KTM STREAMLINE L-IV 50 Operation And Service Manual Download

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SECTION 8

ELECTRICAL SYSTEM

p. 8-5

05148408

Table 8-2. SENSORS/SOLENOIDS - SLIV

No. FUNCTION

COMPONENT DESCRIPTION

LOCATION

1 Intensifier

shift

sensors

Proximity switches

Hydraulic cylinder,
intensifier assy

2 Cutting

water

supply

Solenoid shutoff valve, water

Bulkhead plumbing
assembly

HP water dump
valve

HP shutoff valve, pneumatically-
operated, solenoid valve (pneu)

HP discharge piping,
betw. HP atten. and
bulkhead piping.

4 Intensifier

Shift,

A/B Port Shifting

Solenoid- operated, directional
control valve (DCV), hydraulic
pilot- operated spool

Hydr manifold assy,
motor/ pump group

5 HI/LO

Pressure

Select

Solenoid shutoff valve, hydr
cartridge style

Hydr manifold assy,
motor/ pump group

Low oil level/
temperature

Combination level/ temp switch,
immersed in hyd fluid

Hydraulic reservoir

7 High

Booster

Pump Temp

Temperature sensor

LP water filter assy,
manifold block

Low cutting water
supply pressure

Pressure switch, 30 psig

LP water filter assy,
manifold block

9 Low

booster

pump pressure

Pressure switch, 60 psig

LP water filter assy,
manifold block

Summary of Contents for STREAMLINE L-IV 50

Page 1: ...Printed 12 02 04 80081573 doc STREAMLINE HIGH PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL SL IV 50 HSEC 230V Manual No 80082837...

Page 2: ...s the information described in this manual to be accurate and reliable Much care has been taken in its preparation however the Company cannot accept any responsibility financial or otherwise for any c...

Page 3: ...ockout Tagout Procedure 1 5 Warning Labels 1 6 Emergency Medical Treatment 1 8 1 6 Worldwide Product Support 1 9 1 7 Spare Parts 1 9 1 8 Manual Organization 1 9 1 9 Equipment and Service Manual Questi...

Page 4: ...un Screen Alarms 4 3 4 6 Alarm Banners 4 5 4 7 Alarm History 4 7 Changing the Date and Time 4 7 4 8 Set Up Screen 4 8 4 9 Stroke Rate Screen 4 8 4 10 Hours Screen 4 9 4 11 Maintenance Screen 4 10 4 12...

Page 5: ...8 9 5 High and Low Pressure Water Piping 9 9 9 6 High Pressure Cylinder Assembly 9 9 High Pressure Cylinder Assembly Removal 9 10 High Pressure Cylinder Assembly Installation 9 12 High Pressure Cylind...

Page 6: ...Specifications 11 2 Cutting Water Supply 11 2 Recirculation System 11 3 Water Quality Standards 11 3 11 4 Electrical Specifications 11 6 Electrical System 11 6 Ampacity and Power Voltage Requirements...

Page 7: ...Intensifier Pumps Motor Horsepower Rating Plunger Quantity and Diameter inches Hp Kw Intensifier Model HP Water Max Oper Pressure psi 7 8 0 875 22 mm 1 1 8 1 125 29 mm Frame Dim L inches Redundant Opt...

Page 8: ...with 10 micron double length filter High efficiency heat exchanger in independent recirculation pump circuit Stand alone unit with built in motor starter wye delta or across the line High pressure saf...

Page 9: ...er to Table 1 2 for HP water performance limits for various power levels of SL IV waterjet pumps TABLE 1 2 HP WATER PERFORMANCE SL IV WATERJET INTENSIFIER PUMPS 55 000 psi 60 000 psi Horsepower Orific...

Page 10: ...training is also available 1 3 1 Service Department To contact the KMT Waterjet Service Department USA Customer Service Manager Europe Technical Manager KMT Waterjet Systems KMT Waterjet Systems GmbH...

Page 11: ...ts Yes No 2 Is the unit a convenient size Yes No 3 Controls a Are the controls user friendly b Is the unit easy to operate Comments Yes Yes No No 4 Performance a Does the unit perform smoothly and mee...

Page 12: ...antity of the photos illustrations Comments Yes No Text 1 Does the information in the manual adequately explain how to operate and service the equipment Comments Yes No 2 Are there paragraphs or proce...

Page 13: ...if the caution instruction is ignored Indicates the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning instruction is ignored ISO 3021 High...

Page 14: ...SECTION 1 INTRODUCTION Page 1 8 49831878 Rear of Waterjet Pump HP Water OUT Plant Air IN Cooling Water IN Cooling Water OUT Cutting Water IN Drain...

Page 15: ...ee if the power goes off Each device should be checked on a specified schedule Each time the device is checked it must function or be replaced before operating the system Apply High Purity Goop P N 10...

Page 16: ...ent Make sure the safety devices are operational To panic stop the pump and bleed the high pressure the EMERGENCY STOP buttons must be pushed in The system pressure dump valves must be open Do not att...

Page 17: ...HP water present a jet of HP water will exit the nearest weep hole with possible hazardous results Use extreme caution when handling high pressure equipment Possible failure from fatigue cracking or o...

Page 18: ...KS 66713 620 856 2151 Back Side This person has been working with water jetting at pressures to 55 000 psi 374MPa 3740 bar 3867 Kg cm2 with a jet velocity of 3 000 fps 914 mps Foreign material sand ma...

Page 19: ...dy of this manual to understand the system in detail 2 1 Installation Overview Read the manual and become familiar with the operation of each component and its nomenclature Understand the complete sys...

Page 20: ...c drops with manual shutoff valves Provide all mounting and support brackets and hardware for high pressure tubing runs Provide and install water conditioning equipment necessary to meet water purity...

Page 21: ...or water and pneumatic service Test motor rotation direction and correct if necessary Check and test electrical signal connections between intensifier pump and cutting area Power up and check out pump...

Page 22: ...by qualified personnel and must meet national and local electrical codes 2 2 1 Equipment Location Environment Space Requirements There should be a minimum of 900mm 36 inches clearance on all sides of...

Page 23: ...ter IN Supply piping must be properly sized to handle the necessary flow and pressure Piping must meet national and local piping codes HP Water OUT Properly rated sized and well supported high pressur...

Page 24: ...in the following table Cut tubing to length and deburr High pressure piping and fittings rated for 4 138 bar 60 000 psi must be used Failure to do so may cause component failure causing equipment dama...

Page 25: ...tube per following diagram and procedure Cone and Thread Dimensions O D Size mm inch I D size mm inch D max mm inch L max mm inch Thread NF LH 6 35 1 4 2 11 0 083 3 58 0 141 14 3 0 562 1 4 28 9 52 3...

Page 26: ...one and Threading Tool Item Description 1 Cutter Handle 2 Cutter Support 3 Feed Nut 4 Cutting Blades 5 Collet 6 Housing 7 Gland Nut Tube Size inch 1 4 3 8 9 16 A mm inch 3 30 0 13 4 07 0 16 7 11 0 28...

Page 27: ...3 clockwise until cutting blades 4 contact end of tubing Rotate cutter handle 1 in clockwise direction while simultaneously turning the feed nut 3 in a clockwise direction at a rate to assure that th...

Page 28: ...ure 1 Slip gland nut 2 on tubing 1 as shown and lubricate thread with High Purity Goop Thread collar 3 on tubing until one to two threads are exposed between collar item 3 and tube cone 2 Lubricate ma...

Page 29: ...on end connection to take load alone Proper piping support and guide must be provided 1 Slip gland nut 2 and collet 4 on tubing 1 thread collar 3 until one to two threads are exposed between collar a...

Page 30: ...the functions available in the control and how to select and use them Following is an explanation of the functions of the control logic including the start up sequence The intensifier is equipped wit...

Page 31: ...y logic along with the software revision number running on the machine are shown on the Maintenance Screen The PLC monitors the motor overload relay and displays a message when the overloads trip The...

Page 32: ...screen will always default to the Run screen after being on any other screen more than 5 minutes If the intensifier is equipped with a HP transducer the displayed pressure can be shown in psi or Bar R...

Page 33: ...et function idle shutdown time Transducer and Proportional Pressure Select Redundant select Screen configures display for a particular machine Analog Also contains PSI BAR select button Stroke Rate Sc...

Page 34: ...s screen After 5 minutes on any screen display will return to Run Screen Recirc Select this to toggle the recirculation mode on or off The recirc mode runs the machine without generating high pressure...

Page 35: ...sure indicates that cutting supply water pressure is inadequate to permit proper machine operation and shutdown is pending less than 30psi 6 Bleed High Pressure Lines Indicates that the intensifier is...

Page 36: ...TION 3 OPERATION p 3 7 05146410 RUN SCREEN 2 RUN SCREEN 3 REDUNDANT This screen will be displayed if REDUNDANT button on the SETUP screen is ON SELECT INT button is used to select intensifier one or t...

Page 37: ...rom this screen HOURS This screen displays total machine hours and resettable maintenance hours to 9 999 999 for intensifiers 1 and 2 TOTAL HOURS cannot be reset MAINTENANCE HOURS on intensifiers 1 an...

Page 38: ...410 EXAMPLE ALARM HISTORY SCREEN The alarm list stores the last 100 triggered alarms indicating date time and type of alarm Scroll up and down to see alarm history The Alarm History Screen does not ha...

Page 39: ...g THIS UNIT IS NOT EQUIPPED WITH PROPORTIONAL CONTROL The PRESSURE CONTROL SCREEN that is required can be selected on the SET UP SCREEN for the appropriate pressure control used if a proportional valv...

Page 40: ...RATE SCREEN Set STROKE RATE 2 to 4 strokes above normal running rate to shutdown machine in case of overstroke condition RESET Press to reset intensifier stroke count STROKES MIN is actual stroke rat...

Page 41: ...transducer and or a proportional valve are installed on the machine WATER RESET FUNCTION Press on I to shut water off five 5 minutes after machine shuts down Selecting this function will insure that...

Page 42: ...ll stop unit Jog right will extend piston to the right giving full exposure to the right plunger once the unit is disassembled Jog left will do the same to the left plunger CAUTION Unit must be comple...

Page 43: ...pressure will shut down the machine 40 seconds after alarm condition is detected HIGH BOOSTER TEMPERATURE Alarm indicates high booster pump temperature The machine will shut down 30 seconds after this...

Page 44: ...PERATION p 3 15 05146410 NO PRESSURE CONTROL This screen will appear if the pressure control on main menu is selected and machine does not have PROPORTIONAL control The machine cannot be stopped from...

Page 45: ...SECTION 3 OPERATION p 3 16 05146410 LANGUAGE Scroll up and down for desired language and press ENTER to select FRENCH GERMAN ITALIAN SWEDISH or ENGLISH...

Page 46: ...gauge on the reservoir check for leaks Oil Temp High Check cooling water flow with a flow meter Low Booster Pressure Check the booster pressure adjustment and check booster condition Low Inlet Water...

Page 47: ...nce of the five systems is necessary and is described in their respective sections Refer to the following sections for detailed information on the operator console and systems maintenance Operator Con...

Page 48: ...back of the variable piston pump which has a through shaft Booster Pump includes a stainless steel vane type pump with pressure adjustment and high temperature switch low pressure water filter bypass...

Page 49: ...ck Valve Port Sealing Head X X Temperature Checks Cooling Water Inlet Outlet Oil Water Heat Exchanger X F Motor Bearings Lube Hydraulic Power Unit X R Lubrication Filter Checks Hydraulic Filter Hydrau...

Page 50: ...ench in a dust and dirt free work area Use lint free material for wipe cloths When blowing off parts with compressed air use only clean dry air When flushing parts with a solvent use only clean filter...

Page 51: ...g any high pressure components flush the high pressure water system by operating the waterjet pump for a short period with the nozzle valve open and no orifice in place Next shut down the waterjet pum...

Page 52: ...eparate sheets of paper Note that if there are two intensifiers on the pump redundant option then indicate which intensifier I or II in the column labeled Intensifier Note that intensifier I is locate...

Page 53: ...ater Abrasive Operating Pressure _____________bar psi No of Orifices Orifice Size _____ each x ______ mm inch SL IV Service Log Page ____ Date Person Hours 1 2 3 4 TW CYL 5 6 7 8 9 10 11 12 13 14 15 1...

Page 54: ...nger Cartridge 8 05144506 Plunger Ceramic 9 05144555 Liner HP Cylinder 10 05059712 Cylinder HP 12 05116579 Seat HP Check Valve Wear out first side then reverse and use opposite side 13 05116579 Seat H...

Page 55: ...SECTION 4 MAINTENANCE Page 4 9 49831902...

Page 56: ...Turned Off Reset water valve by pressing RESET on Run menu 5 1 2 Console Display and Lights Fail to Illuminate E STOP Button Depressed Pull out E STOP button Check all remote E STOP pushbuttons Push C...

Page 57: ...ve Check left inlet check valve Right Overstroke Check right HP seal Check left discharge check valve Check right inlet check valve T W Overstroke Check plumbing for leaks Check HP orifice Check HP du...

Page 58: ...shifting of 4 way directional control valve Verify proper proximity switch operation 5 2 2 Hot Surfaces On HP Cylinder Components HP Discharge Check Leaking Inspect check valve seat poppet spring and...

Page 59: ...with 600 emery cloth 5 2 4 HP Check Valve Leak If there are no visible HP water leaks but there are higher temperatures on HP cylinder or sealing head this indicates a HP or LP check valve leak Use co...

Page 60: ...nger improve flow of cooling water or replace heat exchanger Recirculation Pump Hydraulic Pressure below 20psi Replace hydraulic oil filter If filter is new replace recirculation pump 5 4 2 Hydraulic...

Page 61: ...h the intensifier will shut down and the display will tell you where to look for the problem For instance if the display indicates a Left Stroke Warning or Shutdown the probable problem is either at L...

Page 62: ...e oil to water heat exchanger The low pressure water system supplies the pump with the following Water of sufficient cleanliness and pressure to the inlets of the HP cylinders Cooling water of suffici...

Page 63: ...LIV Waterjet Pumps 1 Heat Exchanger Oil to Water Cooler 2 Water Modulating Valve 3 Hydraulic Pump Gear Type Recirculating 4 Hydraulic Filter Return Line 5 Main Hydraulic Pump 6 Electric Motor 7 Hydrau...

Page 64: ...er from a cooling manifold or series circuit Issues with low supply pressure or high supply temperature may arise in connection with this cooling system To raise or lower hydraulic oil operating tempe...

Page 65: ...maging the pump However when the low pressure water filter gets loaded up with dirt contaminants the water pressure exiting this filter may be too low to supply the booster pump The cutting water supp...

Page 66: ...at port B of 4 bar 58 psi The pump may require adjustment if local inlet pressure is different because discharge pressure depends on inlet pressure Inlet pressure is affected by filter condition as w...

Page 67: ...y 4 Filter Assembly LP Water 5 Pressure Switch 60psig Low Booster Pump Pressure 6 Pressure Switch 30psig Low Supply Water Pressure 7 Temperature Switch High Booster Pump Out 8 Pressure Gage Cutting Wa...

Page 68: ...ve pressure 6 2 4 Low Pressure System Protection System pressurization over 8 6 bar 125 psi is prevented by the relief valve 15 Note that a leaking check valve in a sealing head 13 could cause relief...

Page 69: ...proper operation it is necessary to replace the water filter and or adjust the booster pump The guidelines for servicing these parts are described below Figure 6 5 Item Description 1 Booster Pump 2 Te...

Page 70: ...unthread tool to turn housing Container to capture some water spill Rags Parts Elements for water 10 micron quantity 2 Polymer mixer 40 micron quantity 2 Water Filter Element Replacement Procedure 1 T...

Page 71: ...re control knob Container To capture some water spill Rags Parts None required Booster Pump Adjustment Procedure 1 Turn on cutting water supply 2 Start waterjet pump and observe booster discharge pres...

Page 72: ...include the hydraulic intensifier HP attenuator s HP dump valve HP pressure indicator optional and HP piping Maintenance on the intensifier is discussed in detail in this section In addition to HP co...

Page 73: ...ttenuator is discussed but no disassembly procedures are included Note that HP attenuators are not considered to be serviceable by the customer Some special terms used in this section include 1 HSEC H...

Page 74: ...r Seal Cartridge 9 Retaining Flange 10 Jackbolt 11 Cylinder Liner 12 O ring 14 Retainer Ring 15 Hydraulic Cylinder 16 Back up Ring 17 O ring 19 Proximity Switch 20 Cap Screw 21 Piston Assembly 28 Spac...

Page 75: ...d the following operations can be performed HP cylinder can be removed from hydraulic cylinder head HP plunger seal can be serviced After the pump has been reassembled then the HP water piping and LP...

Page 76: ...isassembly re assembly practices Due to the weight approx 55 lbs of the HP cylinder jug adequate support should be provided to prevent damage to the plunger or seals during disassembly re assembly See...

Page 77: ...down sequence HP Cylinder Jug Re Installation 1 Verify that HP cylinder threads are adequately lubed with High Purity Goop and that the threads have been sanded dressed if galling was encountered dur...

Page 78: ...paragraph 7 2 1 above 3 Loosen jackbolts 4 Remove HSEC Note that sealing head may be removed with end cap 5 Remove sealing head Note that a white plastic spacer ring used to position the sealing head...

Page 79: ...screws will result in hydraulic oil spraying in general directions 6 Restart KMT Waterjet pump first operating in LOW pressure mode to flush out air in HP components and also to check for obvious lea...

Page 80: ...wer to insure a good seal for hydraulic seal removal 5 Place shop rag around plunger to avoid splash back 6 Lightly drive plunger into HP cylinder using dead blow hammer until plunger seal components...

Page 81: ...replace plunger Refer to Paragraph 7 2 6 for procedure regarding plunger removal installation Seal Installation Procedure 1 Lightly coat seal components with FML grease refer to Table 7 2 item 1 prior...

Page 82: ...bolt Tightening Hand Tight Torque ft lb 20 Torque N m 27 2nd Stage Tightening Sequence Crossing Pattern Note 1 Torque ft lb 35 Torque N m 48 3rd Stage Tightening Sequence Crossing Pattern Note 1 Torqu...

Page 83: ...8 Table 7 6 Lube Specs KMT Waterjet Intensifier Pumps Item No KMT P N Description Applications 1 10087385 FML Grease White Lube Parts HP Cylinder 2 10084440 High Purity Goop SS Threads SS Threads 3 49...

Page 84: ...ef Part No 7 2 1 7 2 1 7 2 2 7 2 3 7 2 5 7 2 6 1 Outlet HP Check Valve Sealing Head Yes No No No No No 2 Inlet HP Check Valve Sealing Head Yes Yes No Yes No No 3 HP Plunger Seal HP Cylinder Yes Yes Ye...

Page 85: ...r head in place Slide the cartridge plunger removal tool over the plunger with the hex shaped smaller end toward the plunger button Note orientation of plunger button retainer pins 6 each then align h...

Page 86: ...removed The proximity switch mounting flats provide a small lip for loosening the cylinder head 5 To remove the hydraulic piston 21 from the hydraulic cylinder 15 remove one cylinder head remove the p...

Page 87: ...IGH PRESSURE WATER p 7 16 80078868 Figure 7 8 Item Description 1 Cylinder Head 4 Bushing Retainer Flange 2 Plunger 5 Retaining Ring 6 Hydraulic Cylinder 3 Hydraulic Cartridge Plunger Seal 7 Plunger Re...

Page 88: ...Cartridge Plunger Seal Assy 17 Backup Ring 28 Spacer 7 3 Intensifier Subassemblies Inspection and Repair The inspection and repair of the following subassemblies will be discussed Discharge HP Check V...

Page 89: ...emoved by carefully dislodging it with a screwdriver The seat is removed with a magnet Inspect the seat for damage or cracking A cracked seat should be replaced The seat is symmetrical and can be inst...

Page 90: ...s Install the gland nut into the sealing head The gland nut should be hand tightened until there is a gap of 5mm 0 20 between the gland nut and sealing head No threads should show If the gap exceeds 5...

Page 91: ...2 and spring 7 on poppet retainer 11 Apply small amount of Loctite 222 thread locker to thread of poppet retainer taking care not to get Loctite on poppet or other inlet check valve sealing surfaces 5...

Page 92: ...ION 7 HIGH PRESSURE WATER p 7 21 80078868 Figure 7 11 Item Description 1 Sealing Head 2 Poppet Inlet Check 3 Gland Nut 4 HP Cylinder 5 Spacer Ring 6 Hard seal End Cap 7 Jackbolt 8 O ring 9 Cylinder Li...

Page 93: ...for pits scratches or jetting erosion Refinishing the seal head inlet poppet face is mandatory when rebuilding the sealing head Using a piece of plate glass not window glass on a sturdy table place a...

Page 94: ...ngernail across it will cause it to appear as a surface flaw It is usually necessary to clean the area before performing an inspection 4 Use 600 grit wet dry sandpaper to polish HP cylinder inside dia...

Page 95: ...ecome discolored or dull in appearance If any of these conditions become severe the plunger HP seal and possibly the hydraulic seals will leak excessively Repair of plunger surface flaws usually canno...

Page 96: ...ring 6 O Ring 7 Back Up Ring 8 U cup Seal NOTE It is important to examine the inside diameter surfaces of cartridge seal grooves for scratches especially any scratches in the axial direction that mig...

Page 97: ...piston opposite side These check valves prevent hydraulic pressure from building behind the plunger button Replace Piston Seal 1 Remove bearing rings 10 and worn seal ring assembly 9 Do not scratch bo...

Page 98: ...may show the impression of the plunger on it due to the high contact forces between piston and plunger This compression mark is normal Service Piston Internal Check Valves NOTE Check valve 4 servicin...

Page 99: ...on seal assembly must be compressed before the piston assembly will slide into the hydraulic cylinder A ring compression tool such as shown in the figure below is recommended 1 Check that hydraulic cy...

Page 100: ...SECTION 7 HIGH PRESSURE WATER p 7 29 80078868 Figure 7 16 Item Description 15 Hydraulic Cylinder 20 Seal Ring Compression Tool P460 19 Proximity Switch 21 Hydraulic Piston Assy...

Page 101: ...c cylinder should be inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed Excessive grooving on this bore is indicative of piston seal wear Figure 7 17 Item...

Page 102: ...ed in the Parts Lists Section 12 Bulkhead Piping Assy 7 5 HP Attenuator There is no servicing of the HP attenuator at the customer level The seals in the HP attenuator are tested at KMT Waterjet to hi...

Page 103: ...SURE WATER p 7 32 80078868 Figure 7 18 1 Plunger Removal Tool 6 Seal Removal Tool Stand 2 Vee Block Cradle 7 3 8 Plug 3 Cylinder Wrench 8 3 8 Gland Fitting 4 End Cap Wrench 6x 8x 9 Seal Removal Tool 5...

Page 104: ...cuit diagnostics malfunction warning and protection The electrical enclosure and the display buttons lights and electrical harnesses into and out of this enclosure can be exposed to occasional water s...

Page 105: ...2 3 Phase Line Service Drop Power 11 Optical Relays 3 Enclosure Door Disconnect Circuit Breaker 12 Touch Screen Interface Panel 4 Motor Starter Contactor s 13 Modem Optional 5 Contractor Coil s 230V 1...

Page 106: ...put side of the main circuit breaker door disconnect To make the SL IV Intensifier Pump electrically safe one should switch the wall disconnect 1 OFF and observe LOCK OUT TAG OUT safety practices Note...

Page 107: ...e Motor Overload Motor Feedback Failure Oil Level Low Oil Temp High Low Booster Pressure Low Inlet Water Pressure Long Idle Time Shutdown Booster Temp High Left Overstroke Shutdown Right Overstroke Sh...

Page 108: ...Intensifier Shift A B Port Shifting Solenoid operated directional control valve DCV hydraulic pilot operated spool Hydr manifold assy motor pump group 5 HI LO Pressure Select Solenoid shutoff valve hy...

Page 109: ...0 seconds after motor is started after which pressure will go to high if high is selected otherwise the pump will stay in low pressure The final pressure may also be set on the PRESSURE CONTROL screen...

Page 110: ...0 seconds after motor is started after which pressure will go to high if high is selected otherwise will stay in low The purpose for this is to allow entrapped air to be bled from any HP cylinder that...

Page 111: ...tor starter in the control panel is activated and the motor starts The intensifier assembly starts operating Reversal position is sensed by proximity switches which send signals to the PLC inside the...

Page 112: ...d to two places 1 motor contactor s 5 and 2 24 volt DC power supply 8 To minimize the load requirement on the 24 volt DC power supply motor contactor coil s 5 use 230 volt AC coil s while the relay lo...

Page 113: ...on the switch Symptoms of a failed proximity switch are 1 the LED lights do not change state indicating not sensing the piston or 2 the LED lights are continuously flashing Replace the switch when fai...

Page 114: ...m 1 8 inch Parts Optical Relay Replace Optical Relay Switch 1 Turn off waterjet pump disconnect and LOCKOUT electric power 2 Open control panel 3 Unscrew optical relay switch mounting bolts remove and...

Page 115: ...ump is directly coupled to the motor rather than a conventional standalone housing and shaft coupling assembly Reference hydraulic gage used for adjusting pressures in the HI LO relief valves Displays...

Page 116: ...ted to the motor The main pump control includes hi and lo preset pressures The operator is able to switch between pressures at the operator s console Item Description 1 HI pressure control 2 LO pressu...

Page 117: ...e programmable controller PLC This PLC in turn activates the directional control valve 8 to change flow and to reverse direction of movement of piston until activating the opposite end of stroke proxi...

Page 118: ...Decrease Maximum Minimum High Pressure 1 Clockwise Counterclockwise 207 3 000 1 7 25 Low Pressure 2 Clockwise Counterclockwise 103 1 500 1 7 25 Main Relief 3 Fixed Fixed 234 3 400 Not applicable NOTE...

Page 119: ...and filter maintenance see Section 10 Recirculation System The hydraulic system components that require periodic maintenance are the motor and the manifold The motor needs to be serviced every 5000 h...

Page 120: ...few minutes 9 3 2 Manifold Service 1 Check operating pressure 2 If pressure adjustment is necessary 3 Adjust high pressure control valve Turn locking nut counterclockwise then turn the knob clockwise...

Page 121: ...d together with the hydraulic tank removing air bubbles entrained in the oil due to agitation and turbulent flow in the main pump circuit 10 1 Components The cooling and filtration system recirculatio...

Page 122: ...CULATION SYSTEM Page 10 2 49836026 Figure 10 1 Recirculation System Item Description 1 Recirculation Pump 2 Water Modulating Valve 3 Heat Exchanger 4 Visual Indicator 5 Oil Filter 7 Oil Fill Port 8 Hy...

Page 123: ...indicator 4 indicates when the filter element needs replacement It should be read when both the water jet pump is running and the oil temperature is approximately 115 F Oil fill port must be used when...

Page 124: ...the drain The operating oil temperature is factory set at 46 C 115 F based on the temperature and flow of cooling water at the factory Field adjustment may be necessary 10 3 System Pressure Protection...

Page 125: ...l with additives such as zinc diophosphate ZDDP for anti wear are not recommended because of reaction with water Tools Open End Wrench 1 1 4 Rags Container to collect oil Oil transfer pump with hoses...

Page 126: ...iteria Components 1 Oil Filter Head 2 Element 3 Visual Indicator Parts Element Tools Filter Wrench Rags Container to collect oil spills Replace Oil Filter 1 Unscrew element from filter head with the f...

Page 127: ...when the level rises Drain valve and Fill components The fill components consists of the Oil Filter Head Fill Port and the Fill Port Cap The breather is not a fill component and must not be used as a...

Page 128: ...fill port This will assure clean filtered oil is pumped into the tank Oil must be filtered through an equivalent filter such as a 10 micron filter element Failure to do so will cause damage to the pr...

Page 129: ...mum Operating Temp 95 95 Electrical see note 3 Motor type TEFC TEFC see note 4 200 3 50 92 150 208 3 60 88 144 240 3 60 80 130 400 3 50 46 75 415 3 50 44 72 480 3 60 40 65 Voltage Service Amps 575 3 6...

Page 130: ...e must be maintained within operating specifications 2 When relative humidity is above 50 frequently check oil in tank for water content 3 Not all motor voltages are readily available check with facto...

Page 131: ...r psi Maximum inlet pressure 7 100 bar psi Maximum outlet pressure 8 3 120 bar psi Maximum inlet temperature 29 85 C F Optimum inlet temperature 18 65 C F Factory Booster Pump Settings Inlet Pressure...

Page 132: ...larger than 10 microns upstream of the filter for each particle per ml greater than 10 microns downstream of the filter Note 7 ISO 4406 fluid cleanliness ratings 17 1 300 particles per ml 25 microns 1...

Page 133: ...Fitting Gland Nuts 1 4 Nut 34 25 5 8 Crowfoot 3 8 Nut 67 50 13 16 Crowfoot 9 16 Nut 149 110 1 3 16 Crowfoot See Section 7 for complete tightening procedure NOTE Measurements are made with lubricated...

Page 134: ...g l 25 25 10 Oxygen mg l 2 1 0 1 pH Value 6 5 8 5 6 5 8 5 6 5 8 5 Silica mg l 15 10 1 Sodium mg l 50 10 1 Sulfate mg l 25 25 1 Total Dissolved Solids mg l 200 100 5 Total Hardness as CaCO3 mg l 25 15...

Page 135: ...uilibrium with respect to calcium carbonate 11 5 Orifice Support Capacity The SL IV Waterjet Pump supplies high pressure HP water up to 3 800 bar 55 000 psi The following table shows size ratings and...

Page 136: ...epartment USA Parts Department Europe Spare Parts Manager KMT Waterjet Systems KMT Waterjet Systems GmbH P O Box 231 Wasserstrahl Schneidetechnik 635 West 12th Street Auf der Laukert 11 Baxter Springs...

Page 137: ...ble 12 1 Part Description Abbreviations and Nominal Size Guide Item Description Item Description Assy Assembly mm sq Square millimeters 1 4 9 16 3 4 Nominal sizes in fractions of an inch eg 1 2 NPT 0...

Page 138: ...High Pressure Piping 80078447 12 17 12 8 Hydraulic Manifold Assembly 05071766 12 19 12 9 Bulkhead Piping 80080500 12 21 12 10 Low Pressure Filter Assembly 49838378 12 23 12 11 Hydraulic Power Unit 49...

Page 139: ...33262 Decal Package 7 1 05128087 Start Up Tag 9 1 80080500 Bulkhead Assembly 10 1 05143714 Frame Assembly 11 1 05041660 Reservoir Assembly 12 1 49834757 Cover Assembly 13 1 49834229 Hydraulic Power Pa...

Page 140: ...SECTION 12 PARTS LISTS Aug 2003 page 12 5 80081540...

Page 141: ...20 x 2 31 14 2 05034798 Ring Retaining 15 1 05034764 Cylinder Hydraulic 16 2 10075000 O ring 17 2 05034855 Ring Backup 18 16 05141106 Cap Screw Socket Head M14x60 19 2 05127584 Switch Proximity 20 25...

Page 142: ...SECTION 12 PARTS LISTS Aug 2003 page 12 7 80081540...

Page 143: ...RT No DESCRIPTION 1 1 49834039 Body Sealing Head 2 1 05144662 Poppet Inlet Cutting Water 3 1 05116777 Gland HP Sealing Head 4 1 05112768 Seat HP Sealing Head 5 1 05116561 Poppet Valve HP Check 6 1 051...

Page 144: ...SECTION 12 PARTS LISTS Aug 2003 page 12 9 80081540...

Page 145: ...261 Body Hydraulic Piston 2 12 05074380 Pin Clevis 3 2 05049887 Screw Set Socket with Through Hole 4 2 10148757 Valve Check Cartridge with O ring 5 49877509 Adhesive Thread Locker 6 2 05088364 Ring Sn...

Page 146: ...SECTION 12 PARTS LISTS Aug 2003 page 12 11 80081540...

Page 147: ...SEMBLY 05130091 ITEM No QTY PART No DESCRIPTION 1 1 05130109 Body Seal Cartridge 2 2 05015060 Seal U Cup with O ring 3 1 10193522 O ring 4 1 05050760 Ring Backup 5 1 05129481 O ring 6 1 05013024 O rin...

Page 148: ...SECTION 12 PARTS LISTS Aug 2003 page 12 13 80081540...

Page 149: ...e Assembly Hydraulic 25 ID 4 JIC Swivel Both Ends 32 10 1 05049713 Hose Assembly Hydraulic 75 ID 12 JIC Swivel Both Ends 27 11 2 05071105 Hose Assembly Hydraulic 75 in ID 12 JIC 90 deg x 12 JIC Swivel...

Page 150: ...SECTION 12 PARTS LISTS Aug 2003 page 12 15 80081540...

Page 151: ...cu in 4 200 bar TUV 11 2 49830599 Tee HP 56 60ksi stainless 12 10 10083897 Ferrule 25 Hose 13 4 95413696 Washer Lock 13 14 4 05144837 Spacer Accumulator 15 4 95383790 Cap Screw Socket Head 13 x 1 in...

Page 152: ...SECTION 12 PARTS LISTS Aug 2003 page 12 17 80081540...

Page 153: ...5497 Gage Pressure Hydraulic O 5 000 psig 4 SAE O ring Bottom Mount 7 1 10187052 Valve Relief Hydraulic 100 3 000 psi Range Knob Adjustable 8 1 10187060 Valve Relief Hydraulic 25 800 psi Range Adjusta...

Page 154: ...SECTION 12 PARTS LISTS Aug 2003 page 12 19 80081540...

Page 155: ...Low Pressure 13 1 49834328 Adapter 25 OD Tube x NPT 14 2 05061312 Seal Hole 2 20 in Conduit 15 2 05111406 Adapter Str 25 NPT x 8 JIC 16 1 10077055 Adapter Bulkhead 4 15 Brass 17 2 49830722 Adapter Pip...

Page 156: ...SECTION 12 PARTS LISTS Aug 2003 page 12 21 80081540...

Page 157: ...8 6 1 05140751 Pressure Switch 7 1 05142062 Pressure Switch 8 1 49868813 Temperature Sensor 9 1 05070982 Valve Relief 50 150 psi NPT 10 1 05135645 Adapter Pipe Hose Barb 8NPT x 8 Hose 11 1 05135652 Ch...

Page 158: ...SECTION 12 PARTS LISTS Aug 2003 page 12 23 80081540...

Page 159: ...3 95572897 Hex Head Screw 1 4 20 x 5 8 4 3 95838314 Lock Washer 1 4 5 1 49887094 Vane Water Pump 12 1 10092302 Shaft Coupling 13 2 10116952 Cap Plug 14 2 95750394 Lock Washer 3 8 15 2 95416319 Hex He...

Page 160: ...SECTION 12 PARTS LISTS Aug 2003 page 12 25 80081540...

Page 161: ...d 71 cc rev 5 2 05037593 Socket Head Screw M10 x 1 50 x 25mm 6 2 10069714 Flat Washer 3 8 7 1 05071766 Manifold Assembly 8 1 05047451 Adapter JIC O ring 90 Degrees 12 12 9 1 05045364 Gear Pump Double...

Page 162: ...SECTION 12 PARTS LISTS Aug 2003 page 12 27 80081540...

Page 163: ...95830766 Lock Washer 31 14 6 10103232 Neoprene Nitrile 0 13 x 1 15 1 10091858 Bulb Well 16 4 95119897 Hx Hd Screw 5 16 18 x 1 2 17 2 05145974 Heat Exchanger Bracket 18 4 95716890 Lock Washer 50 19 4 1...

Page 164: ...SECTION 12 PARTS LISTS Aug 2003 page 12 29 80081540...

Page 165: ...op Cover 4 2 49834708 End Cover Left 5 2 49834690 End Cover Right 7 4 49837511 Bracket 8 4 49837529 Bracket 9 4 49837503 Spring 10 32 49837743 Screw Button Head 3 8 16 x 1 1 4 11 32 05091988 Nut 3 8 1...

Page 166: ...SECTION 12 PARTS LISTS Aug 2003 page 12 31 80081540...

Page 167: ...9 Ring Terminal 4 18 10098788 Flexible Conduit 5 1 10114932 Flexible Conduit Connector 6 1 49885627 Lock Nut 7 12 80080344 10 Terminal Ring 8 4 10069763 Washer 50 9 124 10180768 00 Wire Black 10 42 05...

Page 168: ...SECTION 12 PARTS LISTS Aug 2003 page 12 33 80081540...

Page 169: ...2 Auxiliary Contact 14 1 49833460 Mechanical Interlock 15 1 49836984 Contactor Non Reversing 16 1 49830367 Y Delta Kit 17 2 05095609 Ground Lug 18 2 95423620 Screw Hx Hd 5 16 18 x 3 4 19 24 10170140 6...

Page 170: ...SECTION 12 PARTS LISTS Aug 2003 page 12 35 80081540...

Page 171: ...1 5 05112826 Terminal Block 24 1 49830268 Cable Channel 26 1 05049432 Legend Plate Holder 28 1 05140504 Sub plate 29 1 10156859 I O Rack 30 4 10146363 Single Point Module 31 2 10157659 Lock Washer 25...

Page 172: ...SECTION 12 PARTS LISTS Aug 2003 page 12 37 80081540...

Page 173: ...Date 7 29 2003 Time 11 47 13 AM Title J cad Release 4983 49835622 DWG...

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KTM STREAMLINE L-IV 50, Operation And Service Manual

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Summary of Contents for STREAMLINE L-IV 50

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