Gradual pressure drops in the KMT Streamline SL-V Plus series are caused by seals and connections beginning to leak slowly or suddenly through specially designed weep holes. Water or oil dripping from a weep hole indicates that internal seals or valves are starting to fail, signaling the need for maintenance.

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Summary of Contents for KMT Streamline SL-V Plus series

Page 1 STREAMLINE SL-V 100 PLUS WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL 20413130(R13) MANUAL...
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 and Options ............1-1 Operational Overview ................1-3 Low Pressure Water System ..............1-3 Recirculation System ................1-3 Hydraulic System ................... 1-3 High Pressure Water System ..............
Page 4 Power Coning..................2-12 Hand Threading ..................2-12 Power Threading ..................2-13 High Pressure Connections ..............2-13 Standard Connections ................2-14 Anti-Vibration Connections ..............2-14 Commissioning ..................2-15 2.10 Decommissioning .................. 2-18 Maintenance ...................... 3-1 Overview ....................3-1 Maintenance ................... 3-1 Daily Inspection ..................
Page 5 Booster Pump Adjustment ..............5-5 Recirculation System ..................6-1 Overview ....................6-1 Operation (Oil-to-Water Models) ............6-1 Operation (Oil-to-Air Models) ............... 6-3 Service and Maintenance Procedures ............ 6-4 Hydraulic Oil Maintenance ..............6-4 Electric Motor Bump ................6-6 Oil Filter Maintenance ................6-7 Operating Temperature Adjustment (Oil-to-Water Models) ....
Page 6 High Pressure Cylinder Assembly ............9-10 High Pressure Cylinder Assembly Removal .......... 9-11 High Pressure Cylinder Assembly Installation ........9-12 High Pressure Cylinder Maintenance ............ 9-13 Hard Seal End Caps ................9-14 Hard Seal End Cap Removal ..............9-14 Hard Seal End Cap Installation .............. 9-15 Sealing Head ..................
Page 7: Appendix
Water Quality Standards ................ 11-5 11.4 Electrical Specifications ................. 11-7 Electrical System ................... 11-7 Ampacity and Power Voltage Requirements ......... 11-7 11.5 Hydraulic and High Pressure Water System Specifications ....11-8 Hydraulic System ................... 11-8 High Pressure Water System ..............11-8 Orifice Capacity ..................
Page 8: Introduction
SECTION 1 INTRODUCTION Overview The Streamline SL-V Plus series combines all the unique capabilities and advantages of waterjet cutting systems with the reliability, ease of operation and service support that have made KMT Waterjet Systems a leader in waterjet technology.
Page 9 Performance options are available at the time of purchase, or as upgrades for existing equipment.  The KMT Customer Service Department can provide real time diagnostics, troubleshooting and data analysis through a modem interface for remote monitoring of the programmable logic controller (PLC).
Page 10: 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 9. 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 11: Operating System
Section 1 Introduction Figure 1-2: High Pressure Water System Components Operating System A programmable logic controller (PLC) provides basic intensifier shift control and monitors out of limit conditions. Operator interface is through the control panel display where operating parameters are set and monitored. Figure 1-3: Control Panel Main Menu 20412914 8-2012/Rev 09...
Page 12: 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 13: Warning Labels
Section 1 Introduction 4. Close, lockout and tag the manual shutoff valves for all service connections: cutting water in, cooling water in and out, and air. Warning Labels Warning labels are posted on the machine to indicate potential hazards. The operator and service personnel shall pay particular attention to these warning labels.
Page 14 Section 1 Introduction Table 1-2 Warning Label Precautions High pressure water and/or hydraulic pressure can remain in the system even when the pump has been shut off. All pressure can be safely bled from the system by opening the high pressure cutting water valve for a few seconds after shutting off the pump.
Page 15: 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 16: Spare Parts
Email: order.service@kmt-waterjet.com Email: wj.parts@kmtwaterjet.com Spare Parts KMT Waterjet maintains a well-stocked Spare Parts Department, staffed by trained, knowledgeable personnel. If required, emergency shipment is available. Contact the Customer Service Department to order spare parts, or for additional information. Manual Organization This manual contains operating and maintenance procedures for the complete SL-V series.
Page 17: Equipment And Service Manual Questionnaire
Introduction 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 18 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 19 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 20: 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 21: 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 22: Transporting
Section 2 Installation Table 2-1 Equipment Dimensions and Weight Horsepower Length Width Height Weight Redundant Models (same dimensions as above) 30 HP 2,200 lbs (998 kg) 50 HP 3,000 lbs (1,360 kg) 60 HP 3,500 lbs (1,588 kg) 100 HP 4,600 lbs (2,087 kg) Transporting The weight of the machine is not evenly distributed from one end to the other, particularly on the...
Page 23: Power Requirements
Section 2 Installation Table 2-2 Fork Pockets Fork Pocket Dimensions Height 3.0” (76.2 mm) Width 8.0” (203.2 mm) Length 36.75” (933.45 mm) Distance Between Pockets 36.0” (914.4 mm) If the machine will be installed in an overhead location, a forklift or crane can be used to position the pump.
Page 24: Service Connections
Section 2 Installation Table 2-3 Ampacity and Power Voltage Requirements Motor Full Load Circuit Breaker Power Voltage Horsepower Amps Amps 230/3/60 380/3/50 400/3/50 415/3/50 460/3/60 575/3/60 230/3/60 380/3/60 460/3/60 200/3/50-60 200-208/3/50-60 248/242 230/3/60 400/3/50 415/3/50 460/3/60 575/3/60 Service Connections The intensifier requires two incoming water sources, cooling water and cutting water; two drain lines, cooling water and wastewater;...
Page 25: Cooling Water (Oil-To-Water Models)
Section 2 Installation Figure 2-3: Service Connections Table 2-4 Service Connections Connection Height Drain 1/2” NPT 7.50” (191 mm) Cutting Water In 1/2” NPT 10.50” (267 mm) Cooling Water In (oil-to-water models) 1/2” NPT 13.50” (343 mm) Hydraulic Oil In (air-to-water models) 3/4”...
Page 26: Cutting Water
Section 2 Installation Table 2-5 Chilled Water Systems Cooling Requirements at Full Capacity Horsepower BTU/HR 13,400 22,000 26,800 45,000 Note: Coolant flow to the heat exchanger is regulated by the temperature of the contents in the hydraulic reservoir and will be shut off at times. Cutting Water Inlet cutting water is filtered and routed to the intensifier where it is pressurized and delivered to the cutting head.
Page 27: Contaminated Waste Drain
Section 2 Installation Table 2-6 ISO Air Quality Classifications Maximum Maximum Pressure ISO Quality Particle Size Dew Point Maximum Oil Content Class (microns) (water @ 100 psi) (Mg/m -94° F (-60° C) 0.01 -40° F (-40° C) -4° F (-20° C) +38°...
Page 28: High Pressure Piping
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 2-8.
Page 29: Measurements And Dimensions
Section 2 Installation Table 2-8 Coning and Threading Tools Part Number Hand Tools Power Tools 1/4” Coning Tool 05108832 05109897 3/8” Coning Tool 05108857 05109889 9/16” Coning Tool 05108840 05109871 1/4” Threading Tool 05108865 05122742 3/8” Threading Tool 05108873 05120258 9/16”...
Page 30: Hand Coning
Section 2 Installation Hand Coning 1. Place the body of the coning tool in a vise allowing adequate clearance for the rotation of the cutter handle. Position the tool so the cutter handle is elevated slightly so the lubricant will flow to the cutting blade. Figure 2-7: Hand Coning Tool 2.
Page 31: Power Coning
Section 2 Installation NOTE Clean the machining chips from the blade and from the collet before coning the next tube. Power Coning 1. Secure the tubing in a tube vise. No more than the recommended length of tubing should extend beyond the face of the vice. See Table 2-11, Recommended Extension Length. 2.
Page 32: Power Threading
Section 2 Installation 5. Continue threading until the proper thread length is reached, see Table 2-10, Column L. Remove the tool from the end of the tubing. NOTE Clean the machining chips from the die and body of the tool before threading the next tube.
Page 33: Standard Connections
Section 2 Installation Standard Connections Standard connections are used for general applications where internal pressure is the only load on the tubing. Figure 2-8: Standard High Pressure Connections 1. Deburr the tubing ID and thoroughly clean the tubing threads. 2. Slip the gland nut onto the tubing. 3.
Page 34: Commissioning
Section 2 Installation Figure 2-9: Anti-Vibration Connections 1. Deburr the tubing ID and thoroughly clean the tubing threads. 2. Slip the gland nut and the collet 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 35 Section 2 Installation 4. Check the connection between the main power disconnect and the disconnect/circuit break on the enclosure door. Verify the proper voltage supply. Close the enclosure door and turn the control power on. 5. To activate the control panel display, pull the button out and press the EMERGENCY STOP reset button.
Page 36 Section 2 Installation If the machine is equipped with proportional pressure control, the high pressure adjustment is made from the Pressure Control Screen on the control panel. Refer to Section 4, Operation, for additional information. From the Run Screen, press the tool icon to go to the Main Menu. Select Pressure Control to display the Pressure Control Screen.
Page 37: Decommissioning
Section 2 Installation 13. Observe the Booster Pressure Gauge on the front of the machine to ensure the inlet cutting water pressure is between 90-120 psi (6-8 bar). If not, the booster pump pressure must be adjusted. Refer to Section 5, Low Pressure Water System, for additional information. Remove the acorn nut on the side of the booster pump and use a flat blade screwdriver to turn the adjustment screw.
Page 38: Maintenance
SECTION 3 MAINTENANCE Overview The entire SL-V series 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 39: 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 40: 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 41 Section 3 Maintenance Table 3-2 Tool Kits Tool Kit Tool Kit 05072723 80075930 Part Number Description 7/8” Plunger 1-1/8” Plunger 05146618 HP Seal Installation Tool 10149029 Emery Cloth, 320 Grit 10149037 Emory Cloth, 400 Grit 10149045 Emory Cloth, 600 Grit 10149052 Glass Pane 20477460...
Page 42: Operation
Remote monitoring of the PLC is available as an option. A modem interface allows KMT Waterjet to access to the machine’s PLC program. The KMT Customer Service Department can perform real time diagnostics, remote troubleshooting, data analysis and software updates.
Page 43: Startup Sequence
Section 4 Operation Startup Sequence The startup sequence varies depending on the previous stop condition, and whether the machine is equipped with the optional pressure transducer. Startup after Motor Stop After a normal motor stop the safety dump valve will be closed and high pressure will be present in the intensifier.
Page 44: Display Controls
Section 4 Operation Display Controls Table 4-1 illustrates controls common to all displays. Table 4-1 Display Controls Control Function Comments The Run Screen is the only location where START The start button only displays on the the machine can be started to create Run and Maintenance Screens pressure.
Page 45: Main Menu
Section 4 Operation Main Menu The Main Menu provides a list of available setup and monitoring screens. Press the ▲ or ▼ arrow to highlight the desired screen. Press enter () to display the selected screen. Figure 4-2: Main Menu 20412948 8-2012/Rev 04...
Page 46: Run Screens
Run screens are configured according to equipment options. If machines are connected to a header system that is controlled by the KMT Waterjet Balancing System, a number displays on the top of the Run Screen to indicate the machine’s position within the system, as illustrated in Figure 4-3.
Page 47: Pressure Control Screen
Section 4 Operation  switch; select the on position to recirculate the machine. The machine RECIRCULATION will recirculate for 10 minutes before the switch shuts off. Recirculation can be manually stopped by pressing the stop button. Recirculation time is indicated below the switch. The Run Screen in Figure 4-4 will display if the machine is equipped with a pressure transducer.
Page 48: Setup Screens
Section 4 Operation Setup Screens Setup screens are configured for the specific machine, displaying only the available functions. Figure 4-8: Setup Screen - Standard Units The Setup Screen for a standard machine displays the following functions:  automatically shuts the inlet water solenoid valve five minutes after the WATER RESET machine shuts down;...
Page 49: Stroke Rate Screens
Section 4 Operation  selector changes the pressure display on the Run Screen and the Pressure Control Screen, if applicable; press the button to display output pressure as psi or bar. Recalibration of the transducer is automatic and does not require operator input. ...
Page 50 Section 4 Operation  increases or decreases the allowed stroke rate; press the ▲ or ▼ STROKE RATE ALLOWED arrow to select the rate. Stroke rate should be set slightly higher than the desired operating rate to shutdown the machine quickly in the event of an overstroke condition. Figure 4-11: Stroke Rate Screen - Redundant The upper limit points displayed on the Stroke Rate Screen are preset according to the horsepower rating of the machine.
Page 51: Hours Screens
Section 4 Operation Hours Screens The Hours Screen displays total machine operating hours and maintenance hours. Operating hours cannot be reset. Maintenance hours can be reset by pressing the RESET MAINT HOURS button. The Hours Screen in Figure 4-12 displays when the machine has a single intensifier. The Hours Screen in Figure 4-13 displays when the machine is a redundant model.
Page 52: Run Screen Alarms
Section 4 Operation 4.10 Run Screen Alarms In an alarm state, the last alarm sensed by the machine will be displayed on the Run Screen. If multiple alarm conditions have occurred they can be viewed on the Alarms Screen. Run Screen alarms are listed in Table 4-3.
Page 53 Section 4 Operation Table 4-3 Run Screen Alarms Alarm Indication Comments Left/Right/Intensifier Abnormally high stroke rate caused by Overstroke warnings, pending Overstroke an external or internal leak. Shutdown shutdowns and shutdowns are issued will occur if condition persists. as left, right or intensifier. An intensifier warning or shutdown indicates the intensifier is shifting too fast in both directions.
Page 54: Alarm Banners
Section 4 Operation 4.11 Alarm Banners When a shutdown condition occurs an Alarm Banner will appear over the current screen. The banner displays the type of shutdown and lists possible remedies. Potential remedies are listed in order of most to least probable. Figure 4-15: Alarm Banner Pressing the button will clear the alarm banner, but it will not clear the fault.
Page 55: Alarms Screen
Section 4 Operation Table 4-4 Alarm Banner Shutdowns Alarm Indication Possible Remedies Low Booster Pressure Low water pressure from Check booster adjustment booster pump Check booster condition Low Inlet Water Pressure Low inlet water pressure Check water supply Check water filter Motor Feedback Failure Start relay did not close at start- Check the motor starter relay...
Page 56 Section 4 Operation Figure 4-16: Alarms Screen Table 4-5 Alarms Screen Alarm Indication Result Overstroke High stroke rate caused by First a warning, and then a pending external or internal leak shutdown alarm will occur. If the condition persists a shutdown will occur.
Page 57: Installing A New Battery
Section 4 Operation Installing a New Battery The following procedure is used to change the replacement battery. Do not attempt to remove the permanent battery. 1. Insert the new battery into the replacement battery pocket with the wires facing up. 2.
Page 58: Changing The Date And Time
Section 4 Operation Changing the Date and Time The following procedure is used to change the date and time. 1. Remove power from the display by pressing the e-stop button. 2. Pull the e-stop button out and press the button to energize the display panel. RESET 3.
Page 59: Language Screen
Section 4 Operation Figure 4-19: Maintenance Screen The machine must be started from the Maintenance Screen to access the following functions:  button will start the machine in recirculation mode and open the dump valve START  button will stop the machine STOP ...
Page 60 Section 4 Operation Figure 4-20: Language Screen 20412948 8-2012/Rev 04 4-19...
Page 61 SECTION 5 LOW PRESSURE WATER SYSTEM Overview The SL-V series utilizes two low pressure circuits: cutting water supply and cooling water supply. This section will discuss the cutting water supply circuit. See Section 6, Recirculation System, for a detailed explanation of the cooling water supply circuit. The cutting water supply circuit supplies the intensifier with the required cutting water flow and pressure.
Page 62: Low Pressure Water System
Section 5 Low Pressure Water System Cutting Water Supply The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance. Impurities in the water create grinding and corrosive effects on all components. See Section 11, Specifications, for details regarding water quality standards. Operation Cutting water is introduced through the 1/2-inch NPT connection on the rear bulkhead of the machine.
Page 63 Section 5 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 contaminants from damaging the check valves and seals in the intensifier.
Page 64: Service And Maintenance Procedures
Section 5 Low Pressure Water System Service and Maintenance Procedures To ensure water quality and supply to the high pressure system, the filter element, strainer and booster pump will require routine servicing and maintenance. The procedures for servicing these components are detailed below. NOTE Refer to Section 12, Parts List for a complete listing of replacement parts and part numbers.
Page 65: Booster Pump Adjustment
Section 5 Low Pressure Water System 4. Install the new element over the rod in the center of the housing. 5. Apply FML-2 grease to the gasket in the filter head and to the gasket on the cap nut. 6. Position the housing in the filter head and install the cap nut. Figure 5-4: Strainer 7.
Page 66 Section 5 Low Pressure Water System 4. Stop the intensifier and remove the acorn nut on the side of the pump to access the adjustment screw. It is normal for water to leak out when the acorn nut is removed. 5.
Page 67: Recirculation System
SECTION 6 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. System components include the water modulating valve (oil-to-water models), recirculation pump, heat exchanger, oil filter assembly and the hydraulic oil reservoir.
Page 68 Section 6 Recirculation System Figure 6-2: Recirculation System Components (Oil-to-Water) The recirculation pump pulls oil from the reservoir and sends it to the heat exchanger. The oil-to- water heat exchanger controls heat build-up in the hydraulic oil. The plate style design allows cooling water and oil to flow side by side through alternating plates.
Page 69: Operation (Oil-To-Air Models)
Section 6 Recirculation System NOTE To conserve water usage it is recommended that the cooling water be shut off at the end of the day. A sensor bulb from the modulating valve is submerged in the reservoir. Even when the control power is off, the valve will remain open, allowing water to flow until the oil is cooled.
Page 70: Service And Maintenance Procedures
Section 6 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) on 30, 50 and 60 horsepower models, 25 psi (1.7 bar) on 100 horsepower models.
Page 71 Section 6 Recirculation System Figure 6-4: Hydraulic Reservoir Before proceeding, disconnect and lockout the main power supply and the electrical enclosure; and ensure that all high pressure water and hydraulic pressure has been bled from the system. Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before performing maintenance.
Page 72: Electric Motor Bump
Section 6 Recirculation System 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. 5. Connect the discharge hose from the oil transfer pump to the fill port and pump the fresh oil into the reservoir.
Page 73: Oil Filter Maintenance
Section 6 Recirculation System 1. Start the pump in recirculation mode, count two seconds and turn the pump off. 2. Repeat this process six times before allowing the hydraulic pump to create pressure. Oil Filter Maintenance If the filter element is not properly serviced and fills with debris, the oil will be forced through the relief valve, bypassing the filter.
Page 74: Operating Temperature Adjustment (Oil-To-Water Models)
Section 6 Recirculation System NOTE If the pressure gauge reads 40 psi (2.8 bar) or greater, or the indicator is in the red zone after the filter is changed, check the operating condition of the gauge or indicator. These components may require replacement. 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.
Page 75: Hydraulic System
SECTION 7 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. System components include the electric motor, hydraulic pump, 4-way directional control valve and the hydraulic manifold.
Page 76: Optional System Components
Section 7 Hydraulic System Optional System Components Optional proportional pressure control enhances the standard high and low pressure selection by allowing the operator to select or vary the hydraulic operating pressure from the control panel or from a remote console. From the Pressure Control Screen the high pressure can be set as a percentage, from 0% to 100%.
Page 77 Section 7 Hydraulic System The hydraulic system operates at high or low pressure settings up to the maximum flow capacity of the hydraulic pump. The high and low limit compensators mounted on the pump regulate the flow of hydraulic fluid to maintain constant operating pressures. Operating pressures are set and adjusted at the high and low pressure control valves on the manifold.
Page 78: Service And Maintenance Procedures
Section 7 Hydraulic System Service and Maintenance Procedures The extreme duty cycles demanded of the hydraulic system make routine inspection and maintenance acutely important. Leaks must be detected and remedied as soon as possible. The operating pressure settings must be checked daily, and the electric motor must be inspected at regular intervals.
Page 79 Section 7 Hydraulic System Figure 7-3: High Pressure Control Valve 1. Check the operating pressure to determine if adjustment is necessary. 2. If high pressure adjustment is required, loosen the locking nut on the high pressure control valve by turning counter-clockwise. 3.
Page 80: Proportional Valve Maintenance
Section 7 Hydraulic System Proportional Pressure Valve Maintenance The screen in the optional proportional valve can become blocked with debris resulting in erratic pressure fluctuations or the inability to reach or maintain the operating pressure. Figure 7-5: Proportional Valve 1. Unscrew and remove the retaining nut on the proportional pressure valve. 2.
Page 81: Flexible Coupling Replacement
Section 7 Hydraulic System Flexible Coupling Replacement When the flexible coupling fails, the pump shaft will not turn and pressure will not be created. Typically, failure will be sudden, without any warning signs. The electric motor and hydraulic pump are mounted in tandem on all SL-V models. Although the configuration is the same, the motor, pump, mountings, connections and components vary slightly according to horsepower.
Page 82 Section 7 Hydraulic System NOTE A forklift can also be used by trained, experienced personnel to support the pump and manifold assembly. 3. Remove the bolts attaching the hydraulic pump to the electric motor. 4. Slide the motor away from the pump and manifold assembly to expose the flexible coupling.
Page 83: Hydraulic Compensator Maintenance
Section 7 Hydraulic System 13. Reinstall the electrical panel to the end of the frame, if necessary. 14. Start the motor and apply full high pressure water pressure. Note any unusual sounds from the motor or pump assembly. Hydraulic Compensator Maintenance The high and low limit compensators regulate the flow of hydraulic fluid to the system.
Page 84 Section 7 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 85 Section 7 Hydraulic System 13. Set the high and low pressure control valves on the hydraulic manifold to the minimum setting by turning then counter-clockwise. If the machine is equipped with proportional pressure control, adjust the high pressure setting on the Pressure Control Screen. 14.
Page 86: Hydraulic Pump Or Electric Motor Replacement
Section 7 Hydraulic System 20. While the machine is running and high pressure water is flowing, select low pressure operating mode. Set the desired low operating pressure by adjusting the low pressure control valve. Hydraulic Pump or Electric Motor Replacement The following procedures are used to replace the hydraulic pump or the electric motor.
Page 87 Section 7 Hydraulic System Figure 7-8: Hydraulic Reservoir 4. Disconnect all hydraulic hoses and connections to the case drain, hydraulic pump, hydraulic manifold and recirculation pump. 5. Loosen the hydraulic gauge and turn it out of the way. Remove all electrical sensors and connections to the hydraulic manifold.
Page 88 Section 7 Hydraulic System 8. Remove the bolts that attach the hydraulic pump to the electric motor. 9. Support the hydraulic pump and slide it away from the motor, disengaging the flexible coupling. 10. Inspect the flexible coupling for damage. If the flexible coupling is damaged it must be replaced.
Page 89 Section 7 Hydraulic System 18. Verify that the mating surfaces of the motor and pump meet without resistance from the coupling. 19. Replace the pump mounting bolts and torque to the specifications in Table 7-3, Torque Specifications. 20. Install the recirculation pump, adapter and booster pump. 21.
Page 90: Hydraulic Oil Replacement
Section 7 Hydraulic System Figure 7-11: Motor Coupling Half 5. Apply Loctite 222 to the bolts and attach a new motor coupling half to the motor shaft. Torque to the specifications in Table 7-3. 6. Place the flexible coupling on the motor coupling half. Follow Step 12 and 14 in the previous procedure to determine if the coupling half on the hydraulic pump is in the proper position.
Page 91: Electric Motor Bump
Section 7 Hydraulic System 2. Connect the discharge hose from an oil transfer pump to the fill port and pump the fresh oil into the reservoir. NOTE Oil from a new drum does not meet the cleanliness requirements of the hydraulic system.
Page 92: Electrical System
SECTION 8 ELECTRICAL SYSTEM Overview All SL-V Plus models are equipped with integral motor starter and control circuitry, enclosed in the electrical panel. The operator controls the machine primarily through a touch-screen control panel that communicates with the programmable logic controller (PLC). A series of sensors provide automatic shutdown logic and diagnostics.
Page 93: Operation
Section 8 Electrical System Operation Electrical power from the utility grid enters the main circuit breaker/disconnect on the electrical enclosure door as 3-phase alternating current. The power is then distributed in two directions. The 3-phase AC, at the voltage provided from the grid, is routed to the motor starter contactor(s) and then to the main motor.
Page 94 Section 8 Electrical System Softstarters combine contactors, overload, timers and internal power/control wiring into a single device. They utilize a current limit starting method to greatly reduce mechanical and electrical shock to the system. Figure 8-2: Wye-Delta Configuration Figure 8-3: Across-the-Line Configuration Figure 8-4: Softstart Configuration 20412989 1-2012/Rev 08...
Page 95 Section 8 Electrical System The circuit breaker/door disconnect provides the primary over current protection for the machine. All power is automatically disconnected from the machine when the main disconnect on the enclosure door is opened. However, power is still present on the input side of the circuit breaker/door disconnect.
Page 96: Sensors And Solenoids
Section 8 Electrical System Sensors and Solenoids Warning and shutdown sensors monitor operating conditions, and electronically operated solenoids provide basic intensifier shift control. The harness cable connects these sensors and solenoids to the PLC. Figure 8-6: Sensors and Solenoids 20412989 1-2012/Rev 08...
Page 97 Section 8 Electrical System Table 8-1 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 98 Section 8 Electrical System Table 8-1 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 99 Section 8 Electrical System Table 8-1 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 100: Softstarter
Section 8 Electrical System Table 8-1 Sensors and Solenoids Component Function Pressure Transducer The optional pressure transducer reads the output pressure from the attenuator in the high pressure system. A signal is sent to the PLC module that allows the operating pressure to be viewed from the control panel.
Page 101: Service And Maintenance Procedures
Section 8 Electrical System DIP Switch Settings DIP switches are used to set the start/stop profile, overload trip class and auxiliary contact characteristics. Open the tab on the top, right of the softstarter to access the eight DIP switches. Table 8-2 illustrates the switch settings, starting from the left. Table 8-2 DIP Switch Settings Number...
Page 102: Proximity Switch Maintenance
Section 8 Electrical System 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, or if the appropriate input is not noted on the PLC processor annunciator light panel in the electrical enclosure.
Page 103: Optical Relay Maintenance
Section 8 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. Optical Relay Maintenance The four optical relays identified in Table 8-3 change the state of the associated solenoid valves.
Page 104 Section 8 Electrical System Figure 8-8: Optical Relays 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 on the system components.
Page 105: High Pressure Water System
SECTION 9 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 106: System Options
Section 9 High Pressure Water System System Options The following system options are available at the time of purchase, or as upgrade kits for existing equipment.  A redundant intensifier allows operation to continue if a problem is detected on the active intensifier.
Page 107: Redundant Intensifiers
Section 9 High Pressure Water System Figure 9-3: High Pressure Cylinder Low pressure water is routed through the inlet water ports to the inlet passages in the sealing heads. When the plunger retracts, the inlet check valve opens to allow water to fill the high pressure cylinder.
Page 108 Section 9 High Pressure Water System When a machine is equipped with redundant intensifiers, operation can continue on the secondary unit if the primary unit requires maintenance. However, maintenance must not be performed while the machine is in operation. Maintenance must never be performed on any high pressure components while the machine is operating.
Page 109: System Components
Section 9 High Pressure Water System System Components The following figures illustrate the individual high pressure water system components. NOTE System components, specifications, and some maintenance procedures are determined by the horsepower rating and/or plunger diameter. The information in this section is organized and presented accordingly. Figure 9-4: High Pressure Cylinder Assembly Figure 9-5: Hydraulic Cylinder Assembly 20412997...
Page 110: 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 12, Parts List for a complete listing of replacement parts and part numbers.
Page 111: Torque Specifications
Section 9 High Pressure Water System Torque Specifications Table 9-1, Torque Specifications, details the torque specifications and tightening sequences for the high pressure components and connections. Table 9-1 Torque Specifications High Pressure Water System 7/8” Diameter Plunger 1-1/8” Diameter Plunger Hard Seal End Cap Jackbolts 6 (7/16”) each...
Page 112 Section 9 High Pressure Water System Table 9-1 Torque Specifications High Pressure Water System 7/8” Diameter Plunger 1-1/8” Diameter Plunger Proximity Switch Socket Head Screws 2 (M6) each 2 (1/4”) each Torque 140-160 in-lbs (16-18 Nm) 140-160 in-lbs (16-18 Nm) Hex Key 3/16 inch Topworks Support...
Page 113: 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 9-7, Specialized Maintenance Tools, and part numbers are provided in Table 9-2.
Page 114: 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 115: High Pressure Cylinder Assembly Removal
Section 9 High Pressure Water System High Pressure Cylinder Assembly Removal Prior to removing electrical power or any high or low pressure piping, start the machine from the Maintenance Screen on the control panel. The machine will start in recirculation mode; the dump valve will open and relieve the high pressure in the system.
Page 116: High Pressure Cylinder Assembly Installation
Section 9 High Pressure Water System Figure 9-8: 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 117: High Pressure Cylinder Maintenance
High Pressure Water System NOTE An alignment mark is located on the hydraulic cylinder head under the KMT logo. To ensure the high pressure cylinder is properly tightened and fully seated in the hydraulic cylinder head, it is recommended that a corresponding mark be placed on the high pressure cylinder after installation.
Page 118: Hard Seal End Caps
High Pressure Water System 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 from the Maintenance Screen on the control panel.
Page 119: Hard Seal End Cap Installation
Section 9 High Pressure Water System Hard Seal End Cap Installation 7/8” Diameter Plunger 1-1/8” Diameter Plunger Apply FML-2 grease to the two o-rings Apply FML-2 grease to the two o-rings and verify they are properly installed in and verify they are properly installed in the inside diameter grooves of the HSEC.
Page 120: Sealing Head
Section 9 High Pressure Water System Sealing Head The sealing head is sealed to the outboard end of the high pressure cylinder by a metal-to-metal compression seal. The pre-loading jackbolts in the hard seal end cap hold the sealing head against the end of the cylinder.
Page 121 Section 9 High Pressure Water System 5. Inspect the poppet pin for wear and replace the pin if worn. 6. Inspect both faces of the seat for damage or cracking. A cracked or damaged seat must be replaced. The seat can be installed with either face toward the discharge poppet. If one face is worn, but the opposite is not, the seat can be reversed, placing the new surface toward the poppet.
Page 122: Low Pressure Inlet Check Valve
Section 9 High Pressure Water System Low Pressure Inlet Check Valve The inlet check valve components differ, depending on the plunger diameter. See Figure 9-12, Low Pressure Inlet Check Valve. Figure 9-12: Low Pressure Inlet Check Valve 7/8” Plunger 1-1/8” Plunger The inlet check valves should be serviced on a regular, preventive maintenance schedule.
Page 123: 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 124: High Pressure Seal Assembly
Section 9 High Pressure Water System 9.10 High Pressure Seal Assembly The following procedure should be used to replace the high pressure seal assembly. Seal components differ slightly, depending on the plunger diameter. See Figure 9-13, High Pressure Seal Assembly. Figure 9-13: High Pressure Seal Assembly 7/8”...
Page 125 Section 9 High Pressure Water System 2. Disconnect the high and low pressure water piping, following the procedure, High and Low Pressure Water Piping. 3. Remove the high pressure cylinder assembly, following the procedure, High Pressure Cylinder Assembly Removal. Figure 9-14: High Pressure Seal Removal 4.
Page 126: Hydraulic Cartridge Seal And Plunger Removal
Section 9 High Pressure Water System 8. Remove the cylinder liner from the bore and inspect for possible heat or wear damage, or for debris. If cracks or brittleness are detected on the tabs on the ends of the liner, the liner must be replaced.
Page 127 Section 9 High Pressure Water System 4. Remove the high pressure cylinder assembly, following the procedure, High Pressure Cylinder Assembly Removal. 5. Use a flat screwdriver to remove the retaining ring from the hydraulic cylinder head. 6. Remove the bushing retainer flange and clean the surfaces, weep holes and grooves. Check the retainer flange for cracks.
Page 128: 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 9-17: Plunger...
Page 129: Hydraulic Cartridge Seal
Section 9 High Pressure Water System Hydraulic Cartridge Seal Installation Seals in the hydraulic cartridge can be removed and replaced, or the complete cartridge can be replaced. Seal components differ slightly, depending on the plunger diameter. See Figure 9-18, Hydraulic Cartridge Seal. Use caution during the removal and installation of the seal components to avoid scratching the surface of the cartridge.
Page 130: Hydraulic Piston
Section 9 High Pressure Water System 8. Thoroughly clean the bushing retainer flange, including the cross-drilled weep holes. Install the retainer flange over the plunger. 9. Install the retaining ring, ensuring the retaining ring fully seats inside the groove in the hydraulic cylinder head.
Page 131: Hydraulic Piston Removal
Section 9 High Pressure Water System Hydraulic Piston Removal The following procedure is used to remove the hydraulic piston. 1. Turn the machine off and observe the appropriate Lockout/Tagout procedures. Severe injury can result if the machine is not properly locked out. Observe electrical Lockout/Tagout procedures before proceeding.
Page 132: Bearing Rings And Seal Assembly
Section 9 High Pressure Water System 7. Remove the hydraulic cylinder head with the o-ring and backup ring. The mounting flat for the proximity switch provides a small lip for loosening the cylinder head. 8. Grasp the plunger firmly and pull the piston out of the hydraulic cylinder. Bearing Rings and Seal Assembly 1.
Page 133: Internal Check Valves
Section 9 High Pressure Water System 3. Remove the plunger button o-ring and backup ring from each plunger socket. Take care not to scratch or damage the seal groove surfaces. 4. Clean and inspect the seal grooves for residue buildup or surface marks that could cause seal leaks.
Page 134: Hydraulic Piston Installation
Section 9 High Pressure Water System Hydraulic Piston Installation 1. Ensure that the hydraulic cylinder bore is free of grit or contamination. 2. Lubricate the bearing rings and seal assembly, and lightly lubricate 2-3 inches of the cylinder bore with FML-2 grease. Figure 9-22: Hydraulic Piston Installation 3.
Page 135: Hydraulic Cylinder Maintenance
9.14 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 136: High Pressure Dump Valve
Section 9 High Pressure Water System 9.15 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 SL-V 30, 50 and 60 are equipped with a round, three port dump valve assembly.
Page 137 Section 9 High Pressure Water System Severe injury can result if the machine is not properly locked out. Observe electrical Lock Out/Tag Out procedures before proceeding. Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding. 1.
Page 138 Section 9 High Pressure Water System Figure 9-25: 3-Port Dump Valve Components 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.
Page 139 Section 9 High Pressure Water System 11. Place the seal positioning tool into the opposite end of the valve body as shown in Figure 9-26, Valve Seal Installation. Thread the high pressure adapter into the valve body until light contact is made with the positioning tool. Tighten finger-tight only. 12.
Page 140: 2-Port Pneumatic Control Dump Valve (Sl-V 100)
Section 9 High Pressure Water System 18. Remove the high pressure adapter and the seal positioning tool. 19. Apply Pure Goop anti-seize compound to the threads of the actuator and carefully thread it into the valve body, guiding the stem head into the hole in the actuator. Turn the actuator clockwise until resistance is felt.
Page 141 Section 9 High Pressure Water System Figure 9-28: 2-Port High Pressure Dump Valve 3. Loosen and remove the high pressure gland connection and the drain connection. 4. Remove the valve and actuator assembly from the machine. Figure 9-29: 2-Port Dump Valve Components 5.
Page 142 Section 9 High Pressure Water System Figure 9-30: Valve Seal Installation 11. Place the seal positioning tool into the end of the valve body as shown above. Thread the high pressure bushing into the valve body until light contact is made with the positioning tool.
Page 143 Section 9 High Pressure Water System Figure 9-31: Valve Stem Placement 18. Remove the high pressure bushing and the seal positioning tool. 19. Apply Pure Goop anti-seize compound to the threads of the actuator and carefully thread it into the valve body, guiding the stem head into the hole in the actuator. Turn the actuator clockwise until resistance is felt.
Page 144: Pneumatic Actuator
Section 9 High Pressure Water System Pneumatic Actuator The following procedure is used to service the pneumatic actuator. Figure 9-32: 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 145: 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 146 Section 9 High Pressure Water System Table 9-3 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 147 Section 9 High Pressure Water System Table 9-3 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 148: Troubleshooting
SECTION 10 TROUBLESHOOTING 10.1 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 boosted water temperature Booster pump pressure drop is greater than 30 psi (2 bar) during stroke condition Outlet booster pump pressure is falling below 60 psi (4 bar) Inlet water flow is poor and the filter housing is not filling completely Water is leaking around the cap nut on the filter head...
Page 149: 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 150 Section 10 Troubleshooting Table 10-1 SL-V Series Troubleshooting Guide Malfunction Indication Comments High oil temperature Oil-to-Water Models resulting in shutdown Cooling water flow is Check cooling water source for restricted proper temperature and flow rate. Water modulating valve is Replace the valve. stuck open or closed Scale build up in the heat The heat exchanger will need to...
Page 151 PLC failure If there are inputs from the proximity switches, but no outputs, contact the KMT Customer Service Department for a logic review and verification of PLC failure. Erratic fluctuations in the...
Page 152 Section 10 Troubleshooting Table 10-1 SL-V Series Troubleshooting Guide Malfunction Indication Comments Pump will not start Emergency stop button is Pull the e-stop button out. depressed Check all remote e-stop buttons. Main power is disconnected Check the main power and verify that the main power disconnect is on.
Page 153 Section 10 Troubleshooting Table 10-1 SL-V Series Troubleshooting Guide Malfunction Indication Comments Pump quits running Unsafe operation has been Check the display panel for fault detected messages. Electrical power has been Check the power supply circuit interrupted for a tripped breaker. Check the input and output of the 24 volt DC power supply.
Page 154 Section 10 Troubleshooting Table 10-1 SL-V Series Troubleshooting Guide Malfunction Indication Comments Red light on operator’s An alarm condition has Check the display panel for fault console is flashing occurred messages. Refer to Section 4, Operation, for additional information regarding warning and alarm conditions and recovery procedures.
Page 155 Section 10 Troubleshooting Table 10-1 SL-V Series Troubleshooting Guide Malfunction Indication Comments Hot surfaces on the high Leaking discharge check Inspect the condition of the seat, pressure cylinder valve poppet valve, spring, poppet pin components and sealing head surface on the discharge end of the sealing heads.
Page 156 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 157 Section 10 Troubleshooting Table 10-1 SL-V Series 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 158 Section 10 Troubleshooting Table 10-1 SL-V Series 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 cone seal surface. If end cap detected, polish to remove following the procedure, High Pressure Cylinder Maintenance, detailed in Section 9, High...
Page 159: Softstarter
Section 10 Troubleshooting 10.3 Softstarter A flashing red LED indicates a fault, either internal to the softstarter, or with the incoming power or motor. The number of flashes in sequence indicates the fault. Table 10-2 Softstarter Troubleshooting Guide Pre-start LED off Check control power Motor fails to start connections and the power...
Page 160 Section 10 Troubleshooting Table 10-2 Softstarter Troubleshooting Guide Motor stops inadvertently LED off Check control power and fails to start connections and the power source to the softstarter. LED on Check isolation contactor for proper closure. Check presence of line power. LED flashing one time;...
Page 161: Specifications
SECTION 11 SPECIFICATIONS 11.1 Overview A comprehensive listing of specifications for the SL-V Plus models listed in Table 11-1 are provided in this section. Table 11-1 SL-V Plus Models Motor Horsepower Rating Model SL-V 30 SL-V 50 SL-V 60 SL-V 100 11.2 Installation Specifications Environment Installation location...
Page 162: Sound Level
Section 11 Specifications Sound Level 30 HP 50 HP 60 HP 100 HP Sound level [dB(A)] 72.5 72.5 77.5 77.5 Equipment Dimensions and Weights Horsepower Length Width Height Weight 30 HP 67.98” (1,727 mm) 36.00” (914 mm) 57.19” (1,453 mm) 1,920 lbs (870 kg) 50 HP 67.98”...
Page 163: Plant Air
Section 11 Specifications Plant Air The facility compressed air connection should provide clean, dry air regulated to 85 psi (5.9 bar). Air usage is minimal, normally less than 1 scf/m. The following table provides specifications for each ISO air quality classification. recommends adherence to Quality Class 4.
Page 164: Cooling Water Supply
Section 11 Specifications Cooling Water Supply (Recirculation System) 30 HP 50 HP 60 HP 100 HP Reservoir capacity 40 gal (151 L) 40 gal (151 L) 40 gal (151 L) 48 gal (182 L) Low oil level shutdown 28 gal (106L) 28 gal (106L) 28 gal (106L) 37 gal (140 L) Maximum consumption at 75...
Page 165: Water Quality Standards
Section 11 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 166 Section 11 Specifications Table 11-4 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 167: Electrical Specifications
Section 11 Specifications 11.4 Electrical Specifications Electrical System Motor type TEFC (Totally Enclosed Fan Cooled) Controls Voltage 24 volts DC Power supply 10 amps DC Ampacity and Power Voltage Requirements Motor Circuit Breaker Power Voltage Horsepower Full Load Amps Amps 208/3/60 230/3/60 400/3/50...
Page 168: Hydraulic And High Pressure Water System Specifications
Section 11 Specifications Ampacity and Power Voltage Requirements Motor Circuit Breaker Power Voltage Horsepower Full Load Amps Amps 460/3/60 575/3/60 11.5 Hydraulic and High Pressure Water System Specifications Hydraulic System 30 HP 50 HP 60 HP 100 HP Maximum operating pressure 3,000 psi (207 bar) 2,600 psi (179 bar) Main system relief valve...
Page 169: Orifice Capacity
Section 11 Specifications Orifice Capacity The following tables provide horsepower requirements for some of the more popular orifices. Table 11-5 Single Orifice Diameter Motor Horsepower Maximum Maximum Single Rating Operating Orifice Diameter Model Pressure (at full pressure) SL-V 30 0.010 inch (0.254 mm) SL-V 50 0.013 inch (0.330 mm) 60,000 psi...
Page 170 Section 11 Specifications Table 11-6 Horsepower Requirements Orifice Size 45,000 psi 50,000 psi 55,000 psi 60,000 psi inches (mm) (3,103 bar) (3,447 bar) (3,792 bar) (4,137 bar) 0.020 (0.508) 73.9 86.6 99.9 113.8 0.021 (0.533) 81.5 95.4 110.1 125.5 0.022 (0.559) 89.4 104.8 120.9...
Page 171: Torque Specifications
Section 11 Specifications 11.6 Torque Specifications Measurements are made with lubricated components and a certified, calibrated torque wrench. Inconsistencies in wrench settings, lubrication and technique may not produce a leak free seal. If leakage occurs, the torque can be increased to seal the components. However, do not exceed the recommended torque value by more than 15 percent.
Page 172 Section 11 Specifications Torque Specifications 7/8 inch (22 mm) 1-1/8 inch (29 mm) Diameter Plunger Diameter Plunger Hydraulic Cylinder Head Socket Head Screws 8 (14M) each 6 (3/4”) each Torque 75-80 ft-lbs (102-108 Nm) 170-175 ft-lbs (230-237 Nm) Hex Key 5/8 inch Proximity Switch Socket Head Screws...
Page 173: 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...
Page 174: Index
Section 12 Parts List 12.2 Index Part lists are arranged in the following sequence: Parts List Index Part Part Table Description Number Page Table Description Number Page 12-1 100 HP Intensifier Unit 12-4 12-13 Reservoir Assembly 05104153 12-26 12-2 Intensifier Assembly 72122493 12-6 12-14...
Page 175 Section 12 Parts List Parts List Index Part Part Table Description Number Page Table Description Number Page 12-23 High Pressure Tube Coning Tools 12-48 12-32 Autoline™ Abrasive Nozzle Assembly 12-65 12-24 High Pressure Tube Threading Tools 12-49 12-33 Autoline II™ Abrasive Nozzle Assembly 12-66 12-25 Maintenance Tools and Lubricants...
Page 176 Section 12 Parts List Table 12-1 SL-V 100 Horsepower Intensifier Unit Part Item Number Description Quantity 20429831 High Pressure Piping Assembly 49830938 Electrical Assembly 20431316 Redundant Kit (Optional) 20461179 Decal Package, 100 Horsepower Single 05128087 Startup Tag 80079668 Bulkhead Pipe Assembly 05141569 Frame Assembly 05104153...
Page 177 Section 12 Parts List Figure 12-1: SL-V 100 Horsepower Intensifier Unit 20413146 8-2012/Rev 12 12-5...
Page 178 Section 12 Parts List Table 12-2 Intensifier Assembly 72122493 Part Part Item Number Description Quantity Item Number Description Quantity 72119536 HP Cylinder 05120092 Backup Ring, 5.25 x 5.50 05144506 Ceramic Plunger 10074771 O-Ring, 5.25 x 5.50 x .13 72110979 Sealing Head Assembly 20413955 Socket Head Screw, 3/4-16 x 3-1/4 20416445...
Page 179 Section 12 Parts List Figure 12-2: Intensifier Assembly 20413146 8-2012/Rev 12 12-7...
Page 180 Section 12 Parts List Table 12-3 Hydraulic Cartridge Seal 05146584 Part Part Item Number Description Quantity Item Number Description Quantity 05144530 Seal Bushing 10168912 O-Ring, 1.25 x 1.38 x .06 10142032 Packing Ring, 1.38 x 1.13 x .25 05116124 O-Ring, 1.50 x 1.63 x .06 10145431 O-Ring, 1.44 x 1.63 x .09 05116132...
Page 181 Section 12 Parts List Table 12-4 Sealing Head Assembly 72110979 Part Part Item Number Description Quantity Item Number Description Quantity 72110961 Sealing Head Body 05116603 Discharge Poppet Valve 72112002 Inlet Poppet Valve 72106104 Button Head Screw, 8-32 x 3/8 05116595 Gland Nut 05147863 Compression Spring...
Page 182 Section 12 Parts List Table 12-5 Pneumatic Valve/Actuator Assembly, Normally Open 10184760 Part Part Item Number Description Quantity Item Number Description Quantity 10189181 Valve Body 10189553 Actuator Assembly, Normally Open 10178697 Valve Seat BV401184 Pneumatic Cylinder 20435636 Valve Stem BV601184 Cylinder Head 10188233 Backup Ring, Brass...
Page 183 Section 12 Parts List Figure 12-5: Pneumatic Valve/Actuator Assembly, Normally Open 20413146 8-2012/Rev 12 12-11...
Page 184 Section 12 Parts List Table 12-6 Hydraulic Piston Assembly 05146576 Part Item Number Description Quantity 05144589 Hydraulic Ram Piston 05074380 Plunger Retainer Pin, Clevis 05049887 Set Screw, Socket, 3/8-16 x 3/8 10148757 Check Valve 49877509 Adhesive, Thread Locker 05130216 Flat Snap Ring, .032 x .375 x 2.20 05146568 Backup Ring, 1.50 x 1.75 x .125 10074821...
Page 185 Section 12 Parts List Figure 12-6: Hydraulic Piston Assembly 20413146 8-2012/Rev 12 12-13...
Page 186 Section 12 Parts List Table 12-7 High Pressure Piping 20429831 Part Part Item Number Description Quantity Item Number Description Quantity 72122493 Intensifier Assembly 10184760 Pneumatic Valve/Actuator Assembly 20413237 Attenuator Assembly 10078608 HP Gland, .56 05144837 Spacer, Attenuator Bracket 10079580 Bushing, HP, .56 x .25 10079465 Tee, HP, .56 05086905...
Page 187 Section 12 Parts List Figure 12-7: High Pressure Piping 20413146 8-2012/Rev 12 12-15...
Page 188 Section 12 Parts List Table 12-8 Low Pressure Water Filter Assembly 80087976 Part Part Item Number Description Quantity Item Number Description Quantity 05070982 Relief Valve, 50-150 psi 05135652 Check Valve 49838386 Pipe Nipple, .75 x 4.0 49833882 Adapter, Hose/ORB, .50 x .50 10119253 Elbow, Pipe, .50 x .50 95838314...
Page 189 Section 12 Parts List Figure 12-8: Low Pressure Water Filter Assembly 20413146 8-2012/Rev 12 12-17...
Page 190 Section 12 Parts List Table 12-9 Hydraulic Power Package 49835846 Part Part Item Number Description Quantity Item Number Description Quantity 80076458 Motor/Pump Assembly, 100 HP 10091510 Arrow Decal 05103411 Adapter, Water Pump 20437206 Directional Control Valve, 24V DC 95572897 Hex Head Screw, 1/4-20 x 5/8 95055059 Socket Head Screw, 1/2-13 x 2-1/2 95838314...
Page 191 Section 12 Parts List Figure 12-9: Hydraulic Power Package 20413146 8-2012/Rev 12 12-19...
Page 192 Section 12 Parts List Table 12-10 Motor/Pump Assembly 80076458 Part Part Item Number Description Quantity Item Number Description Quantity 10075877 Hex Head Screw, 3/4-10 x 2-3/4 05103247 Socket Head Screw, 1/2-13 x 6 95688735 Lock Washer, .75 95688750 Lock Washer, .50 05103205 Motor Mount 49882087...
Page 193 Section 12 Parts List Figure 12-10: Motor/Pump Assembly 20413146 8-2012/Rev 12 12-21...
Page 194 Section 12 Parts List Table 12-11 Hydraulic Manifold Assembly 72112043 Part Item Number Description Quantity 72112035 Hydraulic Manifold 10187417 O-Ring, 1.50 x 1.69 x .09 05071055 Plug, ORB, .75 05103189 Check Valve 49876089 Adapter, JIC/ORB, .25 x .25 49889769 Plug, ORB, .25 20413146 8-2012/Rev 12 12-22...
Page 195 Section 12 Parts List Figure 12-11: Hydraulic Manifold Assembly 20413146 8-2012/Rev 12 12-23...
Page 196 Section 12 Parts List Table 12-12 Hydraulic Hose Connections 05142351 Part Part Item Number Description Quantity Item Number Description Quantity 05106950 Hydraulic Hose Assembly, .75 x 19.0 05112750 Hydraulic Hose Assembly, .25 x 26.0 05106968 Hydraulic Hose Assembly, 1.25 x 26.50 05051214 Hydraulic Hose Assembly, .25 x 39.0 05106976...
Page 197 Section 12 Parts List Figure 12-12: Hydraulic Hose Connections 20413146 8-2012/Rev 12 12-25...
Page 198 Section 12 Parts List Table 12-13 Reservoir Assembly 05104153 Part Part Item Number Description Quantity Item Number Description Quantity 20444146 Reservoir Weldment 95829248 Hex Head Screw, 5/16-18 x 1 72118430 Gasket, Reservoir 20424011 Adapter, JIC/ORB, 1.25 x 1.25 05050026 Temperature/Level Switch 05079967 Gasket, Oil Sensor 05092739...
Page 199 Section 12 Parts List Figure 12-13: Reservoir Assembly 20413146 8-2012/Rev 12 12-27...
Page 200 Section 12 Parts List Table 12-14 Bulkhead Pipe Assembly 80079668 Part Part Item Number Description Quantity Item Number Description Quantity 49887011 Adapter, JIC/Pipe, .50 x .50 49830714 Adapter, Hose/Pipe, .25 x .25 10091866 Water Modulating Valve 95157418 Adapter, JIC/Pipe, .50 x .50 05060207 Pipe Nipple, .50 x 5.0 49834302...
Page 201 Section 12 Parts List Table 12-14 Bulkhead Pipe Assembly 80079668 Part Part Item Number Description Quantity Item Number Description Quantity 49831480 Grommet, Rubber, 3.0 49868813 Temperature Sensor 05142062 Pressure Switch, 60 psi 20453730 Check Valve 20413146 8-2012/Rev 12 12-29...
Page 202 Section 12 Parts List Figure 12-14: Bulkhead Pipe Assembly 20413146 8-2012/Rev 12 12-30...
Page 204 Section 12 Parts List Table 12-15 Cover Assembly 80074768 Part Item Number Description Quantity 80074750 Support Assembly 80074735 Multi-Pin Hinge 80074727 Cover, Top 49834708 Cover, Left End 49834690 Cover, Right End 49837511 Mounting Bracket 49837529 Mounting Bracket 49837503 Spring, Gas 49837743 Button Head Screw, 3/8-16 x 1.0 05091988...
Page 205 Section 12 Parts List Figure 12-15: Cover Assembly 20413146 8-2012/Rev 12 12-32...
Page 206 Section 12 Parts List Table 12-16 Electrical Assembly 49830938 Part Part Item Number Description Quantity Item Number Description Quantity 05148531 Harness, Sensor/Solenoid Cable 05113923 Ring Terminal, #6 10098804 Flexible Conduit Connector, 2.0 95716890 Lock Washer, .50 80080237 Terminal Lug, #14-2/0 10125912 Cable Tie, .87 10098788...
Page 207 Section 12 Parts List Figure 12-16: Electrical Assembly 20413146 8-2012/Rev 12 12-34...
Page 208 Section 12 Parts List Table 12-17 Controls Subassembly 80077845 Part Part Item Number Description Quantity Item Number Description Quantity 10176410 Wire, #16, Blue 3000.0" 20416825 Illuminated Operator 10170165 Wire, #16/1 MM 2, Green/Yellow 190.0" 05140637 Contact Block 05032420 Terminal Block, #24-#12 10149094 Pilot Light, Green 10103034...
Page 209 Section 12 Parts List Table 12-17 Controls Subassembly 80077845 Part Part Item Number Description Quantity Item Number Description Quantity Not used on this assembly 05140157 Panelview Display, 550 20463222 Electrical Enclosure 05115134 End Barrier, 3 Level Terminal Block Not used on this assembly 49833411 Selector Switch, Keyed, 2 Position 10170157...
Page 210 Section 12 Parts List Figure 12-17: Controls Subassembly 20413146 8-2012/Rev 12 12-37...
Page 212 Table 12-18 Control Panel Configuration Wye-Delta 80074156 Part Part Item Number Description Quantity Item Number Description Quantity 80077894 Circuit Breaker, 175A, 600V 05019898 Wire, #14, Black 90.0” 05031620 Socket Head Screw, 10-32 x 1-3/4 05019617 Connector, Crimp Ferrule, #14/2.5 MM 80080377 Rotary Drive, Circuit Breaker, AB, 250A 05140686...
Page 213 Section 12 Parts List Figure 12-18: Control Panel Configuration – Wye-Delta 20413146 8-2012/Rev 12 12-39...
Page 214 Section 12 Parts List Table 12-19 Control Panel Configuration Softstart 20493065 Part Part Item Number Description Quantity Item Number Description Quantity 20434991 Circuit Breaker, 150A, 600V 05095609 Ground Lug 05031620 Socket Head Screw, 10-32 x 1-3/4 95423620 Hex Head Screw, 5/16-18 x 3/4 80080377 Rotary Drive, Circuit Breaker, AB, 250A 10170140...
Page 215 Section 12 Parts List Figure 12-19: Control Panel Configuration – Softstart 20413146 8-2012/Rev 12 12-41...
Page 216 Section 12 Parts List Table 12-20 Proportional Pressure Control 80075732 Part Item Number Description Quantity 80071087 Hydraulic Solenoid Valve, 24V, Cartridge 49867104 Cable, #18, 4 Conductor 96.0” 10067205 Cable Connector, .50 10176410 Wire, #16, Blue 100.0” 10185395 Connector, Crimp Ferrule, #16 20413146 8-2012/Rev 12 12-42...
Page 217 Section 12 Parts List Figure 12-20: Proportional Pressure Control 20413146 8-2012/Rev 12 12-43...
Page 218 Section 12 Parts List Table 12-21 High Pressure Transducer 20431959 Part Item Number Description Quantity 10069326 HP Tube, .56 x 4.0 10079465 Tee, HP, .56 20412627 HP Tube, .56 x 11.50 10079580 Bushing, HP, .56 x .25 05071782 HP Tube, Bent, .25 49838478 Pressure Transducer, 0-75,000 psi 10067205...
Page 219 Section 12 Parts List Figure 12-21: High Pressure Transducer 20413146 8-2012/Rev 12 12-45...
Page 220 Section 12 Parts List Table 12-22 Redundant Kit 20431316 Part Part Item Number Description Quantity Item Number Description Quantity 72122493 Intensifier Topworks, HSEC 05112057 HP Tube, .56 x 4.97 05111406 Adapter, JIC/Pipe, .50 x .25 10078525 Elbow, HP, .56 x .56 80079536 Hydraulic Hose Assembly, 1.0 x 36.0 10079465...
Page 221 Section 12 Parts List Figure 12-22: Redundant Kit 20413146 8-2012/Rev 12 12-47...
Page 222 Section 12 Parts List Table 12-23 High Pressure Coning Tools Part Item Number Description 05108832 Hand Coning Tool Assembly, .25 Figure 12-23: High Pressure Coning Tools 05108857 Hand Coning Tool Assembly, .38 Hand Coning Tool Assembly 05108840 Hand Coning Tool Assembly, .56 05109897 Power Coning Tool Assembly, .25 05109889...
Page 223 Section 12 Parts List Table 12-24 High Pressure Threading Tools Part Item Number Description 05108865 Hand Threading Tool Assembly, .25 Figure 12-24: High Pressure Threading Tools 05108873 Hand Threading Tool Assembly, .38 Hand Threading Tool Assembly 05108881 Hand Threading Tool Assembly, .56 05122742 Power Threading Tool Assembly, .25 05120258...
Page 224 Section 12 Parts List Table 12-25 Maintenance Tools and Lubricants Part Item Number Description 20477460 Plunger Removal Tool, .88 Plunger Figure 12-25: Maintenance Tools and Lubricants 20477469 Plunger Removal Tool, 1.13 Plunger Maintenance Tools 20484961 Vee Block Cradle 05066139 Cylinder Wrench 80079239 End Cap Wrench, HSEC, 6x/8x 80078330...
Page 225 Section 12 Parts List Table 12-25 Maintenance Tools and Lubricants Part Item Number Description 20470475 Seal Tool Kit, Pneumatic Control Valves Seal Tool Kit, Pneumatic Control Valves 20470417 Seal Installation Tool 05067350 Seal Positioning Tool, NO/NC Valves, 2-Port Dump Valve 49833114 Seal Positioning Tool, Quick Release Valve, 3-Port Dump Valve 20470413...
Page 226 Section 12 Parts List Table 12-26 Focusing Tubes Part Number Description 05147889 R-100 0.018” (0.457 mm) x 2.00” (50.8 mm) Figure 12-26: Focusing Tubes 10139426 R-100 0.021” (0.533 mm) x 2.00” (50.8 mm) R-100 Focusing Tubes 20451227 R-100 0.021” (0.533 mm) x 3.13” (79.4 mm) 20452309 R-100 0.025”...
Page 227 Section 12 Parts List Table 12-26 Focusing Tubes Part Number Description 05097928 R-500 0.021” (0.533 mm) x 2.00” (50.8 mm) R-500 Focusing Tubes 05105366 R-500 0.043” (1.092 mm) x 2.75” (69.9 mm) 05097944 R-500 0.030” (0.762 mm) x 3.13” (79.4 mm) 05116652 R-500 0.036”...
Page 228 Section 12 Parts List Table 12-27 Standard Sapphire Orifice Part Part Part Number Description Number Description Number Description A2260001 0.001” (0.025 mm) A2260009 0.009" (0.229 mm) A2260018 0.018" (0.457 mm) Figure 12-27: Standard Sapphire Orifice A2260002 0.002” (0.051 mm) A2260010 0.010"...
Page 229 Section 12 Parts List Table 12-29 High Pressure Water Filter Assemblies Part Item Number Description Quantity 05114137 Inline Water Filter, .25 Figure 12-29: High Pressure Water Filter Assemblies 05114129 Filter Body HP Inline Water Filter, .25 05114152 Retainer, Filter Element 05110531 Filter Element 05114145...
Page 230 Section 12 Parts List Table 12-29 High Pressure Water Filter Assemblies Part Item Number Description Quantity BF103473 Inline Water Filter, .56 HP Inline Water Filter, .56 AF413972 HP Gland, Outlet AF303473 Seal Head, Outlet AF503473 Filter Element BF203473 Filter Body AF913972 HP Gland, Inlet 10074599...
Page 231 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity CJ211388 HP Swivel Joint, Straight, .25, M/F Figure 12-30: High Pressure Swivel Joints 10084713 Thrust Needle Bearing HP Swivel Joint, Straight, M/F Connection, .25 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8...
Page 232 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity CJ218088 HP Swivel Joint, Straight, .25, F/F HP Swivel Joint, Straight, F/F Connection, .25 10084713 Thrust Needle Bearing 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8 10154680 Clamp Collar CJ318088...
Page 233 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity 10134708 HP Swivel Joint, Straight, .38, M/F HP Swivel Joint, Straight, M/F Connection, .38 10084713 Thrust Needle Bearing 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8 10134716 Swivel Body CJ401288...
Page 234 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity CJ201288 HP Swivel Joint, 90D, .25, M/F HP Swivel Joint, 90D, M/F Connection, .25 10084713 Thrust Needle Bearing 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8 DJ301288 Swivel Body CJ401288...
Page 235 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity CJ218188 HP Swivel Joint, 90D, .25, F/F HP Swivel Joint, 90D, F/F Connection, .25 10084713 Thrust Needle Bearing 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8 10154680 Clamp Collar CJ318088...
Page 236 Section 12 Parts List Table 12-30 High Pressure Swivel Joints Part Item Number Description Quantity 10134682 HP Swivel Joint, 90D, .38, M/F HP Swivel Joint, 90D, M/F Connection, .38 10084713 Thrust Needle Bearing 10094647 Thrust Washer 10103505 Setscrew, 6-32 x 1/8 10134690 Swivel Body CJ401288...
Page 237 Section 12 Parts List Table 12-31 Nozzle Tubes Part Part Number Description Number Description Actual Nominal Actual Nominal in (mm) in (mm) in (mm) in (mm) 10181113 2.65 (67.31) 3.00 (76.20) 10138451 8.65 (219.71) 9.00 (228.60) Figure 12-31: Nozzle Tubes 10138402 3.65 (92.91) 4.00 (101.60)
Page 238 Section 12 Parts List Table 12-31 Nozzle Tubes Part Part Number Description Number Description Actual Nominal Actual Nominal in (mm) in (mm) in (mm) in (mm) 10138477 2.65 (67.31) 3.00 (76.20) 10138527 7.65 (194.31) 8.00 (203.20) .56 Nozzle Tube, Nozzle Nut Connection 10138485 3.65 (92.91) 4.00 (101.60)
Page 239 Section 12 Parts List Table 12-32 Autoline™ Abrasive Nozzle Assembly Part Item Number Description Quantity 05078530 Autoline Nozzle Assembly, .030 Wear Insert Figure 12-32: Autoline™ Abrasive Nozzle Assembly 05147970 Autoline Nozzle Assembly, .043 Wear Insert 05076971 Nozzle Cap 05073820 Nozzle Body 05076955 Wear Insert, .030 x .156 05135827...
Page 240 Section 12 Parts List Table 12-33 Autoline™ II Abrasive Nozzle Assembly Part Item Number Description Quantity 20453949 Autoline II Nozzle Assembly, .030 Wear Insert Figure 12-33: Autoline™ II Abrasive Nozzle Assembly 20454108 Autoline II Nozzle Assembly, .043 Wear Insert 20453952 Nozzle Cap 20453958 Nozzle Body...
Page 241 Section 12 Parts List Table 12-34 Autoline™ Sapphire Orifice Part Part Number Description Number Description 05109079 0.007" (0.178 mm) 20412569 0.013” (0.330 mm) Figure 12-34: Autoline™ Sapphire Orifice 05109087 0.008" (0.203 mm) 05109137 0.014" (0.356 mm) 05109095 0.009" (0.229 mm) 20448541 0.016”...
Page 242 Section 12 Parts List Table 12-36 Pneumatic Control Valve, Normally Closed 10138824 Part Item Number Description Quantity 10177855 Pneumatic Actuator Assembly, NC Figure 12-36: Pneumatic Control Valve, NC 10189181 Valve Body BV701184 HP Gland 10188233 Brass Backup Ring 20428052 Seal Assembly 20435636 Valve Stem 10178697...
Page 243 Section 12 Parts List Table 12-37 Pneumatic Actuator Assembly, Normally Closed 10177855 Part Item Number Description Quantity 05145990 Piston Figure 12-37: Pneumatic Actuator Assembly, NC 20411554 Cylinder Cap 10177780 Wiper Seal 10177772 Retaining Ring 10176543 Pneumatic Cylinder 10177806 O-Ring, 2.63 x 2.75 x .06 05054119 Compression Spring, .72 x .105 x 1.50 49895584...
Page 244 Section 12 Parts List Table 12-38 Pneumatic Control Valve, Normally Open 10184760 Part Item Number Description Quantity 10189553 Pneumatic Actuator Assembly Figure 12-38: Pneumatic Control Valve, NO 10189181 Valve Body BV701184 HP Gland Fitting 10188233 Brass Backup Ring 20428052 Seal Assembly 20435636 Valve Stem 10178697...
Page 245 Section 12 Parts List Table 12-39 Pneumatic Actuator Assembly, Normally Open 10189553 Part Item Number Description Quantity BV401184 Pneumatic Cylinder Figure 12-39: Pneumatic Actuator Assembly, NO BV601184 Cylinder Head BV501184 Piston 10187250 SST Backup Ring 10074714 O-Ring, 2.44 x 2.63 x .09 10074565 O-Ring, 2.25 x 2.38 x .06 20413146...
Page 246 Section 12 Parts List Table 12-40 Bulk High Pressure Tubing Part Number Description 10064376 .25 x .083, 20 ft (6.10 m) 10184810 .25 x .083, up to 40 ft (12.19 m) 10064665 .38 x .125, 20 ft (6.10 m) 10061190 .56 x .188, 20 ft (6.10 m) High Pressure Tubing also available coned, threaded and/or autofrettaged Figure 12-40: Bulk High Pressure Tubing Coned/Threaded Both Ends...
Page 247 Section 12 Parts List Table 12-41 High Pressure Fitting and Valve Assemblies Part Part Number Description Number Description 10079028 Coupling, .25 x .25, F/F HP Coupling 10079473 Bushing, .38 x .25, F/M HP Bushing 10079614 Coupling, .38 x .25, F/F 10079432 Bushing, .38 x .25, M/F 10078905...
Page 248 Section 12 Parts List Table 12-41 High Pressure Fitting and Valve Assemblies Part Part Number Description Number Description 10078426 Collar, .25 HP Collar 10116333 Adapter Cone, .25 HP Cone Adapter 10078715 Collar, .38 10078509 Adapter Cone, .38 10079119 Collar, .56 10079291 Adapter Cone, .56 49832686...
Page 249 Section 12 Parts List Table 12-41 High Pressure Fitting and Valve Assemblies Part Part Number Description Number Description 10079259 2 Way Straight, .25 2-Way Straight Valve 10079002 2 Way Angle, .25 2-Way Angle Valve 10078863 2 Way Straight, .35 10078749 2 Way Angle, .38 10078889 2 Way Straight, .56...
Page 261 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 262 • 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 263 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 264 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 265 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 266 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 267 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 268 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 269 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 270 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 271 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 272 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 273 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 274 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 275 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 276 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 277 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 278 (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 279 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 280 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 281 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 282 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 283 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 284 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 285 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 286 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 287 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 288 - 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 289 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 290 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 291 - 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 292 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 293 ___________________________________________________________________________ ___________________ SECTION 14 - TRANSPORT INFORMATION __________________ DOT HAZARDOUS MATERIAL INFORMATION: * Not otherwise DOT regulated. ___________________________________________________________________________ __________________ SECTION 15 - REGULATORY INFORMATION __________________ FEDERAL REGULATIONS: KMT 20461677...
Page 294 Prepared by ... . . : Corporate Regulatory Compliance Date of issue ... . : 07/26/2007 Last Revision Date ..: 11/01/2006 C4302368 ___________________________________________________________________________ KMT 20461677...
Page 295 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 296 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 297 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 298 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 299 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 300 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 301 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 302 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 303 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 304 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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KMT Streamline SL-V Plus series Operation And Maintenance Manual

Appendix

1 Introduction

2 Installation

3 Maintenance

4 Operation

5 Low Pressure Water System

6 Recirculation System

7 Hydraulic System

8 Electrical System

9 High Pressure Water System

10 Troubleshooting

11 Specifications

12 Parts List

Quick Links

Troubleshooting

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