KMT Streamline SL-IV 75S Operation And Service Manual
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KMT Streamline SL-IV 75S Operation And Service Manual

High pressure waterjet pump
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STREAMLINE HIGH PRESSURE
WATERJET PUMP
OPERATION and SERVICE MANUAL
SL-IV 75S
HSEC
Manual No. 80080336
Printed: 02/08/05
80079114.doc

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  • Page 1 STREAMLINE HIGH PRESSURE WATERJET PUMP OPERATION and SERVICE MANUAL SL-IV 75S HSEC Manual No. 80080336 Printed: 02/08/05 80079114.doc...
  • Page 2 NOTICE This document contains subject matter in which KMT Waterjet Systems has proprietary rights. Recipients of this document shall not duplicate, use, or disclose information contained herein, in whole or in part, for other than the purpose for which this manual was provided.

  • 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 7-23 7.3.6 Hydraulic Seal Cartridge 7-24 7.3.7 Hydraulic Piston 7-26 7.3.8 Hydraulic Cylinder 7-30 HP Dump Valve 7-31 HP Attenuator 7-31 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

    SECTION 2 INSTALLATION Installation The installation, start-up, operation, and maintenance of the SL-IV Waterjet Pump requires complete reading and study of this manual to understand the system in detail. Installation Overview • Read the manual and become familiar with the operation of each component and its nomenclature.

  • Page 19: Buyer Obligations

    Provide, install and connect wiring between the intensifier pumps, 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. 49831894...

  • Page 20: Seller Obligations

    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 boost pump discharge pressure. •...

  • Page 21: Installation Requirements (Utilities)

    SECTION 2 INSTALLATION Installation Requirements (Utilities) Environment: The SL-IV Waterjet Pump must be installed indoors. Ambient conditions must not exceed maximum specifications. Moving: The SL-IV Waterjet Pump has provisions to be moved with a forklift. Check weight specifications. The waterjet pump is top heavy. Avoid situations that could CAUTION result in the equipment overturning Electrical...

  • Page 22: Service Connections

    SECTION 2 INSTALLATION 2.2.2 Service Connections Cooling Water IN/OUT: Supply piping must be properly sized to handle the necessary flow, and pressure. Piping must meet national and local piping codes. Cutting Water IN: Supply piping must be properly sized to handle the necessary flow and pressure.

  • Page 23: Tools And Equipment

    SECTION 2 INSTALLATION 2.2.3 Tools and Equipment 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.
  • Page 24 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 25 (4) Cutting Blades (5) Collet (6) Housing (7) Gland Nut Tube Size (inch) 1/4” 3/8” 9/16” A mm (inch) 3.30 (0.13) 4.07 (0.16) 7.11 (0.28) Coning Tool (KMT Part) 10079556 10097418 10079663 Threading Tool (KMT Part) 10079697 10097434 10097442 49831894 Page 2-8...
  • Page 26 SECTION 2 INSTALLATION Coning • Place appropriate size coning tool in 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 slightly grip tubing.
  • Page 27 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 gland nut (2) on tubing (1) as shown and lubricate thread with High Purity Goop.
  • Page 28 SECTION 2 INSTALLATION HP Tube End Connection – Anti-vibration The following type of connection must be used when tubing is subjected to vibration, rotation, movement, and side loads (i.e. whip tubing). Lubricate threads as above. Do not depend on end connection to take load alone. Proper WARNING piping support and guide must be provided.

  • Page 29: 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 30 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 31 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 32: 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 33 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 34 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 35: 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 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: 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 43 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 44: 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 45: Alarm Banner (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 46 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 47: Section 4 Maintenance

    SECTION 4 MAINTENANCE The following is an overview of the primary components and their location. • Hydraulic Pump – including electric motor, and hydraulic valve manifold block. The pump is a variable displacement, axial piston and pressure compensated type. • Recirculation Pump –...

  • Page 48: 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 Seals Hydraulic Cylinder Leak Checks Plunger Seals HP Cylinder Sealing Head HP Cylinder Low Pressure Filter Water Supply Pressure Assembly...

  • Page 49: General Maintenance

    When blowing off parts with compressed air, use only clean, dry air. When flushing parts with a solvent, use only clean, filtered fluid. • Always use original KMT Waterjet replacement parts, for consistent performance, reliability, safety, and to protect equipment warranty. Safety Recommendations •...
  • Page 50 Make sure all parts are clean, free of burrs, metal particles, dirt, dust, etc. Use High Purity Goop (KMT Waterjet Part 10084440), when assembling any high pressure fitting. After servicing any high pressure components, flush the high pressure water system by operating the waterjet pump for a short period with the nozzle valve open and no orifice in place.

  • Page 51: Service Log Data

    Subtracting operating hours between part changes provides service life information. If questions arise concerning service history, then the Service Log sheets can be faxed to the KMT Waterjet service office. Having a mutually – understood form of recording service history (that is, the Service Log sheets) is an advantage when drawing the attention of KMT Waterjet service personnel to the particular service problem.
  • Page 52 SECTION 4 MAINTENANCE Cutting Conditions Operating Pressure: No. of Orifices & Orifice Size: SL-IV Service Log (Circle One): _____________bar/psi _____ each x ______ mm/inch Page ____ Pure water / Abrasive Date/Person Hours TW CYL 11 12 13 14 15 16 17 21 22 Remarks 49831902...
  • Page 53 SECTION 4 MAINTENANCE SL-IV SERVICE LOG – PARTS REFERENCE LIST Ref. Part No. PART DESCRIPTION (CCN) 10106722 Filter Element, Low Pressure Water, 2 each x 10 microns 05104187 Filter Element, Hydraulic Oil Filter Element, High Pressure Water, ¼ HP, 3/8 HP, or 9/16 HP 05071063 Hydraulic Oil Change 49834294...
  • Page 54 SECTION 4 MAINTENANCE 49831902. Page 4-9...

  • Page 55: 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 56: 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 57: 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 58: 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 59: 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 60: 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 61: Section 6 Low Pressure Water System

    SECTION 6 LOW PRESSURE WATER 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 62 SECTION 6 LOW PRESSURE WATER Figure 6.2 Cooling Water Circuit-SLIV Waterjet Pumps (1) Heat Exchanger, Oil to Water Cooler (2) Water Modulating Valve (3) Hydraulic Pump, Gear Type Recirculating (4) Hydraulic Filter, Return Line (5) Main Hydraulic Pump (6) Electric Motor (7) Hydraulic Reservoir (Tank) (8) Temperature Bulb/Reservoir Well (9) Cutting Water Booster Pump...

  • Page 63: Oil Cooling Water Supply

    SECTION 6 LOW PRESSURE WATER Oil Cooling Water Supply (See Figure 6.2) The hydraulic oil cooling water circuit includes an oil- to- water heat exchanger (1), an automatic water modulating valve (2), and associated bulkhead fittings to connect inlet and outlet water to source/ drain piping/ hoses as appropriate. The water modulating valve provides accurate and reliable regulation of oil temperature in the hydraulic reservoir (8).

  • Page 64: Cutting Water Supply

    SECTION 6 LOW PRESSURE WATER Cutting Water Supply (See Figure 6.4) The cutting water supply includes the following: • Low pressure water filter (2) • Inlet water shutoff valve (solenoid operated) (3) • Booster pump (1) along with sensors and pressure controls The low pressure water fittings are stainless steel with rubber hoses connecting the low pressure water components.

  • Page 65: Operation

    SECTION 6 LOW PRESSURE WATER 6.2.2 Operation (See Figure 6.4) The cutting water enters the pump through port “B”. When the CONTROL POWER ON button on the operator control panel is activated, solenoid valve (3) opens allowing water to flow through the filter (2) to the inlet of the booster pump (1).
  • Page 66 SECTION 6 LOW PRESSURE WATER Figure 6.4 Cutting Water Supply System (1) Booster Pump, Cutting Water Supply (2) Filter, Cutting Water Supply (3) Solenoid Shutoff Valve, Cutting Water (4) Filter Assembly, LP Water Supply (5) Pressure Switch, 60psig, Low Booster (6) Pressure Switch, 30psig, Low Pump Pressure Supply Water Pressure...

  • Page 67: Booster Pump Pressure Adjustment

    SECTION 6 LOW PRESSURE WATER 6.2.3 Booster Pump Pressure Adjustment Adjustment must be made with the pump turned off and the inlet water turned off. The booster pump pressure relief valve (14) is adjusted by turning with a flat blade screwdriver. Turn clockwise to increase pressure or counterclockwise to decrease pressure.

  • Page 68: Maintenance Overview

    SECTION 6 LOW PRESSURE WATER 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. The guidelines for servicing these parts are described below.

  • Page 69: Water Filter Service

    SECTION 6 LOW PRESSURE WATER 6.3.1 Water Filter Service Replace water filter when booster pump inlet pressure drops below 30 psig pressure switch (6), Figure 6-4 with 30 psig or greater on gage (8) Figure 6-4. Components: Bleed Valve Element Head Housing Recommended Tools:...

  • Page 70: Boost Pump

    SECTION 6 LOW PRESSURE WATER 6.3.2 Booster Pump If booster pressure, as read on the booster pump discharge pressure gage is not 8.0-8.3 bar (115-120 psi), the booster pump needs to be adjusted. Components: (1) Booster pump (3) Relief valve set screw Recommended Tools: Flat screwdriver (To turn pressure control knob) Container (To capture some water spill)

  • Page 71: 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 4,137 bar (60,000 psi) supplying orifice diameters appropriate to the waterjet pump’s operating power (See Specifications, Section 11).

  • Page 72: 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.
  • Page 73 SECTION 7 HIGH PRESSURE WATER Figure 7-2 Item Description (1) HP Cylinder (2) Plunger (3) Sealing Head (4) Hydraulic Cylinder Head (5) HP Seal (6) Ring (7) End Cap (8) Hydr Seal Cartridge (9) Retaining Flange (10) Jackbolt (11) Cylinder Liner (12) O-ring (14) Retainer Ring (15) Hydraulic Cylinder...

  • Page 74: 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 pump WARNING observe electrical LOCK OUT/TAG OUT procedures. Loosen and remove HP Piping attached to the discharge HP check valve. Move tubing to clear work area.

  • Page 75: Hp Cylinder

    NOTE— AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. KMT Waterjet DOES NOT recommend loosening jackbolts 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 76 Restart KMT Waterjet pump, first operating in LOW pressure mode to flush out air in HP components and also to check for obvious leaks. Switch to HIGH pressure after 5-10 minutes of LOW pressure operation, watching for obvious leaks.

  • Page 77: Hard Seal End Cap

    7.2.3 Hard Seal End Cap HSEC, Sealing Head—Disassembly / Re-assembly NOTE: KMT Waterjet recommends removing the HP cylinder/ sealing head/ HSEC AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. KMT Waterjet DOES NOT recommend loosening jackbolts except to service the sealing head inlet HP check valve, cone seat, etc.

  • Page 78: Hp Plunger Seal Service

    Failure to tighten proximity switch hold down screws will result in hydraulic oil spraying in general directions. Restart KMT Waterjet pump, first operating in LOW pressure mode to flush out air in HP components and also to check for obvious leaks. Switch to HIGH pressure after 5-10 minutes of LOW pressure operation, watching for obvious leaks.
  • Page 79 SECTION 7 HIGH PRESSURE WATER Figure 7-4 SEAL REMOVAL PROCEDURE Thread plug (3) into seal head gland (5), (hand tight). Position HP cylinder jug (1) upright as shown in fixture (2). Fill HP cylinder with water. Position used or spare plunger (4) in HP cylinder at point “A”. Note that if the bronze packing follower is loose, install it in the HP cylinder bore, then slip the plunger through the packing follower to insure a good seal for hydraulic seal removal.
  • Page 80 SECTION 7 HIGH PRESSURE WATER sandpaper. Sand in rotating motion, avoiding longitudinal motions, which could cause leaks. Note that grooves or ridges are typically caused by seal debris buildup rather than by marks in ID wall of HP cylinder. Inspect plunger surface for flaws. Rotate plunger 360- degrees by hand while viewing light reflection on plunger surface to note any dullness, streaks, pits or other defects.
  • Page 81 SECTION 7 HIGH PRESSURE WATER TABLE 7-5 TORQUE SPECIFICATIONS— HARD SEAL END CAP (HSEC) Nominal Plunger Size (Intensifier) Plunger Diameter 7/8 (0.875”) 1-1/8 (1.125”) Cylinder Bore Diameter 1.125” 1.375” HSEC Jackbolts 6 ea, 7/16-20 thread 8 ea, 7/16-20 thread Wrench Size HSEC Jackbolt 3/8-inch Stage Jackbolt Tightening...
  • Page 82 SECTION 7 HIGH PRESSURE WATER Table 7-6. Lube Specs KMT Waterjet Intensifier Pumps Item KMT P/N Description Applications 10087385 FML Grease, White Lube Parts, HP Cylinder High Purity Goop-SS 10084440 SS Threads Threads 49832199 Moly Disulfide Grease Non-SS Threads p. 7-12...
  • Page 83 SECTION 7 HIGH PRESSURE WATER Table 7-7 HP INTENSIFIER SERVICE TEARDOWN SEQUENCE Disassemble/Re-assemble Retainer Intensifier Related HP Cylinder Hydraulic LP Water Flanges & Component Component HP Piping Sealing Head, HSEC Cylinder Plumbing Hydraulic Maintenance Assembly HSEC [1] Head Cartridge Ref Part No. 7.2.1 7.2.1 7.2.2...

  • Page 84: Plunger And Hydraulic Cartridge

    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.

  • Page 85: Hydraulic Cylinder Head And Piston

    SECTION 7 HIGH PRESSURE WATER Install HP cylinder jug to hydraulic cylinder head per paragraph 7.2.2. 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 86 SECTION 7 HIGH PRESSURE WATER Figure 7-8 Item Description Cylinder Head Bushing Retainer Flange Plunger Retaining Ring Hydraulic Cartridge, Plunger Seal Hydraulic Cylinder Plunger Removal Tool p. 7-16 80078868...
  • Page 87 SECTION 7 HIGH PRESSURE WATER Figure 7-9 Item Description Bushing Retainer Plunger Cap Screw Flange Cylinder Head Proximity Switch Hydraulic Cylinder Cap Screw Hyd Cartridge, O-ring Hyd Piston Assy Plunger Seal Assy Backup Ring Spacer Intensifier Subassemblies Inspection and Repair The inspection and repair of the following subassemblies will be discussed: •...

  • Page 88: Discharge Hp Check Valve

    SECTION 7 HIGH PRESSURE WATER 7.3.1 Discharge HP Check Valve The HP discharge check valve can be serviced with the sealing head either installed in or removed from its intensifier HP cylinder. Remove the gland nut from the sealing head using a pair of wrenches. When the gland nut is removed, the spring guide and spring will normally stay in the gland nut.
  • Page 89 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 ball into the gland nut. Apply a coating of food grade grease to the check poppet to hold it in place when installing gland nut in sealing head.

  • Page 90: 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 91 SECTION 7 HIGH PRESSURE WATER Figure 7-11 Item Description (1) Sealing Head (2) Poppet, Inlet Check (3) Gland Nut (4) HP Cylinder (5) Spacer Ring (6) Hard seal End Cap (7) Jackbolt (8) O-ring (9) Cylinder Liner p. 7-21 80078868...

  • Page 92: Sealing Head

    10-15 degrees every stroke. Be careful not to tilt or tip the head while polishing it as to not scrape the part. When the sealing head is flat and smooth, perform a final polish with 600 grit wet/dry sandpaper. A mirror finish is required. KMT Waterjet offers a refinishing service. p. 7-22...

  • Page 93: Hp Cylinder

    SECTION 7 HIGH PRESSURE WATER 7.3.4 HP Cylinder 1. 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. 2. Remove the bore liner. Use a plastic-faced hammer and the seal removal tool to drive out the plunger HP seal and follower.

  • Page 94: 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 Waterjet offers a plunger reconditioning service. Figure 7-13 Item Description...

  • Page 95: 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. Note any unusual buildups of solid material or debris causing possible leak paths.

  • Page 96: 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. Pins (2) are maintained in place by flat steel band (6).
  • Page 97 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 98 SECTION 7 HIGH PRESSURE WATER 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). Failure to install backup ring can result in plunger being forced out of plunger pocket.
  • Page 99 SECTION 7 HIGH PRESSURE WATER Figure 7-16 Item Description Hydraulic Cylinder Seal Ring Compression Tool (P460) Proximity Switch Hydraulic Piston Assy p. 7-29 80078868...

  • Page 100: 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. Figure 7-17 Item Description (1) Hydraulic Cylinder...

  • Page 101: Hp Dump Valve

    There is no servicing of the HP attenuator at the customer level. The seals in the HP attenuator are tested at KMT Waterjet to high pressure in excess of operating pressure making disassembly difficult. In the event of a HP water leak of a HP attenuator, the attenuator should be replaced.
  • Page 102 SECTION 7 HIGH PRESSURE WATER Figure 7-18 Plunger Removal Tool Seal Removal Tool Stand Vee Block Cradle 3/8” Plug Cylinder Wrench 3/8“Gland Fitting End Cap Wrench (6x/8x) Seal Removal Tool End Cap Wrench (8x) p. 7-32 80078868...

  • Page 103: 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 104 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 105: 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 106: 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 107 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 108: 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 109 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 110 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 111: 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 112: 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 113: 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 114: Section 9 Hydraulic System

    SECTION 9 HYDRAULIC SYSTEM 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. • Close - coupled motor/hydraulic pump – pump mounts directly to the motor, saving approximately 8-10 inches of length on the overall pump/motor assembly, reducing footprint of the waterjet pump package.

  • Page 115: Components

    SECTION 9 HYDRAULIC SYSTEM 9.1.1 Components Following are the hydraulic system components: 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...

  • Page 116: Operation

    SECTION 9 HYDRAULIC SYSTEM Operation The hydraulic system operates at HI or LO pressure settings up to the maximum flow capacity of the variable displacement piston pump. Upon selecting HI or LO, the operator is able to adjust the HI or LO pressure controls within the respective adjustment ranges.

  • Page 117: 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 118: Motor/Hydraulic Service Maintenance

    SECTION 9 HYDRAULIC SYSTEM Motor/Hydraulic Service Maintenance The hydraulic oil filter should be checked daily and replaced when the visual indicator is in the red zone. The hydraulic oil should be replaced every 3000 hours or yearly, whichever occurs first. For hydraulic oil and filter maintenance, see Section 10, Recirculation System.

  • Page 119: Motor Service

    SECTION 9 HYDRAULIC SYSTEM 9.3.1 Motor Service 1. Locate the two zerk fittings, they are located at each end of the motor, remove their plastic caps. 2. Apply one or two strokes of grease. Replace caps on zerk fittings. 3. Run motor a few minutes. 9.3.2 Manifold Service 1.

  • Page 120: 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. conditioning of the hydraulic oil includes cooling it, cleaning it, and together with the hydraulic tank, removing air bubbles entrained in the oil due to agitation and turbulent flow in the main pump circuit.
  • Page 121 SECTION 10 RECIRCULATION SYSTEM Figure 10-1 Recirculation System Item Description (1) Recirculation Pump (2) Water Modulating Valve (3) Heat Exchanger (4) Visual Indicator (5) Oil Filter (7) Oil Fill Port (8) Hydraulic Oil Tank Page 10-2 49836026...

  • Page 122: Operation

    SECTION 10 RECIRCULATION SYSTEM 10.2 Operation The recirculation pump (1) takes oil from the tank (8) and pumps it to the oil to water heat exchanger (3), then to the oil filter (5) and back to the tank. The visual indicator (4) indicates when the filter element needs replacement. It should be read when both the water jet pump is running and the oil temperature is approximately 115°F.

  • Page 123: System Pressure Protection

    SECTION 10 RECIRCULATION SYSTEM Operating Temperature Adjustment The operating temperature is adjusted by turning the water modulating valve (2) adjusting knob with a flat blade screwdriver. Clockwise increases the oil temperature. The water modulating valve regulates the cooling flow that enters at port “D” to the heat exchanger (3) and then discharges through port “C”...

  • Page 124: Maintenance Overview

    Parts: Hydraulic Oil: General service, use Mobil #DTE Heavy Medium, No. 021029 (KMT Waterjet part 05022702) Food service, use Conoco AA-20 (KMT Waterjet part 49835762) Oil with additives such as zinc diophosphate (ZDDP)for anti-wear are not recommended because of reaction with water.
  • Page 125 SECTION 10 RECIRCULATION SYSTEM Oil Filter See Table 10-3 for oil filter change criteria. Components: (1) Oil Filter Head (2) Element (3) Visual Indicator Parts: Element Tools: Filter Wrench Rags Container to collect oil spills Replace Oil Filter 1. Unscrew element from filter head with the filter wrench. 2.
  • Page 126 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 127 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 128: Section 11 Specifications

    SECTION 11 SPECIFICATIONS Specifications Following are the specifications for the SL-IV 100 Waterjet Pump. Included are the specifications for the equipment, torque, cutting water, cooling water, and the maximum quantity of orifices which can be supported. 11.1 Equipment Specifications Installation location Indoors -Air borne dust/contaminants Ambient temperature...
  • Page 129 SECTION 11 SPECIFICATIONS °C(°F) Hot oil shutdown 62(144) β >75 Oil filtration -Hydraulic Pump Type Piston Displacement Variable Pressure Compensated Flow rate 203(53) l/min(gpm) -Hydraulic Hi-Lo Settings (factory) Lo pressure 34(500) bar(psi) Hi pressure 172(2500) bar(psi) -Hydraulic oil cooling Total heat rejection (max) 13(18) kW(hp) Cooling fluid requirements at inlet...

  • Page 130: Torque Specifications

    LIFE OF COMPONENTS. Use of an antiseize thread lubricant, like High Purity Goop (KMT Waterjet 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). 49836067 Page 11-3...

  • Page 131: 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 132: Cooling Water Specifications

    SECTION 11 SPECIFICATIONS 11.4 Cooling Water Specifications Depending on the type of cooling system (closed recirculation, once through, etc.), the following common problems can be experienced: Closed recirculation: Corrosion Fouling Once through: Corrosion Fouling Scale Microbiological Scale control is the most common problem, and is the result of insoluble matter deposited on the heat transfer surface.
  • Page 133 SECTION 11 SPECIFICATIONS 4,137 (60,000) 67(90) 6.1 (1.6) 0.25 (0.010) 4,137 (60,000) 75(100) 6.8 (1.8) 0.18 (0.007) 4,137 (60,000) 75(100) 6.8 (1.8) 0.13 (0.005) 49836067 Page 11-6...

  • Page 134: Section 12 Parts Lists

    SECTION 12 PARTS LISTS PARTS LISTS For: SL-IV PLUS HSEC High Pressure Waterjet Pump To contact the KMT Waterjet Systems Spare Parts Department: Parts Department Europe: Spare Parts Manager KMT Waterjet Systems GmbH Waterjet Systems Wasserstrahl–Schneidetechnik 635 West 12 Street / POB 231...
  • Page 135 SECTION 12 PARTS LISTS SECTION 12 PARTS LISTS 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 136 SECTION 12 PARTS LISTS Fig # Figure Title Part Number Page # 12-1 Waterjet Pump, 75S, 460V 80074149 12-5 12-2 Intensifier Assembly 80075658 12-7 12-3 Seal Head Assembly 80072341 12-9 12-4 Hydraulic Piston 05146576 12-11 12-5 Hydraulic Cartridge 05146584 12-13 12-6 Hydraulic Hose Connections 05142351...
  • Page 137 SECTION 12 PARTS LISTS Figure 12-1. WATERJET PUMP, 80074149-75S, 460V ITEM No. QTY. PART No. DESCRIPTION 80077373 HP Piping Assembly 80077936 Electrical Assembly 49830433 Test Report 80077217 Decal Package 05128087 Start-Up Tag 80079668 Bulkhead Assembly 05141569 Frame Assembly 05104153 Reservoir Assembly 80074768 Cover Assembly 80077225...
  • Page 138 SECTION 12 PARTS LISTS May 2003 page 12-5 80079064...
  • Page 139 SECTION 12 PARTS LISTS Figure 12-2. INTENSIFIER ASSEMBLY 80075658 ITEM No. QTY. PART No. DESCRIPTION 80076797 HP Cylinder Body, 1.13-in. ID 05144506 Plunger, Ceramic 80072341 Sealing Head Assembly 80076805 Cylinder Head, 05149711 HP Seal Assembly 05144597 Ring Spacer 49838220 HP Cylinder Nut 05146584 Seal Assembly, Low Pressure 05145099...
  • Page 140 SECTION 12 PARTS LISTS May 2003 page 12-7 80079064...
  • Page 141 SECTION 12 PARTS LISTS Figure 12-3. SEALING HEAD ASSEMBLY 80072341 ITEM No. PART No. DESCRIPTION 80071293 Body, Sealing Head 05119680 Poppet, Valve 05116595 Gland, HP, Sealing Head 05116579 Seat, HP, Sealing Head 05116603 Poppet, Valve 05119839 05119698 Retainer 05147863 Spring, Compression May 2003 page 12-8 80079064...
  • Page 142 SECTION 12 PARTS LISTS May 2003 page 12-9 80079064...
  • Page 143 SECTION 12 PARTS LISTS Figure 12-4 HYDRAULIC PISTON ASSEMBLY 05146576 ITEM No. PART No. DESCRIPTION 05144589 Body, Hydraulic Piston 05074380 Pin, Clevis 05049887 Screw, Set, Socket, with Through Hole 10148757 Check Valve Cartridge, with O-ring 49877509 Adhesive, Thread Locker 05130216 Ring, Snap, Flat Wire 05146568 Ring, Backup...
  • Page 144 SECTION 12 PARTS LISTS May 2003 page 12-11 80079064...
  • Page 145 SECTION 12 PARTS LISTS Figure 12-5 HYDRAULIC CARTRIDGE SEAL ASSEMBLY 05146584 ITEM No. PART No. DESCRIPTION 05144530 Seal Bushing 10142032 Packing Ring 10145431 O-ring 05116140 Back-up Ring 10168912 O-ring 05116124 O-ring 05116132 Seal, U-Cup Ref 1 05009048 Tool, Seal Installation May 2003 page 12-12 80079064...
  • Page 146 SECTION 12 PARTS LISTS May 2003 page 12-13 80079064...
  • Page 147 SECTION 12 PARTS LISTS Figure 12-6. HYDRAULIC HOSE CONNECTIONS 05142351 ITEM No. PART No. DESCRIPTION 05106950 Hose Assembly 05106968 Hose Assembly 05106976 Hose Assembly 10194207 Hose Clamp 8.5” 10079754 Radiator Hose 49872245 Split Flange 05106984 Split Flange Elbow 05112750 Hose Assembly 05051214 Hose Assembly 80079544...
  • Page 148 SECTION 12 PARTS LISTS May 2003 page 12-15 80079064...
  • Page 149 SECTION 12 PARTS LISTS Figure 12-7. HIGH PRESSURE PIPING 80077373 ITEM No PART No. DESCRIPTION 80075658 Intensifier Assembly, SL-IV 05040696 Accumulator, HP, .96 liter (56 cu. in.), 4,200 bar, TUV 05090717 Nut, Retaining, HP Accumulator 05144837 Spacer, Bracket, HP Accumulator 10079465 Tee, HP, .56, 60ksi, stainless 10078772...
  • Page 150 SECTION 12 PARTS LISTS May 2003 page 12-17 80079064...
  • Page 151 SECTION 12 PARTS LISTS Figure 12-8 HYDRAULIC MANIFOLD ASSEMBLY 05103171 ITEM No. QTY. PART No. DESCRIPTION 05103197 Block, Manifold, Hydraulic 10187417 O-ring, -128 05071055 Plug, -12 SAE O-ring, Hex Socket, Steel 05103189 Valve, Check, Hyd, Cartridge 10187060 Valve, Relief, Hyd, 25 – 800 psi Range, Adjustable 10187052 Valve, Relief, Hyd, 100 –...
  • Page 152 SECTION 12 PARTS LISTS May 2003 page 12-19 80079064...
  • Page 153 SECTION 12 PARTS LISTS Figure 12-9. BULKHEAD PIPING ASSEMBLY 05142344 ITEM QTY PART No. DESCRIPTION 10078335 Reducing Nipple, .25 x .125 49887011 Adapter-Pipe/JIC, 90 Deg, 8-8 95680922 Adapter-Pipe/JIC, 90Deg 8 - 8 10091866 Water Modulating Valve 10189025 Adapter-Hose/JIC, -8 x –8 05060207 Nipple, ½...
  • Page 154 SECTION 12 PARTS LISTS May 2003 page 12-21 80079064...
  • Page 155 SECTION 12 PARTS LISTS Figure 12-10. PNEUMATIC VALVE 10184760 ITEM No PART No. DESCRIPTION 10189181 Body 10178697 Valve Seat BV701184 Gland, .38 HP Tube, Anti-Vibration BV901184 Stem, Valve, 0.080-in Diameter 10188233 Back-up Ring 10178978 Seal Assembly, HP Valve, .25 Bore 10087385 Grease 10189553...
  • Page 156 SECTION 12 PARTS LISTS May 2003 page 12-23 80079064...
  • Page 157 SECTION 12 PARTS LISTS Figure 12-11 LOW PRESSURE WATER FILTER ASSEMBLY 49838378 ITEM No. QTY. PART No. DESCRIPTION 49833924 Low Pressure Manifold 49833957 Low Pressure Manifold 49833742 Low Pressure Manifold 49838386 Nipple, 3/4 NPT x 4-in., Stainless 49833882 Adapter-O-ring/Hose, Straight, 8-8 05140751 Pressure Switch 05142062...
  • Page 158 SECTION 12 PARTS LISTS May 2003 page 12-25 80079064...
  • Page 159 SECTION 12 PARTS LISTS Figure 12-12 HYDRAULIC POWER PACKAGE, 80077225 ITEM No. PART No. DESCRIPTION 80077078 Motor/Pump Assembly 05103411 Water Pump Adapter 95572897 Hex Head Screw, 1/4-20 x 5/8 95838314 Lock Washer, .25 49836778 Vane Water Pump 05103395 Shaft Coupling 95688750 Lock Washer, .50 95750394...
  • Page 160 SECTION 12 PARTS LISTS May 2003 page 12-27 80079064...
  • Page 161 SECTION 12 PARTS LISTS Figure 12-13 MOTOR / PUMP ASSEMBLY-80077078 ITEM No PART NO. DESCRIPTION 95296281 Screw, Hex Head, ¾-10 x 2.00 95688735 Washer, Lock, ¾ 05103205 Mount, Motor 80076714 Electric Motor 10066256 Screw, Hex Head, ¾-10 x 2-1/2 10184802 Grease, Anti-Seize, Optimol 80077076 Pump, Hydraulic, Variable-Displacement, Axial-Piston...
  • Page 162 SECTION 12 PARTS LISTS May 2003 page 12-29 80079064...
  • Page 163 SECTION 12 PARTS LISTS Figure 12-14 RESERVOIR ASSEMBLY 05104153 ITEM No. PART No. DESCRIPTION 05104161 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 164 SECTION 12 PARTS LISTS May 2003 page 12-31 80079064...
  • Page 165 SECTION 12 PARTS LISTS Figure 12-15. TOP COVER ASSEMBLY 80074768 ITEM No. QTY. PART No. DESCRIPTION 80074750 Support Assembly 80074735 Hinge 80074727 Cover, Top 49834708 Cover, End 49834690 Cover, End 49837511 Mounting Bracket 49837529 Mounting Bracket 49837503 Gas Spring 49837743 Screw-Button Head, 3/8-16 x 1.25 05091988 Nut, Flanged, 3/8 –...
  • Page 166 SECTION 12 PARTS LISTS May 2003 page 12-33 80079064...
  • Page 167 SECTION 12 PARTS LISTS Figure 12-16. ELECTRICAL ASSEMBLY 80077396 ITEM No. PART No. DESCRIPTION 05148531 Harness, Cable, Sensor/Solenoid 10098804 Flexible Conduit Connector 05097464 Terminal Ring, #4 42” 10098788 Flexible Conduit 10114932 Flexible Conduit 05081377 Conduit Bushing 05113923 #6 Terminal Ring 10069763 Washer 246”...
  • Page 168 SECTION 12 PARTS LISTS May 2003 page 12-35 80079064...
  • Page 169 SECTION 12 PARTS LISTS Figure 12-17 CONTROL PANEL CONFIGURATION, 80077944 ITEM PART No DESCRIPTION 42” 10170157 #10 Wire, Green/Yellow 05138078 Circuit Breaker 90” 05019898 #14 Wire, Black 05031620 Socket Hd Screw, 10-32 x 1 3/4 05019617 Crimp Connector 05137963 Rotary Drive 05140686 Circuit Breaker, 600v 05137989...
  • Page 170 SECTION 12 PARTS LISTS May 2003 page 12-37 80079064...
  • Page 171 SECTION 12 PARTS LISTS Figure 12-18. CONTROLS SUBASSEMBLY 80077845-400v ITEM PART No DESCRIPTION 10170132 Rivet 10176410 #16 Wire, Blue 49874191 Hole Seal 10170165 #16 Wire, Green/Yellow 05140926 #16 Wire, Orange 05032420 Terminal Block 10185395 Crimp Connector 36” 10103034 Din Rail 10069888 Lock Washer, #6 10157667...
  • Page 172 SECTION 12 PARTS LISTS May 2003 page 12-39 80079064...
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