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KMT SL-IV PLUS Series Operation And Service Manual

60 hp treamline high pressure waterjet pump
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STREAMLINE HIGH PRESSURE
WATERJET PUMP
OPERATION and SERVICE MANUAL
SL-IV PLUS
60 HP
Manual No. 80072994
Printed: 12/21/04
80073471.doc

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Antonio Reis
May 23, 2025

Pump PF1 shuts down after a few hours of operation. What can be checked?

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1 comments:
Mr. Anderson
May 25, 2025

If the KMT SL-IV PLUS Series pump PF1 shuts down after a few hours of operation, check the following:

- Ensure the motor is running continuously; if it stops for 2 minutes, the solenoid valve (11) shuts off and must be reset by pressing F6.
- Verify pressure readings:
- Filter pressure drop should not exceed 1 bar (15 psi).
- Booster pump inlet pressure must be above 2 bar (30 psi).
- Booster pump discharge pressure should be between 8.0–8.3 bar (115–120 psi).
- Intensifier LP cutting water supply pressure should be above 4 bar (60 psi).
- Check for pressure fluctuations greater than 2 bar (30 psi) during intensifier direction changes.
- Confirm water temperature at the booster pump outlet is below 128°F.
- Inspect for any leaks and repair them immediately.
- Perform regular maintenance checks on pressures, temperatures, and system components.

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Summary of Contents for KMT SL-IV PLUS Series

  • Page 1 STREAMLINE HIGH PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL SL-IV PLUS 60 HP Manual No. 80072994 Printed: 12/21/04 80073471.doc...
  • Page 2 KMT Waterjet Systems 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 SECTION 1 INTRODUCTION SL-IV Waterjet Pump General Information Physical Description 1.1.1 Standard Equipment Functional Description 1.2.1 Functional Features Worldwide Product Support 1.3.1 Service Department 1.3.2 Spare Parts 1.3.3 Questionnaire Safety 1.4.1 Labels and Abbreviations 1.4.2 Safety Procedures 1.4.3 High Pressure (HP) Piping Safety 1-11...
  • Page 4 SECTION 5 TROUBLESHOOTING Troubleshooting Troubleshooting - Electrical 5.1.1 Pump Will Not Start 5.1.2 Console Display And Lights Fail To Illuminate 5.1.3 Pump Quit Running 5.1.4 No Control Power (24vdc) 5.1.5 Red Light, Message On Operator’s Console Troubleshooting – Hp Water 5.2.1 Hp Water Signal Abnormal Fluctuation 5.2.2...
  • Page 5 7.3.5 Plunger 7-20 7.3.6 Hydraulic Seal Cartridge 7-21 7.3.7 Hydraulic Piston 7-23 7.3.8 Hydraulic Cylinder 7-27 HP Dump Valve 7-28 HP Attenuators 7-28 SECTION 8 ELECTRICAL SYSTEM Electrical System Electrical Overview 8.1.1 Motor Starter Circuit 8.1.2 Control Circuits and Logic 8.1.3 Operation 8.1.4...

  • Page 6: Section 1 Introduction

    SECTION 1 INTRODUCTION SL-IV Waterjet Pump General Information The Streamline SL-IV Waterjet Pump, maintains the level of component reliability and ease of installation and maintenance that have made the Streamline waterjet pumps the standard of the industry for both water and Hydrobrasive™...

  • Page 7: Standard Equipment

    SECTION 1 INTRODUCTION 1.1.1 Standard Equipment Following is an overview of the standard equipment for the SL-IV Waterjet Pump: • Variable displacement, pressure compensated hydraulic pump • Water pressure booster and filtration system with 10-micron double-length filter • High efficiency heat exchanger in independent recirculation pump circuit •...

  • Page 8: Functional Description

    SECTION 1 INTRODUCTION Functional Description The SL-IV Waterjet Pump meets the automotive and industrial markets needs of low to high volume production of water jet pumps. The maximum HP water pressure is limited by a hydraulic relief valve that is factory certified and sealed. No HP rupture disk is required.

  • Page 9: Worldwide Product Support

    Email: wj_service@kmtwaterjet.com Email: order.service@kmt-waterjet.com 1.3.2 Spare Parts KMT Waterjet maintains a well stocked Spare Parts Department staffed by well trained knowledgeable personnel. Emergency shipment is available. Contact the Customer Service Department of KMT Waterjet. 1.3.3 Questionnaire The following equipment and service manual questionnaire will provide information to allow us to serve you better.
  • Page 10 SECTION 1 INTRODUCTION EQUIPMENT AND SERVICE MANUAL QUESTIONNAIRE We have just installed a new SL-IV Waterjet Pump at your location. We are interested in your initial impressions of the unit and its installation. Please take a few moments and answer the following questions. 1.
  • Page 11 SECTION 1 INTRODUCTION Manual Organization 1. Does the table of contents help you find topics easily? Comments: 2. Is the information well organized? Comments: 3. Is the page layout suitable for the material being presented? Comments: Graphics 1. How do you rate the quality and quantity of the photos/illustrations? Comments: Text 1.

  • Page 12: Safety

    SECTION 1 INTRODUCTION Safety Safety procedures and safe practices must be followed during installation, operation, and maintenance of the waterjet pump. In this section we have provided label and sign descriptions used in this manual, as well as recommended safety procedures. 1.4.1 Labels and Abbreviations The following describes hazard classifications of the waterjet pump.
  • Page 13 SECTION 1 INTRODUCTION Rear of Waterjet Pump • HP Water "OUT" • Plant Air "IN" • Cooling Water "IN" • Cooling Water "OUT" • Cutting Water "IN" • Drain 49831878 Page 1-8...

  • Page 14: Safety Procedures

    SECTION 1 INTRODUCTION 1.4.2 Safety Procedures Safety procedures must be observed while working on the pump, or any high pressure part of the installation. Service should only be performed by qualified personnel. • The high pressure water, 4,136 bar (60,000 psi) in waterjet cutting systems should not be a cause for concern.
  • Page 15 SECTION 1 INTRODUCTION Never do any work on the unit without making sure the WARNING electrical panel disconnect is locked out with a padlock in the OFF position. Never work on any high pressure component, or loosen any WARNING high pressure fittings without first bleeding the system and assuring there is no high pressure water present.

  • Page 16: High Pressure (Hp) Piping Safety

    SECTION 1 INTRODUCTION 1.4.3 High Pressure (HP) Piping Safety High pressure piping must be installed without torsional or bending stresses. Proper supports and guides must be provided. 9/16” outside diameter HP tubing and fittings are recommended between the pump and the cutting station.

  • Page 17: Emergency Medical Treatment

    This card is to be carried by personnel working with high pressure waterjet equipment. Obtain medical treatment immediately for ANY high pressure waterjet injuries. KMT Waterjet Systems P.O. box 231, 635 West. 12 Street Baxter Springs, KS 66713 (620) 856-2151...

  • Page 18: Section 2 Installation

    Provide, install and connect wiring between the intensifier pump(s), and the cutting station control system. • KMT Waterjet supplies a pre-filled hydraulic system. If fluid is low or empty due to leakage during transit, the system must be filled per specifications. Seller Obligations If KMT Waterjet Service is requested, the following tasks will be the responsibility of the KMT Waterjet technician at installation.

  • Page 19: Installation Requirements (Utilities)

    Test motor rotation direction and correct if necessary. • Check and test electrical signal connections between intensifier pump and cutting area. • Power up and check out pump (and cutting station, if supplied by KMT Waterjet) for proper operation. • Set booster pump discharge pressure. •...

  • Page 20: Service Connections

    SECTION 2 INSTALLATION Control Wiring: Wiring for remote control of the pump must be in accordance with national and local electrical codes. The SL-IV+ Waterjet Pump has a 24vdc electrical control system and has a connector port for remote operation wiring on the pump control enclosure.
  • Page 21 SECTION 2 INSTALLATION in galling of the parts, and will generally render them unusable. Do not use High Purity Goop on ANYTHING but stainless steel! Drain: Cutting water released in the activation of EMERGENCY STOP will be discharged from the intensifier drain port and must be piped to an appropriate location (i.e.

  • Page 22: High Pressure Plumbing Installation

    SECTION 2 INSTALLATION High-pressure Plumbing Installation HP Tube Coning and Threading Procedures Determine Tube Length - Measure the distance (L) between the fittings, then add two times the tube engagement length in the following table. Cut tubing to length and deburr. High-pressure piping and fittings rated for 4,138 bar (60,000 psi) must be used.
  • Page 23 SECTION 2 INSTALLATION Cone and Thread Tube Cone and thread both ends of the tube per following diagram and procedure. Cone and Thread Dimensions O.D. Size I.D. size D (max) L (max) Thread mm (inch) mm (inch) mm (inch) mm (inch) NF-LH 6.35 (1/4") 2.11 (0.083)
  • Page 24 SECTION 2 INSTALLATION To cone the tubing, use the following figure as reference. Cone and Threading Tool Item Description (1) Cutter Handle (2) Cutter Support (3) Feed Nut (4) Cutting Blades (5) Collet (6) Housing (7) Gland Nut Tube Size (inch) 1/4”...
  • Page 25 SECTION 2 INSTALLATION Coning • Place the appropriate size coning tool in a vise so that lubricant can flow to cutting blades (4). • Set feed nut (3) location as shown in dimension A. • Slide tubing through collet (5) until end contacts cutting blades (4) and tighten gland nut (7) just enough to firmly grip tubing.
  • Page 26 SECTION 2 INSTALLATION HP Tube End Connection - Regular The following type of connection is for general applications, where the only load on tubing is due to internal pressure. 1. Slip the gland nut (2) on the tubing (1) as shown and lubricate the threads with a light coat of High Purity Goop.
  • Page 27 SECTION 2 INSTALLATION HP Tube End Connection - Antivibration The following type of connection must be used when tubing will be subjected to vibration, rotation, movement, and side loads (i.e. whip tubing). Lubricate threads as above. Do not depend on end connection to take the tubing load WARNING 1.1.1.4 alone.

  • Page 28: Section 3 Operation

    Section 3 OPERATION SL-IV PUMP OPERATION- Note: all operational control functions for this KMT Waterjet SL-IV pump are provided by the motion / cutting table / box OEM. For a description of the KMT Waterjet model SL-IV pump sensors and solenoids, see Section 8: ‘Electrical Systems’.
  • Page 29 SECTION 3 OPERATION ● Overstroke (no longer called Leak) shutdown level is adjustable between 30% and 120% of full capacity. The overstroke warning level is automatically set 10% below the shutdown level set by the operator. Overstroke warnings, pending shutdowns and shutdowns are issued in three types, left, right and intensifier.
  • Page 30 SECTION 3 OPERATION (3) Machine equipped with HP transducer-start up after E-stop: same as (1) above. (4) Machine equipped with HP transducer-start up after normal stop: If pressure is allowed to bleed through orifice to below 1,000 psi, dump valve will open and start up will be like (1) above, if pressure is not allowed to bleed, start up will be as (2) above.

  • Page 31: Main Menu

    SECTION 3 OPERATION MAIN MENU Scroll up and down to page through the various screens and press ENTER to select desired screen Run Screens -(4) Start, stop, recirc, recirc time, select high or low pressure, select intensifier if redundant. Run Screens appear according to options. Pressure Control Screens - (2) Increment or decrement pressure setting.
  • Page 32 SECTION 3 OPERATION RUN SCREEN THIS IS THE ONLY SCREEN WITH A MACHINE START FUNCTION START On all screens this indicates start or on. STOP On all screens this indicates stop or off. Pressure When equipped with pressure transducer (Run Screen 2). ALARM In alarm state, the last alarm sensed by machine will be displayed.
  • Page 33 SECTION 3 OPERATION Run Screen ALARMS High Oil temperature – Indicates high hydraulic oil temperature-150º F. High Pressure Warning – Indicates that output pressure is above 64,000 psi or 4,413 BAR. Booster Temperature High – Indicates booster pump water temperature is high and machine shutdown is pending-128º...

  • Page 34: Run Screen 2

    SECTION 3 OPERATION RUN SCREEN 2 RUN SCREEN 3 (REDUNDANT) This screen will be displayed if REDUNDANT button on the SETUP screen is ON. SELECT INT button is used to select intensifier one or two 05146410 p. 3-7...

  • Page 35: Hours

    SECTION 3 OPERATION HOURS Machine can be Stopped from this screen. HOURS This screen displays total machine hours resettable maintenance hours to 9,999,999 for intensifiers 1 and 2. TOTAL HOURS cannot be reset. MAINTENANCE HOURS on intensifiers 1 and 2 can be reset by pressing the RESET MAINT HOURS display button.

  • Page 36: Alarm History Screen

    SECTION 3 OPERATION (EXAMPLE) ALARM HISTORY SCREEN The alarm list stores the last 100 triggered alarms indicating date, time and type of alarm. Scroll up and down to see alarm history. The Alarm History Screen does not have an intensifier STOP function. 05146410 p.

  • Page 37: Pressure Control Screen

    SECTION 3 OPERATION PRESSURE CONTROL SCREEN SET PRESSURE Set pressure to desired setting from 0 to 100 % in 1 % increments. UP arrow to increase pressure, DOWN arrow to decrease pressure. PRESSURE CONTROL SCREENS will not appear if analog module (pressure transducer and/or proportional valve) is not installed on the machine.

  • Page 38: Stroke Rate Screen

    SECTION 3 OPERATION STROKE RATE SCREEN Set STROKE RATE 2 to 4 strokes above normal running rate to shutdown machine in case of overstroke condition. RESET Press to reset intensifier stroke count. STROKES/MIN is actual stroke rate. The bar graph illustrates strokes/minute. 05146410 p.

  • Page 39: Set Up Screen

    SECTION 3 OPERATION SET-UP SCREEN (2) This screen will be displayed if analog control present. Select if Proportional Pressure, Pressure Transducer, or both are in unit. PSI/BAR selector button changes pressure display on RUN screen and PRESSURE CONTROL screen There are two SET-UP SCREENS – If analog pressure control is not installed on the machine, a screen will appear that does not include the TRANSDUCER and PROPORTIONAL SELECT buttons.

  • Page 40: Maintenance Screen

    SECTION 3 OPERATION MAINTENANCE SCREEN Start button will start unit in RECIRC mode and will open dump valve. STOP button will stop unit. Jog right will extend piston to the right giving full exposure to the right plunger once the unit is disassembled. Jog left will do the same to the left plunger.

  • Page 41: Alarm Screen

    SECTION 3 OPERATION ALARM SCREEN In ALARM condition, Message/Alarm, will flash. Messages are not visible if an alarm condition does not exist. All alarm conditions are visible on this screen and on START screen. OIL Indicates high oil temperature. High oil temperature will shut the machine off 60 seconds after detection of this alarm condition.
  • Page 42 SECTION 3 OPERATION NO PRESSURE CONTROL This screen will appear if the pressure control on main menu is selected and machine does not have PROPORTIONAL control. The machine cannot be stopped from this screen. 05146410 p. 3-15...

  • Page 43: Language

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

  • Page 44: (Example)

    SECTION 3 OPERATION ALARM BANNER (EXAMPLE) When a shut-down condition occurs, an ALARM BANNER will appear hiding the current screen. The ALARM BANNER will display the type of shutdown and remedy to clear the alarm. Pressing the reset button will clear the ALARM BANNER but does not clear the alarm.

  • Page 45: Section 4 Maintenance

    SECTION 4 MAINTENANCE Section 4 MAINTENANCE Maintenance This section provides an overview of “Scheduled Maintenance” and “Preventive Maintenance”. In addition, maintenance of the five systems is necessary and is described in their respective sections. Refer to the following sections for detailed information on the operator console and systems maintenance: •...
  • Page 46 SECTION 4 MAINTENANCE Item Description (1) Hydraulic Pump (2) Recirculation Pump (3) Booster Pump (4) Intensifier Assembly (5) Control Panel (6) Intensifier Ass’y Redundant-Option (7) End Closure Detail (Plus Intensifier) (T-series) July 2002 p. 4-2 49836224...

  • Page 47: Scheduled Maintenance

    SECTION 4 MAINTENANCE Scheduled Maintenance Check Item to be Checked Major Component Description Oil Level Hydraulic Oil Tank Oil Sample Hydraulic System Fluid Level Hydraulic Cartridge & Leak Hydraulic Cylinder Seals Checks Plunger Seals HP Cylinder Sealing Head HP Cylinder Low Pressure Filter Water Supply Pressure Assembly...

  • Page 48: General Maintenance

    SECTION 4 MAINTENANCE General Maintenance Proper maintenance is important for reliable and consistent performance. Preventive maintenance reduces unscheduled downtime, and extends component life. High pressure water will cut almost anything it contacts. Any leaks must be repaired immediately to prevent damage CAUTION 1.1.1.1 or serious personal injury.
  • Page 49 Check all high pressure connections for leaks. Unusual requirements should be referred to the Technical Services group at Ingersoll-Rand. To contact the KMT Waterjet Spare Parts Department: USA: Parts Department Europe: Spare Parts Manager KMT Waterjet Systems...

  • Page 50: Troubleshooting

    SECTION 5 TROUBLESHOOTING Section 5 TROUBLESHOOTING TROUBLESHOOTING - ELECTRICAL 5.1.1 Pump Will Not Start E-STOP Button Depressed Pull out E-STOP button. Check all remote E-STOP pushbuttons. Push CONTROL POWER ON button – white light on CONTROL POWER ON button should illuminate.

  • Page 51: No Control Power (24Vdc)

    SECTION 5 TROUBLESHOOTING 5.1.4 No Control Power (24vdc) Circuit Breaker Tripped Check input circuit breaker of power supply. Check output circuit breaker (24vdc) of power supply. Power Supply Fault Check power supply input and output voltages. E-stop Button Depressed Pull out E-stop button. Check all remote E-stop pushbuttons Control Power On Button Check for voltage through switch when button is...

  • Page 52: Troubleshooting - Hp Water

    SECTION 5 TROUBLESHOOTING TROUBLESHOOTING – HP WATER 5.2.1 HP Water Signal Abnormal Fluctuation Orifice Large/ Worn/ Check that orifices in use do not exceed capacity of Damaged pump. Check that orifices are in good working order. Verify that a jewel is not missing from the orifice mount. Check Piping Leaks Check system components for leaks including dump valve condition.

  • Page 53: Hp Check Valve Leak

    SECTION 5 TROUBLESHOOTING Water Leak at HP Plunger Replace seal assembly if leak exceeds one drop in 10 Seal strokes. Check plunger surface and cylinder bore for build-up of seal material and polish off with 600 emery cloth, polishing the cylinder circumferential and plunger any direction Check Plunger surface and cylinder bore for scratches circumferential and longitudinal, if any are found,...

  • Page 54: Troubleshooting - Hydraulic

    SECTION 5 TROUBLESHOOTING Booster pump pressure If at anytime the pump is running and the booster above 125 psi pump pressure is above 125 psi, the relief valve is opening up and sending water to the drain. TROUBLESHOOTING – HYDRAULIC 5.4.1 Hot Hydraulic Oil Restricted or No Cooling Check cooling water flow to and from heat exchanger.

  • Page 55: Special Procedure-Hp Water Check Valve

    SECTION 5 TROUBLESHOOTING 5.5 SPECIAL PROCEDURE—HP WATER CHECK VALVE TROUBLESHOOTING 5.5.1 HP Check Valve Troubleshooting A leaking HP check valve is suspected if either HP cylinder or sealing head is unusually hot. Compare temperatures of opposing sealing heads or HP cylinders to decide location of hot spot.

  • Page 56: Section 6 Low Pressure Water System

    SECTION 6 LOW PRESSURE WATER Section 6 LOW PRESSURE WATER SYSTEM Low Pressure Water System The SL-IV Waterjet Pump is equipped with two low pressure circuits: • Cutting water supply for HP intensifier assembly. • Cooling water supply for the oil-to-water heat exchanger. The low pressure water system supplies the pump with the following: •...

  • Page 57: Normal Operating Condition

    If the motor does not run for 2 minutes, the solenoid valve (11) will shut off. To re-open the valve, press F6. Note that pressure gages for T series KMT Waterjet pumps are installed in a frame leg for easy access. Pressure gages provide a qualitative measure of LP water system performance, while pressure switches on the T&Q series pumps provide automatic shutdown protection against out of...
  • Page 58 SECTION 6 LOW PRESSURE WATER NOTE The booster pump (1) is factory set to deliver 8 bar (120 psi) with an inlet pressure at port “B” of 4 bar (58 psi). The pump may require adjustment if local inlet pressure is different, because discharge pressure depends on inlet pressure.
  • Page 59 SECTION 6 LOW PRESSURE WATER Figure 6.2 LP Cutting Water Supply Circuit May 2003 05148390...
  • Page 60 SECTION 6 LOW PRESSURE WATER Figure 6.3 LP Water Cooling Circuit Item Description 1 Water/Oil Heat Exchanger 2 Water Modulating Valve 3 Hydraulic Filter 4 Hydraulic Reservoir 5 Recirculating Hydraulic Pump 6 Water Booster Pump 7 Main Hydraulic Pump 8 Electric Motor May 2003 05148390...

  • Page 61: Low Pressure System Protection

    PLC that stops the main electric motor (pumps stop rotating). Note that temperature switch (2) is located on manifold (18) for Q and later T series KMT Waterjet pumps, but is located on the booster pump for earlier series pumps (see Detail A, Figure 6.2)

  • Page 62: Maintenance Overview

    Automatic shutoff of the cutting water supply prevents unnecessary water spillage in the event of an external leak that triggers an automatic shutdown on an unattended KMT Waterjet pump. Maintenance Overview In order to maintain necessary fluid pressure for the pump and to keep the water clean for proper operation it is necessary to replace the water filter and/or adjust the booster pump.

  • Page 63: Boost Pump

    SECTION 6 LOW PRESSURE WATER 6.3.2 Booster Pump If booster pressure, as read on the booster pump discharge pressure gage (14) is less than 8.0-8.3 bar (115-120 psi), the booster pump needs to be adjusted. Components: (1) Booster pump (3) Pressure control knob Recommended Tools: Flat screwdriver (To turn pressure control knob)

  • Page 64: High Pressure (Hp) Water

    SECTION 7 HIGH PRESSURE WATER Section 7 HIGH PRESSURE WATER High Pressure Water The high pressure (HP) water system takes the relatively low pressure water inlet to up to maximum pressure in excess of 3,400 bar (50,000 psi) supplying orifice diameters appropriate to the waterjet pump’s operating power (See Specifications, Section 11).

  • Page 65: Intensifier Disassembly And Reassembly

    SECTION 7 HIGH PRESSURE WATER Intensifier Disassembly and Reassembly Detailed instructions are provided on disassembly and reassembly of the hydraulic intensifier, including HP seal maintenance. A discussion of detailed inspection and repair for individual HP components and subassemblies is also provided. The HP attenuator is discussed but no disassembly procedures are included.

  • Page 66: Hp & Lp Water Piping

    SECTION 7 HIGH PRESSURE WATER 7.2.1 HP & LP Water Piping Disconnect from/Reconnect to Waterjet Pump Before performing maintenance on the waterjet WARNING pump observe electrical LOCK OUT/TAG OUT procedures. Loosen and remove HP Piping attached to the discharge HP check valve.

  • Page 67: Hp Cylinder "Jug

    NOTE—KMT Waterjet flanges AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. KMT Waterjet DOES NOT recommend loosening stud nuts except to service the sealing head inlet HP check valve, cone seat, etc. Refer to Table 7.1 for recommended disassembly / re-assembly practices.

  • Page 68: Stud Nuts And End Flange, Sealing Head

    NOTE—KMT Waterjet recommends removing the HP cylinder/ sealing head/ flanges AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. KMT Waterjet DOES NOT recommend loosening stud nuts except to service the sealing head inlet HP check valve, cone seat, etc. Refer to Table 7.1 for recommended disassembly / re-assembly practices.
  • Page 69 SECTION 7 HIGH PRESSURE WATER Remove sealing head. Note that a white plastic ring used to position the sealing head relative to the HP cylinder bore may not have been removed with the sealing head. This ring should be removed prior to re-installing a sealing head to avoid pushing the ring further into the HP cylinder bore.

  • Page 70: Hp Plunger Seal Service-- Disassembly / Re-Assembly

    SECTION 7 HIGH PRESSURE WATER 7.2.4 HP Plunger Seal Service-- Disassembly / Re-assembly Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2, above. Thread HP plug and gland fitting (items C1 & C2, Special Tools, Table 7.3) into HP check valve gland nut.
  • Page 71 257-285 190-210 257-285 190-210 Max Out-of Parallel 1.8mm 0.070” 1.8mm 0.070” Socket Wrench Size 1-7/16” 1-7/16” Table 7-2. Lube Specs KMT Intensifier Pumps Item IR P/N Description Applications FML Grease, Lube Parts, 10087385 White HP Cylinder High Purity 10084440 SS Threads...
  • Page 72 SECTION 7 HIGH PRESSURE WATER Table 7.2 HP INTENSIFIER SERVICE TEARDOWN SEQUENCE Disassemble/Re-assemble Related HP Cylinder Retainer Intensifier Hydraulic Compone LP Water Sealing Head, Stud Nuts & Flanges & Component HP Piping Cylinder Plumbing Flanges & End Flange Hydraulic Maintenance Head Assembly Studs [1]...

  • Page 73: Plunger And Hydraulic Cartridge Removal And Installation

    SECTION 7 HIGH PRESSURE WATER 7.2.5 Plunger and Hydraulic Cartridge Removal and Installation Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2 above. Remove the proximity switch on the intensifier side nearest HP cylinder to be serviced. This procedure will allow hydraulic oil to drain to tank and will minimize oil spillage.
  • Page 74 SECTION 7 HIGH PRESSURE WATER 7.2.6 Hydraulic Cylinder Head and Piston—Removal / Re-Installation Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2 above. Remove proximity switch (19) at cylinder end to be serviced. Loosen the remaining proximity switch to drain hydraulic oil in tank.
  • Page 75 SECTION 7 HIGH PRESSURE WATER Item Description Cylinder Head Bushing Retainer Flange Plunger Retaining Ring Hydraulic Cartridge, Plunger Hydraulic Cylinder Seal Plunger Removal Tool May 2003 p. 7-12 49831951...
  • Page 76 SECTION 7 HIGH PRESSURE WATER Item Description Bushing Retainer Plunger Cap Screw Flange Cylinder Head Proximity Switch Hyd Cartridge, Hydraulic Cylinder Cap Screw Plunger Seal Assy O-ring Hyd Piston Assy Backup Ring Spacer May 2003 p. 7-13 49831951...

  • Page 77: Discharge Hp Check Valve

    SECTION 7 HIGH PRESSURE WATER Intensifier Subassemblies Inspection and Repair The inspection and repair of the following subassemblies will be discussed: • Discharge HP Check Valve, Section 7.3.1 • Inlet Check Valve, Section 7.3.2 • Sealing Head, Section 7.3.3 • HP Cylinder, Section 7.3.4 •...
  • Page 78 SECTION 7 HIGH PRESSURE WATER Item Description (1) Sealing Head (2)Poppet (3) Gland Nut (4) Poppet Seat (5) Spring (6) Guide Pin May 2003 p. 7-15 49831951...
  • Page 79 SECTION 7 HIGH PRESSURE WATER 3. Inspect the poppet, spring, and guide for wear. Replace the spring and guide if worn. 4. Apply a thin film of High Purity Goop to the sealing face of the gland nut. Install the guide, spring, and poppet into the gland nut. 5.

  • Page 80: Inlet Check Valve

    SECTION 7 HIGH PRESSURE WATER 7.3.2 Inlet Check Valve Use a ½” flat bladed screwdriver to unscrew the poppet retainer from the sealing head. The inlet check valve is disassembled. Inspect and refinish the sealing head face seal surface per instructions in Section 7.3.3.
  • Page 81 SECTION 7 HIGH PRESSURE WATER Item Description (1) Sealing Head (2) Poppet (3) Gland Nut (5) Seal Head Spacer (6) Flange Ring (7) Suction Spring (9) End Flange (11) Retainer May 2003 p. 7-18 49831951...

  • Page 82: Sealing Head

    SECTION 7 HIGH PRESSURE WATER 7.3.3 Sealing Head The sealing head should be inspected for scratches and wear on two surfaces: • HP cone ring seal contact surface • Inlet HP check valve poppet contact surface Polish the cone ring 45 degree surface to achieve a smooth finish. Grooves or machine tool marks should be barely discernable by fingernail test.

  • Page 83: Hp Cylinder

    SECTION 7 HIGH PRESSURE WATER 7.3.4 HP Cylinder At a workbench, use the seal removal tool to prevent scratching the cylinder bore sealing surface. Use a pulling action to remove the sealing head HP seal. Remove the bore liner. Use a plastic-faced hammer and the seal removal tool to drive out the plunger HP seal and follower.

  • Page 84: Plunger

    If any of these conditions become severe, the plunger HP seal and possibly the hydraulic seals will leak excessively. Repair of plunger surface flaws usually cannot be accomplished on site. KMT Watejet offers a plunger reconditioning service. Item Description...

  • Page 85: Hydraulic Seal Cartridge

    SECTION 7 HIGH PRESSURE WATER 7.3.6 Hydraulic Seal Cartridge Carefully remove worn seals and O-rings from cartridge by pushing them with a dowel or similar object. Remove seals positioned close to the open ends first, working toward the interior. Examine seals for unusual wear, deformation or cuts.
  • Page 86 SECTION 7 HIGH PRESSURE WATER During seal installation, orient U-cup packing seals (2) (8) so that they match figure above. Apply food grade grease to seals and cartridge seal components to aid in installation and seal seating. Use installation tool, if available, for installation of U-cup seals (2) (8).

  • Page 87: Hydraulic Piston

    SECTION 7 HIGH PRESSURE WATER 7.3.7 Hydraulic Piston The hydraulic piston contains a seal assembly, bearing rings, pins and flat spring bands, and check valves. Bearing rings (10) provide wear contact between piston and cylinder ID. Plungers (12) are held in place by 6 each pins (2) per plunger.
  • Page 88 SECTION 7 HIGH PRESSURE WATER With seal and bearings removed, inspect seal groove bottom for marks or scratches and residue buildup. Clean and /or repair groove surfaces as required. Install replacement bearing rings (10). Install replacement piston seal assembly (9). First install inner ring, taking care that this ring is not twisted after installation.
  • Page 89 SECTION 7 HIGH PRESSURE WATER second plug acting to lock in the first. Allow 24 hours for thread locking compound to set. Install Plunger Button Seals and Retainer Pins in Hydraulic Piston Install new backup ring (7) and O-ring (8) in each internal groove in each plunger pocket (2 places).
  • Page 90 SECTION 7 HIGH PRESSURE WATER Item Description Hydraulic Cylinder Seal Ring Compression Tool (P460) Proximity Switch Hydraulic Piston Assy May 2003 p. 7-27 49831951...

  • Page 91: Hydraulic Cylinder

    SECTION 7 HIGH PRESSURE WATER 7.3.8 Hydraulic Cylinder The inside diameter surface of the hydraulic cylinder should be inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed. Excessive grooving on this bore is indicative of piston seal wear. Item Description (1) Hydraulic Cylinder (2) Cylinder Head...

  • Page 92: Hp Dump Valve

    In the event of a HP water leak of a HP attenuator, the attenuator should be replaced. The defective attenuator should be returned to KMT Waterjet for replacement or servicing. May 2003 p.
  • Page 93 SECTION 7 HIGH PRESSURE WATER May 2003 p. 7-30 49831951...

  • Page 94: Section 8 Electrical System

    SECTION 8 ELECTRICAL SYSTEM Section 8 ELECTRICAL SYSTEM Electrical System The electrical system contains all functions necessary for turnkey operation. This includes the control and starter panel, intensifier reversal circuit, diagnostics, malfunction warning and protection. The electrical enclosure and the display, buttons, lights, and electrical harnesses into and out of this enclosure can be exposed to occasional water spray and dust per NEMA-12 standards.
  • Page 95 SECTION 8 ELECTRICAL SYSTEM Figure 8-1 ELECTRICAL CONTROL POWER Item Description Wall Disconnect-Main Power Programmable Logic Controller 3-Phase Line (Service Drop) Power Optical Relays Enclosure Door Disconnect/Circuit Touch Screen Interface Panel Breaker Motor Starter Contactor(s) Modem (Optional) Contractor Coil(s) (230V) Emergency Stop Button Electric Motor Proportional Control (Optional)

  • Page 96: Motor Starter Circuit

    SECTION 8 ELECTRICAL SYSTEM 8.1.1 Motor Starter Circuit All horsepower levels of SL-IV Waterjet Pumps are available with built-in starter/ control panels . Two starter circuits are typically used: ♦ Wye-Delta for reduced voltage starting: Required in Europe and standard on the SL-IV for motors of 75 hp or greater.

  • Page 97: Control Circuits And Logic

    SECTION 8 ELECTRICAL SYSTEM 8.1.2 Control Circuits and Logic The operator controls the waterjet pump primarily through the digital display panel. The digital interface (display) communicates with the PLC controller located inside the electrical enclosure. In order to avoid costly damage to the pump, automatic shutdown logic and diagnostic messages are displayed to the operator as to the cause of the impending shutdown.
  • Page 98 SECTION 8 ELECTRICAL SYSTEM Table 8-2. SENSORS/SOLENOIDS - SLIV FUNCTION COMPONENT DESCRIPTION LOCATION Intensifier shift Proximity switches Hydraulic cylinder, sensors intensifier assy Cutting water Solenoid shutoff valve, water Bulkhead plumbing supply assembly HP water dump HP shutoff valve, pneumatically- HP discharge piping, valve operated, solenoid valve (pneu) betw.

  • Page 99: Operation

    SECTION 8 ELECTRICAL SYSTEM Figure 8-3 CONTROL PANEL/SCREEN, SLIV 8.1.3 Operation (See Figure 8-3) To energize the Control Panel, pull the EMERGENCY STOP button, then press the RESET button. The Control Panel will display the RUN screen. After a five second delay, if all run conditions are met (no alarm conditions, and inlet water pressure above 30 psi) the RUN BAR will flash, indicating machine is ready to start.
  • Page 100 SECTION 8 ELECTRICAL SYSTEM WATER RESET FUNCTION Press on (I) to shut water off five (5) minutes after machine shuts down. Selecting this function will insure that the inlet cutting water is shut off following a shutdown fault. This can prevent water from leaking past a damaged water seal following an overstroke shutdown caused by a seal failure.
  • Page 101 SECTION 8 ELECTRICAL SYSTEM After pressing the Start button: • The motor starter in the control panel is activated and the motor starts. • The intensifier assembly starts operating. Reversal position is sensed by proximity switches, which send signals to the PLC inside the control panel.

  • Page 102: Control Power Circuits

    SECTION 8 ELECTRICAL SYSTEM 8.1.4 CONTROL POWER CIRCUITS (see Figure 8-1) A control power transformer (7) with multiple input taps and 230 VAC output taps provides all control power to the SL-IV Intensifier Pump. A pair of leads from the main breaker/ door disconnect (3) are routed to the transformer (7) input side.

  • Page 103: Maintenance Overview

    SECTION 8 ELECTRICAL SYSTEM Maintenance Overview Electrical components require minimum attention and service. components that require service are the proximity switches on the intensifier assembly, and the optical relay switch in the control panel. 8.2.1 Proximity Switch Service If the pump quits pumping water, the proximity switch may need to be replaced.

  • Page 104: Optical Relay Switch Service

    SECTION 8 ELECTRICAL SYSTEM 8.2.2 Optical Relay Switch Service Components: Optical Relay Switch Recommended Tools: Flat screwdriver, 3mm (1/8 inch) Parts: Optical Relay Replace Optical Relay Switch 1. Turn off waterjet pump, disconnect and LOCKOUT electric power. 2. Open control panel. 3.

  • Page 105: Section 9 Hydraulic System

    SECTION 9 HYDRAULIC SYSTEM Features In addition to “slow start”, other features of the hydraulic system are listed below: • Hydraulic 4-way valve – directional control valve (DCV)–solenoid– operated. Used for HP cylinder shifting. • Reference hydraulic gage – used for adjusting pressures in the HI/LO relief valves.

  • Page 106: Operation

    SECTION 9 HYDRAULIC SYSTEM NOTE The main pump is direct-mounted to the motor. The main pump control includes hi and lo preset pressures. The operator is able to switch between pressures at the operator’s console. Item Description (1) HI pressure control (2) LO pressure control (3) Fixed relief valve (4) Gage (5) Manifold...

  • Page 107: Hydraulic Pressure Adjustment

    SECTION 9 HYDRAULIC SYSTEM (8) to change flow and to reverse direction of movement of piston until activating the opposite end-of-stroke proximity switch. 9.2.1 Hydraulic Pressure Adjustment A variable displacement pressure compensated feature maintains constant operating pressures even under variable flow demands. Dual pressure control is standard.

  • Page 108: Hydraulic System Pressure Protection

    SECTION 9 HYDRAULIC SYSTEM 9.2.2 Hydraulic System Pressure Protection Besides the HI-LOW Pressure Control Valves, the hydraulic system pressure is limited by the main relief valve (3). The operating hydraulic pressure is indicated by hydraulic gage (4). Hyd. Pressure Bar (psi) Pressure Adjustment Increase Decrease...

  • Page 109: Motor Service

    SECTION 9 HYDRAULIC SYSTEM Item Description (1) Motor (2) Manifold (3) Recirculation Pump (4) Hydraulic Pump (5) Housing (6) Motor Coupling (7) Pump Coupling (8) Soft Coupling 9.3.1 Motor Service 1. Locate the two zerk fittings, they are located at each end of the motor, remove their plastic caps.
  • Page 110 SECTION 9 HYDRAULIC SYSTEM • 9.3.3 Motor/ Pump Coupling 1. Remove access cover on item (5). See Section 12 “Motor Pump Assembly” for soft coupling part number information. 2. Remove pump assembly items (2, 3, 4 etc). NOTE: Pump shaft must be moved backwards approximately 1.00 inches. Support pump assembly with wood blocks, remove mount screws, attempt to move pump assembly without removing attaching hoses.

  • Page 111: Section 10 Recirculation System

    SECTION 10 RECIRCULATION SYSTEM Section 10 RECIRCULATION SYSTEM Recirculation System The recirculation system keeps the hydraulic oil at operating temperature while using the minimum amount of cooling water flow. The system also provides the necessary oil conditioning and filtration to maintain oil cleanliness.

  • Page 112: System Pressure Protection

    SECTION 10 RECIRCULATION SYSTEM Item Description (1) Recirculation Pump (2) Water Modulating Valve (3) Heat Exchanger (4) Pressure Gage (5) Oil Filter (6) Hydraulic Oil Tank (7) Oil Fill Cap Operating Temperature Adjustment The operating temperature is adjusted by turning the water modulating valve (2) adjusting knob with a flat blade screwdriver.

  • Page 113: Maintenance Overview

    SECTION 10 RECIRCULATION SYSTEM Adjustment Setting Control Valve Increase Decrease Maximum Minimum Clockwise Counter- Temperature clockwise (110 (125 Oil Pressure Fixed Fixed 4.2 bar 3.8 bar (60 psi) (55 psi) 10.4 Maintenance Overview During normal operating condition, the oil will be maintained at the correct operating temperature.
  • Page 114 SECTION 10 RECIRCULATION SYSTEM Oil Filter Replace filter element when the pressure reading is 1.4 bar (20psi) above normal when at operating temperature. Maximum normal pressure is 1.7 bar (25psi). Components: (1) Oil Filter Head (2) Element (3) Pressure Gage Parts: Element Tools:...
  • Page 115 SECTION 10 RECIRCULATION SYSTEM Oil Tank The oil tank is equipped with the following: • Visual temperature and level indicator • Air breather and filter that prevents dirt from being sucked into the tank whenever the oil level drops, then allows air to escape when the level rises •...
  • Page 116 SECTION 10 RECIRCULATION SYSTEM Replace Hydraulic Oil 1. Drain the tank, by connecting the inlet hose of the oil transfer pump to the drain valve. Open valve and pump oil to container. 2. Close hand valve, remove oil transfer pump inlet hose from hand valve. NOTE Never assume a new drum of oil is free of damaging contaminants.

  • Page 117: Specifications

    SECTION 11 SPECIFICATIONS SECTION 11 SPECIFICATIONS Specifications Following are the specifications for the Waterjet Pump. Included are the specifications for the equipment, torque, cutting water, cooling water, and the maximum quantity of orifices that can be supported. 11.1 Equipment Specifications SL-IV Waterjet Pump Size 45 (60) kW (hp)
  • Page 118 SECTION 11 SPECIFICATIONS 45 (60) kW (hp) SL-IV Waterjet Pump Size °C(°F) Optimum temperature 46(115) Hot oil shutdown 62(144) °C(°F) Fluid Filtration Rating Beta 10 >/= 100 Note [6] Fluid Cleanliness Level 17/14 Note [7] -Hydraulic Pump Type Piston Displacement Variable Pressure Compensated...

  • Page 119: Torque Specifications

    LIFE OF COMPONENTS. Use of an antiseize thread lubricant, like High Purity Goop (P/N 10084440) is highly recommended for tightening of stainless steel HP water fittings. A torque wrench kit is available from KMT Waterjet. (P/N 49895436). Jan 2003 80073455 p. 11...

  • Page 120: Cutting Water Specifications

    SECTION 11 SPECIFICATIONS 11.3 Cutting Water Specifications The cutting water supply to the waterjet pump must meet the following specifications. High concentration of dissolved solids, especially calcium, silica, and chlorides, will affect high pressure component life. A water analysis will indicate the type of water treatment necessary.

  • Page 121: Orifice Support Capacity

    SECTION 11 SPECIFICATIONS To predict the tendency of scale formation, the Langelier's saturation index can be used as a guide. Saturation Index = pH-pHs where pHs is calculated at saturation with calcium carbonate. A positive index indicates a tendency to deposit calcium carbonate, the higher the positive value, the higher the scale formation.
  • Page 122 SECTION 12 PARTS LISTS PARTS LISTS For: SL-IV PLUS 60HP High Pressure Waterjet Pump To contact the KMT Waterjet Systems Spare Parts Department: Parts Department Europe: Spare Parts Manager KMT Waterjet Systems KMT Waterjet Systems GmbH Production Equipment Group Wasserstrahl–Schneidetechnik...

  • Page 123: Section 12 Parts Lists

    SECTION 12 PARTS LISTS SECTION 12 PARTS LISTS 480/3φ/60 – 50 hp SL-IV Single & Redundant 12.1 General This section contains parts lists for service procedures and part identification, along with electrical and plumbing schematics of the SL-IV 50 hp HP Waterjet Pump. The reader can use these parts lists to identify the part on a drawing, then find the part number and part description corresponding to the drawing balloon number.
  • Page 124 SECTION 12 PARTS LISTS Fig # Figure Title Part Number Page # 12-1 Waterjet Pump 80072648 12-5 12-2 Intensifier Assembly 05144217 12-7 12-3 Seal Head Assembly 05144688 12-9 12-4 Hydraulic Piston 05132253 12-11 12-5 Hydraulic Cartridge 05130091 12-13 12-6 Hydraulic Plumbing Assembly 80073000 12-15 12-7...
  • Page 125 SECTION 12 PARTS LISTS Figure 12-1. WATERJET PUMP 80072648 ITEM No. QTY. PART No. DESCRIPTION 80072804 Frame Assembly 80072978 Hydraulic Power Package 80073083 Electrical Assembly 80073703 Decal Package 05059605 Spring 05022702 Hydraulic Fluid 05128087 Start-Up Tag 05135702 Test Report 80073000 Hydraulic Hose Connections 80074073 Reservoir Assembly...
  • Page 126 SECTION 12 PARTS LISTS page 12-5 Jan 2003 80073505...
  • Page 127 SECTION 12 PARTS LISTS Figure 12-2. INTENSIFIER ASSEMBLY 05144217 ITEM No. QTY. PART No. DESCRIPTION 05144647 Body, Cylinder, HP, 1.13-in. ID 05119151 Plunger, Ceramic 05144688 Head Assembly, Sealing 05147913 Head, Cylinder 05149703 HP Seal Assembly 05144696 Sealing Head Spacer 05144225 Flange Ring 05130091 Low Pressure Hydraulic Cartridge Seal Assembly...
  • Page 128 SECTION 12 PARTS LISTS page 12-7 Jan 2003 80073505...
  • Page 129 SECTION 12 PARTS LISTS Figure 12-3. SEALING HEAD ASSEMBLY 05144688 ITEM No. PART No. DESCRIPTION 05144357 Body, Sealing Head 05144662 Poppet, Inlet, Cutting Water 05116777 Gland, HP, Sealing Head 05112768 Seat, HP, Sealing Head 05116561 Poppet, Valve, HP Check 05144670 Retainer, Poppet 05147863 Spring, Compression...
  • Page 130 SECTION 12 PARTS LISTS page 12-9 Jan 2003 80073505...
  • Page 131 SECTION 12 PARTS LISTS Figure 12-4 HYDRAULIC PISTON ASSEMBLY 05132253 ITEM No. PART No. DESCRIPTION 05132261 Body, Hydraulic Piston 05074380 Pin, Clevis 05049887 Screw, Set, Socket, with Through Hole 10148757 Valve, Check, Cartridge, with O-ring 49877509 Adhesive, Thread Locker 05088364 Ring, Snap, Flat Wire 05049994 Ring, Backup...
  • Page 132 SECTION 12 PARTS LISTS page 12-11 Jan 2003 80073505...
  • Page 133 SECTION 12 PARTS LISTS Figure 12-5 HYDRAULIC CARTRIDGE SEAL ASSEMBLY 05130091 ITEM No. PART No. DESCRIPTION 05130109 Body, Seal, Cartridge 05015060 Seal, U-Cup, with O-ring 10193522 O-ring 05050760 Ring, Backup 05129481 O-ring 05013024 O-ring 05129515 Back-up Ring 05027255 Seal, U-Cup Ref 1 05015136 Tool, Seal Smoothing...
  • Page 134 SECTION 12 PARTS LISTS page 12-13 Jan 2003 80073505...
  • Page 135 SECTION 12 PARTS LISTS FIGURE 12-6 HYDRAULIC PLUMBING 80073000 ITEM No PART No. DESCRIPTION 05106950 Hose Assembly, Hydraulic, .75" ID, -12 JIC Swivel, Both Ends, 19” 05106968 Hose Assembly, Hydraulic, 1.00" ID, 1.25 JIC Swivel, Both Ends 80074099 Hose Assembly, Hydraulic, 1.00” ID, -16 JIC Swivel, Both Ends 10083517 Hose Clamp 6.3”...
  • Page 136 SECTION 12 PARTS LISTS page 12-15 Jan 2003 80073505...
  • Page 137 SECTION 12 PARTS LISTS FIGURE 12-7. HIGH PRESSURE PIPING 80072655 ITEM No PART No. DESCRIPTION 49830599 Tee, .38-in. HP Tube, 60 ksi, Stainless 05148846 Tube, Bent, .38-in. HP, 60 ksi, Stainless 10078590 Tee, .38-in. HP Tube, 60 ksi, Stainless 05148853 Tube, Bent, .38-in.
  • Page 138 SECTION 12 PARTS LISTS page 12-17 Jan 2003 80073505...
  • Page 139 SECTION 12 PARTS LISTS Figure 12-8. HYDRAULIC MANIFOLD ASSEMBLY 05071766 ITEM No. QTY. PART No. DESCRIPTION 05044144 Block, Manifold, Hydraulic 05071055 Plug, -12 SAE O-ring, Hex Socket, Steel 05071717 Valve, Relief, Hydraulic, 234 bar (3,400 psi), Non-adjustable, TUV 05055017 Plug, -2 SAE O-ring, Hex Socket, Steel 10185585 Valve, Solenoid, Hydraulic, 24 –...
  • Page 140 SECTION 12 PARTS LISTS page 12-19 Jan 2003 80073505...
  • Page 141 SECTION 12 PARTS LISTS Figure 12-9. BULKHEAD PIPING ASSEMBLY 80073661 ITEM 49830581 Bulkhead Coupling, .38 x .56 QTY PART No. DESCRIPTION 10189025 Adapter-Hose/JIC, -8 x –8 10147460 Elbow, 90 Deg, ½ - NPT x –8 05111398 Quad Stem 10091866 Water Modulating Valve 49832959 Screw-Hex Head, 5/8-11 x 1.75 05060207 Nipple, ½...
  • Page 142 SECTION 12 PARTS LISTS page 12-21 Jan 2003 80073505...
  • Page 143 SECTION 12 PARTS LISTS Figure 12-10 LOW PRESSURE WATER FILTER ASSEMBLY 05149810 ITEM No. QTY. PART No. DESCRIPTION 05044052 Gage, Pressure, O–200 psig, ¼ NPT, Stainless, Bottom-Mount 10100428 Adapter, Bushing, ½ x ¼ NPT, Stainless 05070982 Valve, Relief, 50 – 150 psi, ½ NPT 05074067 Nipple, ½...
  • Page 144 SECTION 12 PARTS LISTS page 12-23 Jan 2003 80073505...
  • Page 145 SECTION 12 PARTS LISTS Figure 12-11. HYDRAULIC POWER UNIT 80072978 ITEM No PART No. DESCRIPTION 80072846 Motor/Pump Assembly 05049168 Water Pump Adapter 95572897 Hex Head Screw, 1/4-20 x 5/8 95838314 Lock Washer, ¼ 49887094 Vane Water Pump 05123591 Stud, .63 80073190 Spacer Block 49884216...
  • Page 146 SECTION 12 PARTS LISTS Jan 2003 page 12-25 80073505...
  • Page 147 SECTION 12 PARTS LISTS Figure 12-12. MOTOR/PUMP ASSEMBLY 80072846 ITEM No. PART No. DESCRIPTION 80072820 Shaft Coupling 80072838 Shaft Coupling 80072937 Vibration Isolation, Motor Base 05045513 Motor, Electric, 60hp 80072937 Flexible Coupling Insert 80072853 Flange-Motor/Pump 05045505 Piston Pump, Axial, Variable-Displacement, Pressure-Compensated, 71 cc/rev 05037593 Socket Head Screw, M10 x 1.50 x 25mm 10069714...
  • Page 148 SECTION 12 PARTS LISTS Jan 2003 page 12-27 80073505...
  • Page 149 SECTION 12 PARTS LISTS Figure 12-13 RESERVOIR ASSEMBLY 80074073 ITEM No. QTY PART No. DESCRIPTION 80074040 Weldment, Reservoir 05104179 Gasket, Cover, Reservoir 05050026 Switch, Temperature / Level, Hyd, Cartridge- Type, 149 deg F 05092739 Breather, Air 10168862 Gage, Dual Scale, Level/Temperature, Oil 05103809 Housing, Filter, Hyd Oil, w/Gage 05104187...
  • Page 150 SECTION 12 PARTS LISTS Jan 2003 page 12-29 80073505...
  • Page 151 SECTION 12 PARTS LISTS Figure 12-14 ELECTRICAL ASSEMBLY 49831498 ITEM No. QTY PART No. DESCRIPTION 05148531 Harness, Cable, Sensor/Solenoid 10080661 Flexible Conduit Connector 80073059 Terminal Ring 18” 10086700 Flexible Conduit 10115830 Flexible Conduit Connector 05081377 Conduit Bushing 10159143 #8 Terminal Ring 10069763 Washer, .50 124”...
  • Page 152 SECTION 12 PARTS LISTS Jan 2003 page 12-31 80073505...
  • Page 153 SECTION 12 PARTS LISTS Figure 12-15 CONTROL PANEL CONFIGURATION 80073117 ITEM No. QTY PART No. DESCRIPTION 05075635 Circuit Breaker, 200A 05081955 Screw, Socket Head, #8-32 x 2 05137963 Rotary Drive Mechanism 05075650 Extension, Shaft, Circuit Breaker 05075643 Handle, Open, Circuit Breaker 05106406 Terminal Cover 54”...
  • Page 154 SECTION 12 PARTS LISTS Jan 2003 page 12-33 80073505...
  • Page 155 SECTION 12 PARTS LISTS Figure 12-16 CONTROLS SUBASSEMBLY 49836620 ITEM No PART No. DESCRIPTION 05021944 Wiring Duct 10170132 Rivet 10176410 #16 Wire, Blue 49874191 Hole Seal 10170165 #16 Wire, Green/Yellow 05140926 #16 Wire, Orange 05032420 Terminal Block 10185395 Crimp Connector 10103034 Din Rail 10069888 Lock Washer, #6...
  • Page 156 SECTION 12 PARTS LISTS Jan 2003 page 12-35 80073505...
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