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KMT STREAMLINE S50 Operation And Maintenance Manual

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STREAMLINE S50
WATERJET INTENSIFIER
OPERATION AND MAINTENANCE MANUAL
MANUAL 20479050(R04)

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Summary of Contents for KMT STREAMLINE S50

  • Page 1 STREAMLINE S50 WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL MANUAL 20479050(R04)
  • Page 2 KMT Waterjet believes 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Title Page Notice Table of Contents Appendix Section Page Introduction ....................... 1-1 Overview ....................1-1 Performance Features................1-1 Operational Overview ................1-2 Low Pressure Water System ..............1-2 Recirculation System ................1-2 Hydraulic System ................... 1-2 High Pressure Water System ..............1-2 Safety .....................
  • Page 4 High Pressure Piping................2-7 Measurements and Dimensions ............. 2-8 Hand Coning ..................2-9 Power Coning..................2-10 Hand Threading ..................2-11 Power Threading ..................2-11 High Pressure Connections ..............2-12 Standard Connections ................2-12 Anti-Vibration Connections ..............2-13 Commissioning ..................2-14 2.10 Decommissioning ..................
  • Page 5 Electrical System ....................7-1 Overview ....................7-1 Sensors and Solenoids................7-1 Service and Maintenance Procedures ............ 7-5 Proximity Switch Maintenance .............. 7-5 High Pressure Water System ................8-1 Overview ....................8-1 Operation....................8-1 System Components................8-3 Service and Maintenance Overview ............8-4 Torque Specifications ................

  • Page 6: Appendix

    Troubleshooting ....................9-1 Overview ....................9-1 Troubleshooting Guide ................9-2 Specifications ..................... 10-1 10.1 Overview ....................10-1 10.2 Installation Specifications ..............10-1 Environment ................... 10-1 Equipment Dimensions and Weights ............. 10-1 Service Connections ................10-2 Plant Air ....................10-2 10.3 Water Specifications ................

  • Page 7: Introduction

    The S50 is designed with the same convenience and ease of access for maintenance and service you have come to expect from KMT Waterjet. The hydraulic 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.

  • Page 8: Operational Overview

    Section 1 Introduction Operational Overview The following provides a brief overview of the function and primary components associated with the individual systems. A detailed discussion of each system is provided in Sections 4 through 8. Low Pressure Water System The low pressure water system supplies the cutting water flow to the intensifier. Major system components include the water filter assembly and the booster pump.

  • Page 9: Safety

    All personnel operating, servicing or working near the waterjet cutting equipment shall adhere to the following safety precautions, as well as the applicable plant safety precautions.  Only KMT factory trained, qualified personnel shall service and maintain the equipment. ...

  • Page 10: Lockout/Tagout Procedure

    Section 1 Introduction Lockout/Tagout Procedure This lockout/tagout procedure is designed to protect all employees from injuries caused by the unexpected energizing or startup of the machine, or the release of stored energy during service and maintenance. This is accomplished with energy isolating devices that prevent the transmission or release of energy.
  • Page 11 Section 1 Introduction Table 1-2 Warning Label Precautions The surface of high pressure water and hydraulic components becomes hot during normal operation. Failed, or failing components, can become extremely hot during operation. P/N 05114970 High pressure water and/or hydraulic pressure can remain in the system even when the pump has been shut off.

  • Page 12: Emergency Medical Treatment

    An emergency medical card is included in the binder of this manual. This information should be used to aid in the treatment of a waterjet injury. Additional cards may be obtained by contacting KMT Waterjet Systems using the address or telephone number shown on the card. This person has been working with water jetting...

  • Page 13: Worldwide Product Support

    Section 1 Introduction Worldwide Product Support The KMT Waterjet Customer Service Department is available to answer your questions regarding equipment installation and service. Technical assistance is available by phone and on-site support is available on request. On-site technical assistance is available during equipment installation and startup. Additionally, technical support for service and maintenance issues and training of operators and maintenance personnel is available.

  • Page 14: Equipment And Service Manual Questionnaire

    Equipment and Service Manual Questionnaire We are interested in your impression of the KMT Waterjet System recently installed at your location. Your comments and recommendations will aid us in our continuing goal to improve our products, and make our technical information more useful to our customers.
  • Page 15 Equipment and Service Manual Questionnaire General Appearance Was the unit received in good condition? Comments: Is the unit a convenient size? Controls Are the controls user friendly? Is the unit easy to operate? Comments: Performance Does the unit perform smoothly and meet your expectations? Does the unit run quietly? Comments: Did the installation and startup go smoothly?
  • Page 16 Equipment and Service Manual Questionnaire Manual Organization Does the Table of Contents help you find topics easily? Comments: Is the information well organized? Comments: Is the page layout suitable for the material being presented? Comments: Graphics Are the illustrations suitable for the material being presented? Comments: Text Does the information adequately explain how to operate and service the...

  • Page 17: Terms And Conditions Of Sale

    The Terms and Conditions of Sale outlined herein shall apply Neither Purchaser nor any affiliated company or assignee shall to the sale by KMT Waterjet Systems Inc. (hereinafter referred to have the right to claim compensation or to set off against any...
  • Page 18 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. EAST\44198159.2 KMT Waterjet Systems Inc. (LD-101) 07/2009...

  • Page 19: Terms And Conditions Part Sales

    The Terms of Conditions outlined herein shall apply to the The remedies of the Purchaser set forth herein are exclusive, sales of parts by KMT Waterjet Systems (hereinafter referred to as and the liability of the Company with respect to this order shall not Company.) No additional or contrary terms shall be binding upon...
  • Page 21 (hereinafter called the Supervisor) to consult with and advise the Purchaser in the installation, starting up and/or overhaul or maintenance of equipment of KMT Waterjet manufacture, such Supervisor shall not be responsible for the procurement of labor or mechanical work performed by others. The Service Supervisor’s services shall be furnished under the following conditions: 1.
  • Page 23 (hereinafter called the Supervisor) to consult with and advise the Purchaser in the installation, starting up and/or overhaul or maintenance of equipment of KMT Waterjet manufacture, such Supervisor shall not be responsible for the procurement of labor or mechanical work performed by others. The Service Supervisor’s services shall be furnished under the following conditions: 1.

  • Page 24: Installation

    All personnel involved in the installation, operation and/or service of the intensifier must carefully review this manual prior to installing and commissioning the machine. The Technical Service Department at KMT Waterjet Systems is available to assist in the installation and commissioning process. Service and repair training for maintenance personnel is also available.

  • Page 25: Site Requirements

    Section 2 Installation Site Requirements The intensifier must be installed indoors where air borne dust and contaminants are minimal. The ambient temperature should be between 40 F (5 C) and 104 F (40 C), with a maximum relative humidity of 95%. Refer to Table 2-1, Equipment Dimensions and Weight, to establish a suitable installation site.

  • Page 26: Power Requirements

    Section 2 Installation Figure 2-2: Fork Pockets If the machine will 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 across the bottom, and wrapped around the sides of the machine so they meet on the top.

  • Page 27: Service Connections

    Section 2 Installation Table 2-2 Ampacity and Power Voltage Requirements Motor Full Load Circuit Breaker Power Voltage Horsepower Amps Amps 400/3/50 415/3/50 460/3/60 575/3/60 Service Connections Depending on the model, the intensifier requires one or two incoming water sources, cooling water and cutting water;...

  • Page 28: Cooling Water (Oil-To-Water Models)

    Section 2 Installation Table 2-3 Service Connections Connection Height Drain 1/2” NPT 12.21” (310 mm) Cutting Water In 1/2” NPT 16.26” (413 mm) Contaminated Waste 1/2” NPT 20.26” (515 mm) Cooling Water In (oil-to-water models) 1/2” NPT 23.76” (604 mm) Cooling Water Out (oil-to-water models) 1/2”...

  • Page 29: Drain

    Section 2 Installation Cutting water supply piping must be sized to meet the flow and pressure requirements listed in Section 10. Only PVC, copper or rubber hose should be used between the cutting water source and the machine. The inlet cutting water must be maintained at a minimum pressure of 35 psi (2 bar) at all times. If the facility water pressure is below, or can fall below 35 psi (2 bar), a water pressure booster pump is required.

  • Page 30: Flow Requirements

    Section 2 Installation Flow Requirements Figure 2-4, Pressure Drop Values, illustrates the pressure drop for four different pipe sizes. The graph can be used to calculate the minimum source water pressure. 1. Enter the graph at the required GPM and note the pressure drop figures for the different pipe sizes.

  • Page 31: Measurements And Dimensions

    Section 2 Installation 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 2-6.

  • Page 32: Hand Coning

    Section 2 Installation Figure 2-6: Cone and Thread Dimensions Table 2-8 Cone and Thread Dimensions Thread Tube OD Tube ID (Maximum) (Maximum) 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”...

  • Page 33: Power Coning

    Section 2 Installation 3. Loosen the gland nut and insert the tubing through the collet. The end of the tubing should just make contact with the cutting blade. Loosely tighten the gland nut to slightly grip the 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.

  • Page 34: Hand Threading

    Section 2 Installation NOTE Clean the machining chips from the blade and body of the tool before coning the next tube. Table 2-9 Recommended Extension Length 1/4” Tubing 1.25-1.50” (31.8-38.1 mm) 3/8” Tubing 1.25-1.50” (31.8-38.1 mm) 9/16” Tubing 1.75-2.00” (44.5-50.8 mm) Hand Threading 1.

  • Page 35: High Pressure Connections

    Section 2 Installation 4. Apply cutting oil frequently and liberally throughout the cutting operation. A medium weight cutting oil with high sulfur content is recommended. 5. Continue threading until the proper thread length is reached, see Table 2-8, Column L. Reverse the direction of the drill and remove the threading tool.

  • Page 36: Anti-Vibration Connections

    Section 2 Installation 2. Slip the gland nut onto the tubing. 3. Apply Pure Goop to the threads on the tubing. Screw the collar onto the threaded end of the tubing leaving 1-1/2 to 2-1/2 threads exposed on the tubing between the collar and the coned tubing.

  • Page 37: Commissioning

    Section 2 Installation When a flexible whip is used to allow cutting nozzle movement, anti-vibration fittings and proper supports and guides must be provided to prevent failures 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.
  • Page 38 Section 2 Installation 6. Check the motor rotation. Start the motor, and observe the hydraulic pressure gauge on the front of the machine. 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 turn the control power off.

  • Page 39: 2.10 Decommissioning

    Section 2 Installation NOTE It is strongly recommended that the high pressure plumbing be purged under high pressure operating conditions, using a large, inexpensive orifice. Contamination can be released when the tubing expands under pressure. Early orifice failures could be experienced if the piping is not adequately purged. 2.10 Decommissioning All local regulations must be adhered to when the intensifier is decommissioned and taken out of service for any reason.

  • Page 40: Maintenance

      SECTION 3 MAINTENANCE Overview The S50 has been designed to fail safely. Systems fail gradually; seals and connections begin to leak slowly or suddenly through specially designed weep holes. Water or oil dripping from a weep hole indicates internal seals or valves are beginning to fail, a warning that maintenance will be required.

  • Page 41: High Pressure System Maintenance

    If parts bind during assembly, they must be disassembled and re-aligned.  Use only original KMT Waterjet replacement parts for consistent performance and reliability; and to protect equipment warranty. To avoid unsafe conditions and the risk of equipment damage, operating personnel and service technicians must carefully read and follow the procedures in this manual.

  • Page 42: Maintenance Precautions

    Section 3 Maintenance   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 button. The normal operating position is pulled out. Turn the EMERGENCY STOP 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.
  • Page 43 Section 3 Maintenance   Table 3-2 Tool Kit 05072723 Part Number Description 10149029 Emery Cloth, 320 Grit 10149037 Emory Cloth, 400 Grit 10149045 Emory Cloth, 600 Grit 10149052 Glass Pane 20477460 Plunger Removal Tool 80078256 Torque Wrench, 5-75 Ft/Lbs 05103957 Hex Driver, 12MM 20470475 Seal Installation Tool Kit, Pneumatic Valve...

  • Page 44: Overview

    SECTION 4 LOW PRESSURE WATER SYSTEM Overview The low pressure water system, cutting water supply circuit, supplies the intensifier with the required cutting water flow and pressure. Cutting Water Supply The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance.

  • Page 45: Service And Maintenance Procedures

    Section 4 Low Pressure Water System Cutting water then passes through a strainer to remove debris before the water enters the booster pump. The booster pump increases the pressure to the relief valve setting, up to a maximum of 120 psi (8 bar) to ensure proper supply to the intensifier assembly. Pressurized water passes through the filter assembly where debris is removed to prevent contaminates from damaging the check valves and seals in the intensifier.

  • Page 46: Filter Assembly And Strainer Maintenance

    Section 4 Low Pressure Water System Filter Assembly and Strainer Maintenance The life of the filter element is directly related to the quality of the inlet water. The condition of the filter element can be monitored by observing the Booster Pressure Gauge on the front of the machine.

  • Page 47: Booster Pump Adjustment

    Section 4 Low Pressure Water System Figure 4-3: Strainer 5. Unscrew and remove the strainer body. Remove and clean the mesh liner. 6. Ensure the gasket is properly positioned in the body, install the liner and screw the strainer body into the strainer head, hand tighten. 7.
  • Page 48 Section 4 Low Pressure Water System 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 component damage. 6.

  • Page 49: Recirculation System

    SECTION 5 RECIRCULATION SYSTEM Overview The oil recirculation circuit is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system. Hydraulic oil is maintained at the proper operating temperature and condition by continuous recirculation. Operation (Oil-to-Water Models) Cooling water is introduced through the 1/2-inch NPT connection on the bulkhead of the machine.

  • Page 50: Operation (Oil-To-Air Models)

    Section 5 Recirculation System If the element is not replaced, and fills with debris, the bypass relief in the filter head will open to prevent over pressurization. The relief valve opens at 50 psi (3.4 bar). When the valve opens, the oil bypasses the filter and unfiltered oil is allowed to return to the reservoir.

  • Page 51: Service And Maintenance Procedures

    Section 5 Recirculation System If the element is not replaced, and fills with debris, the bypass relief in the filter head will open to prevent over pressurization. The relief valve opens at 50 psi (3.4 bar). When the valve opens, the oil bypasses the filter and unfiltered oil is allowed to return to the reservoir.
  • Page 52 Section 5 Recirculation System Figure 5-3: Hydraulic Reservoir 1. Turn the machine off and observe the appropriate Lockout/Tagout procedures. Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance. Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance.
  • Page 53 Section 5 Recirculation System 5. Remove the cap from the fill port on the oil filter. To ensure cleanliness, the oil fill port must be used to pump oil into the reservoir. Filling at this point guarantees the hydraulic oil will pass through the oil filter before entering the reservoir.

  • Page 54: Electric Motor Bump

    Section 5 Recirculation System Electric Motor Bump Bumping is defined as allowing the electric motor to start rotating, but stopping it before the motor gets up to full speed. Whenever the hydraulic reservoir is emptied or the hydraulic pump has been changed, bumping the electric motor is suggested.

  • Page 55: Operating Temperature Adjustment (Oil-To-Water Models)

    Section 5 Recirculation System Operating Temperature Adjustment (Oil-to-Water Models) The cooling water flow through the heat exchanger is regulated by the water modulating valve, a manually adjusted, thermostatic control valve. The valve is factory set to maintain the operating oil temperature at 115 F (46 C). It is adjusted by increasing or decreasing the spring tension on the valve.

  • Page 56: Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Overview The main hydraulic power circuit supplies the intensifier assembly with the hydraulic oil required to produce high pressure water. High pressure cutting water is generated from the oil pressure in the hydraulic cylinder. Operation The electric motor drives three pumps mounted in tandem; the main hydraulic pump, the recirculation pump and the booster pump.

  • Page 57: Service And Maintenance Procedures

    Section 6 Hydraulic System The main system relief valve provides system protection by monitoring the oil pressure entering the manifold. If the hydraulic pressure exceeds 3,407 psi (235 bar), the valve opens to limit the pressure. The valve is factory calibrated and is not serviceable. A drain line from the valve prevents oil from collecting behind the relief valve to ensure a constant pressure under all operating conditions.

  • Page 58: Hydraulic Operating Pressure

    Section 6 Hydraulic System Hydraulic Operating Pressure Hydraulic operating pressure settings should be checked daily and adjusted as necessary. High and low operating pressure is adjusted at the high and low pressure control valves per the specifications in Table 6-1. Table 6-1 Hydraulic Operating Pressure Limits Adjustment...

  • Page 59: Motor Maintenance

    Section 6 Hydraulic System 3. Turn the hex clockwise to increase operating pressure. Turn the hex counter-clockwise to decrease pressure. 4. Tighten the locking nut and verify the low pressure setting. Motor Maintenance The motor should be inspected at regular intervals, approximately every 500 hours of operation or every three months, whichever occurs first.
  • Page 60 Section 6 Hydraulic System PLUG O-RING LOW LIMIT COMPENSATOR ORIFICE O-RING HIGH LIMIT COMPENSATOR 4. Disassemble the compensators one at a time by first removing the hexagon sealing cap. 5. Loosen the lock nut, and then remove the plug nut. 6.
  • Page 61 Section 6 Hydraulic System 13. Set the high and low pressure control valves on the hydraulic manifold to the minimum setting by turning then counter-clockwise. 14. Set the compensators to the minimum setting by turning the adjusting screws counter- clockwise. 15.

  • Page 62: Electrical System

    SECTION 7 ELECTRICAL SYSTEM Overview Major components of the electrical system for the S50 include the electric motor, the wiring harness that connects the sensors and solenoid valves to the customer supplied controller and, if applicable, wiring for the fan motor. The 12-lead electric motor can be wired for either wye-delta or across-the-line starting.
  • Page 63 Section 7 Electrical System Table 7-2 Sensors and Solenoids Component Function Inlet Water Solenoid Valve The normally closed, inlet water solenoid valve is located at the service bulkhead. When the control power is turned on, the valve opens and allows low pressure cutting water to enter.
  • Page 64 Section 7 Electrical System Table 7-2 Sensors and Solenoids Component Function Hydraulic Reservoir The temperature/low level switch monitors the oil temperature and level in the reservoir. Although the float switch and the temperature switch are combined in a single unit, the two switches function independently.
  • Page 65 Section 7 Electrical System Table 7-2 Sensors and Solenoids Component Function Hydraulic Cylinder As pressurized hydraulic oil is sent to one side of the hydraulic cylinder, it pushes against the piston, moving it in one direction until it activates the proximity switch at the end of the stroke.

  • Page 66: Service And Maintenance Procedures

    Section 7 Electrical System Service and Maintenance Procedures Electrical components require minimal service. The proximity switches on the hydraulic cylinder may require replacement. NOTE Refer to Section 11, Parts List for a complete listing of replacement parts and part numbers. Proximity Switch Maintenance A proximity switch has failed and needs to be replaced if the LEDs do not change state, indicating they are not sensing the piston, if an LED flashes continuously.
  • Page 67 Section 7 Electrical System Ensure that the proximity switch is properly installed and secured prior to starting the machine. Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil. 20479287 1-2009/Rev 0...

  • Page 68: Overview

    SECTION 8 HIGH PRESSURE WATER SYSTEM Overview The high pressure water system is supported by both the cutting water supply circuit and the hydraulic circuit. Cutting water of sufficient flow and pressure is routed from the cutting water supply circuit to the intensifier where it is pressurized up to 60,000 psi (4,137 bar) and delivered to the cutting head.
  • Page 69 Section 8 High Pressure Water System The green light on the proximity switch indicates there is power to the switch. The red light illuminates when the switch is activated. The proximity switches are magnetically activated by the presence of the metallic surface of the piston. When the switch is activated, it sends a signal to the PLC to change the flow of the directional control valve and reverse direction.

  • Page 70: System Components

    Section 8 High Pressure Water System System Components The following figures illustrate the individual high pressure water system components. Figure 8-3: High Pressure Cylinder Assembly Figure 8-4: Hydraulic Cylinder Assembly 20479291 2-2012/Rev 04...

  • Page 71: Service And Maintenance Overview

    Some high pressure components are not serviceable at the customer level, others require precise refinishing. KMT Waterjet Systems offers maintenance and refinishing services for these components. NOTE Refer to Section 11, Parts List for a complete listing of replacement parts and part numbers.

  • Page 72: Torque Specifications

    Section 8 High Pressure Water System Torque Specifications Table 8-1, Torque Specifications, details the torque specifications and tightening sequences for the high pressure components and connections. Table 8-1 Torque Specifications High Pressure Water System Hard Seal End Cap Jackbolts 6 (7/16”) each 1st Stage Hand Tight 2nd Stage...
  • Page 73 Section 8 High Pressure Water System Table 8-1 Torque Specifications High Pressure Water System Stem Mount Socket Head Screws 4 (M10) each Torque 60-65 ft-lbs (80-88 Nm) Hex Key Sealing Head Discharge Gland Nut 130 ft-lbs (176 Nm) Poppet Retainer 30 in-lbs (3.4 Nm) 3-Port Pneumatic Valve HP Adapter...

  • Page 74: Specialized Maintenance Tools

    High Pressure Water System Specialized Maintenance Tools KMT Waterjet has designed tools to facilitate the removal and installation of specialized system components. These tools are illustrated in Figure 8-6, Specialized Maintenance Tools, and part numbers are provided in Table 8-2.

  • Page 75: High And Low Pressure Water Piping

    8. Install the orifice and operate at high pressure to check for leaks. High Pressure Cylinder Assembly KMT Waterjet recommends removing the high pressure cylinder, sealing head and end cap as an assembly for servicing the plunger, high pressure seals, hydraulic piston and seal cartridge.

  • Page 76: High Pressure Cylinder Assembly Removal

    Section 8 High Pressure Water System High Pressure Cylinder Assembly Removal Prior to removing electrical power or any high or low pressure piping, start the machine and extend the plunger on the end to be serviced to allow full exposure when the unit is disassembled. 1.

  • Page 77: High Pressure Cylinder Assembly Installation

    Section 8 High Pressure Water System Figure 8-7: High Pressure Cylinder Assembly Removal and Installation NOTE If thread or metal surface galling is detected during removal, galled surfaces and threads must be filed, sanded and lubricated prior to reassembly. See the procedure, High Pressure Cylinder Maintenance.

  • Page 78: High Pressure Cylinder Maintenance

    3. Clean the residue from the inside diameter of the cylinder and re-inspect for surface defects. Hard Seal End Caps KMT Waterjet recommends loosening the jackbolts and removing the hard seal end caps (HSEC) only to service the inlet check valve and the cone seat on the sealing head. Hard Seal End Cap Removal Prior to removing electrical power or any high or low pressure piping, start the machine and extend the on the end to be serviced to allow full exposure when the unit is disassembled.

  • Page 79: Hard Seal End Cap Installation

    Section 8 High Pressure Water System 2. Disconnect the high and low pressure water piping, following the procedure, High and Low Pressure Water Piping. 3. Loosen the jackbolts in the hard seal end cap. 4. Unscrew and remove the HSEC from the high pressure cylinder. 5.

  • Page 80: Sealing Head

    Section 8 High Pressure Water System 8. Connect the high and low pressure water piping and turn the low pressure water supply 9. Start the machine in low pressure mode to flush air from the high pressure components and to check for obvious leaks. After 5-10 strokes, switch to high pressure operation and check for leaks.
  • Page 81 Section 8 High Pressure Water System 3. Use two wrenches to remove the gland nut. The poppet pin, spring and discharge poppet will normally remain in the gland nut when it is removed. Remove the components from the gland nut. 4.

  • Page 82: Low Pressure Inlet Check Valve

    Section 8 High Pressure Water System Low Pressure Inlet Check Valve The inlet check valves should be serviced on a regular, preventive maintenance schedule. Service is recommended every 1,000 hours. The hard seal end cap must be removed to service the inlet check valve.

  • Page 83: Sealing Head Maintenance

    The sealing head should be inspected for scratches, excessive sealing damage or erosion marking on the cone ring contact surface, and on the inlet poppet valve contact surface. If defects are detected, the surfaces must be refinished. The sealing head can be returned to KMT Waterjet for refinishing.
  • Page 84 Section 8 High Pressure Water System Prior to removing electrical power or any high or low pressure piping, start the machine and extend the plunger on the end to be serviced to allow full exposure when the unit is disassembled. 1.

  • Page 85: 8.10 Hydraulic Cartridge Seal And Plunger Removal

    Section 8 High Pressure Water System Do not stand the cylinder assembly on the top pan of the machine. The assembly is heavy and must be properly supported to prevent it from falling. 6. Fill the cylinder with water and slide the seal removal tool or a used plunger into the bronze packing follower to ensure a good seal for the removal of the seal assembly.
  • Page 86 Section 8 High Pressure Water System 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.
  • Page 87 Section 8 High Pressure Water System Figure 8-15: Hydraulic Cartridge Seal Removal 9. With the cartridge removed, the plunger can now be removed with the hydraulic cylinder head in place. The plunger is held in position by six retainer pins. The pins close around the plunger button to retain the plunger, and retract to release the plunger.

  • Page 88: Plunger Maintenance

    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 8-17: Plunger...
  • Page 89 Section 8 High Pressure Water System Figure 8-18: Hydraulic Cartridge Seal 1. Carefully remove the worn seals and o-rings from the cartridge by pushing them with a plastic or wooden dowel, or similar object. Remove the seals closest to the open ends first, and work toward the center.

  • Page 90: 8.11 Hydraulic Piston

    Section 8 High Pressure Water System 10. Install the high pressure cylinder assembly into the hydraulic cylinder head, following the procedure, High Pressure Cylinder Assembly Installation. 11. Connect the high and low pressure water piping and turn the low pressure water supply 8.11 Hydraulic Piston Two bearing rings provide wear contact between the piston and the inside diameter of the hydraulic cylinder.
  • Page 91 Section 8 High Pressure Water System 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.

  • Page 92: Bearing Rings And Seal Assembly

    Section 8 High Pressure Water System Bearing Rings and Seal Assembly 1. Remove the plungers. 2. Use a smooth, dull-edged blade made from brass or similar soft metal material to remove the two bearing rings and the seal assembly. NOTE Do not scratch the surfaces of the piston seal groove.

  • Page 93: Internal Check Valves

    Section 8 High Pressure Water System 5. Inspect the plunger button sockets for unusual wear. NOTE Due to the high contact force between the piston and the plunger, the plunger may make an impression in the bottom of the socket. This compression mark or indentation is normal.
  • Page 94 Section 8 High Pressure Water System Figure 8-22: Hydraulic Piston Installation 3. Install the piston into the hydraulic cylinder bore. If necessary, use a plastic head hammer to drive the piston into position between the holes for the proximity switches. 4.

  • Page 95: 8.13 High Pressure Attenuator

    8.13 High Pressure Attenuator The high pressure attenuator is not serviceable at the customer level. KMT Waterjet Systems tests the seals in the attenuator at pressures exceeding normal operating pressure, making disassembly difficult. If the attenuator develops a high pressure water leak, it should be replaced.

  • Page 96: 8.14 High Pressure Dump Valve

    Section 8 High Pressure Water System 8.14 High Pressure Dump Valve The high pressure dump valve assembly includes a normally open high pressure water valve and a solenoid operated air valve. The following procedure is recommended for servicing the high pressure dump valve.
  • Page 97 Section 8 High Pressure Water System 1. Turn the air supply off. 2. Remove the air supply hose, and the electrical connection to the solenoid valve. Figure 8-24: High Pressure Dump Valve 3. Loosen and remove the high pressure gland connections and the drain connection. 4.
  • Page 98 Section 8 High Pressure Water System 5. Loosen the cylinder head on the actuator. Unscrew and remove the actuator from the valve body. 6. Unscrew the high pressure adapter and remove the adapter and valve seat. 7. Remove the stem, SST backup ring and brass backup ring from the valve body. 8.
  • Page 99 Section 8 High Pressure Water System Do not push the o-ring on the seal assembly past the inlet port on the valve body. This will damage the seal o-ring. Figure 8-27: Valve Stem Placement 18. Remove the high pressure adapter and the seal positioning tool. 19.

  • Page 100: Pneumatic Actuator

    Section 8 High Pressure Water System Pneumatic Actuator The following procedure is used to service the pneumatic actuator. Figure 8-28: Pneumatic Actuator 1. Unscrew and remove the cylinder head using a strap wrench and a pin spanner. Remove the piston from the cylinder. Do not install the pneumatic cylinder in a vise to remove the cylinder head.

  • Page 101: 8.15 Weep Holes

    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 following the procedure, Plunger Maintenance. Damaged high pressure cylinder...
  • Page 102 Section 8 High Pressure Water System Table 8-3 Weep Holes High Pressure Water System Location Indication Comments Sealing Head Water leaking from the weep Seat in the discharge check valve Make sure the gland nut is hole in the sealing head is not sealing properly tightened to the proper torque specification.
  • Page 103 Section 8 High Pressure Water System Table 8-3 Weep Holes High Pressure Water System Location Indication Comments Hard Seal End Cap Water leaking from the weep Damaged high pressure cylinder Check for scratches or grooves on holes in the hard seal end cap the cone seal surface.

  • Page 104: Troubleshooting

    SECTION 9 TROUBLESHOOTING Overview The troubleshooting guide will help identify the probable cause of a system malfunction and assist in providing corrective action. The following symptoms are discussed in this section: High oil temperature Low oil level Restricted or no cooling flow Hydraulic pressure but no high pressure water pressure No hydraulic oil pressure Pump shaft will not turn...

  • Page 105: Troubleshooting Guide

    If the symptoms in the guide do not correspond to the malfunction, or if the problem is not resolved by the recommended corrective action, contact the KMT Customer Service Department for assistance.
  • Page 106 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Restricted or no cooling Oil-to-Water Models flow Check cooling water flow to The water pressure differential and from the heat exchanger across the heat exchanger requires a minimum of 35 psi (2.4 bar) for flow through the exchanger.
  • Page 107 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Abnormal fluctuations in Large, worn or damaged Make sure the orifice does not high pressure water signal orifice exceed the capacity of the pump. Make sure the orifice is in good working condition.
  • Page 108 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Low cutting water supply Restricted water supply Check cutting water supply flow pressure and pressure. Clogged water filter Check the condition of the low pressure water filter and replace the filter element if necessary.
  • Page 109 Damaged plunger Check the plunger for longitudinal scratches or flaws. If detected, replace the plunger or return to KMT Waterjet for evaluation and rework. Seal material buildup on Polish the plunger surface plunger following the procedure,...
  • Page 110 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Water leaking from the Seat in the discharge check Make sure the gland nut is weep hole in the sealing valve is not sealing properly tightened to the proper torque head specification.
  • Page 111 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Water leaking from the Damaged high pressure Check for scratches or grooves weep holes in the hard seal cylinder on the coned seal surface. If end cap detected, polish to remove following the procedure, High Pressure Cylinder Maintenance, detailed in Section 8, High...
  • Page 112 Section 9 Troubleshooting Table 9-1 S50 Troubleshooting Guide Malfunction Indication Comments Outlet booster pump Inlet water pressure is low pressure is falling below 60 psi (4 bar) Filter element is dirty and needs to be replaced Booster pump needs to be Booster pump should be adjusted or replaced adjusted to 120 psi (8 bar) when...

  • Page 113: Specifications

    SECTION 10 SPECIFICATIONS 10.1 Overview Comprehensive listings of specifications for the Streamline S50 are provided in this section. Table 10-1 Motor Horsepower Rating Model 10.2 Installation Specifications Environment Installation location Indoors Air borne dust/contaminants Minimal Ambient temperature Minimum storage 36 F (2 C) Minimum operating 40...

  • Page 114: Service Connections

    Section 10 Specifications Service Connections Connection Height Drain 1/2” NPT 12.21” (310 mm) Cutting Water In 1/2” NPT 16.26” (413 mm) Contaminated Waste 1/2” NPT 20.26” (515 mm) Cooling Water In (oil-to-water models only) 1/2” NPT 23.76” (604 mm) Cooling Water Out (oil-to-water models only) 1/2”...

  • Page 115: Recirculation System

    Section 10 Specifications Cutting Water Supply (Low Pressure Water System) Booster pump factory set outlet pressure 120 psi (8.3 bar) Optimum inlet water temperature 65 F (18 C) Maximum inlet water temperature 85 F (29 C) Booster pump overheat 128 F (53 C) Recirculation System 3.0 gpm (11.4 L/min) Maximum consumption at 75...

  • Page 116: Water Quality Standards

    Section 10 Specifications Water Quality Standards The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance. Water treatment requirements can be determined by a water analysis. The cutting water supply must meet the following standards. A high concentration of dissolved solids, especially calcium, silica and chlorides will affect high pressure component life.
  • Page 117 Section 10 Specifications Table 10-4 Water Impurities Constituent Chemical Formula Comments Alkalinity Bicarbonate (HCO Acid neutralizing capacity of water. Foaming Carbonate (CO and carryover of solids, causes embrittlement of Hydrate (OH), steel, can produce CO , a source of corrosion. expressed as CaCO Calcium When dissolved makes water hard;...

  • Page 118: 10.4 Electrical Specifications

    Section 10 Specifications 10.4 Electrical Specifications Electrical System Motor type TEFC (Totally Enclosed Fan Cooled) Ampacity and Power Voltage Requirements Motor Full Load Circuit Breaker Power Voltage Horsepower Amps Amps 200/3/50-60 208/3/50-60 240/3/60 380/3/50 400/3/50 415/3/50 480/3/60 575/3/60 10.5 Hydraulic and High Pressure Water System Specifications Hydraulic System Maximum operating pressure 3,000 psi (207 bar)

  • Page 119: Orifice Capacity

    Section 10 Specifications High Pressure Water System Pneumatic Control Valve Maximum water pressure 60,000 psi (4,137 bar) Regulated air pressure 85 psi (5.9 bar) Maximum flow rate 1.0 cfm (0.028) m /min Orifice Capacity The following tables provide horsepower requirements for some of the more popular orifices. Table 10-5 Single Orifice Diameter Motor...

  • Page 120: Torque Specifications

    Section 10 Specifications The horsepower requirements for operating multiple orifices are determined by adding the requirements in Table 10-6 for each orifice. Examples are shown below. Orifice Size Number of Operating Total inches (mm) Orifices Pressure Calculation Horsepower 0.008 (0.203) 50,000 3 x 13.9 41.7...
  • Page 121 Section 10 Specifications Torque Specifications 6-Bolt Crossing Pattern * Note: Crossing Pattern: 1, 2, 3, 4, 5, 6 Hydraulic Cylinder Head Socket Head Screws 8 (M14) each Torque 75-80 ft-lbs (102-108 Nm) Hex Key Proximity Switch Socket Head Screws 2 (M6) each Torque 140-160 in-lbs (16-18 Nm) Hex Key...

  • Page 122: Parts List

    To facilitate the ordering of replacement parts, item numbers in each table correspond to the identifying numbers in the accompanying figures. Use the following information to contact the Customer Service Department at KMT Waterjet Systems. Europe Customer Service Department...

  • Page 123: 11.2 Index

    Section 11 Parts List 11.2 Index Part lists are arranged in the following sequence. Parts List Index Table Description Part Number Page Table Description Part Number Page 11-1 S50 Intensifier Unit 11-3 11-13 Electrical Assembly 20478862 11-25 11-2 Intensifier Assembly 72122394 11-5 11-14...
  • Page 124 Section 11 Parts List Table 11-1 Streamline S50 Intensifier Unit Item Part Number Description Quantity 72103660 High Pressure Water Assembly 20478862 Electrical Assembly 20478939 Heat Exchanger Kit, Oil-to-Water 20478694 Heat Exchanger Kit, Oil-to-Air 20478935 Decal Package 20478821 Bulkhead Pipe Assembly...
  • Page 125 Section 11 Parts List Figure 11-1: Streamline S50 Intensifier Unit 20479307 2-2012/Rev 04 11-4...
  • Page 126 Section 11 Parts List Table 11-2 Intensifier Assembly 72122394 Part Part Item Number Description Quantity Item Number Description Quantity 72119544 HP Cylinder 05034764 Hydraulic Cylinder 05119151 Plunger 05034855 Backup Ring, 3.75 x 4.0 20481005 Sealing Head Assembly 10075000 O-Ring, 3.75 x 4.0 x .13 05034772 Hydraulic Cylinder Head 05141106...
  • Page 127 Section 11 Parts List Figure 11-2: Intensifier Assembly 20479307 2-2012/Rev 04 11-6...
  • Page 128 Section 11 Parts List Table 11-3 Hydraulic Cartridge Seal 05130091 Part Part Item Number Description Quantity Item Number Description Quantity 05130109 Seal Bushing 05129515 Backup Ring, 1.127 x 0.891 05015060 Packing Ring W/O-Ring 05027255 Packing Seal, U-Cup W/O-Ring 10193522 O-Ring, 1.19 x 1.38 x .09 05050760 Backup Ring, 1.188 x 1.375 80084759...
  • Page 129 Section 11 Parts List Table 11-4 Sealing Head Assembly 20481005 Part Part Item Number Description Quantity Item Number Description Quantity 20481009 Sealing Head 05147863 Compression Spring 20453619 Inlet Poppet Valve 20474391 Poppet Retainer 05116777 Gland 05116751 Poppet Pin 05112768 Seat 05116561 Discharge Poppet Valve 20489495...
  • Page 130 Section 11 Parts List Table 11-5 Hydraulic Piston Assembly 05132253 Part Item Number Description Quantity 05132261 Hydraulic Ram Piston, 4.03 05074380 Plunger Retainer Pin, Clevis, .25 05049887 Set Screw, Socket, 3/8-16 x 3/8 10148757 Check Valve 49877509 Adhesive, Thread Locker 05088364 Flat Snap Ring, .032 x .375 x 2.010 05049994...
  • Page 131 Section 11 Parts List Figure 11-5: Hydraulic Piston Assembly 20479307 2-2012/Rev 04 11-10...
  • Page 132 Section 11 Parts List Table 11-6 High Pressure Piping 72103660 Part Part Item Number Description Quantity Item Number Description Quantity 72122394 Intensifier Topworks 20427739 Valve/Actuator Assembly 20481652 HP Tube, Bent, .25 49830581 Coupling, HP Bulkhead, .56 x .38 80087745 HP Tube, Bent, .38 20455068 Socket Head Screw, M12 x 1.75 10078715...
  • Page 133 Section 11 Parts List Figure 11-6: High Pressure Piping 20479307 2-2012/Rev 04 11-12...
  • Page 134 Section 11 Parts List Table 11-7 Hydraulic Power Package 20479025 Part Part Item Number Description Quantity Item Number Description Quantity 80087935 Motor/Pump Assembly 10069714 Flat Washer, .38 05049168 Adapter, Water Pump 20437164 Directional Control Valve 95572897 Hex Head Screw, 1/4-20 x 5/8 95055059 Socket Head Screw, 1/2-13 x 2-1/2 95838314...
  • Page 135 Section 11 Parts List Figure 11-7:Hydraulic Power Package 20479307 2-2012/Rev 04 11-14...
  • Page 136 Section 11 Parts List Table 11-8 Motor/Pump Assembly 80087935 Part Part Item Number Description Quantity Item Number Description Quantity 80076573 Coupling, Flexible Drive, Motor Shaft 95055265 Socket Head Screw, 3/8-16 x 1.25 80076557 Flexible Drive Coupling Insert 05091756 Socket Head Screw, 7/16-14 x 6 05101613 Vibration Isolation Mount 05050356...
  • Page 137 Section 11 Parts List Figure 11-8: Motor/Pump Assembly 20479307 2-2012/Rev 04 11-16...
  • Page 138 Section 11 Parts List Table 11-9 Hydraulic Manifold Assembly 05071766 Part Item Number Description Quantity 05044144 Hydraulic Manifold 05071055 Plug, ORB, .75 05055017 Plug, ORB, .13 10185585 Solenoid Valve, 24V DC 10187052 Relief Valve, 25-3000 psi 10187060 Relief Valve, 25-1500 psi 49889744 Retainer, Cartridge Valve 49889736...
  • Page 139 Section 11 Parts List Figure 11-9: Hydraulic Manifold Assembly 20479307 2-2012/Rev 04 11-18...
  • Page 140 Section 11 Parts List Table 11-10 Hydraulic Hose Connections 20478858 Part Part Item Number Description Quantity Item Number Description Quantity 20449078 Hose Assembly, Hydraulic, 1.0 x 15.50 05064407 Adapter, JIC/ORB, 1.0 x .75 10091163 Adapter, JIC/ORB, .75 x .75 80086192 Adapter, JIC/ORB, 1.0 x 1.0 10083517 Hose Clamp...
  • Page 141 Section 11 Parts List Figure 11-10: Hydraulic Hose Connections 20479307 2-2012/Rev 04 11-20...
  • Page 142 Section 11 Parts List Table 11-11 Reservoir Assembly 20477002 Part Part Item Number Description Quantity Item Number Description Quantity 20454042 Reservoir Weldment 80087687 Diffuser, Return Line 20454105 Reservoir Lid 10085033 Plug, Pipe, .75 20462991 Gasket 95.0" 20423326 Ball Valve, 2-Way 20451474 Gauge, Level/Temperature 05025176...
  • Page 143 Section 11 Parts List Figure 11-11: Reservoir Assembly 20479307 2-2012/Rev 04 11-22...
  • Page 144 Section 11 Parts List Table 11-12 Bulkhead Pipe Assembly 20478821 Part Part Item Number Description Quantity Item Number Description Quantity 10077055 Coupling, Bulkhead, .94 x .25 10127298 Elbow, Pipe, .50 x .50 10078335 Coupling, Pipe, .25 x .13 20412815 Strainer 20453730 Check Valve 95680922...
  • Page 145 Section 11 Parts List Figure 11-12: Bulkhead Pipe Assembly 20479307 2-2012/Rev 04 11-24...
  • Page 146 Section 11 Parts List Table 11-13 Electrical Assembly 20478862 Part Item Number Description Quantity 20478805 Junction Box 10107118 Flat Washer, M6 10064723 Lock Washer, M6 49892003 Hex Head Screw, M6 x 1 x 16MM 20478931 Harness, Sensor/Solenoid 49874191 Hole Seal, .50 10120921 Mount, Cable Tie 10125920...
  • Page 147 Section 11 Parts List Figure 11-13: Electrical Assembly 20479307 2-2012/Rev 04 11-26...
  • Page 148 Section 11 Parts List Table 11-14 Junction Box 20478805 Part Part Item Number Description Quantity Item Number Description Quantity 20478785 Enclosure 10170165 Wire, #16, Green/Yellow 6.0” 10139962 Panel Insert 10181873 Ring Terminal 10103034 DIN Rail 6.0” 20436867 Plug, Disconnect 10073492 Pan Head Screw, 8-32 x 1/2 10189355 Hourmeter...
  • Page 149 Section 11 Parts List Figure 11-14: Junction Box 20479307 2-2012/Rev 04 11-28...
  • Page 150 Section 11 Parts List Table 11-15 Pneumatic Valve/Actuator Assembly, Normally Open 20427739 Part Part Item Number Description Quantity Item Number Description Quantity 20427648 Valve Body 10189553 Actuator Assembly, Normally Open 10178697 Valve Seat BV401184 Pneumatic Cylinder 49830904 Adapter, HP Water Valve BV601184 Cylinder Head 20435636...
  • Page 151 Section 11 Parts List Figure 11-15: Pneumatic Valve/Actuator Assembly, Normally Open 20479307 2-2012/Rev 04 11-30...
  • Page 152 Section 11 Parts List Table 11-16 Low Pressure Water Filter Assembly 80087976 Part Item Number Description Quantity 05070982 Relief Valve 49838386 Pipe Nipple, .75 x 4.0 10119253 Elbow, Pipe, .50 x .50 20413848 Manifold 49833924 Manifold 49835804 Adapter, Hose/Pipe, .50 x .50 72118339 Filter Housing Assembly 05135652...
  • Page 153 Section 11 Parts List Figure 11-16: Low Pressure Water Filter Assembly 20479307 2-2012/Rev 04 11-32...
  • Page 154 Section 11 Parts List Table 11-17 Heat Exchanger Kit, Oil-to-Water 20478939 Part Item Number Description Quantity 10078194 Coupling, Bulkhead, 1.50 x .50 10127801 Pipe Nipple, .50 x 3.0 95680922 Adapter, JIC/Pipe, .50 x .50 10173805 Hose Barb, .50 10091866 Water Modulating Valve 20421272 Hose, Push-On, .50 72.0"...
  • Page 155 Section 11 Parts List Figure 11-17: Heat Exchanger Kit, Oil-to-Water 20479307 2-2012/Rev 04 11-34...
  • Page 156 Section 11 Parts List Table 11-18 Heat Exchanger Kit, Oil-to-Air 20478694 Part Item Number Description Quantity 20472981 Heat Exchanger 49883580 Flat Washer, M10 10064715 Lock Washer, M10 10126829 Socket Head Screw, M10 x 1.50 x 25MM 20479033 Hose Assembly, Hydraulic, .75 x 41.0 20479042 Hose Assembly, Hydraulic, 1.0 x 23.0 05114962...
  • Page 157 Section 11 Parts List Figure 11-18: Heat Exchanger Kit, Oil-to-Air 20479307 2-2012/Rev 04 11-36...
  • Page 160 Medical information: Unlikely to cause ill effects. Inhaling fumes of decomposition products can cause temporary influenza-like symptoms which are described as “polymer fume fever”. Symptoms include fever, cough, and malaise. 5. FIRE FIGHTING MEASURES KMT 20416083 Page 1 of 4...
  • Page 161 • Respiratory protection: None required. • Hand protection: Rubber gloves are recommended to minimize exposure. • Eye protection: Safety glasses or goggles are recommended to minimize exposure. • Skin protection: Wash hands after use. KMT 20416083 Page 2 of 4...
  • Page 162 IARC 12. ECOLOGICAL INFORMATION • Mobility: Paste-like viscosity. • Degradability: Not established. • Accumulation: No known adverse bioaccumulation or biomagnification effects. • Short / Long term effects on ecotoxicity: No known ecological effects. KMT 20416083 Page 3 of 4...
  • Page 163 This Material Safety Data Sheet was designed to give the distributors and users of PURE GOOP information to handle and use the product in a responsible manner. Preparation Data Environmental and Safety Department (440) 349-5955 November 2003 KMT 20416083 Page 4 of 4...
  • Page 164 Not expected to be harmful by ingestion. Ingestion: Eye, skin, and respiratory disorders. Existing conditions aggravated by exposure: See Section 11 for additional toxicological information. 21464 Item No. : Product name: Loctite(R) 222 Threadlocker Low Strength 1 of 5 KMT 20416099...
  • Page 165 No specific ventilation requirements noted, but forced ventilation may still be required if concentrations Engineering controls: exceed occupational exposure limts. Use NIOSH approved respirator if there is potential to exceed exposure limit(s). Respiratory protection: 21464 Item No. : Product name: Loctite(R) 222 Threadlocker Low Strength 2 of 5 KMT 20416099...
  • Page 166 Polyglycol oleate Oral LD50 None 9004-96-0 (Mouse) > 25 g/kg Silica, amorphous, treated None None 68909-20-6 Saccharin Oral LD50 None 81-07-2 (Mouse) = 17 g/kg 21464 Item No. : Product name: Loctite(R) 222 Threadlocker Low Strength 3 of 5 KMT 20416099...
  • Page 167 Identification number: None Packing group: WaterTransportation (IMO/IMDG): Unrestricted Proper shipping name: None Hazard class or division: None Identification number: None Packing group: None Marine pollutant: 21464 Item No. : Product name: Loctite(R) 222 Threadlocker Low Strength 4 of 5 KMT 20416099...
  • Page 168 Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damages of any kind, including lost profits. 21464 Item No. : Product name: Loctite(R) 222 Threadlocker Low Strength 5 of 5 KMT 20416099...
  • Page 169 For this and other reasons, we do not assume responsibility and expressly disclaim liability for loss, damage, or expense arising out of or in any way connected with the handling, storage, use or disposal of the product. Page 1 of 1 KMT 20416125...
  • Page 170 Cool exposed containers with water. Use air-supplied breathing equipment for enclosed or confined spaces. Unusual Fire and Explosion Hazards: Do not store or mix with strong oxidants. Empty containers retain residue. Do not cut, drill, grind, or weld, as they may explode. KMT 20416107...
  • Page 171 Brothers Refining Company. The data on these sheets relates only to the specific material designated herein. Fiske Brothers Refining Company assumes no legal responsibility for use or reliance upon this data. Date Prepared: January, 2006 Prepared by: James R. Kontak KMT 20416107...
  • Page 172 Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness occurs, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or use KMT 72104303...
  • Page 173 US regulations require reporting releases of this material to the environment which exceed the applicable reportable quantity or oil spills which could reach any waterway including intermittent dry creeks. The National Response Center can be reached at (800)424-8802. KMT 72104303...
  • Page 174 Personal protective equipment selections vary based on potential exposure conditions such as applications, handling practices, concentration and ventilation. Information on the selection of protective equipment for use with this material, as provided below, is based upon intended, normal usage. KMT 72104303...
  • Page 175 Flash Point [Method]: >204C (399F) [ ASTM D-92] Flammable Limits (Approximate volume % in air): LEL: 0.9 UEL: 7.0 Autoignition Temperature: N/D Boiling Point / Range: > 316C (600F) Vapor Density (Air = 1): > 2 at 101 kPa KMT 72104303...
  • Page 176 May cause mild, short-lasting discomfort to eyes. Based on assessment of the components. CHRONIC/OTHER EFFECTS Contains: Base oil severely refined: Not carcinogenic in animal studies. Representative material passes IP-346, Modified Ames test, and/or other screening tests. Dermal and inhalation studies showed minimal effects; lung non- KMT 72104303...
  • Page 177 (40 CFR, Part 261D), nor is it formulated to contain materials which are listed as hazardous wastes. It does not exhibit the hazardous characteristics of ignitability, corrositivity or reactivity and is not formulated with contaminants as determined by the Toxicity Characteristic Leaching Procedure (TCLP). However, used product may be regulated. KMT 72104303...
  • Page 178 18 = PA RTK 4 = OSHA Z 9 = TSCA 12b 14 = LA RTK 19 = RI RTK 5 = TSCA 4 10 = CA P65 CARC 15 = MI 293 Code key: CARC=Carcinogen; REPRO=Reproductive SECTION 16 OTHER INFORMATION KMT 72104303...
  • Page 179 ExxonMobil Chemical Company, Exxon Mobil Corporation, or any affiliates in which they directly or indirectly hold any interest. ----------------------------------------------------------------------------------------------------------------------------------------------------- Internal Use Only MHC: 0, 0, 0, 0, 0, 0 PPEC: A DGN: 2007812XUS (546747) ----------------------------------------------------------------------------------------------------------------------------------------------------- Copyright 2002 Exxon Mobil Corporation, All rights reserved KMT 72104303...
  • Page 180 Clear and bright liquid / mild petroleum hydrocarbon odor. OSHA REGULATORY STATUS This material is classified as non-hazardous under OSHA Regulations. HMIS RATING Health: Flammability: Physical Hazard: NFPA RATING Health: Flammability: Instability: ___________________________________ Potential Health Effects Primary Route of Entry: Skin KMT 20418732...
  • Page 181 FIRE FIGHTING MEASURES --------------------------------------------------------------------------- Flammable Properties Flash Point (minimum): 365 F (185 C) (Grade 32) 374 F (190 C) (Grade 46) 410 F (210 C) (Grade 68) 428 F (220 C) (Grade 100) 440 F (227 C) (Grade 150) KMT 20418732...
  • Page 182 Wash contaminated clothing prior to reuse. Handling (Physical Aspects) Close container after each use. Do not pressurize, cut, weld, braze, solder, grind, or drill on or near full or empty container. Empty container retains residue (liquid and/or vapor) and may explode in KMT 20418732...
  • Page 183 0.85-0.90 @ 60 F (16 C) Pounds Per Gallon: 7.1-7.5 @ 60 F (16 C) Viscosity (typical): cSt @ 40 C cSt @ 100 C ISO 32 32.5 ISO 46 ISO 68 68.2 8.77 ISO 100 101.1 11.3 ISO 150 14.6 KMT 20418732...
  • Page 184 Shipping Information DOT: Not regulated. IATA/IMDG: Not restricted. Canada: Not regulated. --------------------------------------------------------------------------- REGULATORY INFORMATION --------------------------------------------------------------------------- U.S. Federal Regulations OSHA HAZARD DETERMINATION This material is not known to be hazardous as defined by OSHA's Hazard Communication Standard, 29 CFR 1910.1200. KMT 20418732...
  • Page 185 These lubricants can produce carbon monoxide when subjected to high temperatures. ____________________ The data in this Material Safety Data Sheet relates only to the specific material designated herein and does not relate to use in combination with any other material or in any process. KMT 20418732...
  • Page 186 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 187 - SKIN EXPOSURE - Short term skin contact is not expected to cause skin irritation. Prolonged or repeated direct exposure to the skin may result in KMT 20461677...
  • Page 188 If small amounts are ingested, first aid measures are not likely to be necessary. If larger amounts are ingested or if symptoms of ingestion occur, dilute stomach contents with two glasses of water or milk. (NOTE: Do NOT give anything by mouth to an unconscious person.) Do not induce KMT 20461677...
  • Page 189 Small volumes or residues may be soaked up with absorbents. Spill response materials should be collected for proper disposal. ___________________________________________________________________________ ____________________ SECTION 7 - HANDLING AND STORAGE ___________________ HANDLING: KMT 20461677...
  • Page 190 - RESPIRATORY PROTECTION - A respirator may be worn to reduce exposure to vapors, dust, or mist. Select a NIOSH/MSHA approved respirator appropriate for the type and physical character of the airborne material. A self-contained breathing KMT 20461677...
  • Page 191 Combustion byproducts may include: oxides of carbon, incompletely burned hydrocarbons as fumes and smoke. CONDITIONS TO AVOID: Avoid contact with incompatible materials and exposure to extreme temperatures. POLYMERIZATION: This product is not expected to polymerize. STABILITY: KMT 20461677...
  • Page 192 ___________________________________________________________________________ ___________________ SECTION 14 - TRANSPORT INFORMATION __________________ DOT HAZARDOUS MATERIAL INFORMATION: * Not otherwise DOT regulated. ___________________________________________________________________________ __________________ SECTION 15 - REGULATORY INFORMATION __________________ FEDERAL REGULATIONS: KMT 20461677...
  • Page 193 Prepared by ... . . : Corporate Regulatory Compliance Date of issue ... . : 07/26/2007 Last Revision Date ..: 11/01/2006 C4302368 ___________________________________________________________________________ KMT 20461677...
  • Page 194 This document does not create any express or implied product warranties. Since conditions of use are beyond the control of Fuchs Lubricants Co., all risks associated with product use are assumed by the user. ___________________________________________________________________________ KMT 20461677...
  • Page 195 May cause allergic skin reaction. May cause skin irritation. Skin contact: Contact with eyes will cause irritation. Eye contact: Not expected to be harmful by ingestion. Ingestion: 24231 Item No. : Product name: 242 Threadlocker 1 of 5 KMT 72102733...
  • Page 196 For information on product shelf life contact Henkel Customer Service at (800) 243-4874. 8. EXPOSURE CONTROLS / PERSONAL PROTECTION No specific ventilation requirements noted, but forced ventilation may still be required if concentrations Engineering controls: exceed occupational exposure limts. 24231 Item No. : Product name: 242 Threadlocker 2 of 5 KMT 72102733...
  • Page 197 Polyglycol dimethacrylate 25852-47-5 Polyglycol oleate 9004-96-0 Saccharin 81-07-2 Silica, amorphous, fumed, crystalline-free 112945-52-5 Cumene hydroperoxide 80-15-9 Propylene glycol 57-55-6 Literature Referenced Target Organ & Other Health Effects 24231 Item No. : Product name: 242 Threadlocker 3 of 5 KMT 72102733...
  • Page 198 Hazard class or division: None Identification number: None Packing group: WaterTransportation (IMO/IMDG): Unrestricted Proper shipping name: None Hazard class or division: None Identification number: None Packing group: None Marine pollutant: 24231 Item No. : Product name: 242 Threadlocker 4 of 5 KMT 72102733...
  • Page 199 Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damages of any kind, including lost profits. 24231 Item No. : Product name: 242 Threadlocker 5 of 5 KMT 72102733...
  • Page 200 Vapors may irritate eyes. Contact with eyes will cause irritation. Eye contact: Harmful if swallowed. Ingestion: Eye, skin, and respiratory disorders. Existing conditions aggravated by exposure: See Section 11 for additional toxicological information. 19269 Item number: Product name: Loctite(R) 7649 Primer N 1 of 4 KMT 72102741...
  • Page 201 Use local ventilation if general ventilation is insufficient to maintain vapor concentration below Engineering controls: established exposure limits. Use NIOSH approved respirator if there is potential to exceed exposure limit(s). Respiratory protection: 19269 Item number: Product name: Loctite(R) 7649 Primer N 2 of 4 KMT 72102741...
  • Page 202 Information provided is for unused product only. Dispose of according to Federal, State and local governmental regulations. Recommended method of disposal: D001: Ignitable. EPA hazardous waste number: 19269 Item number: Product name: Loctite(R) 7649 Primer N 3 of 4 KMT 72102741...
  • Page 203 Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damages of any kind, including lost profits. 19269 Item number: Product name: Loctite(R) 7649 Primer N 4 of 4 KMT 72102741...

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