KTM STREAMLINE L-IV 50, Operation And Service Manual, Page: 77 / 178

SECTION 7
HIGH PRESSURE WATER
p. 7-6 80078868
WARNING
!
WARNING
!
HP Cylinder Jug Removal
1. Prior to removing electrical power from the KMT Waterjet pump, extend
plunger on end to be serviced. Remove electrical connector from proximity
switch on end of hydraulic cylinder closest to HP cylinder jug to be removed.
Start the pump in LOW pressure mode, allow approximately 20 seconds for
appropriate startup and cycling of intensifier to extend and stop toward the
disconnected proximity switch. Shut off KMT Waterjet pump, shut off LP
water supply, and observe LOCK-OUT/ TAG-OUT safety rules.
Before performing maintenance on the waterjet pump observe
electrical LOCK OUT/TAG OUT procedures.
2. Disconnect HP and LP piping / hoses per paragraph 7.2.1 above.
3. With support cradle tool (2) Figure 7-3 located under HP cylinder jug (1),
unthread and remove jug from plunger and hydraulic cylinder head (6).
NOTE: If thread or metal surface galling was noticed during jug removal, galled
surfaces/threads should be filed, sanded and/or re-lubricated prior to re-assembly.
NOTE: With HP cylinder jug removed from hydraulic cylinder head, plunger and HP
seal can be replaced or maintenance can be performed on plunger, hydraulic piston
and seals. Refer to Table 7-7 for recommended tear-down sequence.
HP Cylinder Jug Re-Installation
1. Verify that HP cylinder threads are adequately lubed with High Purity Goop
and that the threads have been sanded/ dressed if galling was encountered
during HP cylinder jug removal.
2. Verify that the HP plunger seal assembly, packing follower, and plastic
cylinder liner tube are correctly installed. Align HP cylinder jug (1) with
plunger and hydraulic cylinder head (6) using cradle tool (2) to support
weight. Carefully push/ lift jug (1) into place until threads are ready to
engage cylinder head (6).
3. Continuing to support HP cylinder jug (1) with cradle fixture (2), thread HP
cylinder (3) into cylinder head (6).
NOTE: Any galling of cylinder to cylinder head must be addressed. If galling occurs
during threading, remove jug, inspect mating surfaces/threads, repair/blend
surfaces using file, sandpaper, etc., then attempt to rethread.
4.
Re-connect HP and LP piping / hoses per paragraph 7.2.1 above.
Check that all proximity switches are properly installed and
secured prior to starting the motor. Failure to tighten
proximity switch hold down screws (2 each per proximity
switch) will result in hydraulic oil spraying in general
directions.
5. Restart KMT Waterjet pump, first operating in LOW pressure mode to flush
out air in HP components and also to check for obvious leaks. Switch to
HIGH
pressure after 5-10 minutes of LOW pressure operation, watching for
obvious leaks. Be ready to shut off the pump if leaks appear. Remedy leaks