 11 3 Water Specifications Cutting Water Supply Low Pressure Water System Minimum consumption 11 0 gpm 41 6 L min Minimum inlet water pressure 35 psi 2 4 bar flowing Maximum inlet water pressure 80 psi 5 5 bar Maximum booster outlet water pressure 120 psi 8 3 bar Booster pump factory set inlet pressure 58 psi 4 bar Booster pump factory set outlet pressure 120 psi 8 3 bar Op...

Page 162: ...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 greater...

Page 163: ...0 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 164: ...When 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 165: ...age Motor Horsepower Full Load Amps Circuit Breaker Amps 200 3 50 100 248 350 200 3 60 100 236 350 208 3 50 100 242 350 208 3 60 100 231 350 230 3 60 100 218 300 380 3 60 100 130 175 400 3 50 100 124 175 415 3 50 100 121 175 460 3 50 100 114 175 480 3 60 100 106 175 575 3 60 100 91 125 11 5 Hydraulic and High Pressure Water System Specifications Hydraulic System Maximum operating pressure 2 815 ps...

Page 166: ...t pressure 35 000 psi 2 413 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 flow data for some of the more popular orifices Table 1 1 SL V SRP 100 Motor Horsepower Rating HP Kw Maximum Operating Pressure Maximum Si...

Page 167: ...11 0 279 0 45 0 48 0 012 0 305 0 53 0 57 0 013 0 330 0 62 0 67 0 014 0 356 0 72 0 78 0 015 0 381 0 83 0 90 0 016 0 406 0 94 1 02 0 017 0 432 1 07 1 15 The flow requirements for operating multiple orifices are determined by adding the requirements in Table 11 5 for each orifice Examples are shown below Orifice Size inches mm Number of Orifices Operating Pressure Calculation Total Flow 0 008 0 203 3...

Page 168: ...ent If leakage persists there is a component problem Excessive torque can cause component damage or failure resulting in potential hazards to equipment and personnel Torque Specifications Hard Seal End Cap Jackbolts 8 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...

Page 169: ...em Mount Socket Head Screws 4 3 8 each Torque 35 40 ft lbs 47 54 Nm Hex Key 5 16 inch Sealing Head Discharge Gland Nut 200 ft lbs 271 Nm Poppet Retainer 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 ...

Page 170: ...ccompanying figures Use the following information to contact the Spare Parts Department at KMT Waterjet Systems USA Europe Customer Service Department KMT Waterjet Systems PO Box 231 635 West 12th Street Baxter Springs KS 66713 0231 USA Spare Parts Manager KMT Waterjet Systems GmbH Wasserstrahl Schneidetechnik Auf der Laukert 11 D 61231 Bad Nauheim Germany Phone Fax Email 800 826 9274 620 856 2242...

Page 171: ...ns 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 Engi...

Page 172: ...ly 10184760 12 10 12 20 Controls Subassembly 380 415 50 60 80077845 12 42 12 6 Hydraulic Piston Assembly 05146576 12 12 12 21 Control Panel Configuration 200 208 50 60 20413542 12 45 12 7 High Pressure Piping 20432786 12 14 12 22 Control Panel Configuration 230 50 60 20434678 12 47 12 8 Low Pressure Water Filter Assembly 80087976 12 16 12 23 Control Panel Configuration 380 415 50 60 20434274 12 49...

Page 173: ...50 60 1 20434686 Electrical Assembly 230 50 60 20424282 Electrical Assembly 380 415 50 60 6 20461182 Decal Package 1 7 05128087 Startup Tag 1 9 20436131 Bulkhead Pipe Assembly 1 10 05141569 Frame Assembly 1 11 05104153 Reservoir Assembly 1 12 80074768 Cover Assembly 1 13 20435207 Hydraulic Power Package 230 380 415 50 60 1 20428358 Hydraulic Power Package 200 208 50 60 14 05142351 Hydraulic Hose C...

Page 174: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 5 Figure 12 1 SL V SRP 100 Intensifier Unit ...

Page 175: ...4 HP Seal Assembly 1 50 2 19 05130224 Proximity Switch 20 250V AC DC 2 6 20429756 Spacer Sealing Head 2 20 95119012 Socket Head Screw 1 4 x 20 x 1 4 7 49838220 HP Cylinder Nut HSEC 2 21 05146576 Piston Assembly 5 50 1 8 20429980 Hydraulic Cartridge Seal Assembly 2 23 05144522 Stem 2 9 20429823 Bushing Retainer Flange 2 25 05041058 Socket Head Screw 3 8 16 x 2 1 4 8 10 80070352 Jackbolt 7 16 20 x 2...

Page 176: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 7 Figure 12 2 Intensifier Assembly ...

Page 177: ...ion Quantity 1 20429987 Seal Bushing 1 Figure 12 3 Hydraulic Cartridge Seal 2 20430029 Packing Ring 1 75 x 1 50 x 0 25 2 3 20430021 O Ring 1 81 x 2 0 x 0 09 1 4 20430005 Backup Ring 1 81 x 2 0 1 5 20430055 O Ring 1 63 x 1 75 x 0 06 1 6 20430013 O Ring 1 88 x 2 0 x 0 06 1 7 20430037 U Cup Seal 150 x 1 75 x 0 13 1 20429980 ...

Page 178: ...art Number Description Quantity 1 20429706 Sealing Head Body 1 Figure 12 4 Sealing Head Assembly 2 20432760 Inlet Poppet Valve 1 3 05116595 Gland Nut 1 4 05116579 Seat 1 5 05116603 Discharge Poppet Valve 1 6 05119698 Poppet Retainer 1 7 05147863 Compression Spring 1 8 05119839 Poppet Pin 1 80072341 ...

Page 179: ...Description Quantity 1 10189181 Valve Body 1 10189553 Actuator Assembly Normally Open 2 10178697 Valve Seat 1 6 BV401184 Pneumatic Cylinder 1 3 20435636 Valve Stem 1 7 BV601184 Cylinder Head 1 4 10188233 Backup Ring Brass 1 8 BV501184 Piston 1 5 20428052 Seal Assembly 1 9 10187250 Backup Ring SST 1 10 10074715 O Ring 2 44 x 2 63 x 09 1 11 10074565 O Ring 2 25 x 2 38 x 06 2 ...

Page 180: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 11 Figure 12 5 Pneumatic Valve Actuator Assembly Normally Open ...

Page 181: ...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 001 6 05130216 Flat Snap Ring 0 032 x 0 375 x 2 20 2 7 05146568 Backup Ring 1 50 x 1 75 x 0 125 2 8 10074821 O Ring 1 1 2 x 1 3 4 x 1 8 2 9 05120118 Seal Assembly Hydraulic Piston 1 10 05120100 Bearing Ring Hydraulic Piston 2 80085079 Rebuild Kit Includes Items 4 ...

Page 182: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 13 Figure 12 6 Hydraulic Piston Assembly 05136684 ...

Page 183: ... Thread 1 22 10078913 HP Gland Anti Vibration 0 38 1 8 10078525 HP Elbow 0 56 x 0 56 7 23 10077030 Adapter Tube Pipe 0 25 x 0 13 90D 1 9 49895642 HP Tube 0 56 x 0 188 x 9 25 Cone Thread 1 24 05112552 HP Tube 0 25 x 0 83 x 34 0 Cone Thread 1 10 10069326 HP Tube 0 56 x 0 188 x 4 0 Cone Thread 5 25 10079705 HP Coupling 0 56 x 0 56 1 11 05145271 HP Tube 0 56 x 0 188 x 55 19 1 26 95413696 Lock Washer 0...

Page 184: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 15 Figure 12 7 High Pressure Piping ...

Page 185: ...070982 Relief Valve 50 150 psi 1 11 05135652 Check Valve Inlet Outlet 1 4 49838386 Pipe Nipple 75 x 4 0 2 12 49833882 Adapter ORB Hose 50 x 50 3 5 10119253 Elbow Pipe 50 x 50 1 13 95838314 Lock Washer 25 4 6 20413848 Manifold LP Water Outlet 1 14 49834716 Filter Element 10 Micron 1 7 49833924 Low Pressure Manifold Left 1 15 95391322 Flat Washer 25 4 9 49835804 Adapter Pipe Hose 50 x 50 2 16 100833...

Page 186: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 17 Figure 12 8 Low Pressure Water Filter Assembly ...

Page 187: ...3 95572897 Hex Head Screw 1 4 20 x 5 8 3 4 95838314 Lock Washer 25 3 5 20433281 Water Pump Vane 1 6 20432794 Pressure Gauge 0 5000 psi 1 7 05103429 Shaft Spline 1 8 05071717 Relief Valve 1 9 80079684 Adapter FSOR ORB 1 0 x 75 2 10 05103395 Shaft Coupling 1 11 95688750 Lock Washer 50 6 12 95750394 Lock Washer 38 2 13 05041033 Socket Head Screw 3 8 16 3 x 1 1 4 2 14 10091510 Arrow Decal 1 15 2043720...

Page 188: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 19 Figure 12 9 Hydraulic Power Package ...

Page 189: ... O Ring Pump Seal 1 5 10066256 Hex Head Screw 3 4 10 x 2 1 2 4 19 05085758 Adapter ORB JIC 38 x 25 1 6 80076656 Flange Motor Pump Adapter 1 20 10091163 Adapter JIC ORB 75 x 75 1 7 05103239 Piston Pump 3000 psi 1 21 10118057 Plug ORB 75 1 8 10192961 Socket Head Screw M12 x 1 75 x 30 mm 2 22 10099760 Adapter JIC ORB 1 25 x 1 25 1 9 10069763 Flat Washer 50 2 23 05139639 Adapter M14 x 4 M F O Ring 1 1...

Page 190: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 21 Figure 12 10 Motor Pump Assembly ...

Page 191: ...g 1 50 x 1 69 x 09 1 3 05071055 Plug ORB 75 3 4 05103189 Cartridge Check Valve 1 5 10187060 Relief Valve 25 1500 psi 1 6 10187052 Relief Valve 25 3000 psi 1 7 05055017 Plug ORB 13 2 8 10185585 Solenoid Valve 24V DC 1 9 05064407 Adapter JIC ORB 1 0 x 75 1 10 10144749 Adapter JIC ORB 25 x 25 1 11 49876089 Adapter JIC ORB 25 x 25 1 12 10142644 Adapter JIC ORB 25 x 25 1 13 49889769 Plug ORB 25 1 ...

Page 192: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 23 Figure 12 11 Hydraulic Manifold Assembly ...

Page 193: ...ose Assembly 1 25 x 26 50 1 12 80085889 Hydraulic Hose Assembly 25 x 20 0 1 3 05106976 Hydraulic Hose Assembly 1 25 x 24 50 1 13 05061163 Hydraulic Hose Assembly 75 x 31 0 1 4 20419045 Hose Clamp 3 0 2 14 05049713 Hydraulic Hose Assembly 75 x 27 0 1 5 10079754 Radiator Hose 2 50 10 5 6 49872245 Split Flange 2 50 1 7 05106984 Adapter Hose Flange 2 50 x 2 50 1 8 05112750 Hydraulic Hose Assembly 25 x...

Page 194: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 25 Figure 12 12 Hydraulic Hose Connections ...

Page 195: ...reather 1 20 10170645 Adapter ORB Pipe 1 0 x 75 1 5 20451474 Level Temperature Gauge 1 21 05079371 Adapter JIC BSPP 75 x 75 1 6 05103809 Hydraulic Filter Head 1 22 05006291 Diffuser Return Line 1 7 05104187 Oil Filter Element 1 23 10142644 Adapter JIC ORB 25 x 25 2 8 10151470 Adapter ORB JIC 1 0 x 75 1 24 10080901 Ball Valve 1 9 05069976 Cap 75 1 25 10091163 Adapter JIC ORB 75 x 75 2 10 20455107 T...

Page 196: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 27 Figure 12 13 Reservoir Assembly ...

Page 197: ...ex Head Screw 3 8 16 x 1 16 8 49888035 Solenoid Valve 24V 1 27 95750394 Lock Washer 38 16 9 10070092 Jam Nut 1 14 5 28 05135660 Adapter JIC ORB 50 x 50 1 10 10073823 Tee 50 x 50 1 29 10078095 Coupling Tube 25 x 13 1 11 20413789 Manifold LP Water Inlet 1 30 10079903 Tube Clear 0 25 36 0 12 80087976 LP Water Filter Assembly 1 31 49834310 Adapter Tube Pipe 50 x 50 1 13 49834328 Adapter Pipe Tube 25 x...

Page 198: ... Number Description Quantity Item Part Number Description Quantity 39 10069763 Flat Washer 50 6 43 05140751 Pressure Switch 30 psi 1 40 95716890 Lock Washer 50 6 44 49868813 Temperature Sensor 1 41 95716882 Hex Head Screw 1 2 13 x 1 1 4 6 45 20453730 Check Valve 1 42 49831480 Grommet Rubber 3 00 x 2 25 7 ...

Page 199: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 30 Figure 12 14 Bulkhead Pipe Assembly ...

Page 200: ...Cover Right End 2 7 49837511 Mounting Bracket 4 8 49837529 Mounting Bracket 4 9 49837503 Spring Gas 4 10 49837743 Flange Head Screw Button Head 3 8 16 x 1 0 32 11 05091988 Flange Nut 3 8 16 32 12 95897948 Button Head Screw 10 24 x 1 2 24 13 49832181 Flange Nut 10 24 24 14 80074719 Gasket Not Shown 1 15 95670972 Lock Washer 38 6 16 05091954 Button Head Screw 3 8 16 x 1 00 6 17 80076748 Cable Lanyar...

Page 201: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 32 Figure 12 15 Cover Assembly ...

Page 202: ...Conduit Connector 2 50 1 3 80080344 Terminal Lug 10 250 9 4 20426246 Flexible Conduit 2 50 42 0 5 20426262 Flexible Conduit Connector 2 50 1 6 20426254 Conduit Bushing 2 50 x 2 50 1 7 10069763 Flat Washer 50 4 8 20451607 Weld Cable 360 0 9 05139498 Wire 3 Green 60 0 11 05097464 Ring Terminal 4 0 312 2 12 95716890 Lock Washer 50 4 13 10125912 Cable Tie 87 5 14 20413542 Starter Control Panel Configu...

Page 203: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 34 Figure 12 16 Electrical Assembly 200 208 50 60 ...

Page 204: ...Flexible Conduit Connector 2 50 1 3 80080344 Terminal Lug 10 250 9 4 20426246 Flexible Conduit 2 50 42 0 5 20426262 Flexible Conduit Connector 2 50 1 6 20426254 Conduit Bushing 2 50 x 2 50 1 8 05019799 Weld Cable 360 0 9 20452905 Wire 4 Green Yellow 60 0 11 05097464 Ring Terminal 4 0 312 1 12 95716890 Lock Washer 50 4 13 10125912 Cable Tie 87 5 14 20434678 Starter Control Panel Configuration 1 ...

Page 205: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 36 Figure 12 17 Electrical Assembly 230 50 60 ...

Page 206: ... Hex Nut 1 2 13 4 4 10098788 Flexible Conduit 2 0 42 0 17 05062344 Lock Nut 1 4 20 2 5 10114932 Flexible Conduit Connector 2 0 1 18 95716890 Lock Washer 50 4 6 05147251 Conduit Bushing 2 0 x 2 0 1 19 10125912 Cable Tie 5 7 05113923 Ring Terminal 6 13 20 20424274 Starter Control Panel Configuration 1 8 10069763 Flat Washer 50 4 21 80078140 Conduit Bushing 2 50 x 2 0 1 9 05014972 Weld Cable 360 0 22...

Page 207: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 38 Figure 12 18 Electrical Assembly 380 415 50 60 ...

Page 208: ...el 1 To 550 1 7 49833403 Emergency Stop Switch Push Pull Red 1 24 05140629 Legend Plate Holder Black 1 8 20419143 Contact Block 3 25 20414500 Subplate 1 9 05049473 Legend Plate 1 26 10156859 I O Rack 4 Slot 24V DC 1 10 05032438 Terminal Block 22 14 28 27 10146363 Single Point Output Module DC 24 4 11 05032362 End Anchor Terminal Block 4 28 10157659 Lock Washer Star 0 25 2 12 05032370 End Barrier 1...

Page 209: ... Illuminated Operator 1 39 10102242 Spiral Wrap 0 38 12 0 Optional 40 05144316 Base Controller 1500 24V 1 51 10069888 Lock Washer 6 x 0 031 4 41 05140157 Panelview Display 550 1 52 05140967 Gasket 37 Pin Box Receptacle 1 42 05115134 End Barrier 3 Level Terminal Block 1 53 05140975 Cap 37 Pin Connector 1 43 49833411 Selector Switch Keyed 2 Position 1 54 10069797 Flat Washer 6 x 0 047 4 44 05114889 ...

Page 210: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 41 Figure 12 19 Controls Subassembly 200 208 230 50 60 ...

Page 211: ...hannel 1 To 550 1 7 20416802 Emergency Stop Switch 1 24 05140629 Legend Plate Holder Black 1 8 20419143 Contact Block 3 25 20414500 Subplate 1 9 05049473 Legend Plate 1 26 10156859 I O Rack 4 Slot 24V DC 1 10 05032438 Terminal Block 22 14 28 27 10146363 Single Point Output Module DC 24 4 11 05032362 End Anchor Terminal Block 4 28 10157659 Lock Washer Star 0 25 2 12 05032370 End Barrier 1 29 050219...

Page 212: ...lluminated Operator 1 39 10102242 Spiral Wrap 0 38 12 0 Optional 40 05144316 Base Controller 1500 24V 1 51 10069888 Lock Washer 6 x 0 031 4 41 05140157 Panelview Display 550 1 52 05140967 Gasket 37 Pin Box Receptacle 1 42 05115134 End Barrier 3 Level Terminal Block 1 53 05140975 Cap 37 Pin Connector 1 43 49833411 Selector Switch Keyed 2 Position 1 54 10069797 Flat Washer 6 x 0 047 4 44 05114889 Le...

Page 213: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 44 Figure 12 20 Controls Subassembly 380 415 50 60 ...

Page 214: ...mp Ferrule 18 27 49833429 Timing Relay 1 5 30 Second 1 9 20413583 Contactor Non Reversing 180A 24V DC 2 28 10185395 Connector Crimp Ferrule 16 8 10 10157667 Pan Head Screw 10 32 x 3 4 24 29 10176410 Wire 16 Blue 48 0 11 10103034 DIN Mounting Rail 15 0 30 10170165 Wire 16 1 MM 2 Green Yellow 48 0 12 80083603 Overload Relay 20 180A 1 34 10098226 Tube Base Relay 24V DC 1 13 80083660 Auxiliary Contact...

Page 215: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 46 Figure 12 21 Control Panel Configuration 200 208 50 60 ...

Page 216: ...0434660 Contactor Non Reversing 140A 24V DC 2 27 49833429 Timing Relay 1 5 30 Second 1 10 10157667 Pan Head Screw 10 32 x 3 4 24 28 10185395 Connector Crimp Ferrule 16 8 11 10103034 DIN Mounting Rail 15 0 29 10176410 Wire 16 Blue 48 0 12 80083603 Overload Relay 20 180A 1 30 10170165 Wire 16 1 MM 2 Green Yellow 48 0 13 80083660 Auxiliary Contact 1 NO 1 NC 2 34 10098226 Tube Base Relay 24V DC 1 14 8...

Page 217: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 48 Figure 12 22 Control Panel Configuration 230 50 60 ...

Page 218: ...upply 24V DC 1 8 05149778 Connector Crimp Pin 21 26 80077845 Controls Subassembly 1 9 49839814 Contactor Non Reversing 85A 230V AC 2 27 49833429 Timing Relay 1 5 30 Second 1 10 10157667 Pan Head Screw 10 32 x 3 4 8 28 10185395 Connector Crimp Ferrule 16 8 11 10103034 DIN Mounting Rail 29 0 29 10176410 Wire 16 Blue 48 0 12 05111448 Overload Relay 26 85A 1 30 10170165 Wire 16 1 MM 2 Green Yellow 48 ...

Page 219: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 50 Figure 12 23 Control Panel Configuration 380 415 50 60 ...

Page 220: ...80075732 Item Part Number Description Quantity 1 80071087 Hydraulic Solenoid Valve 24V 1 2 49867104 Cable 18 4 Conductor 96 0 3 10067205 Cable Connector 50 1 4 10176410 Wire 16 Blue 100 0 5 10185395 Connector Crimp Ferrule 16 10 6 0514647725 EEPROM 1 7 80088560 End Cap 4 Way Modulating Valve 1 ...

Page 221: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 52 Figure 12 24 Proportional Pressure Control 80075732 ...

Page 222: ... HP Tube 56 x 188 x 11 50 1 4 10079580 HP Bushing 56 x 25 1 5 05071782 HP Tube Bent 25 x 83 1 6 49838478 Pressure Transducer 0 75 000 psi 1 7 10067205 Cable Connector 50 1 8 10176410 Wire 16 Blue 100 0 9 10185395 Connector Crimp Ferrule 16 10 10 10078459 HP Gland 25 1 11 10078426 HP Collar 25 1 12 05086905 Flexible Conduit 63 12 0 13 05131347 Ferrule 50 2 14 0514647725 EEPROM 1 15 0514192420 Flash...

Page 223: ...Section 12 Parts List 20428786 2 2008 Rev 05 12 54 Figure 12 25 High Pressure Transducer ...

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Page 240: ... 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 with eye...

Page 241: ... 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 fluoride...

Page 242: ...void aluminum 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 Mutagen...

Page 243: ... 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 244: ...t Contact with eyes will cause irritation Ingestion Not expected to be harmful by ingestion Existing conditions aggravated by exposure Eye skin and respiratory disorders See Section 11 for additional toxicological information 1 of 5 Loctite R 222 Threadlocker Low Strength Issue date 12 13 2004 Item No 21464 Material Safety Data Sheet Product Use Sealant Region Canada Revision Date 12 10 2004 Compa...

Page 245: ...rritating organic vapors Sensitivity to mechanical impact Not available Sensitivity to static discharge Not available 6 ACCIDENTAL RELEASE MEASURES Environmental precautions Prevent product from entering drains or open waters Clean up methods Soak up with inert absorbent Store in a partly filled closed container until disposal 7 HANDLING AND STORAGE Handling Avoid contact with eyes skin and clothi...

Page 246: ...products Oxides of carbon Oxides of sulfur Oxides of nitrogen Irritating organic vapors Incompatability Strong oxidizers Conditions to avoid See Handling and Storage Section 7 and Incompatabilty Section 10 11 TOXICOLOGICAL INFORMATION Product toxicity data Acute oral LD50 greater than 10 000 mg kg rat Acute dermal LD50 greater than 5000 mg kg rabbit Toxicologically synergistic products Not availab...

Page 247: ...d class or division None Identification number None Packing group None Marine pollutant None 4 of 5 No No No Cumene hydroperoxide 80 15 9 Inhalation LC50 Mouse 200 ppm Inhalation LC50 Rat 220 ppm Oral LD50 Rat 382 mg kg None No No No No Propylene glycol 57 55 6 Oral LD50 Rat 20 g kg Dermal LD50 Rabbit 20800 mg kg Oral LD50 Mouse 22 g kg Item No 21464 Product name Loctite R 222 Threadlocker Low Str...

Page 248: ...or information only and are believed to be reliable However Henkel Corporation does not assume responsibility for any results obtained by persons over whose methods Henkel Corporation has no control It is the user s responsibility to determine the suitability of Henkel s products or any production methods mentioned herein for a particular purpose and to adopt such precautions as may be advisable f...

Page 249: ... 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 250: ...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 251: ...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 252: ...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 253: ... 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 254: ...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 255: ...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 256: ...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 257: ... 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 258: ...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 259: ...llect 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 hydrocarbon...

Page 260: ...ps 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 physici...

Page 261: ...nt 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 Recove...

Page 262: ...posure 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 m3 8 Hr...

Page 263: ...oxicological 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 shippe...

Page 264: ...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 ACT In...

Page 265: ...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 KMT 20418732 ...

Page 266: ... EXTREME HEALTH 1 PROTECTION G FLAMMABILITY 1 SEE MSDS FOR PROTECTIVE REACTIVITY 0 MEASURES Hazardous Ingredients of Materials Chemical Identity Percent CAS NA ADDITIONAL INGREDIENT INFORMATION WHMIS NOT CONTROLLED MINERAL OIL Physical Data For Product PHYSICAL STATE LIQUID ODOUR AND APPEARANCE COLORLESS TO LIGHT AMBER FLUID LOW ODOUR ODOUR THRESHOLD NE SPECIFIC GRAVITY DENSITY g mL 0 87 16 C VAPO...

Page 267: ...REACTIVITY NE HAZARDOUS DECOMPOSITION PRODUCTS NE Health Hazard Information Based on Component Information PRIMARY HEALTH HAZARDS NONE AT NORMAL USE TEMPERATURES ROUTES OF ENTRY SKIN CONTACT NOT AN IRRITANT SKIN ABSORPTION NE EYE MAY CAUSE SLIGHT IRRITATION INHALATION NE INGESTION NE ACUTE OR CHRONIC OVER EXPOSURE EFFECTS NE IRRITANCY OF PRODUCT SENSITIZATION TO PRODUCT NA CARCINOGENICITY TERATOGE...

Page 268: ...RESH AIR IMMEDIATELY IF BREATHING HAS STOPPED APPLY ARTIFICIAL RESPIRATION AND ADMINISTER OXYGEN IF NECESSARY SEEK MEDICAL ATTENTION Preparation Date of Material Safety Data Sheet PREPARED BY PRODUCT SAFETY AND ENVIRONMENT DEPARTMENT PHONE NUMBER OF PREPARER 905 827 9087 DATE PREPARED 03 13 02 DATE REVISED 03 13 02 MINIMUM CONTACT WITH THIS AND ALL CHEMICALS IS RECOMMENDED AS A GOOD GENERAL POLICY...

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