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SECTION 7

HIGH PRESSURE WATER

Nov 2002

p. 7-18

05126826

7.3.5

Plunger

Plunger surfaces can become streaked with longitudinal scratches or flaws, the
surface can become discolored or dull in appearance, or the outboard end can
become smeared with stainless steel due to contact with the bore liner. 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
cannot be accomplished on site. KMT Waterjet offers a plunger reconditioning
service.

Item Description

(1) Plunger Button

(2) Plunger

(3) Button Chamfer

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Содержание Streamline SL-IV

Страница 1: ...STREAMLINE HIGH PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL SL IV 15hp HSEC 208 230 Manual No 05139142 Printed 12 09 03 05139134 doc ...

Страница 2: ... 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 to advise of such changes and or additions KMT WATERJET SYSTEMS KMT Wat...

Страница 3: ... 2 2 Installation Requirements Utilities 2 2 2 2 1 Equipment Location Environment 2 2 2 2 2 Service Connections 2 3 2 2 3 Tools and Equipment 2 5 SECTION 3 OPERATION 3 Features 3 1 3 1 Operation Overview 3 1 3 2 Operator Console 3 2 3 2 1 Component Description 3 4 3 2 2 Operating Procedures 3 4 3 2 3 Remote Operation 3 4 3 3 Special Start Up Procedures 3 5 3 3 1 Start Up Following HP Maintenance 3...

Страница 4: ...Plunger 7 8 7 2 5 Hydraulic Cylinder Head Hydraulic Piston 7 10 7 3 Intensifier Subassemblies Inspection Repair 7 12 7 3 1 Discharge HP Check Valve 7 13 7 3 2 Inlet Check Valve 7 15 7 3 3 Sealing Head 7 16 7 3 4 HP Cylinder 7 17 7 3 5 Plunger 7 18 7 3 6 Hydraulic Seal Cartridge 7 19 7 3 7 Hydraulic Piston 7 21 7 3 8 Hydraulic Cylinder 7 15 7 4 HP Dump Valve 7 26 7 5 HP Attenuator 7 26 SECTION 8 EL...

Страница 5: ...TION SYSTEM 10 Features 10 1 10 1 Components 10 1 10 2 Operation 10 1 10 3 System Pressure Protection 10 2 10 4 Maintenance Overview 10 3 SECTION 11 SPECIFICATIONS 11 Specifications 11 1 Equipment Specifications 11 1 Torque Specifications 11 3 Cutting Water Specifications 11 4 Cooling Water Specifications 11 4 Orifice Support Capacity 11 5 SECTION 12 PARTS LISTS 12 1 12 Parts Lists Hydraulic Schem...

Страница 6: ...jet Pump uses low pressure water which meets certain quality requirements and increases the pressure up to 3 800 bar 55 000 psi for ultra high pressure waterjet cutting hydrobrasive cutting cleaning surface preparation etc This manual provides information for installation operation and maintenance of the KMT Waterjet SL IV 11 kW 15 hp Waterjet Pump 1 1 Physical Description The SL IV waterjet pump ...

Страница 7: ...SECTION 1 INTRODUCTION July 2003 1 2 05130661 Dimension Letter mm inch G 140 5 50 H 203 8 00 J 267 10 50 K 419 16 50 L 400 15 75 M 483 19 00 N 554 21 82 P 33 1 31 R 832 32 78 S 1422 56 00 T 711 28 00 ...

Страница 8: ...st of the unit quickly for maintenance and serviceability 1 1 1 Standard Equipment Following is an overview of the standard equipment for the SL IV 11 kW 15 hp waterjet Pump Variable displacement pressure compensated hydraulic pump Filtration system with 10 micron filter High efficiency heat exchanger in independent recirculation pump circuit Stand alone unit with built in Wye Delta motor starter ...

Страница 9: ... at high pressure while the HP attenuator reduces the routine fluctuations in the HP water pressure signal The compression ratio is 20 1 with a maximum hydraulic pressure set at 214 bar 3 100 psi The recirculation hydraulic loop for cooling and filtering oil runs continuously whenever the motor is running 1 2 1 Functional Features Following is a list of SL IV 11 kW 15 hp Waterjet Pump features 4 1...

Страница 10: ...at KMT Waterjet designated training locations On site training is also available 1 3 1 Service Department To contact the KMT Waterjet Service Department USA Service Manager Europe Technical Manager KMT KMT Waterjet GmbH Waterjet Systems Wasserstrahl Schneidetechnik 635 West 12th Street Auf der Laukert 11 Baxter Springs KS 66713 D 61231 Bad Nauheim USA Germany Phone 620 856 2151 Phone 49 0 6032 997...

Страница 11: ..._______________________________________ Yes No Is the unit a convenient size Yes No 1 Controls a Are the controls user friendly b Is the unit easy to operate Comments Yes Yes No No 2 Performance a Does the unit perform smoothly and meet your expectations b Does the unit run quietly Comments Yes Yes No No 3 Did installation and start up go smoothly Comments Yes No 4 What feature s do you consider t...

Страница 12: ... quantity 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 procedures you feel need clarification Please identify them by page number and add your comments Comments Yes No 3 Is there anything you would add or delete from the manual to make it more useful Commen...

Страница 13: ...nal injury or property damage if the caution instruction is ignored WARNING Indicates the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning instruction is ignored High pressure waterjet can cause eye injury Wear eye protection when operating or working near machine Hazardous noise can cause hearing loss Wear ear protection when operating...

Страница 14: ...gainst the hazard of trapped HP water or hydraulic pressure after the pump has been shut off Typically all pressure can be safely bled off if the operator will leave the HP cutting water valve open for a few seconds after shutting off the pump Electrical shock hazard warns of electrical shock hazard when in the vicinity of the electrical enclosure or motor junction box Hot surface warning warns of...

Страница 15: ... Everyone associated with the waterjet cutting system must realize that the force of the waterjet cutting stream can penetrate many dense or strong materials Keep all untrained people away from the waterjet cutting area Use barriers or partitions if needed Safety glasses must be worn at all times in the waterjet cutting area All EMERGENCY STOP buttons must be checked periodically The normal operat...

Страница 16: ...r work on any high pressure component or loosen any high pressure fitting without first bleeding the system and assuring there is no high pressure water present WARNING Make sure the safety devices are operational To panic stop the pump and bleed the high pressure an EMERGENCY STOP button must be pushed in while the system is active The intensifier high pressure dump valve will automatically open ...

Страница 17: ...ent Possible failure from fatigue cracking or over pressurization can result in a hazardous high pressure leak or component failure WARNING A flexible HP tube whip is frequently used on the cutting system to allow cutting nozzle movement Supports and guides for the whip must be used anti vibration fittings and proper support must be provided to prevent failures from external loads non water relate...

Страница 18: ... with a jet velocity of 3 000 fps 914 mps Foreign material sand may have been injected with water Unusual infections with microaerophilic organisms occurring at lower temperatures have been reported such as gram negative pathogens as are found in sewage Bacterial swabs and blood cultures may therefore be helpful This injury must be treated as an acute surgical emergency and be evaluated by a quali...

Страница 19: ... customer site The waterjet cutting equipment should be uncrated positioned and leveled with electrical and fluid services brought to the unit Provide and install power drops with fused disconnects sized to the equipment power requirements Provide and install pneumatic drops with manual shutoff valves Provide all mounting and support brackets and hardware for high pressure tubing runs Provide and ...

Страница 20: ...rements Utilities Environment The SL IV Waterjet Pump must be installed indoors Ambient conditions must not exceed maximum specifications Moving The SL IV Waterjet Pump has provisions to be moved with a forklift Check weight specifications CAUTION The waterjet pump is top heavy Avoid situations that could result in the equipment tipping or overturning WARNING Electrical connections must be made by...

Страница 21: ... meets minimum standards listed in Section 11 Specifications Operation without proper water quality will shorten the life of certain intensifier parts and void their warranty Use only plastic or copper plumbing from the cutting water source to the SL IV pump cutting water supply filter Thoroughly purge the cutting water supply plumbing prior to connecting to the SL IV pump HP Water OUT Properly ra...

Страница 22: ...e location i e sewer line Piping must meet national and local piping codes Compressed Air The facility air connection to the SL IV Pump should provide clean dry air at 5 9 bar 85 psig Air usage is minimal that is far less than 1 SCFM Rear of Waterjet Pump A HP Water OUT B Plant Air IN C Cooling Water IN D Cooling Water OUT E Cutting Water IN F Drain ...

Страница 23: ...two times the tube engagement length 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 damage personal injury or death Tube Engagement Length HP Tube Diameter inch Engagement Length EL mm inch 1 4 12 7 0 50 3 8 17 5 0 69 9 16 21 3 0 84 1 1 1 1 WARNING ...

Страница 24: ... the 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 8 3 18 0 125 5 56 0 219 19 1 0 750 3 8 24 14 27 9 16 4 78 0 188 7 14 0 281 23 8 0 938 9 16 18 ...

Страница 25: ...erence Cone 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 Coning Tool Part 10079556 10097418 10079663 Threading Tool Part 10079697 10097434 10097442 ...

Страница 26: ...nut 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 the cutting blades 4 are taking a light cut at all times Continue rotating cutter handle until feed nut bottoms on housing 6 then rotate cutter handle several more revolutions to face off end of cone...

Страница 27: ...essure 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 male threads of gland with High Purity Goop Insert tubing in fitting engage gland nut and tighten finger tight 3 Tighten gland to specified torque as given in the torque table specifications ...

Страница 28: ...ne Proper piping support and guide must be provided WARNING Do not subject the tubing to torsional rotational stress To do so will cause premature failure 1 Slip gland nut 2 and collet 4 on tubing 1 thread collar 3 until one to two threads are exposed between collar and tube cone 2 Lubricate male threads of gland nut with High Purity Goop Insert tubing in fitting engage gland nut and finger tighte...

Страница 29: ...n Overview The I R SL IV Waterjet Pump can be started and stopped from either the pump mounted controls or from optional remote controls located at or near the cutting system operator s console The following provides the component overview Item Description 1 Electric Motor 2 Hydraulic Pump 3 Manifold 6 Solenoid Shutoff Valve 7 Hydraulic Gear Pump 8 Heat Exchanger 9 Directional Control Valve 13 HP ...

Страница 30: ...otor hydraulic pumps and intensifier assembly stop The high pressure HP dump valve is opened HP water is bled from the pump piping circuit To reset the E STOP button pull out For normal shutoff use the STOP button on keypad STOP Item 7 Stops the pump in all but emergency stop situations Pressing the STOP button shuts off electric motor and hydraulic pump Electric control power 24vdc stays on START...

Страница 31: ...ription 1 Palmbutton Emergency Stop 2 Handle Electrical Disconnect 3 Pushbutton Control Power On White Light 4 Selector Switch Local Remote Control 5 Pushbutton Stop Pump Fault Red Light 6 Pushbutton Start Pump Green Light 7 Hourmeter 8 Decal Shock Hazard ...

Страница 32: ...light 6 ON Green CONTROL POWER light 3 ON White SL IV Pump Running Push STOP button RUN light Green will go OFF CONTROL POWER ON light White will stay ON SL IV Pump will stop 3 2 3 Remote Operation The waterjet pump is equipped with a REMOTE LOCAL switch 4 The switch transfers control from the local panel signified by symbol to a remote panel signified by the symbol The following list of functions...

Страница 33: ...nnector HP water dump valve RECONNECT 7 Start switch ON Check for HP water leaks 8 Verify normal HP water signal pattern and pressure level This completes startup procedure following HP maintenance 3 3 2 Initial Pump Start Up Procedure Make all connections for both electrical and water supply Check the system for all correct connections before the unit is started for the first time Assure safety s...

Страница 34: ...e motor backwards as the hydraulic pump will likely be damaged Motor direction of rotation should be checked any time electrical maintenance modification is performed on the motor starter wiring or on the service wiring to the pump Check that inlet cutting water is present before starting SL IV Pump At initial startup run the intensifier at low pressure refer to procedure in paragraph 3 3 4 with a...

Страница 35: ...pushbuttons Jog the motor by using both hands on the control panel one finger on the STOP button ready to shut off the motor as soon as the START button is pushed It should be possible to jog the motor in a START STOP action that lasts less than one second Note that if the motor rotates in the wrong direction swap a pair of wires at the starter panel s main disconnect then recheck motor direction ...

Страница 36: ...WER ON pushbutton should be lit Press START pushbutton to start pump The intensifier assembly will stroke and stop when the HP lines are filled The pump will maintain a constant HP water signal even though the nozzle is closed and no water is circulating This is called standby or deadheaded condition 3 Check for any leaks throughout the installation 4 Remove front cover and locate the pump compens...

Страница 37: ...e is at least 30 C 86 F 5 Open nozzle control valve the SL IV pump will start stroking again Turn inboard pressure compensator adjustment clockwise until reaching 1 034 bar 15 000 psi Check for leaks 6 Continue increasing pressure by 345 bar 5 000 psi steps checking for leaks every time until reaching desired operating pressure 7 To stop pump press STOP button It is recommended to bleed out the pr...

Страница 38: ...BOARD while outboard adjustment screw is used for pump internal case drain pressure Use a 3mm Allen wrench to increase clockwise or decrease counter clockwise pump compensator pressure View a HP water pressure gage while adjusting the pump compensator Increase pressure slowly while the pump is supplying HP water to a nozzle orifice Verify the static HP water setting by blocking flow to the HP wate...

Страница 39: ...formed at a remote work station through wiring connections provided on the pump starter control panel This control option is useful when the operator is controlling the motion of a machine robot cutting box X Y motion table etc without leaving the work station 3 5 Fault Messages Overview The pump will shutdown as a result of the following conditions 3 5 1 High Oil Temperature Shutdown 1 ABNORMAL C...

Страница 40: ...wing Fill to proper level Observe all safety procedures Check for cause of low level leaks etc Make required repairs 3 After problem is corrected the following occurs ABNORMAL CONDITION red light should go OFF 4 Push START button and follow the start procedure to resume normal operation ...

Страница 41: ...8 Hydraulic System Section 9 Recirculation System Section 10 The following is an overview of the primary components and their location Hydraulic Pump including electric motor and hydraulic valve manifold block The pump is a variable displacement axial piston and pressure compensated type Recirculation Pump including a fixed displacement gear type pump oil to water heat exchanger hydraulic return l...

Страница 42: ...SECTION 4 MAINTENANCE July 2003 p 4 2 05130679 Item Description 1 Hydraulic Pump 2 Recirculation Pump 3 Intensifier Assembly 4 Control Panel 5 HP Attenuator ...

Страница 43: ...HP Check 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 Hydraulic Oil Tank X X R Electric Motor F Vibrations Rotating Equip Hydraulic Pump F Hydraulic Pump F HP Tubing Valves Fittings F Hydraulic Manifold Hydraulic Intensifier F Control Panel Electrical En...

Страница 44: ...ing off parts with compressed air use only clean dry air When flushing parts with a solvent use only clean filtered fluid Always use original KMT Waterjet replacement parts for consistent performance reliability safety and to protect equipment warranty Safety Recommendations Carefully read the Safety Guidelines in Section 1 of this manual Lock out all electrical power Close all incoming supply val...

Страница 45: ...ng any high pressure fitting After servicing 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 pump install an orifice and slowly increase the discharge water pressure in stages Check all high pressure connections for leaks Unusual requirements should be ...

Страница 46: ...on should illuminate Main Power Disconnected Check main power Door Unlatched locked out Check that the door disconnect switch is properly engaged Control Power Not Available Check power supply circuit protection tripped breaker Check power supply 24vdc input and output Pump Quit Running Unsafe Operation Detected Check fault indication on operator s console If red light illuminated problem may be h...

Страница 47: ...ty of pump Check that orifices are in good working order Check Piping Leaks Check system components for leaks Check HP Dump Valve for leaks including through stem seat Check Valve Leakage Inspect pump discharge HP check valves Inspect pump inlet low pressure LP check valves Check Seal Leakage Inspect plunger sealing head seals Hydraulic Control Malfunction Check hydraulic valve operation Verify pr...

Страница 48: ...ng Flow Check cooling water flow to and from heat exchanger Check setting of water modulating valve Check water pressure differential across heat exchanger 2 75 bar 40 psi minimum required for flow through the exchanger Check operation of water modulating valve Water Modulating Valve Set High Check and adjust setting of water modulating valve Heat Exchanger Clogged Flush heat exchanger improve qua...

Страница 49: ...h light will turn ON it indicates an inlet check valve problem If the plunger does not move it indicates a HP discharge check valve problem Normal Temperature but Check Valve Problem Since the HP check valves are interconnected to determine which of the two inlet check valves or two discharge check valves is causing the problem follow these procedures Check inlet HP check valve 1 Follow the proced...

Страница 50: ...ow rate and low temperature to the oil to water heat exchanger 1 Motor Electric 19 Valve Water Modulating 2 Pump Main Hyd 20 Thermal Bulb Water Modulating 3 Pump Recirculating Hyd 29 Pressure Gage Cutting Water 4 Reservoir Hyd 30 Intensifier Assy 5 Filter Assy Hyd 31 Valve LP Water Relief 6 Heat Exchanger Oil to Water 32 Valve HP Water Dump 18 Filter LP Water 6 1 Oil Cooling Water Supply The oil c...

Страница 51: ... HP cylinder inlet check valve sealing head ports for ease of maintenance preventing low pressure water from spraying out when this connection is broken 6 2 1 Normal Operating Condition During normal operation the low pressure water system maintains the following conditions Pressure gage reads 2 bar 30 psig or greater while intensifier is pumping at maximum flow rate Components feel cool to touch ...

Страница 52: ...on periodic maintenance on the water filter is necessary The guidelines for servicing these parts are described below 6 3 1 Water Filter Service Replace filter element when cutting water pressure gage reads less than 2 bar 30 psig Components Bleed Valve Element Head Housing Recommended Tools Supplied filter thread unthread tool to turn housing Container to capture some water spill Rags Parts Eleme...

Страница 53: ...s Section 11 7 1 Components The high pressure water components include the hydraulic intensifier HP attenuator HP dump valve and HP piping Maintenance on the intensifier is discussed in detail in this section In addition to HP components and assemblies the hydraulic cylinder aspects of the intensifier are discussed in this section Item Description 1 Bulkhead Fittings 2 Inlet Check Valve 3 Discharg...

Страница 54: ...ailed inspection and repair for individual HP subassemblies is also provided The HP attenuator is discussed but no disassembly procedures are included since attenuators are not serviceable by the customer Item Description 1 Sealing Head 2 Collar 3 Sealing Head Nut 4 Head Seal 5 Cylinder Body 6 Cylinder Liner 7 Plunger 8 Plunger Seal 9 Cylinder Head 10 Hydraulic Cartridge Seal 11 Flange 12 Piston 1...

Страница 55: ...cylinder can be removed from hydraulic cylinder head HP seals sealing head and plunger can be serviced After the pump has been reassembled then the HP water piping quick disconnect and collar are reinstalled as follows 5 Slide inlet water collar over sealing head until it rests against the head nut Connect LP inlet water quick disconnect to collar 6 Install the HP water piping Tighten HP connectio...

Страница 56: ...apping the pin spanner wrench with plastic hammer may be required 3 Unscrew head nut until it is flush with the water inlet groove on the sealing head With a screwdriver in the groove and supported by the head nut gently pry the sealing head out as far as possible continue repeating the process until the sealing head is loose from the cylinder Continue unscrewing the head nut and remove nut from H...

Страница 57: ...cing the inlet HP check valve 9 Lightly lubricate the inside of the HP cylinder outboard end with food grade grease Ensure threads are clean and undamaged Lubricate cylinder threads with High Purity Goop 10 Fit the sealing head assembly and head nut together While holding the sealing head assembly securely against the head nut thread nut onto the HP cylinder Avoid knocking the end of the seal head...

Страница 58: ...ed and the complete cylinder can be inspected and polished as described in Section 7 3 4 Remove the plunger HP seal and seal follower from the HP cylinder using the special aluminum seal removal tool Be careful not to scratch the bore of the HP cylinder 4 Remove cartridge retainer flange from hydraulic cylinder head by first removing retaining ring using a flat blade screwdriver Wipe and clean sur...

Страница 59: ...head Note that shoulder guides are close fitting smooth diameters located at either end of cylinder threads Be sure to support the weight of the HP cylinder As the HP plunger seal goes into the cylinder the cylinder will become difficult to rotate Use the special cylinder wrench to assist as necessary 8 Tighten the HP cylinder hand tight with the cylinder wrench then tap the cylinder wrench with t...

Страница 60: ...e the proximity switch on the intensifier side nearest HP cylinder to be serviced This procedure will allow hydraulic oil to drain to tank and will minimize oil spillage Draining takes about 5 minutes 2 To remove the hydraulic seal cartridge use a screwdriver to remove the internal retaining snap ring that holds in the cartridge retainer flange Remove cartridge retainer flange Item Description 1 C...

Страница 61: ...ghtly to cause pins to retract enough to release plunger Plunger can now be extracted from hydraulic piston See Section 7 3 5 for servicing the plunger 5 To install new plunger slip cartridge plunger removal tool over plunger hex end toward plunger button to help center plunger in cylinder head Position plunger in mating pocket of piston then force into place by hand Using a flashlight verify that...

Страница 62: ...this stage Note that potential plunger damage can be avoided if plunger is removed prior to unbolting cylinder head 4 Loosen and remove 8 each socket head cap screws 18 retaining cylinder head 4 to hydraulic cylinder 15 The cylinder head and its O ring 16 can be removed The proximity switch mounting flats provide a small lip for loosening the cylinder head 5 To remove the hydraulic piston 21 from ...

Страница 63: ...2 Plunger 4 Cylinder Head 8 Hyd Cartridge Plunger Seal Assy 9 Bushing Retainer Flange 14 Retaining Ring 15 Hydraulic Cylinder 16 O ring 17 Backup Ring 18 Cap Screw 19 Proximity Switch 20 Cap Screw 21 Hyd Piston Assy 23 Manifold 25 Cap Screw 26 Lockwasher 27 O ring 28 Spacer ...

Страница 64: ...pection and repair of the following subassemblies will be discussed Discharge HP Check Valve Section 7 3 1 Inlet Check Valve Section 7 3 2 Sealing Head Section 7 3 3 HP Cylinder Section 7 3 4 Plunger Section 7 3 5 Hydraulic Seal Cartridge Section 7 3 6 Hydraulic Piston Section 7 3 7 Hydraulic Cylinder Section 7 3 8 ...

Страница 65: ...poppet is removed by carefully dislodging it with a screwdriver The valve 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 installed with either face toward the poppet Note that a slight burr at the hole edge identifies the used side of the poppet seat When reinstalling the seat apply a thin film of High Puri...

Страница 66: ...ads 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 5mm 0 20 then the poppet has slipped out of place and the parts must be removed inspected and reassembled 6 Using a 30mm 1 3 16 crowfoot torque wrench combination torque the gland nut to 88 Nm 65 ft ...

Страница 67: ... both sides are worn replace poppet 4 Insure the poppet retainer threads and the mating threads in the port sealing head are clean and dry Install small O ring over threads 5 Assemble the inlet poppet spring and retainer to the sealing head using a flat blade screwdriver 6 Inspect the assembled unit to insure the following The poppet moves freely The spring is fully guided on the poppet retainer T...

Страница 68: ...ppet face is mandatory when rebuilding the sealing head Using a piece of plate glass not window glass on a sturdy table place a piece of 400 grit wet dry sandpaper atop the plate of glass which provides the absolutely flat surface necessary for the polishing process Using even deliberate strokes polish the sealing head until smooth Rotate the head about 10 15 degrees every stroke Be careful not to...

Страница 69: ...unning a fingernail 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 diameter where the seal will locate Polish only in a circumferential motion Do not polish or drag the sandpaper along the length of the cylinder Hold the sandpaper on the end of your finger an...

Страница 70: ...ce or the outboard end can become smeared with stainless steel due to contact with the bore liner 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 cannot be accomplished on site KMT Waterjet offers a plunger reconditioning service Item Description 1 Plunger Button 2 Plunger 3 Button Chamfer ...

Страница 71: ...artridge body 1 surfaces for scratches signs of metal to metal contact deformation or other unusual wear Item Description 1 Cartridge Body 2 U cup Seal 3 O Ring 4 Back Up Ring 5 O 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 might offer a leak path ...

Страница 72: ...eals 2 8 so that they match figure above 4 Apply food grade grease to seals and cartridge seal components to aid in installation and seal seating Use installation tool if available for installation of U cup seals 2 8 Verify that U cup O rings are in place in their respective U cup seals after installation ...

Страница 73: ...to the piston opposite side These check valves prevent hydraulic pressure from building behind the plunger button Replace Piston Seal CAUTION Do not scratch bottom surface of piston seal groove Scratches to the seal groove sides and or bottom can result in a hydraulic leak 1 Remove bearing rings 10 and worn seal ring assembly 9 NOTE Use a smooth dull edged blade made from brass or similar soft rel...

Страница 74: ...ause seal leaks 3 Inspect plunger button sockets for unusual wear NOTE Plungers may make an indentation in the bottom of the plunger socket The bottom of this socket 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 servicing is not necessary unless there is ...

Страница 75: ... Use plunger removal tool to verify that pins retract release plunger and close retain plunger in a uniform manner Install Hydraulic Piston Assy into Hydraulic Cylinder NOTE Piston 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 cylinder bore is free gr...

Страница 76: ...SECTION 7 HIGH PRESSURE WATER Nov 2002 p 7 24 05126826 15 Hydraulic Cylinder 19 Proximity Switch 20 Seal Ring Compression Tool P460 21 Hydraulic Piston Assy ...

Страница 77: ...the hydraulic 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 Item Description 1 Hydraulic Cylinder 2 Cylinder Head 3 Proximity Switch 5 Cap Screw 8 Back up ring 9 O ring 10 Spacer ...

Страница 78: ... in the Parts Lists Section 12 see Figure 12 7 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 high pressure in excess of operating pressure making disassembly difficult In the event of a HP water leak of a HP attenuator the attenuator should be replaced The defective attenuator sho...

Страница 79: ...dard Wye delta starter circuit The built in starter circuit includes the following Manual disconnect with door handle interlock Over current protection Thermal overload devices The hydraulic circuit automatically unloads hydraulic pressure to allow the motor to achieve full speed for approximately 2 seconds The motor is also provided with terminal blocks for wire termination 8 1 2 Control Circuits...

Страница 80: ...itch Local Remote keyed 8 Decal Shock Hazard Warning During normal operation the control power reset light white and the START pushbutton light green are illuminated If the SL IV Pump shuts down due to one of the automatic features the control power reset light and STOP pushbutton light red will be illuminated High oil temperature and low oil level are the two automatic shutdown circuits When eith...

Страница 81: ... 1 Proximity Switch Service If the pump quits pumping water the proximity switch may need to be replaced Check the LED lights 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 failure occurs Recommended Tools Allen hex Wrench M5 Torque Wrench Rags Compo...

Страница 82: ... p 8 3 05130703 Replace Proximity Switch 1 Turn off waterjet pump disconnect and LOCKOUT electric power 2 Disconnect cable 3 Unscrew bolts remove proximity switch 4 Install new switch Install bolts 5 Torque bolts to 16 18 Nm 140 160 in lbs ...

Страница 83: ...irectional control valve DCV are used to control the intensifier hydraulic cylinder The hydraulic manifold which includes the solenoid operated DCV is mounted beneath the intensifier hydraulic cylinder The hydraulic system also includes plumbing to connect pump valve manifold and reservoir 9 1 1 Features Features of the hydraulic power and control system are listed below Hydraulic unloading during...

Страница 84: ...or The main pump pressure control is adjusted at the pump compensator 1 Electric Motor 15 hp 2 Piston Pump 3 Gear Pump 4 Hydraulic Reservoir 5 Filter Housing 7 Pressure Gage 8 Check Valve 9 Unloading Valve Startup 11 Hyd Directional Control Valve 12 Plunger 13 HP Cylinder 14 Hyd Cylinder Intensifier 17 HP Attenuator 22 Pressure Compensator Control 23 Proximity Switch 24 Main Relief Valve 25 Hydrau...

Страница 85: ...hifts the hydraulic directional control valve 11 The hydraulic valve shifts to reverse direction of movement of the piston 29 until activating the opposite end of stroke proximity switch 9 2 1 Hydraulic Pressure Compensation A pressure compensation 22 feature on the variable displacement piston pump 2 maintains constant hydraulic operating pressure even under variable flow demands When the HP wate...

Страница 86: ... require re adjustment NOTE The outer pressure adjustment screw 35 is set in the range of 10 22 bar 145 320 psi Standard setting is 20 bar 290 psi Use a 3mm hex Allen wrench 31 to turn the compensator adjustment screw 34 Adjust pressure while the HP water is blocked and the pump is producing little or no flow Loosen the jam nut 33 Rotate the screw clockwise to increase pressure Replace the cap nut...

Страница 87: ...w The hydraulic system components that require periodic maintenance are the motor and the pump compensator The motor needs to be serviced every 5000 hours of use The operating pressure settings of the manifold need to be checked daily and adjusted if necessary Recommended Tools Manual Grease Gun Open End Wrench 14mm 9 16 Rags Parts Bearing Grease SRI 2 or equivalent ...

Страница 88: ...eservoir has been serviced emptied removed replaced etc the pump should be filled with oil to purge air from the case One means of assuring the pump case is purged of air is to remove an upper plug note that there are 2 case drain plugs on the pump long enough to allow some hydraulic oil to exit the port then re install the plug CAUTION Failure to remove trapped air from the pump case will result ...

Страница 89: ...ief valve should the filter element be allowed to become entirely clogged with dirt contaminants 10 2 Operation The recirculation pump takes oil from the hydraulic reservoir and pumps it to the oil to water heat exchanger then to the oil filter and back to the reservoir Condition of the hydraulic filter is determined by analyzing gage pressure Hydraulic oil is pumped into the reservoir through a t...

Страница 90: ...ulic Reservoir 5 Hydraulic Filter Housing 37 Filter Element 7 Hydraulic Pressure Gage 38 Bypass Filter 10 3 Filter Bypass Pressure Protection Excessive pressure drop across the hydraulic filter is prevented by relief valve 38 located on filter head 5 Adjustment Setting Control Valve Increase Decrease Maximum Minimum Oil Temperature 19 Clockwise Counter clockwise 52oC 1250 F 41oC 1100F Oil Pressure...

Страница 91: ...il DTE Heavy Medium No 021029 Food service use AMOCO FG68EL Oil with additives such as zinc diophosphate for antiwear are not recommended because of reaction with water Tools Open End Wrench 1 1 4 Rags Container to collect oil Oil filter transfer pump with hoses Inlet hose with male pipe connector and pump discharge hose with female JIC connector Oil Filter Replace filter element when the pressure...

Страница 92: ...Filter Element 17 Elbow 7 Tee Fitting Fill Port Ref 1 Reservoir Tank 8 Cap Fill Port Ref 2 Reservoir Cover 9 Elbow Oil Reservoir The oil reservoir is equipped with the following Visual temperature and level indicator Air breather and filter that prevents dirt from being sucked into the reservoir whenever the oil level drops then allows air to escape when the level rises Drain valve and Fill compon...

Страница 93: ...il filter transfer pump discharge to fill port This will assure clean filtered oil is pumped into the reservoir CAUTION Oil must be filtered through an equivalent filter such as a 10 micron filter element or see filter element in figure 12 in section 12 Failure to do so will cause damage to the primary hydraulic components voiding the warranty 5 Check oil sight gage to assure proper fill level Rem...

Страница 94: ...see note 4 200 3 50 42 208 3 60 41 240 3 60 38 400 3 50 21 415 3 50 20 Voltage Service Amps 480 3 60 19 Volts Phase Hertz Amps Sound Level 75 5 dB A Controls Voltage 24 volts DC Power Supply 5 amps DC Safety shutdown switch settings High oil temperature 62 144 C F Low oil level 30 8 liters gal Hydraulic System Oil tank capacity 53 14 liters gal Recommended oil type Regular applications Mobil DTE H...

Страница 95: ... 29 85 C F Optimum inlet temperature 18 65 C F Cutting Water Out Maximum flow rate 1 2 0 3 l min gpm Minimum outlet pressure 345 5 000 bar psi Maximum cont outlet pressure 3 800 55 000 bar psi Intermittent outlet pressure 4 100 60 000 bar psi Compressed Air Flow rate maximum 0 028 1 0 m3 min cfm Inlet pressure range 5 6 75 85 bar psi Service Connections Cutting water in 1 2 NPT Cutting water out 9...

Страница 96: ...t 1 4 Outlet 34 25 5 8 Crowfoot H P 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 NOTE Measurements are made with lubricated components and a calibrated torque wrench Inconsistencies in wrench settings lubrication and technique may not produce a leak tight seal If leakage persists increase the torque until the components seal do not exc...

Страница 97: ...ium 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 10 1 Turbidity NTU 5 6 1 Do not reduce beyond this amount or the water will become too aggressive Cooling Water Specifications Depending on the type of cooling system closed recirculation once through etc the following common problems can be experienced Closed recirculation Corrosion Fouling...

Страница 98: ...y 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 maximum quantity of orifices that can be supported Rated power kW hp Pressure Bar Psi Flow lpm gpm Qty Orifice Diameter mm inch 1 0 20 0 008 1 0 17 0 007 1 0 15 0 006 2 0 12 0 005 11 15 3 800 55 000 1 2 0 30 3 0 10 0 004 1 0 28 0 011 2 0 17 0 007 22 30 3 800 55 000 2 5 0 ...

Страница 99: ...artment USA Parts Department Europe Technical Manager KMT Waterjet Systems KMT Waterjet Systems GmbH P O Box 231 Wasserstrahl Schneidetechnik 635 West 12th Street Auf der Laukert 11 Baxter Springs KS 66713 0231 D 61231 Bad Nauheim USA Germany Phone 620 856 2151 Phone 49 6032 997 117 Fax 620 856 5050 Fax 49 6032 997 270 E mail Wj service kmtwaterjet com E mail order service kmt waterjet com ...

Страница 100: ... parts lists Table 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 e g 1 2 NPT 0 50 inch national pipe thread or 9 16 HP tube 0 56 inch OD HP tubing or tube fitting JIC 37 degree flared threaded hydraulic fitting JIC standard typically used on hydraulic hose end co...

Страница 101: ...91 12 13 12 6 High Pressure Piping 80080153 12 15 12 7 Hydraulic Manifold Assembly 05129721 12 17 12 8 Bulkhead Piping 80080179 12 19 12 9 Low Pressure Water Filter Assembly 05126289 12 21 12 10 Motor Pump Assembly 05125919 12 23 12 11 Reservoir Assembly 05126230 12 25 12 12 Electrical Assembly 05140140 480v 05140801 208v 12 27 12 13 Control Panel Configuration 05140132 480v 05140793 208v 12 29 12...

Страница 102: ...80080179 Bulkhead Pipe Assembly 4 1 05126248 Frame Assembly 5 1 05126230 Reservoir Assembly 6 1 05125919 Motor Pump Assembly 7 1 05130042 Hydraulic Hose Connections 8 1 80080633 Decal Package 9 05072582 Stripping 10 05072590 Stripping 11 1 49838204 Decal Lube Data 12 1 05128087 Start up Tag 13 1 05135710 Test Report 14 05022702 Hydraulic Fluid 16 4 95688750 Lock Washer 50 20 4 95367850 Lock Washer...

Страница 103: ...SECTION 12 PARTS LISTS p 12 5 05139159 ...

Страница 104: ...9 2 05007786 Flange Retaining Bushing 11 2 05144712 Liner HP Cylinder 12 4 10074920 O ring 13 12 80070352 Jackbolt 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 20 250 VAC VDC 20 4 10183572 Cap Screw Socket Head M6x1x22mm 21 1 05132253 Piston Assembly Hydraulic ...

Страница 105: ...SECTION 12 PARTS LISTS p 12 7 05139159 ...

Страница 106: ... 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 05144670 Retainer Poppet 7 1 05147863 Spring Compression 8 1 49884562 Spring Compression 9 1 05116751 Pin Guide ...

Страница 107: ...SECTION 12 PARTS LISTS p 12 9 05139159 ...

Страница 108: ...ody 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 Snap Flat Wire 7 2 05049994 Ring Backup 8 2 05087713 O ring 9 1 05117965 Seal Assembly Hydraulic Piston 10 2 05117940 Bearing Hydraulic Piston ...

Страница 109: ...SECTION 12 PARTS LISTS p 12 11 05139159 ...

Страница 110: ...Y 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 ring 7 1 05129515 Back up Ring 8 1 05027255 Seal U Cup Ref 1 0 05009048 Tool Seal Installation ...

Страница 111: ...SECTION 12 PARTS LISTS p 12 13 05139159 ...

Страница 112: ...tor 10 10 10083897 Ferrule 25 Brass 11 1 05129721 Manifold Assembly 12 100 10186153 Conduit Extra Flexible 38 in ID 13 2 05131107 Manifold Gasket 14 4 05092903 Attenuator Bracket Spacer 15 4 95413696 Lock Washer 50 16 4 95383790 Socket Head Screw 1 2 13 x 1 00 17 1 05129374 Tube Bent 38 in HP 60 ksi Stainless 18 1 05129390 Tube HP 25 x 35 00 19 1 05069703 Pneumatic Valve Assembly 20 1 10094704 Tub...

Страница 113: ...SECTION 12 PARTS LISTS p 12 15 05139159 ...

Страница 114: ...ve Relief Hyd 234 bar 3 400 psi 4 7 05104559 Plug 6 SAE O ring Port 5 1 10192813 Plug 4 SAE O ring Port 6 1 05057567 Adapter 12 SAE O ring x 8 JIC 7 1 10144749 Adapter 4 JIC x 4 SAE O ring Straight 8 1 10087880 Adapter 8 SAE O ring x 8 JIC 9 4 10110567 Cap Screw Socket Head 10 4 95367728 Washer 11 1 05129069 Valve Directional Control Air Operated 12 2 10078095 Coupling Male 25 125 p 12 16 05139159...

Страница 115: ...SECTION 12 PARTS LISTS p 12 17 05139159 ...

Страница 116: ...hylene 25 in OD 10 1 10145829 Nipple Close NPT Brass 11 2 49834302 Adapter Tube Pipe 50 12 2 05128947 Adapter 1 4 NPT x 8 JIC 13 5 10079713 Barb 50 NPT 14 3 10173805 Barb Hose 0 50 x 8JIC 15 5 05113964 Grommet 16 1 10147460 Elbow NPT x 8 JIC 90 degree 17 1 10100477 Bushing x1 8 NPT Brass 18 1 05128715 Valve Solenoid 24vdc 19 1 05112271 Muffler Pneumatic 1 8 NPT 20 2 05143508 Screw Machine 4 40 x 1...

Страница 117: ...SECTION 12 PARTS LISTS p 12 19 05139159 ...

Страница 118: ...x NPT Brass 5 1 10078343 Adapter Bushing x NPT Brass 6 2 10127801 Nipple NPT x 2 50 in Brass 8 1 49870272 Cross NPT Brass 10 1 10073823 Tee NPT Brass 11 2 05123666 Adapter NPT x 8 JIC Straight Brass 12 4 10173805 Barb ID Hose 8 JIC Swivel Brass 13 2 10114023 U Bolt 0 50 Stainless 14 1 10106722 Element Filter LP Water Polypropylene 10 Micron 15 1 10147460 Elbow NPT x 8JIC Brass 16 1 95157418 Adapte...

Страница 119: ...SECTION 12 PARTS LISTS p 12 21 05139159 ...

Страница 120: ...38 in ID 9 2 05037593 Cap Screw Socket Head M10 x 1 50 x 25mm SST 10 1 05126008 Pump Gear Hyd 22cc Rev 11 1 05126339 Elbow Hyd 20 4 Bolt Flange x 20 Hose Barb 13 1 05045497 Pressure Gage Hyd 0 5 000 psi 4 SAE O ring 14 2 05089867 Adapter Hyd 8 JIC x 12 SAE O ring Straight 16 1 05127402 Adapter Hyd 8 JIC x 8 SAE O ring 90 Degree 17 1 49881774 Adapter Hyd 12 JIC x 12 SAE O ring 45 Degree 18 1 101193...

Страница 121: ...SECTION 12 PARTS LISTS p 12 23 05139159 ...

Страница 122: ...degree 12 12 10 1 05129424 Oil Cooler Hyd 11 1 10091858 Bulb Well NPT 12 1 05057559 Adapter 12 SAE O ring x NPT Straight Steel 13 3 10099901 Elbow 1 4 NPT x 4 JIC 90 Degree Steel 14 1 10080901 Ball Valve NPT Bronze 15 1 95033619 Plug Square Head NPT Steel 16 1 05079371 Adapter 12 JIC x 12 BSPP Straight Steel 17 1 10057719 Adapter NPT x 8 JIC 90 Degree Steel 18 4 95416319 Hex Head Screw 3 8 16 x 1 ...

Страница 123: ...SECTION 12 PARTS LISTS p 12 25 05139159 ...

Страница 124: ...nduit 5 10094043 49877152 Wire Black 6 72 05127329 05141734 Wire Green Yellow 7 1 10098796 Conduit Connector 8 1 98423653 Hex Head Screw 1 4 20 x 1 2 9 2 10157659 Lock Washer 25 10 1 95416335 Hex Nut 1 4 20 12 7 05133715 05141700 Ring Terminal 13 12 10094712 Ring Terminal 14 5 10125912 Cable Tie 15 1 05140132 05140793 Control Panel 16 4 10086650 Washer 1 25 17 4 95416319 Hex Head Screw 3 8 16 x 1 ...

Страница 125: ...SECTION 12 PARTS LISTS p 12 27 05139159 ...

Страница 126: ...15134 End Barrier 28 1 10094712 Ring Terminal 29 720 10176410 Wire 16 Blue 30 24 10170165 Wire 16 Green Yellow 31 1 05140678 Circuit Breaker 3 amp 32 1 05140660 Switch Emergency Stop 33 1 05140652 Block Contactor 1 NC 34 1 05005202 Legend Plate 35 28 05032438 Terminal Block 36 1 05032370 End Barrier 37 1 6 05032388 Terminal Block Jumper 38 56 05032412 Terminal Block Marker 39 3 10186104 Relay Tube...

Страница 127: ...ressor 67 4 05032347 Terminal Block Jumper 68 1 05140579 Mounting Adapter 69 2 05140561 Block Contactor 2 NC 70 1 05114962 Decal 71 1 05140553 Auxiliary Contact 72 1 05140546 Timer Module Pneumatic 73 4 10067205 Cable Connector 74 6 10083012 Lock Nut Conduit 50 75 6 10082857 Gasket Assembly 76 140 10108470 18 Cable 77 2 10084184 Plug Connector 78 1 05066576 Plug Connector 79 2 10124287 Cable Conne...

Страница 128: ...SECTION 12 PARTS LISTS p 12 30 05139159 ...

Страница 129: ...Date 3 21 2003 Time 09 31 40 AM Title J cad Release 0512 05129507 DWG ...

Страница 130: ...Date 3 27 2003 Time 11 25 52 AM Title J cad Release 0514 05141015 dwg ...

Страница 131: ...Date 3 27 2003 Time 11 26 31 AM Title J cad Release 0514 05141015 dwg ...

Страница 132: ...Date 3 27 2003 Time 11 26 54 AM Title J cad Release 0514 05141015 dwg ...

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