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1. 4 J SS 20477742 1 Oil Level Temperature 5 4 Way Valve A Solenoid 9 Inlet Water Pressure Switch Switch 2 Dump Valve 6 4 Way Valve B Solenoid 10 Water Inlet V
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3. amp e O E bz S JT e Table 2 4 Service Connections 2 51 G18 mm 16261 nm 2001 Gti mm A B C D 23 76 604 mm E F G Contaminated Waste Dram 1 2 BSPT 28 76 730 mm Cutting Water Out 9 16 HP 36 26 921 mm Plant Air In 1 4 BSPT 40 26 1 023 mm Cooling Water Inlet cooling water flows through the oil to water heat exchanger in the hydraulic system to control heat buildup in the hydraulic oil The cooling water is then discharged through the cooling water out port to either the drain or routed to a customer supplied water chiller Cooling water supply piping must be sized to meet the flow and pressure requirements of the equipment If municipal or well water is used for cooling ensure the supply flow and pressure meet the requirements in Section 11 Specifications If a facility wide chilled water system is used for cooling ensure there is a minimum of 35 psi 2 4 bar pressure differential between the facility supply and discharge plumbing Installation of an in line pressure boosting pump may be necessary to provide adequate cooling flow Dedicated chilled water systems should be sized according to pump horsepower as illustrated in Table 2 5 Chilled Water Systems 8 2010 Rev 02 2 5 Installation P
4. 1 Sealing Head Seal Assembly 3 Wedge Ring 2 Inlet Check Valve 4 Seal w O Ring Sealing Head Maintenance The sealing head should be inspected for scratches excessive sealing damage or erosion marking on the sealing head seal contact surface and on the inlet poppet valve contact surface The inlet water groove should be inspected for cracking If defects are detected the surfaces must be refinished The sealing head can be returned to KMT Waterjet for refinishing l 20480314 7 201 1 Rev 02 Inspect the inlet poppet valve sealing surface for pits scratches or jetting erosion If necessary refinish the surface Place a piece of 1 4 1 2 thick plate glass not window glass on a sturdy table to provide an absolutely flat surface Place a piece of 400 grit wet dry sandpaper on the glass Use even deliberate strokes rotating the sealing head approximately 10 15 degrees after each stroke Polish the sealing head until it is flat and smooth Be careful not to cause additional damage by tilting or tipping the part while polishing When the sealing head is flat and smooth perform a final polish with 600 grit wet dry sandpaper KIMT A 9 8 High Pressure Seal Assembly Section 9 High Pressure Water System The following procedure should be used to replace the high pressure seal assembly Figure 9 13 High Pressure Seal Assembly 20422243
5. 1 U Body Seal Seal Orientation 2 J5 Hyper Seal 6 Plunger 3 O Ring 7 Piston 4 Backup Ring 8 Sealing Head 5 Packing Follower 9 Red Surfaces Prior to removing electrical power or any high or low pressure piping bring the hydraulic piston in the left or right stop position to facilitate maintenance The plunger will extend in the selected direction allowing full exposure when the unit is disassembled Refer to Section 4 Operation 1 Turn the machine off and observe the appropriate Lockout Tagout procedures Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before proceeding Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding 2 Disconnect the high and low pressure water piping following the procedure High and Low Pressure Water Piping 20480314 7 2011 Rev 02 Section 9 High Pressure Water System Remove the high pressure cylinder assembly components following the procedure High Pressure Cylinder Assembly Removal Remove the high pressure seal assembly from the cylinder by inserting the seal removal tool into the cylinder and pushing the seal assembly out Use caution to avoid scratching the cylinder bore Figure 9 14 High Pressure Seal Removal 20480314 7 2011 Rev 02 Ae CO Seal Removal Tool 3 Cylinder Liner 2 High
6. 9 23 Hydraulic Piston and Plunger Removal 9 23 Bearing Rings and Seal Assembly nnnnnnnnnnnnnnnnnnnnssssssssseeseeenssssssssss 9 25 Pl nser VI att Ath CS ee e Dee 9 25 Hydraulic Piston and Plunger Installation 9 26 111 9 11 Hydraulic Cylinder Mamntenance 9 27 QUIA Elo Pressure Atenas 9 27 9 13 High Pressure Dump Valve l y a QQ G Qa Q ss 9 28 Pr eumatic Control Dump Valve asa 9 28 PAID ed 9 33 DNA Weep OE Ee 9 34 10 Troubleshootine cuanta 10 1 LOZERE ENNCeNa a pir IN S MN E AdE 10 1 10 2 Troubleshootmg Guide unicidad 10 1 IL SDECHICAUONS ne en EU I 11 1 keck GEIER 11 1 11 2 Installation Specifications 11 1 a Rene ne As z 11 1 js e M 11 1 Equipment Dimensions and Woechts 11 2 Service COMMCCHONS o Doe in od 11 2 PRE A ed ee UM EE URN ded UE 11 2 LLS ERT e EE 11 3 Cuttine Water SUPPLY AE EE EE 11 3 RE CIRC UIA OM SM is 11 3 Water Quality Standard EA 11 4 ILF te SPECI ALONG E 11 6 PS SEEN Ay Se EEN 11 6 Ampacity and Power Voltage Requiements 11 6 11 5 Hydraulic and High Pressure System Specifications 11 7 J Vr ali 5 kase 11 7 Hish Pressure Water GREEN 11 7 Bee 11 8 Torque SPE RT le EE 11 9 12 Farts TGS E 12 1 A EE 12 1
7. 7 3 Hydraulic Operating EE 7 4 Kloterer 7 5 Hydraulic Compensator Mantenance 7 5 Electrical Stemi 8 1 8 1 EE 8 1 8 2 SSCUI TTE 8 1 Sensors and SOLOS ia 8 4 8 3 Service and Maintenance Procedures 8 8 Proximity Switch Maintenance ia 8 8 High Pressure Water System 9 1 9 1 BE 9 9 2 ODEO EE 9 2 9 3 SVSLem Components E 9 4 9 4 Service and Maintenance OVvervIew 9 6 Torque Specification Sausen a 9 7 Specialized Maintenance Tools eee 9 8 9 5 High and Low Pressure Water Ppmg 9 9 9 6 High Pressure Cylinder Assembly ias 9 9 High Pressure Cylinder Assembly Removal 9 10 High Pressure Cylinder Assembly Installation 9 11 High Pressure Cylinder Maintenance eeeessseeeeeenre 9 12 9 7 Se lis TS A ne cn io ct 9 13 High Pressure Discharge Check Valve 9 13 Low Pressure Inlet Check Valve ya y ane tan 9 15 sealing Head Seal Assembly 9 16 oealimo Head VIamtenadnee ee 9 16 9 8 Eltere 9 17 9 9 Hydraulic Seal Cartridge Replacement 9 19 Hydraulic Seal Caridad a 9 20 9 10 Hydraulic Piston and Plungers
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9. Figure 7 3 High Low Pressure Controls 20480306 2 2009 Rev 0 UL N N A d Ef i YA d N ae E 081 A lt e N GS WZ Re VAN eg 7 i N 1 High Pressure Control 2 Low Pressure Control Check the operating pressure to determine if adjustment is necessary If high pressure adjustment is required loosen the locking thumbscrew on the high pressure control valve by turning counter clockwise Turn the knob on the control valve clockwise to increase operating pressure Turn the knob counter clockwise to decrease pressure Tighten the locking nut and verify the high pressure setting If low pressure adjustment is required loosen the locking nut on the low pressure control valve by turning counter clockwise Turn the hex clockwise to increase operating pressure Turn the hex counter clockwise to decrease pressure Tighten the locking nut and verify the low pressure setting 7 4 Hydraulic System KMT Section 7 A Motor Maintenance The motor should be inspected at regular intervals approximately every 500 hours of operation or every three months whichever occurs first Keep the motor clean and the ventilation openings clear Hydraulic Compensator Maintenance The high and low limit compensators regulate the flow of hydraulic fluid to the system Th
10. Orifice Size Number of Operating Total inches mm Orifices Pressure Calculation Horsepower EN 0 005 0 127 3 3 22000 3x62 XA 18 6 X 0 012 0 305 I 0 009 0 229 I 50 000 31 2 175 48 7 Torque Specifications Measurements are made with lubricated components and a certified calibrated torque wrench Inconsistencies in wrench settings lubrication and technique may not produce a leak free seal If leakage occurs the torque can be increased to seal the components However do not exceed the recommended torque value by more than 15 percent If leakage persists there is a component problem Excessive torque can cause component damage or failure resulting in potential hazards to equipment and personnel 20480327 7 2011 Rev 03 1 1 8 KIMT pr Torque Specifications Hydraulic Cylinder Head Socket Head Screws Torque Hex Key Proximity Switch Socket Head Screws Torque Hex Key Intensifier Mount Socket Head Screws Torque Hex Key Sealing Head Discharge Gland Nut Poppet Retainer Pneumatic Control Valve 3 8 inch HP Inlet Gland Nut 1 4 inch Outlet to Drain Pneumatic Actuator HP Adapter High Pressure Fittings 1 4 inch Gland Nut 3 8 inch Gland Nut 9 16 inch Gland Nut 7 2011 Rev 03 Section 11 Specifications 8 14M each 75 80 ft lbs 102 108 Nm M12 2 M6 each 140 160 in Ibs 16 18 Nm M5 4 M10 each 60 65 ft lbs 80 88 Nm M8 130 ft lbs 176 Nm 25 30 in Ibs 2 8 3 4 Nm
11. Proximity Switch Maintenance A proximity switch has failed and needs to be replaced if the LEDs do not change state indicating they are not sensing the piston if an LED flashes continuously or if the appropriate input is not noted on the PLC processor annunciator light panel in the electrical enclosure Figure 8 5 Proximity Switch Proximity Switch 2 O Ring Spacer 1 Turn the machine off and observe the appropriate Lockout Tagout procedures Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance on the system components Ensure all pressure 1s relieved or blocked from the hydraulic and high pressure circuits before performing maintenance 2 Remove the electrical cable from the failed proximity switch 3 Remove the two socket head screws the failed switch and the o ring spacer 20480310 2 2009 Rev 0 8 8 Electrical System A 20480310 2 2009 Rev 0 4 Install a new proximity switch by positioning the o ring spacer and the switch Ensure the o rings are correctly oriented Apply JL M grease to the threads on the screws and tighten to 140 160 in lbs 16 18 Nm VAN CAUTION Ensure that the proximity switch is properly installed and secured prior to starting the machine Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil 8 9 KIMT r SECTION 9
12. Ji RC T ee ee td 12 2 APPENDIX Exhibit System Schematic Electrical Schematic Material Safety Data Sheets 20480338 8 2010 Rev 02 KIMT r SECTION 1 INTRODUCTION 1 1 Overview The Jetline Series combines all the unique capabilities and advantages of waterjet cutting systems with the reliability ease of operation and service support that have made KMT Waterjet Systems a leader in waterjet technology Table 1 1 Jetline JL 1 Motor Horsepower Maximum Maximum Maximum Single low Operating Flow Rate Orifice Diameter Pressure at full pressure at full pressure 35 3 55 000 psi 3 792 bar 60 gpm 2 3 L min 0 011 inch 0 28 mm 50 55 000 psi 3 792 bar 1 0 gpm 3 8 L min 0 014 inch 0 36 mm 1 2 Product Nameplate The product nameplate contains the pump model serial identification and part numbers for each individual machine Figure 1 1 Nameplate KMT waterjet systems Waterjet Systems P O Box 231 635 WEST IZTH ST ISO 9001 BAXTER SPRINGS Ks 66715 0251 TEL 800 826 927L FAX 620 856 5050 MODEL S N MAX WORKING PRESS KPSI LD 8003841 PART NO 20464958 VOLTS PHASE HZ 3380 3 50 FULL LOAD AMPS SHORT CIRCUIT INTERRUPT RMS SYM AMPS VOLTS 13 Operational Overview The following provides a brief overview of the function and primary components associated with the individual systems A detailed discussion of each system is provided in Sections 4 through 9 Equipment
13. 20480282 Table 2 5 Chilled Water Systems Cooling Requirements at Full Capacity Horsepower BTU HR 30 13 400 50 22 000 Note Coolant flow to the heat exchanger is regulated by the temperature of the contents in the hydraulic reservoir and will be shut off at times Cutting Water Inlet cutting water is routed to the intensifier where it is pressurized and delivered to the cutting head The cutting water supply must meet the minimum water quality standards outlined in Section 11 Specifications Poor water quality will drastically shorten component life and void the warranty Cutting water supply piping must be sized to meet the flow and pressure requirements listed in Section 11 Only PVC copper or rubber hose should be used between the cutting water source and the machine The inlet cutting water must be maintained at a minimum pressure of 35 psi 2 4 bar at all times If the facility water pressure is below or can fall below 35 psi 2 4 bar a water pressure booster pump 1s required NOTE AA AA A A A A A A A A A A A A A A A A A A A A A A A A A A A A A ee ee net Drain Cutting water released through the safety dump valve when the emergency stop button is initiated is discharged from the drain port The discharge is considered wastewater and must be piped to an appropriate location 1 e a sewer line The volume of water released will be minimal and does not require high pressure plumbing however piping must comply with
14. 50 ft Ibs 68 Nm 25 ft Ibs 34 Nm 5 ft Ibs 7 Nm 25 ft Ibs 34 Nm 25 ft Ib 34 Nm 50 ft lb 68 Nm 110 ft Ib 149 Nm I cl urooofrojeA jurq p soieds iopio Tew LC L66 Ct09 67 xe 61 1 L66 Ct09 6h7 uoud AUBULIDD WISUNEN ped ecr9 d I Woyne 19p my xruqoojopreuqog YeISIOSse M Hqwy suiojs S PWM LINA Jogeue A SUP AdS domy 0 9W TIOC L 0t 08v0c woo johoyemjuyM swed Mm pewg wor JohoyeMUYM do1AJos lan reurq TYTT 9S8 O79 Xty LT6 978 008 uouq YSA I ZO E1L99 SA SSULIOS 19xeg 199 115 PCI HIM Sc9 c XOH Od sulojs S PAM LINA juourn1edo T IMAS IWONY vsn SsulojsAS PIJEM LWY Je Juounied G 991A19S IWON IY Jop uoo 03 UOTJEULIOJUI SUIMOTIOJ Su ISN S31NST Sur Aueduiroooe OY ur SIOQUINU sur jJnu pi u 0 puodsaJJo9 21061 qoo ur SISQUINU ut lr syed juourooe do1 JO SULIOpIO ouj ojej rej OL OS LI wn Sutp r ou 107 syed euondo pue prepuejs e Jo IST oArsuoqo1duioo Y surejuoo uorjoos SIQI MIAMAO T I LSTI SLAVd cI NOLLIAS ZW col 117 SID TI UONI 0 ASA TTOT L 0t 08v0c 8069Lv07 aseyoeg Jomod INNBIP H 6 71 OISPSTOC JOVI JVM 9INSSIIJ MOT 9 ZI 9169L P07 A quiassy Joj A 9 SS9IJ YSIH ZI 6T TI 890LLPOT UOHBINSIFUOD eouoo d SI CI SSETIITL K quiessy ugs q OgphEJp H 9 71 LT TI CVLLLYOC A Quiossy eomp v T cCI 6 LLCVOC K quiessy JOJeny9y 9A e A oneumeudq ZI ST TI Y9TLLYOT K quiessy ediq peeing l z
15. 9 9TIN UeuseA PIA reet 61 I suidno eS TOET6OOL c I dung 1899 poccpoS0 I I dHOS JOOP 99H 09F0696F I Ajguen uopndrnosoq 19qQUINN maul AyQuengd uondins q A19QUINN uro Ltd Hed 8069Lv07 288984 TOMO JINNBAIP H 6 71 AALL JST SIADA TI UONI Parts List N w o m Kum Q Y Y 9 Q l E Eo EU CUT DA d Figure 12 9 Hydraulic Power Package gt E pony 1 8069 v0Z 12 18 7 2011 Rev 03 20480330 6I CI CO A9Y TTOZ L O EO8Pr07 cL TAO nd SSOILOSO Ol I osne oinssaig L6PSHOSO 61 9 OC SUSEA MOOT 0 889S 6 6 CI Ft JOUSEM WIA Z6L680S0 8I 9 T I T X EI T I MOIS PUSH I9YIOS 6SOSSOS6 8 I ST TAO Sud 69L6886p LI I 9A EA OHUOT eUuoTOONG Pp9TLEVOC L I DAJEA POD 9 L6886v 9I I SALA FOIA LIL TLOSO 9 I SAJEA OSPEL OUITIOYH ppyL6886b SI I ET XSLTXOST SuURI O ESGHLOOT SS I SALA JOPA 090 8101 vI r pr Isem JOT 9S 0SOSO r I SALA Jo OW CS0Z8IOI eI r 9 X I 9I L MOIS peeH 19YDOG 9SLT60S0 I 9A EA PIOUS OS 68S68IOI cI I PIOHUEN prITVOSO G C cp quo Bid 1066090 II I dung oynerpAH SOSSYOSO I jguen uondrnosoq 19qUINN w AIDUEDO uondrnsoq JOQUNN UL 118 4 EA 96I8LT0C KA quiossy p oprue A dumnQqg OT CTI 918 L ISVT SAD TI UONI Oc cl 0 ASW I T0T L OEEOSHOZ OG GE J96L8 v quassy plofiuvpy dund Q Z
16. Tubing 25 ft lb 34 Nm 3 8 Tubing 50 ft lb 68 Nm 9 16 Tubing 110 ft lb 149 Nm Anti Vibration Connections The bending stresses resulting from excessive vibration or shock on the threaded area of the tubing can cause premature failure at the back of the thread When tubing will be subjected to vibration rotation and movement anti vibration connections must be used The anti vibration collet gland transfers the stress to the unthreaded section of the tubing and the gripping action of the collet strengthens the entire assembly Figure 2 9 Anti Vibration Connections 1 Gland Nut 4 Exposed Threads 2 Collet 5 Tubing 3 Collar 20480282 8 2010 Rev 02 KMT pr l 2 5 Section 2 Installation Deburr the tubing ID and thoroughly clean the tubing threads Slip the gland nut and the collet onto the tubing Apply Pure Goop to the threads on the tubing Screw the collar onto the threaded end of the tubing leaving 1 1 2 to 2 1 2 threads exposed on the tubing between the collar and the coned tubing Apply Pure Goop to the male threads on the gland nut and insert the tubing into the connection Engage the gland nut and tighten finger tight Tighten the gland nut to the torque specifications in Table 2 11 When a flexible whip is used to allow cutting nozzle movement anti vibration fittings and proper supports and guides must be provided to prevent failures from non water related stresses The whip w
17. 4 Use a magnet to remove the seat from the sealing head 5 Inspect the poppet pin for wear and replace the pin if worn 6 Inspect both faces of the seat for damage or cracking A cracked or damaged seat must be replaced The seat can be installed with either face toward the poppet valve If one face is worn but the opposite is not the seat can be reversed placing the new surface toward the poppet valve A slight burr at the hole edge identifies the used side of the seat If both faces are worn the seat must be replaced NOTE The seat spring and poppet valve should be replaced as a set If one component requires replacement replace all components Gland Nut 4 Discharge Poppet Check Valve 2 Poppet Pin S Seat 3 Compression Spring 7 Apply a thin film of Pure Goop to the face of the seat opposite the poppet check valve and install the seat into the sealing head If the existing seat is reused install the seat with the new surface facing the poppet valve 8 Install the poppet pin spring and poppet valve into the gland nut 20480314 7 2011 Rev 02 9 14 KMT pr 9 10 Section 9 High Pressure Water System Apply Pure Goop to the sealing face and the threads on the gland nut and thread the gland nut into the sealing head Hand tighten until there is a 0 20 inch 5 mm gap between the
18. Damaged sealing head Damaged high pressure cylinder Restricted water supply Clogged water filter Trapped air Low hydraulic pressure setting Collapsed element in the high pressure line filter Failed hydraulic cartridge seal Comments Inspect the condition of the seat poppet valve spring poppet pin and sealing head surface on the discharge end of the sealing heads Inspect the condition of the poppet valve poppet retainer and the spring on the inlet end of the sealing heads Check the sealing head for cracks Check the high pressure cylinder for cracks Check cutting water supply flow and pressure Check the condition of the low pressure water filter and replace the filter element if necessary Bleed the air from the cutting water plumbing If operating in low pressure switch to high pressure operation and check the hydraulic pressure setting Clean the high pressure adjustment valve Clean the compensators on the hydraulic pump Check the element in the high pressure line filter Replace the cartridge seal If the leak persists check the plunger for linear scratches or scoring 10 6 Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction Indication Comments Water leaking from the Failed high pressure seal Replace the high pressure seal weep hole on the hydraulic assembly assembly cylinder head flange 16 Water leaking from the weep h
19. JETLINE JL 1 50 WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL KMT Se JETLINE M JL 1 50 WATERJET INTENSIFIER 20480269 R03 TVANVON HINVNHALNIVIA ANV NOLLV IHdO I JETLINE JL 1 50 WATERJET INTENSIFIER OPERATION AND MAINTENANCE MANUAL KMT a MANUAL 20480269 R03 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 KMT Waterjet believes the information described in this manual to be accurate and reliable Much care has been taken in its preparation however the Company cannot accept any responsibility financial or otherwise for any consequences arising out of the use of this material The information contained herein is subject to change and revisions may be issued advising of such changes and or additions KMT WATERJET SYSTEMS 2009 KIMT Eg KMT Waterjet Systems 635 West 12th Street POB 231 Baxter Springs KS 66713 0231 Phone 800 826 9274 Fax 620 856 5050 20480338 8 2010 Rev 02 TABLE OF CONTENTS Title Page Notice Table of Contents Appendix Section Page 1 KO erte E 1 1 1 1 DA IN 1 1 1 2 Product EE ee 1 1 1 3 Operational OYE ds 1 1 Low Pressure Water yaaa 1 2 ee E A e E ES o A 1 2 FLY ee E 1 2 High Pressure Water SYSTEM siii
20. Spray Loctite 7649 on the threads of the poppet retainer and allow to dry Assemble the spring and the inlet poppet valve on the poppet retainer Apply a small amount of Loctite 242 to the poppet retainer threads only Do not get any Loctite on the poppet or any other surfaces on the inlet check valve Use the flat blade screwdriver to tighten the poppet retainer Tighten the poppet retainer to the torque specifications in Table 9 1 Inspect the assembled unit to ensure the poppet moves freely the spring is fully guided on the poppet retainer the spring end is 90 degrees from the screwdriver slot on the retainer and the poppet retainer is seated against the sealing head KIMT A Section 9 High Pressure Water System Sealing Head Seal Assembly Whenever maintenance requires the sealing head to be removed the sealing head seal assembly must be replaced l 2 3 Prior to Installing a new seal assembly Inspect and clean the seal surfaces on the sealing head and the high pressure cylinder bore Inspect and clean the cylinder liner Install the cylinder liner Lightly coat the seal components with FML 2 grease and slide the seal assembly onto the inlet end of the sealing head as illustrated The wedge ring chamfer must be installed against the chamfered shoulder of the sealing head and the o ring must face the inlet check valve Figure 9 12 Sealing Head Seal Assembly
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22. s console is flashing Abnormal fluctuations In high pressure water signal Indication An alarm condition has occurred Large worn or damaged orifice Check valve leakage Seal leakage Hydraulic control malfunction Comments Check the display panel for fault messages Refer to Section 4 Operation for additional information regarding warning and alarm conditions and recovery procedures Make sure the orifice does not exceed the capacity of the pump Make sure the orifice is in good working condition Verify that the jewel is installed in the orifice mount Inspect the discharge check valves in the sealing heads Inspect the inlet check valves in the sealing heads Inspect the high pressure seal on the plunger Inspect the sealing head seal assembly Check the operation of the hydraulic relief valve Verify that the directional control valve is shifting properly Check the operation of the proximity switches 10 5 KMT Eessen Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction 11 Hot surfaces on the high pressure cylinder components 12 Low cutting water supply pressure Low cutting water pressure Hydraulic oil leaking from the weep hole in the hydraulic cylinder head 20480318 2 2009 Rev 0 Indication Leaking discharge check valve hot sealing head body and discharge gland Leaking inlet check valve hot inlet ring
23. Cutting Water Supply Low Pressure Water System JL 1 30 JL 1 50 Maximum required inlet water flow 2 5 gpm 9 5 L min 4 0 gpm 15 1 L min Minimum inlet water pressure 35 psi 2 4 bar flowing Maximum inlet water pressure 80 psi 5 5 bar Maximum booster outlet water pressure 120 psi 8 3 bar Booster pump factory set inlet pressure 58 psi 4 bar Booster pump factory set outlet pressure 120 psi 8 3 bar Optimum inlet water temperature 65 F 18 C Maximum inlet water temperature 85 F 29 C Low inlet water pressure 30 psi 2 bar Low booster pressure 60 psi 4 bar Recirculation System JL 1 30 JL 1 50 Maximum consumption at 75 F 24 C 1 5 gpm 5 7 L min 3 0 gpm 11 4 L min Total heat rejection 5 3 HP 4 0 kW 8 6 HP 6 4 kW Reservoir capacity 40 gal 151 L Low oil level shutdown 30 gal 114 L Minimum operating oil temperature 60 F 15 C Optimum operating oil temperature 115 F 46 C Hot oil shutdown maximum operating oil temperature 145 F 63 C Minimum inlet cooling water pressure 35 psi 2 4 bar Maximum inlet cooling water pressure 100 psi 6 9 bar Oil filtration rating Beta filtration rating B7 1000 Fluid cleanliness rating ISO fluid cleanliness rating 17 14 Nominal recirculation pressure 30 psi 2 bar Recommended oil type General service Mobil DTE Heavy Medium No 021029 Conoco Hydroclear We multi purpose R amp O Food service Fuchs Geralyn AW68 Food Grade Oil
24. HIGH PRESSURE WATER SYSTEM 9 1 20480314 Overview The high pressure water system is supported by both the cutting water supply circuit and the hydraulic circuit Cutting water of sufficient flow and pressure is routed from the cutting water supply circuit to the intensifier where it 1s pressurized up to 55 000 psi 3 792 bar and delivered to the cutting head The directional control valve in the hydraulic system creates the stroking action of the intensifier by sending pressurized hydraulic oil to one side of the hydraulic cylinder or the other As the flow is sent to one side hydraulic fluid is returned to the reservoir from the opposite side Figure 9 1 High Pressure Water System Circuit Cutting Water In 6 Hydraulic Cylinder 11 Drain 2 Inlet Check Valve 7 Hydraulic Piston 12 Air In 3 Sealing Head 8 Discharge Check Valve 13 Cutting Water Out 4 Soft Seal End Cap 9 Attenuator 5 High Pressure Cylinder 10 Safety Dump Valve System components include a double ended hydraulic cylinder reciprocating piston assembly high pressure cylinders attached to each end of the hydraulic cylinder two plungers sealing heads and soft seal end caps a one liter capacity attenuator and a safety dump valve Sophisticated check valves and seal assemblies ensure hydraulic oil and the low pressure and high pressure water travel in the appropriate direction Warning and shutdown sensors monitor system temp
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27. Performance Serviceability Other 9 2009 Rev 01 O L 1L Yes Yes Yes Yes Yes Yes Yes O O L No No KM B Equipment and Service Manual Questionnaire E 7 Manual Oreanization Does the Table of Contents help you find topics easily Yes No Comments Is the information well organized Yes No Comments Is the page layout suitable for the material being presented Yes No Comments 8 Graphics Are the illustrations suitable for the material being presented Yes No Comments 9 Text Does the information adequately explain how to operate and service the O Yes O No equipment Comments Are there paragraphs or procedures you feel need clarification Please identify them by page number and add your comments Yes No Comments Is there anything you would add or delete to make the manual more useful Yes No Comments Is there any information that should receive more emphasis Yes L No Comments Name Title Company Date Address 20480273 9 2009 Rev 01 2 KIMT r SECTION 2 INSTALLATION 2 1 2 2 20480282 Overview Installation and commissioning requirements and procedures are detailed in this section These procedures require a thorough understanding of the individual components and systems safety issues and the overall operation of the intensifier All personnel involved in the installation operation and or service
28. Section 9 High Pressure Water System 9 9 Hydraulic Seal Cartridge Replacement The following procedure is used to remove and replace the hydraulic seal cartridge Prior to removing electrical power or any high or low pressure piping bring the hydraulic piston in the left or right stop position to facilitate maintenance The plunger will extend in the selected direction allowing full exposure when the unit is disassembled Refer to Section 4 Operation 20480314 7 2011 Rev 02 Turn the machine off and observe the appropriate Lockout Tagout procedures VAN WARNING Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before proceeding Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding Disconnect the high and low pressure water piping following the procedure High and Low Pressure Water Piping Remove the proximity switch on the end of the hydraulic cylinder to be serviced This will allow the hydraulic oil to drain back to the reservoir minimizing oil spillage It will take approximately five minutes for the oil to drain Remove the high pressure cylinder assembly components following the procedure High Pressure Cylinder Assembly Removal Use a flat screwdriver to remove the retaining ring from the hydraulic cylinder head Remove the bushing retainer flange and clean the surfaces weep holes and grooves Ch
29. 03 Never service or maintain the equipment while it is operating All high pressure leaks must be repaired immediately Press the EMERGENCY STOP button to turn the control power off and bleed off the high pressure water from the intensifier before performing maintenance Never service or maintain any high pressure component or loosen any high pressure fitting when it is pressurized Press the EMERGENCY STOP button to turn the control power off and bleed off the high pressure water from the intensifier before servicing If leakage occurs at a sealing surface high pressure water is released through weep holes If a pressurized fitting is loosened a jet of high pressure water will exit the nearest weep hole with possible hazardous results 3 3 Maintenance 3 4 Tool Kit Table 3 2 provides a list of the spare parts and maintenance tools included in standard tool kit for Jetline series pumps Components can also be ordered individually Table 3 2 Tool Kit Tool Kit Part Number Description 20471547 10087385 10079986 20470475 72113886 10084440 3 10149052 10149045 6 05066139 10148674 10149029 2 10149037 4 10081370 10127884 20487868 20494983 05103957 20484488 20480285 7 2011 Rev 03 3 4 KMT ES SECTION 4 OPERATION 4 1 4 2 20480289 Overview The Jetline Series utilizes a programmable logic controller PLC to provide fault detection and troubleshooting logic The oper
30. 1 2 ODGFAHBDP EE 1 3 1 4 voll 1 4 Lockout Tagout Procedure ane ike bis 1 4 Wii Label adeste tei een A s 1 5 Emergency Medical Treatment 1 7 Ls Worldwide Product Support eeeeeeesssssseeeeeeeeennnneeeeneenns 1 7 1 6 Pare DAS a 1 8 L7 Manual OS AMZAUON ri 1 8 1 8 Equipment and Service Manual Ouestonnare 1 8 2 PTS CaM irr ER 2 1 2 1 BEE 2 1 2 2 AAA A A 2 1 2 3 gt CCD MEN di 2 2 ran poltin ae ne aie 2 2 24 Power R QUIT MONES id aio 2 3 2 5 DEL VICES COMME e EE 2 4 eiert 2 5 Cutino EIC m Eege ia 2 6 EE 2 6 PDT AN D hukuta huhu ntis um a aaa ode ea in ELE 2 6 Contaminated W ASIC EE 2 7 2 6 Flow Requirements a aa cae 2 7 2 A e cr trie 2 8 Measurements and DIMENSIONS ias 2 10 PE A E 2 11 Power C ODIDO dali 2 12 Hano Dhteadino ai 2 13 Power A ste statini ua diu E d tt 2 13 20480338 8 2010 Rev 02 3 5 20480338 8 2010 Rev 02 2 8 High Pressure Connections smart 2 14 GEIER 2 14 Anti Vibration Connectons nennen eene 2 15 2 9 HEES 2 16 2 10 D COMMISSIONME al 2 18 N Iiiilenantce lies 3 1 3 1 EE 3 1 3 2 Nidji if n ac TTE E 3 1 Daily A y yuna yaaa O 3 1 INS iere te C2 KE e 3 1 High Pressure System Mantenance 3 2 3 3 Maintenance Precautions eenegen 3 3 3 4 A 3 4 did M n 4 1 4 IUS ROI PTT RN UNE 4 4 2 Start 5e qUefie eiie E Ee 4 Startup af
31. 5 4 20480293 Service and Maintenance Procedures To ensure water quality and supply to the high pressure system the filter element strainer and booster pump will require routine servicing and maintenance The procedures for servicing these components are detailed below NOTE x Refer to Section 12 Parts List for a complete listing of replacement parts and part numbers Filter Assembly and Strainer Maintenance The life of the filter element is directly related to the quality of the inlet water The condition of the filter element can be monitored by observing the pressure gauge on the outlet manifold Document the pressure reading when the filter element is new The element should be replaced when the pressure drops to 15 psi 1 bar below the original value When the filter element is replaced the strainer should also be cleaned The following procedure is used to replace the filter element and clean the strainer Figure 5 3 Filter Element 1 Bleed Valve 3 Filter Element 2 Filter Head 4 Filter Housing 1 Turn the cutting water supply off 2 Press the red bleed valve on the filter head to release any pressure trapped inside the housing 3 Use a filter wrench to unscrew the housing and remove the old element 4 Install the new element Apply FML 2 grease to the o ring in the filter housing and use the filter wrench to replace the h
32. N 0000000 10 59 59 AM Capacity 000 000 7 To avoid a sudden increase in pressure it is necessary to adjust the high pressure setting The high pressure adjustment is made at the high pressure control valve on the hydraulic manifold Refer to Section 7 Hydraulic System for additional information Loosen the locking nut on the high pressure control valve by turning counter clockwise Turn the high pressure control valve counter clockwise decreasing the pressure to the lowest setting 1 Hydraulic Manifold 3 High Pressure Control Valve 2 Hydraulic Pressure Gauge 8 Check the motor rotation Press the F1 button from the Run Screen to start the motor and observe the pressure gauge on the hydraulic manifold If the motor rotation is correct pressure will begin to build in just a few seconds If the rotation is not correct the gauge will not move If the motor shaft is rotating in the wrong direction turn the control power off by pressing the EMERGENCY STOP button The electrical power phase must be reversed to any two motor leads The leads can be reversed at the disconnect circuit breaker on the enclosure door or at the main power disconnect VAN CAUTION Do not allow the motor to run backward Incorrect motor rotation will result in damage to the hydraulic pump 9 Remove the cutting orifice and open the nozzle valve 20480282 8 2010 Rev 02 2 17 Installation KMT Sec
33. Note For each particle per milliliter downstream of the filter greater than 7 microns there are 1000 particles per milliliter larger than 7 microns upstream of the filter 20480327 7 201 1 Rev 03 1 1 3 Specifications KMT Section 11 ms Recirculation System Note Indicates ISO 4406 range numbers for maximum permissible number of particles per milliliter greater than 5 and 15 microns 17 lt 1 300 particles per milliliter gt 5 microns 14 lt 160 particles per milliliter gt 15 microns Water Quality Standards The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance Water treatment requirements can be determined by a water analysis The cutting water supply must meet the following standards A high concentration of dissolved solids especially calcium silica and chlorides will affect high pressure component life Table 11 3 Water Quality Standards Constituent Minimum mg l Requirement Better Best Alkalinity 50 25 10 Calcium 25 5 0 5 Chloride 100 15 I Free Chlorine I I 0 05 Iron 0 2 0 1 0 01 Magnesium as Mg 0 5 0 1 0 1 Manganese as Mn 0 1 0 1 0 1 Nitrate 25 25 10 Silica 15 10 I Sodium 50 10 I Sulfate 25 25 I TDS 200 100 2599 Total Hardness 25 10 I pH 6 5 8 5 6 5 8 5 6 5 8 5 Turbidity NTU 5 5 I Note Total dissolved solids 20480327 7 2011 Rev 03 KIMT HA Section 11 Specifications Table 11 3 Water Quality S
34. Pressure Cylinder 4 High Pressure Seal Assembly 5 Remove the cylinder liner from the bore and inspect for possible heat or wear damage 10 11 or for debris If cracks or brittleness are detected on the tabs on the ends of the liner the liner must be replaced Feel approximately one inch into the cylinder bore for obvious ridges or grooves If seal debris is present follow the procedure High Pressure Cylinder Maintenance Inspect the plunger surface for flaws Rotate the plunger 360 degrees by hand while viewing light reflection on the surface to detect any dullness streaks pits or other defects Run a fingernail perpendicular to the direction of the suspected flaws to determine the severity of defects Depending on the seal life achieved with the removed seal assembly make a judgment regarding plunger and or cylinder replacement If seal debris is present on the plunger polish with 600 grit wet dry sandpaper using a radial motion Lightly coat the new seal components with FML 2 grease and install the new components on the plunger Ensure the proper orientation of the backup rings as illustrated in Figure 9 13 High Pressure Seal Assembly Slide the cylinder liner over the plunger Install the high pressure cylinder into the hydraulic cylinder head following the procedure High Pressure Cylinder Assembly Installation Reconnect the high and low pressure water piping and turn the low pressure water supply on KIMT A
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36. a Maintenance un uu D H HoursStrokes de e Use the arrows on the keypad to highlight the START button and press ENTER to start the pump in maintenance mode e Use the arrows on the keypad to highlight the left or right arrow on the screen and press ENTER to initiate The left arrow on the screen will extend the plunger to the left allowing full exposure to the left plunger when the unit is disassembled The right arrow on the screen will extend the plunger to the right allowing full exposure to the right plunger when the unit is disassembled e Use the arrows on the keypad to highlight the STOP button and press ENTER to stop the pump Maintenance Hours Screen Use the arrows on the keypad to highlight the RESET button and press ENTER to reset the maintenance hours Figure 4 15 Maintenance Hours Screen Maint Hours Maint Hours 0000000000 0 2 2009 Rev 0 4 10 4 9 KMT SEN Section 4 Operation Maintenance Strokes Screen Use the arrows on the keypad to highlight the left or right RESET button and press ENTER to reset the maintenance strokes Figure 4 16 Maintenance Strokes Screen Maint Strokes Left 0000000000 Right 0000000000 Alarms When a fault condition occurs an alarm message appears over the screen and a small triangle flashes in the corner of the screen Pressing SHIFT and ESC will initiate the help function Additional information regarding the type of alarm and possible remedies
37. bar or greater during normal operating conditions Normal operating conditions indicate the machine is running and the oil temperature has reached 115 F 46 C Figure 6 4 Oil Filter Assembly 1 Filter Head 2 Filter Element 1 Use a filter wrench to unscrew the filter element from the filter head Make sure the old gasket is removed with the element 2 Lubricate the gasket on the new element with fresh oil 3 Use the filter wrench to screw the new element onto the filter head and hand tighten Do not over tighten 4 Start the machine and check for leaks NOTE wo nnn a If the pressure gauge reads 40 psi 2 8 bar or greater check the operating condition of the gauge or indicator These components may require replacement Operating Temperature Adjustment The cooling water flow through the heat exchanger is regulated by the water modulating valve a manually adjusted thermostatic control valve The valve is factory set to maintain the operating oil temperature at 115 F 46 C It is adjusted by increasing or decreasing the spring tension on the valve 20480302 8 2010 Rev 01 6 6 Section 6 Recirculation System NOTE In most cases adjustment will be required during commissioning and with seasonal changes to the cooling water temperature Figure 6 5 Water Modulating Valve e 5 Locate the adjusting knob a screwdriver slot on the top of the valve 6 Use a flat screwdrive
38. crate The forklift should be positioned accordingly When the machine has been removed from the crate note the position of the fork pockets on the bottom of the machine The pockets are positioned in relationship to the center of gravity to balance the weight on the forklift VAN CAUTION Position the forklift carefully to avoid damage to the high pressure attenuator and high pressure tubing ET 8 2010 Rev 02 2 2 Installation ATA Figure 2 2 Fork Pockets Table 2 2 Fork Pockets A Fork Pocket Dimensions Height 2 0 50 8 mm Width 8 0 203 0 mm Length 36 0 914 4 mm B Distance Between Pockets 36 0 914 4 mm If the machine will be installed in an overhead location a forklift or crane can be used to position the pump Heavy straps or chains properly rated for the weight requirements should be placed through each fork pocket and wrapped around the sides of the machine so they meet on the top The straps can then be attached to a crane or forklift to lift the machine VAN CAUTION The machine must be lifted from the bottom Do not attempt to lift the machine from the intensifier 2 4 Power Requirements Power supplied to the pump and wiring for remote control must comply with local regional and national electrical codes Service voltage and ampacity must meet the requirements of the specific model Voltage fluctuations in excess of 10 percent of nominal voltage m
39. detected turn the machine off and remedy the problem When the problem has been remedied repeat the start up procedure moving from low to high pressure soon after the intensifier starts pumping water There is no further need to flush air from the system High Pressure Cylinder Maintenance The plunger seal area in the high pressure cylinder bore should be inspected and cleaned each time the high pressure seal assembly 1s replaced l 20480314 7 201 1 Rev 02 Clean the sealing area on the inside diameter of the high pressure cylinder and inspect the bore for rings scratches pits residue or other potential leak paths Section 9 High Pressure Water System Seal material or residue can build up forming a ring Running a fingernail across the buildup will cause it to appear as a surface flaw Grooves or ridges are typically seal debris buildup rather than marks on the inside diameter wall of the cylinder 2 Polish the inside diameter of the cylinder where the seals will locate with 600 grit wet dry sandpaper Hold the sandpaper on the end of your finger and move in a cylindrical wiping motion Polish in a circumferential motion only Do not polish or drag the sandpaper along the length of the cylinder 3 Clean the residue from the inside diameter of the cylinder and re inspect for surface defects 97 Sealing Head The sealing head is sealed to the outboard end of the high pressure cylinder by the sealing head seal assembly
40. equipment damage personal injury or death High pressure tubing lengths must be coned and threaded prior to installation KMT Waterjet provides both hand and power tools for coning and threading high pressure tubing Tool descriptions and part numbers are provided in Table 2 7 Table 2 7 Coning and Threading Tools Part Number Hand Tools Power Tools 1 4 Coning Tool 05108832 05109897 3 8 Coning Tool 05108857 05109889 9 16 Coning Tool 05108840 05109871 1 4 Threading Tool 05108865 05122742 3 8 Threading Tool 05108873 05120258 9 16 Threading Tool 05108881 05122759 20480282 8 2010 Rev 02 2 8 Installation AS Table 2 7 Coning and Threading Tools Part Number 1 4 Tube Vise 05108782 3 8 Tube Vise 05108790 9 16 Tube Vise 05108774 20480282 8 2010 Rev 02 2 9 Installation Sis Measurements and Dimensions Tubing must be cut to the proper length both ends of the tubing must then be coned threaded and deburred To determine the tube length measure the distance between the fittings and add two times the engagement allowance shown in Table 2 8 Table 2 9 lists the required cone and thread dimensions illustrated in Figure 2 6 Figure 2 5 Tube Length Table 2 8 1 4 Tubing 0 49 12 4 mm 3 8 Tubing 0 68 17 3 mm 9 16 Tubing 0 86 21 8 mm Tube Length Length 2 EA Figure 2 6 Cone and Thread Dimensions Table 2 9 Cone and Thread Dimensions D
41. occur if the pressure is below 60 psi 4 bar If the booster pump pressure exceeds 125 psi 8 6 bar a relief valve opens allowing water to exit through the 1 2 inch drain connection on the rear bulkhead It is still possible to operate the machine however excess water will continue to be released through the drain Discharge pressure is displayed on the pressure gauge mounted on the outlet manifold The gauge should read approximately 120 psi 8 bar while the machine is idling When it strokes the pressure drop should be no greater than 30 psi 2 bar The water pressure range should remain between 90 120 psi 6 8 bar during operation NOTE While the intensifier assembly reverses direction the boosted pressure will fluctuate slightly above and below the normal setting A relief valve built into the filter assembly prevents excessive discharge pressure and typically operates when the machine is in a deadhead condition The booster pump is factory set to deliver 120 psi 8 bar with an inlet pressure of 58 psi 4 bar The pump may require adjustment to satisfy system requirements To reduce overheating during a deadhead condition water is re circulated through the orifice and check valve and routed back through the strainer to the booster pump inlet From the outlet manifold cutting water is routed to the inlet check valves in the sealing heads on each end of the intensifier 2 2009 Rev 0 5 3 Low Pressure Water System A
42. of the intensifier must carefully review this manual prior to installing and commissioning the machine The Technical Service Department at KMT Waterjet Systems is available to assist in the installation and commissioning process Service and repair training for maintenance personnel is also available Installation Summary The following summary lists the procedures required for the installation and commissioning of the intensifier system Details and requirements for each item are discussed in this section e Upon receipt the machine must be uncrated and moved into position on a level surface e Properly sized power drops with fused disconnects must be installed e A pneumatic drop with a manual shutoff valve and regulator for the air connection must be installed e Plumbing and manual shutoff valves for the inlet and outlet cooling water and the inlet and outlet cutting water must be installed Incoming source water must meet specific water quality standards flow rates and pressure requirements It may be necessary to install water conditioning and or pressure boosting equipment to meet these water purity and pressure requirements e Drain water plumbing must be suitably located and installed for the proper disposal of wastewater e High pressure tubing runs from the intensifier to the cutting station must be installed with the appropriate mountings support brackets and hardware e Wiring must be installed and connected betwee
43. specifications are provided in Section 11 Specifications 20480273 9 2009 Rev 01 1 1 Introduction KMT Section 1 A Low Pressure Water System The low pressure water system supplies the cutting water flow to the intensifier Major system components include the booster pump and low pressure water filter assembly Figure 1 2 System Components 1 Low Pressure Water System 8 Oil Filter Assembly 4 Water Filter Assembly 9 Recirculation Pump 5 Booster Pump 3 Hydraulic System 2 Recirculation System 10 Hydraulic Pump 6 Hydraulic Oil Reservoir 11 Hydraulic Manifold 7 Heat Exchanger 12 Electric Motor Recirculation System The recirculation system is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system Major system components include the recirculation pump heat exchanger oil filter assembly and the hydraulic oil reservoir Hydraulic System The hydraulic system supplies the intensifier with the hydraulic oil required to produce high pressure water Major system components include the electric motor hydraulic pump and the 4 way directional control valve mounted on the hydraulic manifold High Pressure Water System The high pressure water system is the heart of the waterjet system Water is pressurized and continuously delivered to the cutting head As water passes thro
44. the seal installation tool can be used for installation 20480314 7 2011 Rev 02 9 20 KIMT eem Section 9 High Pressure Water System Figure 9 16 Hydraulic Seal Cartridge 1 Seal Bushing O Ring T N 20480314 7 2011 Rev 02 Backup Ring O Ring 80086622 2 Packing Ring w O Ring O Ring Backup Ring U Cup Packing Seal oO N QN tA Carefully remove the worn seals and o rings from the cartridge by pushing them with a plastic or wooden dowel or similar object Remove the seals closest to the open ends first and work toward the center Inspect the seals for unusual wear deformation or cuts Note any unusual buildup of solid material or debris creating possible leak paths Inspect the surface of the cartridge body for scratches deformation signs of metal to metal contact or other unusual wear Carefully examine the surface of the grooves on the inside diameter Note any scratches in the axial direction that could create a leak path Apply FML 2 grease to the inside and outside diameter of the cartridge body and to the individual seal components Install the seals starting in the center and working toward the ends See Figure 9 16 for the proper orientation of the u cup packing seal If available use the seal installation tool to install the u cup packing seal See Figure 9 23 Pneumatic Valve Seal Tools Verify that the u cup o ring is properly positioned after installation When
45. transfer pump to the drain valve on the reservoir 2 Open the shut off valve on the drain and pump the used oil out to a container 3 Close the shut off valve and remove the inlet hose from the drain valve NOTE Oil from a new drum does not meet the cleanliness requirements of the hydraulic system For this reason it is important to use an oil transfer pump that will force oil through the return filter into the reservoir 4 Remove the cap from the fill port on the oil filter 20480302 8 2010 Rev 01 6 4 Section 6 Recirculation System VAN CAUTION To ensure cleanliness the oil fill port must be used to pump oil into the reservoir Filling at this point guarantees the hydraulic oil will pass through the oil filter before entering the reservoir 5 Connect the discharge hose from the oil transfer pump to the fill port and pump the fresh oil into the reservoir NOTE If 3 4 inch BSPP threads are required install the adapter located on the inside of the frame When filling is complete remove the adapter and install the fill port cap 6 Check the oil sight gauge on the reservoir to ensure proper fill level 7 Remove the hose from the case drain on the main hydraulic pump to make sure the pump case fills with oil With the hose removed head pressure from the reservoir will force oil into the pump case Oil in the pump case provides internal lubrication for the main hydraulic pump Failure to the fill the pump
46. understood by operating and maintenance personnel prior to installing operating or servicing the machine Adherence to all Warnings Cautions and Notes is essential to safe and efficient service and operation VAN WARNING Warnings emphasize operating or service procedures or conditions that can result In serious personal injury or death VAN CAUTION Cautions emphasize operating or service procedures or conditions that can result In equipment damage or impairment of system operation NOTE 20480273 9 2009 Rev 01 1 6 Introduction aay Emergency Medical Treatment An emergency medical card is included in the binder of this manual This information should be used to aid in the treatment of a waterjet injury Additional cards may be obtained by contacting KMT Waterjet Systems using the address or telephone number shown on the card This person has been working with water jetting at Medical Alert pressures to 60 000 psi 414 MPa 4137 bar 4 218 Kg cm with a jet velocity of 3 000 fps 914 mps This card is to be carried by personnel Foreign material sand may have been injected working with high pressure waterjet with water Unusual infections with equipment Obtain medical treatment microaerophilic organisms occurring at lower immediately for ANY high pressure waterjet temperatures have been reported such as gram injuries negative pathogens as are found in sewage Bacterial swabs and blood cultures may
47. valve open and the orifice removed Turn the intensifier off and install an orifice Turn the machine on and increase the operating pressure in gradual increments Check all high pressure connections for leaks 3 2 Maintenance Say Many components are lubricated prior to assembly Table 3 1 lists the recommended lubricants and their applications Substitutions are not recommended Table 3 1 Lubrication Specifications Description Application Part Number Pure Goop ounce Stainless steel threads and metal to 10084440 metal joints FML 2 Grease 14 1 2 ounce O rings backup rings bearing rings 10087385 seal components JL M Grease 16 ounce Non stainless steel threads 49832199 3 3 Maintenance Precautions Make sure all safety devices are operational Each device should be checked on a specified schedule If the device does not function it must be replaced before operating the machine Check the EMERGENCY STOP button The normal operating position is pulled out Turn the power on and activate the emergency stop button by pushing it in to verify the power goes off and the safety dump valve opens to bleed the high pressure from the system Before performing any maintenance on the equipment take the system out of service and make sure the controls are properly locked and marked Never perform any maintenance on the equipment without making sure the main control power is locked out in the OFF position 20480285 7 2011 Rev
48. will display Pressing ESC will clear the message allowing you to navigate the screen but 1t will not clear the fault To clear a fault press the A arrow on the keypad to highlight the flashing triangle and press ENTER to display the alarm message Press the ACK button to acknowledge the fault Table 4 2 Alarms Alarm Indication Possible Remedies A left overstroke condition has occurred Left Overstroke Shutdown Check left high pressure seal Check right discharge check valve Check left inlet check valve Low Booster Pressure Discharge pressure from the booster pump is low below 60 psi 4 bar Check the inlet water pressure Check the filter element and replace if dirty Adjust or replace the booster pump 20480289 2 2009 Rev 0 Low Inlet Water Pressure Motor Feedback Failure Inlet cutting water pressure 1s low below 30 psi 2 bar Start relay did not close at start up or opened due to a fault Check pipe sizing for inlet cutting water for pressure and flow Check motor starter relay KMT PET Table 4 2 Alarms Alarm Indication Motor Overload PLC monitors the motor overload relay and displays a message when the overloads trip Overloads are set on automatic reset Oil Level Low Low oil level Oil Temperature High High oil temperature Right Overstroke A right overstroke condition Shutdown has occurred An intensifier overstroke condition has occurred T W Overstroke Shutdown 204802
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50. 2 to display the Information Screen e Press F3 to display the Settings Screen e Press F4 to display the Maintenance Screen 4 6 Information Screen Information screens display equipment and operating information No functions are preformed from these screens The A or Y arrow in the top left hand corner of the screen indicates additional options Use the A or Y arrow on the keypad to view all information options Figure 4 4 Information Screen 20480289 2 2009 Rev 0 4 4 Section 4 Operation AA AAA Hours Screen The Hours Screen displays the total operating hours Figure 4 5 Hours Screen HAUTS Hours 0000000000 0 Capacity Screen The Capacity Screen displays the pump capacity as a percentage based on stroke rate Figure 4 6 Capacity Screen Capacity A MS 40 60 80 100 120 20480289 2 2009 Rev 0 4 5 Operation LI 20480289 Stroke Rate Screen The Stroke Rate Screen displays the actual stroke rate as strokes minute on both the left and right side of the intensifier Figure 4 7 Stroke Rate Screen Stroke Rate Strokes min 00 Left Strokes min 00 Right Date Time Screen The Date Time Screen displays the date and time Figure 4 8 Date Time Screen Date Time 12 51 2000 107 S97 ss AM 2 2009 Rev 0 4 6 Operation E J 4 7 20480289 Program Information Screen The Program Information Screen displays the PLC and HMI program numbers and revision level
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52. 89 2 2009 Rev 0 Section 4 Operation Possible Remedies Check incoming voltage Check overload setting Check the motor amperage Check sight level gauge Check for hydraulic leaks Check the oil level switch Check cooling water source Check water modulating valve Check the oil temperature switch Check right high pressure seal Check left discharge check valve Check right inlet check valve Check plumbing for leaks Check high pressure orifice Check inlet water pressure Check the inlet and discharge check valves Check the incoming water pressure 4 12 KIMT r SECTION 5 LOW PRESSURE WATER SYSTEM Overview The Jetline series utilizes two low pressure circuits cutting water supply and cooling water supply This section will discuss the cutting water supply circuit See Section 6 Recirculation System for a detailed explanation of the cooling water supply circuit The cutting water supply circuit supplies the intensifier with the required cutting water flow and pressure System components include the inlet water solenoid valve strainer booster pump and the low pressure filter assembly Pressure switches connected to the PLC monitor out of tolerance conditions in the cutting water circuit and provide automatic shutdown protection Figure 5 1 Cutting Water Supply Circuit 1 Cutting Water In Pressure Gauge Inlet Water Solenoid Valve Strainer NR Ww N 30 psi Pressure Switch 2 2009
53. E I 0 XOS LdSd oqa 069F0Z 9I OC x 0 LASI DI J3depy ott v I OS X 0 LAS 9L I O69H0T SI Z x OS Sqn odig godepy STEPESG I ET x WING odiq oqnL iadepy 1706907 I Z X0g edig DIr Jadepy 90pIIISO ZE I JIN9 eqnp oq Z06907 I 4000 OS UO Yysng OSOH ZLZTIZPOZ ITE I cV X WINO qn Surjdno 0206907 TI Jeureng IIT 16069707 OF I SAJEA PIOU9IOS 91069P0T II tsd og Yomg omssold S 0vISO 6C I SAJEA 99uO 0069v0c OI tsd QOT 0 Snep amseaid p8v69rOC LT I ST X ZI LASA MOT S668907 o JOM d I PIOJuUe N Tp989P0T 9T S pI T MN Wer Z600L00TI O T XOS LdSH 9 ddiN 8069107 ST S OS XOS T Lasa Peewpng Surdno 88v69p07 L SAJEA prous oS LO6OPOT vC I ST Xp6 peeping Surdno 6p690t0c 9 0 x0sc LdSH SI dIN 0L069v0c EZ I tsd 007 0 Sne omss oid 0S69P0T S OS X OS OIf LdSd J9APPY 99069p07 TT I tsd 09 Ymg oINssalg C90cVISO r 9AJEA SUTJEINPOIN NVM 9069P0T IZ I IM d I A quessy 194 OISPSPOC OC X OS OQNL LdSd oidepy HSO069P0T OZ 9 OS qeg OSOH pyZL89v07 C Ajguen uondrnosoq 19qUINN maul Ajguen uondrnsoq 4Joqumnw uim Ltd Ed pOTLLrOT A quiossy odig peoqamg I CI ALL JSt SIADA TI UONI N o m Kum Q Y Y Parts List Figure 12 13 Bulkhead Pipe Assembly Z Y9ZLLPOZ oU
54. FML 2 grease and slide the seal assembly onto the inlet end of the sealing head Lightly coat the outboard bore of the high pressure cylinder with FML 2 grease Clean and lubricate the cylinder threads with Pure Goop Apply Pure Goop to the sealing surface of the sealing head Position the sealing head in the end cap Hold the sealing head securely against the end cap and thread the end cap onto the cylinder If the sealing head begins to resist turning as the end cap threads onto the cylinder tap the outboard end of the sealing head with a plastic hammer until the sealing head seats against the end of the cylinder x Avoid hitting the end of the sealing head against the cylinder to prevent damage to x the inlet check valve seals and sealing surfaces 11 12 13 Avoid rotating the sealing head relative to the cylinder to avoid premature seal leakage Turn the end cap until it bottoms out Tighten the end cap with the spanner wrench and finish with a single light tap on the wrench handle Do not tighten further Lubricate the o rings on the sealing head collar with FML 2 grease and install the collar Connect the high and low pressure water piping following the procedure High and Low Pressure Water Piping Start the machine in low pressure mode to flush air from the high pressure components and to check for obvious leaks After 5 10 strokes switch to high pressure operation and check for leaks If leaks are
55. Intensifier 12 Inlet Water Solenoid Valve 20480293 2 2009 Rev 0 5 2 Low Pressure Water System A 20480293 Cutting water enters through the normally closed inlet water solenoid valve When the control power is turned on the solenoid valve opens and allows water to flow through the valve The inlet water is monitored by a 30 psi pressure switch mounted on the inlet manifold If the pressure drops below 30 psi 2 bar the switch activates an automatic shutdown circuit in the PLC and the machine will not start NOTE PAR AAA AA A AAA A AAA A A A A A A A A A A A A A _ E z If a shutdown occurs due to an overstroke condition the inlet solenoid valve automatically closes to prevent water waste due to an external leak Cutting water then passes through a strainer to remove debris before the water enters the booster pump The booster pump increases the pressure to the relief valve setting up to a maximum of 120 psi 8 bar to ensure proper supply to the intensifier assembly Pressurized water passes through the filter assembly where debris is removed to prevent contaminants from damaging the check valves and seals in the intensifier The filter assembly consists of a filter head housing and a filter element A bleed valve on the top of the filter head is used to release pressure or air inside the housing As the water enters the outlet manifold the pressure is monitored by a 60 psi pressure switch An automatic shutdown will
56. L Thread Tube OD Tube ID Maximum Maximum UNF LH 1 4 6 35 mm 0 083 2 11 mm 0 125 32mm 0 562 14 3mm 1 4 28 3 8 9 52 mm 0 125 3 18 mm 0 219 5 6 mm 0 750 19 1 mm 3 8 24 9 16 14 29 mm 0 188 4 78mm 0 281 7 1mm 0 938 23 8mm 9 16 18 8 2010 Rev 02 2 10 Installation P 72727 7 7 CU w Hand Coning Figure 2 7 Hand Coning Tool E A 2 Z SESI LE A P gt A 37 Tubing 5 Handle 2 Collet 6 Blade 3 Access Window 7 Body 4 Feed Nut 8 Gland Nut 1 Place the body of the coning tool in a vise allowing adequate clearance for the rotation of the cutter handle Position the tool so the cutter handle is elevated slightly so the lubricant will flow to the cutting blade 2 Turn the feed nut counter clockwise to retract the cutting blade past the access window 3 Loosen the gland nut and insert the tubing through the collet The end of the tubing should just make contact with the cutting blade Loosely tighten the gland nut to slightly grip the tubing 4 Turn the feed nut counter clockwise 1 4 turn to retract the cutting blade away from the tubing and tighten the gland nut with a wrench 5 Apply a liberal amount of cutting oil to the exposed end of the tubing the cutting blade and through the lubrication channel at the cutter handle Apply cutting oil frequently and liberally throughout the cutting operation A medium weight
57. Rev 0 Relief Valve Check Valve 6 7 Booster Pump 8 9 Filter Assembly 10 Air Bleed Valve 11 60 psi Pressure Switch 12 Pressure Gauge 13 Sealing Head 14 Relief Valve 15 Drain 5 1 Low Pressure Water System KMT Section 5 A 5 2 Cutting Water Supply The quality of the inlet cutting water supply is one of the most important factors affecting component life and performance Impurities in the water create grinding and corrosive effects on all components See Section 11 Specifications for details regarding water quality standards 5 3 Operation Cutting water is introduced through the 1 2 inch BSPT connection on the rear bulkhead of the machine Inlet cutting water pressure should be a minimum of 35 psi 2 4 bar flowing and can be monitored from the supply gauge mounted on the inlet manifold Figure 5 2 Low Pressure Water System 1 Filter Head 7 Filter Housing 13 30 psi Pressure Switch 2 60 psi Pressure Switch 8 Filter Element 14 Inlet Manifold 3 Outlet Manifold 9 Infrom Booster Pump 15 Relief Valve Acorn Nut 4 Pressure Gauge 10 Strainer 16 Booster Pump 5 Out to Drain 11 Pressure Gauge 6 Out to
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59. The inlet and discharge check valves in the sealing head ensure the low pressure and high pressure water only travels in the appropriate direction Figure 9 9 Sealing Head NS SS AN g IF WR XXX rs SR fe y Ses 1 Sealing Head 4 Inlet Check Valve 2 Soft Seal End Cap 5 Discharge Check Valve 3 High Pressure Cylinder 6 Inlet Water Groove High Pressure Discharge Check Valve The high pressure discharge check valves require service when water leakage is present at the sealing head weep hole or when the sealing head and discharge gland are warm to the touch The discharge check valve can be serviced with the sealing head either installed or removed from the high pressure cylinder 1 Turn the machine off and observe the appropriate Lockout Tagout procedures 20480314 7 2011 Rev 02 9 13 Section 9 High Pressure Water System Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before proceeding Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding 2 Disconnect the high pressure water piping following the procedure High and Low Pressure Water Piping 3 Use two wrenches to remove the gland nut The poppet pin spring and poppet check valve will normally remain in the gland nut when it is removed Remove the components from the gland nut
60. able function at any given time is displayed above each button For example if the pump has been shut down the inlet water solenoid valve will be closed and the F1 button display will be RESET as illustrated above Pressing the Fl button will reset and open the valve and the display will change to START Pressing the F1 button at this point will start the pump The following functions are performed from the Run Screen e Press the Fl button to reset the inlet water solenoid valve start the pump to create pressure or stop the pump After the pump is stopped there is a five second delay before startup The inlet water solenoid valve is automatically closed five minutes after the pump shuts down Press the F1 button to reset and open the valve e Press the F2 button to start the pump in recirculation mode The pump will recirculate for 10 minutes before the function shuts off Recirculation can be manually stopped by pressing the F2 button Recirculation time 1s indicated in the lower right hand corner of the screen e Press the F3 button to select low or high pressure operation e Press the F4 button to display the System Screen 2 2009 Rev 0 4 3 Operation HB sss 4 5 System Screen Pressing the F4 button on the Run Screen will display the System Screen options information settings and maintenance Figure 4 3 System Screens System Screens Settings el Info Maint e Press F1 to return to the Run Screen e Press F
61. all adhere to the following safety precautions as well as the applicable plant safety precautions e Only KMT factory trained qualified personnel shall service and maintain the equipment e The operator shall practice and promote safety at all times to avoid potential injury and unnecessary downtime The operator shall ensure that the work area around the equipment is clean and free of debris and oil spills All protective guards shields or covers shall be In place on the equipment at all times Safety glasses and ear protection shall be worn when operating or working near the equipment Lockout Taeout Procedure This lockout tagout procedure is designed to protect all employees from injuries caused by the unexpected energizing or startup of the machine or the release of stored energy during service and maintenance This is accomplished with energy isolating devices that prevent the transmission or release of energy An energy source is any source of electrical mechanical hydraulic pneumatic chemical thermal or other energy source that could cause injury to personnel A lockout device utilizes a lock and key to hold an energy isolating device in the safe position and prevents the machine from being energized A tagout device is a prominent warning device that can be securely attached to the machine warning personnel not to operate the energy isolating device This procedure requires the combination of a lockout device
62. alling 1s detected during cylinder removal galled surfaces and threads must be filed sanded and lubricated prior to reassembly See the procedure High Pressure Cylinder Maintenance High Pressure Cylinder Assembly Installation l Verify that the high pressure cylinder threads and alignment surfaces are adequately cleaned and lubricated with Pure Goop and that the threads have been sanded and dressed if galling was encountered during removal 2 Verify that the high pressure seal assembly is correctly installed While supporting the weight with the vee block cradle align the cylinder with the plunger and the hydraulic cylinder head Carefully push the cylinder into position until the threads are ready to engage 3 Thread the cylinder into the hydraulic cylinder head The cylinder will become difficult to rotate as it slides over the high pressure seal assembly Use the cylinder wrench as necessary NOTE em A D D If galling occurs during threading remove the high pressure cylinder and inspect the mating surfaces and threads Repair surfaces thoroughly clean lubricate and thread the cylinder into the hydraulic cylinder head 4 Hand tighten the cylinder with the cylinder wrench Tap the wrench with the palm of your hand to tighten 20480314 7 2011 Rev 02 9 1 1 KMT pr 5 6 Section 9 High Pressure Water System Clean and install the cylinder liner Lightly coat the sealing head seal components with
63. alve 3 Left Proximity Switch 7 2 Pressure Solenoid 4 Right Proximity Switch 8 Booster Outlet Pressure Switch 20480310 2 2009 Rev 0 8 4 Electrical System A Table 8 1 Sensors and Solenoids Component Function Inlet Water Solenoid Valve I The normally closed inlet water solenoid valve is located at the service bulkhead When the control power is turned on the valve opens and allows low pressure cutting water to enter The solenoid valve functions as a safeguard by closing if an overstroke condition occurs Hydraulic Reservoir 2 The temperature low level switch monitors the oil temperature and level in the reservoir Although the float switch and the temperature switch are combined in a single unit the two switches function independently If the operating oil temperature exceeds 145 F 63 C an automatic shutdown occurs If the hydraulic fluid level falls below specifications a low oil level shutdown occurs Hydraulic Manifold 3 The 4 way directional control valve shifts the hydraulics back and forth to the intensifier A shift valve directs pressurized oil to one end of the hydraulic cylinder and returns fluid to the Ke reservoir from the opposite end causing the MN P intensifier to stroke The movement is controlled 4 Cae O electronically by two solenoids signaled by the x v x Qn Tr 5 PLC As power is directed f
64. and a tagout device The lockout tagout procedure applies to any employee who operates and or performs service or maintenance on the machine Before any maintenance or repairs are performed the machine shall be isolated and rendered inoperative as follows 1 Shut down the machine by pressing the F1 key and open the high pressure cutting water valve to bleed the water and hydraulic pressure from the system 2 Disconnect lockout and tag the main customer supplied power source 3 Lockout and tag the circuit breaker disconnect on the electrical enclosure door 9 2009 Rev 01 1 4 KMT pr Warning Labels Section 1 Introduction 4 Close lockout and tag the manual shutoff valves for all service connections cutting water in cooling water in and out and air Warning labels are posted on the machine to indicate potential hazards The operator and service personnel shall pay particular attention to these warning labels Table 1 2 describes the necessary precautions and provides the part number required to order replacement labels 20480273 9 2009 Rev 01 P N 05114962 P N 05114970 P N 80082209 Table 1 2 Warning Label Precautions The electrical enclosure and motor junction box can present an electrical shock hazard Always disconnect and lockout the main power before opening the enclosure Always disconnect and lockout the main power and the circuit breaker disconnect on the electrical enclosure door be
65. ator functions and warnings offer a comprehensive view of impending and shutdown faults The operator interface is through a function button control panel Figure 4 1 Control Panel SIMATIC PANEL Ka 1 Green Light flashes at startup and 4 Emergency Stop remains on during operation 2 Red Light flashes to signal alarm 5 Reset Button condition 3 Function Button Control Panel 6 Keyed switch transfers control to a remote panel Startup Sequence The startup sequence varies depending on the previous stop condition Startup after Motor Stop After a normal motor stop control power remains on and the safety dump valve opens to release high pressure in the system Press the F1 button on the Run Screen to initiate normal operation The pump is held in low pressure for 20 seconds it then goes to high pressure or remains in low pressure depending on the previous pressure setting Startup after Emergency Stop After an emergency stop control power is turned off and the safety dump valve opens to release high pressure in the system The dump valve will close three seconds after the intensifier begins to stroke 2 2009 Rev 0 4 1 KMT EES Section 4 Operation Pull the E STOP button out and push the RESET button to activate control power Press the F1 button on the Run Screen to start the motor The machine will be held in low pressure for 20 seconds to allow trapped air to bleed from the high pressure cylinders It then goes to h
66. attenuator acts as a shock absorber to dampen pressure fluctuations and ensure a steady and consistent supply of water From the attenuator the high pressure water exits to the cutting head The safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines The high pressure dump valve assembly includes a normally open high pressure water valve and an electrically controlled air valve The normally open pneumatic dump valve is held closed by air pressure When the air supply is interrupted and exhausted from an emergency stop or a normal stop the valve opens and allows water to flow through the valve Pressure is released in the intensifier and the high pressure water stream exits through the drain 7 201 1 Rev 02 9 3 High Pressure Water System ms 93 System Components The following figures illustrate the Individual high pressure water system components Figure 9 4 High Pressure Cylinder Assembly 1 O Ring 5 Sealing Head Seal Assembly 2 Sealing Head Collar 6 Cylinder Liner 3 Soft Seal End Cap 7 High Pressure Cylinder 4 Sealing Head 8 High Pressure Seal Assembly 20480314 7 2011 Rev 02 9 4 High Pressure Water System KMT Section 9 FC Figure 9 5 Hydraulic Cylinder Assembly Retaining Ring 6 Backup Ring 2 Bushing Retainer Flange 7 O Ring 3 Hydraulic Seal Cartridge 8 Hydraulic Cylinder 4 Socket Head Screw 9 O Ring Spacer 5 Hydraulic Cylinder Head 10 Proximity Switch F
67. ay damage the machine and void the warranty Refer to Table 2 3 Ampacity and Power Voltage Requirements 20480282 8 2010 Rev 02 2 3 Table 2 3 Ampacity and Power Voltage Requirements Motor Full Load Horsepower Amps Circuit Breaker Power Voltage Amps 208 3 60 am 100 230 3 60 a 100 a 5 m 100 3 50 60 415750 60 460 3 60 50 5753 60 40 200 3 50 60 175 208 3 50 60 175 240 3 60 175 380 3 50 am 6 w 400 3 50 5 66 100 415 3 50 100 480 3 60 50 575 3 60 so Section 2 Installation 2 5 Service Connections The intensifier requires two incoming water sources cooling water and cutting water two drain lines cooling water and wastewater a high pressure discharge line and an air supply line All piping must comply with local regional and national codes All service connections are made on the rear bulkhead of the machine as shown in Figure 2 3 Service Connections Table 2 4 lists the fittings required for each interface connection With the exception of the wastewater drain line manual shutoff valves should be installed for all connections To facilitate service the valves should be located as close as practical to the interface connection Thoroughly purge all supply plumbing prior to connection to remove any residue that could contaminate the system Lmmmmmmmmmmummmmmn mm E AAA AAA 20480282 8 2010 Rev 02 2 4 20480282 Installation KMT Section 2 A Figure 2 3 Service Connections
68. be returned to KMT Waterjet for reconditioning Figure 9 20 Plunger Plunger 3 Button Chamfer 2 Plunger Button Hydraulic Piston and Plunger Installation l Apply FML 2 grease to the new o ring and backup rings Install the backup ring and then the o ring in the groove in the plunger socket 2 Slide the plunger retainer onto the piston and push the plunger onto the plunger socket 3 Make sure the retainer is properly positioned in the socket 4 Install the retaining ring into the cavity of the plunger socket Figure 9 21 Hydraulic Piston Installation 1 Hydraulic Piston 4 Plunger 2 Backup Ring 5 Plunger Retainer 3 O Ring 6 Retaining Ring 5 Repeat steps 1 3 to install the second plunger 6 Ensure that the hydraulic cylinder bore is free of grit or contamination 20480314 7 2011 Rev 02 9 26 Section 9 High Pressure Water System 7 Lubricate the bearing rings and seal assembly and lightly lubricate 2 3 inches of the cylinder bore with FML 2 grease 8 Install the piston and plungers into the hydraulic cylinder bore 9 Verify that the o rings and backup rings are properly positioned in the grooves on the hydraulic cylinder heads and that they are sufficiently lubricated with FML 2 grease 10 Position the cylinder heads in the end of the hydraulic cylinder Apply JL M grease to the threads on the socket head screws Install the screws in the hydraulic cylinder heads and tighten following the torque spe
69. case with oil will allow air to become trapped inside damaging the pump 8 Disconnect the discharge hose from the fill port and replace the fill port cap 9 Follow the initial start up sequence in Section 4 Operation to ensure the system is filled with oil 10 Check the sight gauge again and follow the same procedure to add additional oil if necessary Electric Motor Bump Bumping is defined as allowing the electric motor to start rotating but stopping it before the motor gets up to full speed Whenever the hydraulic reservoir is emptied or the hydraulic pump has been changed bumping the electric motor is suggested This procedure will ensure the hydraulic pump is full of oil and deter cavitation which will cause the hydraulic pump to fail prematurely Do not perform this procedure until the correct motor rotation and the presence of hydraulic oil in the hydraulic pump case drain line has been confirmed 1 Start the pump in recirculation mode count two seconds and turn the pump off 20480302 8 2010 Rev 01 6 5 Recirculation System A 2 Repeat this process six times before allowing the hydraulic pump to create pressure Oil Filter Maintenance If the filter element is not properly serviced and fills with debris the oil will be forced through the relief valve bypassing the filter The bypass relief valve opens at 50 psi 3 4 bar The filter element must be replaced when the pressure gauge reading is 40 psi 2 8
70. cifications in Table 9 1 11 Verify that the plunger moves freely when handled If it feels tight there may be residue buildup in the pocket or the pocket depth may be insufficient 12 Replace the hydraulic cartridge seals bushing retainer flanges and retaining rings in the hydraulic cylinder heads 13 Replace the proximity switches by positioning the o ring spacers and the switches Apply JL M grease to the threads on the socket head screws and tighten following the torque specifications in Table 9 1 Ensure that the proximity switches are properly installed and secured prior to starting the motor Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil 14 Install the high pressure cylinders into the hydraulic cylinder heads and install the remaining cylinder assembly components following the procedure High Pressure Cylinder Assembly Installation 15 Connect the high and low pressure water piping And turn the low pressure water supply on 9 11 Hydraulic Cylinder Maintenance 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 is indicative of piston seal wear 9 12 High Pressure Attenuator The high pressure attenuator is not serviceable at the customer level KMT Waterjet Systems tests the seals in the attenuator at pressures exceeding normal operati
71. cutting oil with high sulfur content is recommended 6 Turn the feed nut clockwise until the cutting blade contact the end of the tubing 7 Inasmooth continuous motion turn the cutter handle in a clockwise direction Simultaneously turn the feed nut in a clockwise direction to establish a constant feed Do not remove too much material at once the cutting blade should make light uninterrupted cuts 20480282 8 2010 Rev 02 2 1 Section 2 Installation NOTE Before interrupting the cut back the cutter blade away from the tubing Use compressed air or a small brush to remove the accumulation of chips from the blade and the tubing throughout the coning operation 8 Continue the operation until the feed nut bottoms on the housing Turn the cutter handle several more rotations to face off the end of the cone 9 Retract the cutter blade loosen the gland nut and remove the tubing Inspect the cone for surface finish and completeness NOTE Clean the machining chips from the blade and from the collet before coning the next tube Power Coning 1 Secure the tubing in a tube vise No more than the recommended length of tubing should extend beyond the face of the vice See Table 2 10 Recommended Extension Length 2 Mount the coning tool in a 3 8 inch or 1 2 inch variable speed power drill Apply cutting oil to the end of the tube and slide the coning tool on the tubing 3 Apply steady pressure against the end of the
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73. disconnect and lockout the main power supply and the electrical enclosure and ensure that all high pressure water and hydraulic pressure has been bled from the system 20480314 7 2011 Rev 02 9 28 Section 9 High Pressure Water System Severe injury can result if the machine is not properly locked out Observe electrical Lock Out Tag Out procedures before proceeding Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding 1 Turn the air supply off 2 Remove the air supply hose and the electrical connection to the solenoid valve Figure 9 23 High Pressure Dump Valve Pneumatic Actuator 5 Signal from PLC 2 HP Water Out to Cutting Head 6 Solenoid Valve 3 Out to Drain 7 Control Air In 4 Valve Assembly 3 Loosen and remove the high pressure gland connections and the drain connection 4 Remove the valve and actuator assembly from the machine 20480314 7 2011 Rev 02 High Pressure Water System ms Figure 9 24 Dump Valve Components Pneumatic Actuator 5 Seal Assembly 2 Stem 6 Valve Body 3 SST Backup Ring 7 Valve Seat 4 Brass Backup Ring 8 High Pressure Adapter 5 Loosen the cylinder head on the actuator Unscrew and remove the actuator from the valve body 6 Unscrew the high pressure adapter and remo
74. dure Sealing Head Maintenance Worn sealing head seal assembly Replace seal assembly KIMT DE SECTION 10 TROUBLESHOOTING 10 1 Overview 10 2 20480318 The troubleshooting guide will help identify the probable cause of a system malfunction and assist in providing corrective action The following symptoms are discussed in this section m je se ow xo HU de I a9 NO NO A Fesch mA Lm x Sa OO OM D High oil temperature resulting In shutdown Low ol level resulting in shutdown Hydraulic pressure but no high pressure water pressure No hydraulic oil pressure Pump will not start Console display and lights do not illuminate Pump quits running No control power Red light on operator s console is flashing Abnormal fluctuations in high pressure water signal Hot surfaces on the high pressure cylinder components Low cutting water supply pressure Low cutting water pressure Hydraulic oil leaking from the weep hole in the hydraulic cylinder head Water leaking from the weep hole on the hydraulic cylinder head flange Water leaking from the weep hole in the sealing head Water leaking from the weep hole in the sealing head gland nut Water leaking from the weep holes in the hard seal end cap Outlet booster pump pressure is falling below 60 psi 4 bar Inlet water flow is poor and the filter housing 1s not filling completely Water is leaking around the bleed valve on the filter head Troublesh
75. dy VAN CAUTION When the compensators are removed the machine loses adjustment The compensators must be reset before operation can begin 11 Start the machine and select the low pressure operating mode on the display panel 12 Deadhead the machine 20480306 2 2009 Rev 0 7 6 13 14 15 16 17 18 19 20 20480306 2 2009 Rev 0 Section 7 Hydraulic System rl dae VE DL ER sE f s m d NO SAL unie I VS b es EM T A A X e M ISS ARA a o AE OU SN ip H A Y eg d J MANE ES Hy ppt Y M I PR Idi ay 7 Low Pressure Control 4 Low Limit Compensator 2 High Pressure Control 5 High Limit Compensator 3 Hydraulic Pressure Gauge Set the high and low pressure control valves on the hydraulic manifold to the minimum setting by turning then counter clockwise Set the compensators to the minimum setting by turning the adjusting screws counter clockwise Select high pressure operating mode on the display panel and set the high pressure control valve on the hydraulic manifold to the maximum setting by turning the knob clockwise Turn the adj
76. e JL 1 Troubleshooting Guide Malfunction Outlet booster pump pressure is falling below 60 psi 4 bar Inlet water flow 1s poor and the filter housing is not filling completely Water 1s leaking around the bleed valve on the filter head Indication Booster pump needs to be adjusted or replaced Inlet water pressure 1s low Filter element is dirty and needs to be replaced Pipe sizing for inlet cutting water should be checked for pressure and flow O ring that closes the passage has deteriorated Comments Booster pump should be adjusted to 120 psi 8 bar when deadheaded Cutting water supply will be lacking capacity or flow A small o ring under the valve can deteriorate causing the passage to remain open The o ring can be replaced by removing the screw and spring on the underneath side 10 9 KIMT pcc SECTION 11 SPECIFICATIONS 11 1 Overview Comprehensive listings of specifications for the Jetline series are provided in this section Table 11 1 Jetline JL 1 Motor Horsepower Rating 11 2 Installation Specifications Environment Installation location Indoors Air borne dust contaminants Minimal Ambient temperature Minimum storage 36 F 2 C Minimum operating 40 F 5 C Maximum operating 104 F 40 C Maximum relative humidity 95 at maximum operating temperature Note When the relative humidity is above 50 the oil in the reservoir should be checked fre
77. e compensators can become blocked with debris resulting in loss of pump control Figure 7 4 Hydraulic Compensator Components wr Z RINLA L 1 Spool 3 Springs 5 Plug Nut 2 Spring Cup 4 Spring Collar 6 Sealing Cap Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance on the system components Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance 1 Remove the hydraulic hose from the low limit compensator 2 Remove the four socket screws that attach the compensators to the pump 3 Remove the compensators and then remove the three plugs and o rings on the back of the housing 20480306 2 2009 Rev 0 7 5 Section 7 Hydraulic System I O Ring 3 O Ring 5 Low Limit Compensator N Orifice 4 Plug 6 High Limit Compensator 4 Disassemble the compensators one at a time by first removing the hexagon sealing cap 5 Loosen the lock nut and then remove the plug nut 6 Disassemble the plug by removing the spring collar springs spring cup and spool 7 Clean the housing and all components with clean fluid and carefully dry with air 8 Check and clean the small internal passages in the spools 9 Check and clean the orifices in both spools 10 Assemble in the reverse order ensuring that the screw slot on the orifice is aligned with the long axis of the bo
78. e dump valve assembly includes a normally open high pressure water valve and a solenoid operated air valve The normally open pneumatic dump valve is held closed by air pressure When the air supply is interrupted from an emergency stop or a normal stop the valve opens and allows water to flow through the valve Pressure is released in the intensifier and the high pressure water stream exits through the drain 8 6 KIMT HA 20480310 2 2009 Rev 0 Component Low Pressure Water Filter Assembly Section 8 Electrical System Table 8 1 Sensors and Solenoids Function To ensure adequate water pressure and supply to the intensifiers the discharge pressure 1s monitored by a 60 psi pressure switch An automatic shutdown occurs 1f the pressure 1s below 60 psi 4 bar The 30 psi pressure switch mounted on the inlet manifold monitors the inlet cutting water If the pressure drops below 30 psi 2 bar the switch activates an automatic shutdown circuit protecting the booster pump from damage due to insufficient water supply pressure Electrical System KMT Section 8 A 8 3 Service and Maintenance Procedures Electrical components require minimal service The proximity switches on the hydraulic cylinder may require replacement NOTE x Refer to Section 12 Parts List for a complete listing of replacement parts and part numbers
79. e machine e Section 11 Specifications contains a comprehensive list of equipment specifications a detailed discussion of water quality standards and treatment guidelines as well as horsepower requirements for various orifice sizes e Section 12 Parts List contains part numbers descriptions and drawings to facilitate the ordering of replacement parts Equipment and Service Manual Questionnaire We are interested in your impression of the KMT Waterjet System recently installed at your location Your comments and recommendations will aid us in our continuing goal to improve our products and make our technical information more useful to our customers At your convenience please take a few minutes to complete the following questionnaire and return it to the applicable Customer Service Department listed above 9 2009 Rev 01 1 8 KMT E 20480273 Equipment and Service Manual Questionnaire General Appearance Was the unit received in good condition Comments Is the unit a convenient size Controls Are the controls user friendly Is the unit easy to operate Comments Performance Does the unit perform smoothly and meet your expectations Does the unit run quietly Comments Did the installation and startup go smoothly Comments What features do you consider the most significant Quiet operation Appearance Performance Operation Repair Maintenance Other What areas could be improved Appearance
80. each pipe size used from the water source to the intensifier Add the values together for a total pressure drop value 3 Add 30 to the total pressure drop to determine the minimum flowing source water pressure required to provide adequate supply to the intensifier Cutting water and cooling water capacity should be calculated separately Note that the cutting water requirements represent instantaneous not average demand 20480282 8 2010 Rev 02 2 7 Installation P i Figure 2 4 Pressure Drop Values Pipe Sizing 0 45 P 0 35 1 2 ID AID LA 0 25 ho 0 15 1 1 4 ID gt m 0 05 Pressure drop PSI FT 012345 67 8 9 1011 1213 1415 1617 18 19 20 Required GPM 2 7 High Pressure Piping High pressure piping is used to transport high pressure cutting water from the machine to the cutting station High pressure piping and fittings must be properly rated and sized When transporting high pressure water over long distances tubing and fittings with an outside diameter of 9 16 inch are recommended The large tubing size reduces vibration strain and motion as well as reducing pressure drop and pulsation x High pressure tubing and fittings must be rated for 60 000 psi 4 136 bar Failure x to use properly rated components may result in component failure causing
81. eck the retainer flange for cracks Replace the proximity switch by positioning the o ring spacer and the switch Apply JL M grease to the threads on the socket head screws and tighten following the torque specifications in Table 9 1 VAN CAUTION It is recommended that the proximity switch be reinstalled as soon as practical Removal of the switch presents the potential of an oil spray hazard Ensure that the proximity switch is properly installed and secured prior to starting the machine Failure to tighten the two hold down screws on each switch will result in the spray of hydraulic oil Thread the large end of the cartridge removal tool onto the hydraulic cartridge seal and pull the cartridge out over the plunger High Pressure Water System KMT Section 9 A Figure 9 15 Hydraulic Seal Cartridge Removal Plunger 5 Retaining Ring 2 Bushing Retainer Flange 6 Hydraulic Cylinder 3 Hydraulic Cylinder Head 7 Hydraulic Seal Cartridge 4 Cartridge Removal Tool Hydraulic Seal Cartridge Seals in the hydraulic cartridge can be removed and replaced or the complete cartridge can be replaced Use caution during the removal and installation of the seal components to avoid scratching the surface of the cartridge The seal removal tool a plastic or wooden dowel or similar object can be used for seal removal Do not use screwdrivers wires or other metal objects that could damage the cartridge To avoid damaging the new seals
82. ect the seat sealing head and gland nut for cracks Replace the sealing head A cracked sealing head can result in water leaking from the high pressure outlet passage to the low pressure inlet passages The sealing head body can become extremely hot Tighten the gland nut to the proper torque specification Polish the surfaces following the procedure Sealing Head Maintenance Tighten the gland nut to the proper torque specification Check the number of exposed threads past the collar on the high pressure piping Only 1 1 2 to 2 1 2 threads should be exposed Check high pressure piping for damage cracks or deformation Inspect the gland nut for deformation of the threads Check the gland nut for cracks due to fatigue If cracks are detected replace the gland nut KMT same Location Soft Seal End Cap Water leaking from the weep holes in the soft seal end cap 20480314 7 2011 Rev 02 Table 9 3 Weep Holes High Pressure Water System Indication Damaged high pressure cylinder External crack in sealing head Damaged sealing head Section 9 High Pressure Water System Comments Check for scratches or grooves on the sealing surface If detected polish to remove following the procedure High Pressure Cylinder Maintenance Replace the sealing head Check for scratches or grooves on the sealing surface of the sealing head If detected polish the surface following the proce
83. erature and fluid levels to safeguard against component damage 7 201 1 Rev 02 9 1 High Pressure Water System ms 9 2 20480314 Operation The directional control valve sends pressurized hydraulic oil to one side of the hydraulic cylinder The pressurized oil pushes against the piston moving it in one direction until it activates the proximity switch at the end of the stroke The hydraulic flow is then sent to the opposite side of the cylinder and the piston reverses direction until it activates the proximity switch at the opposite end of the stroke Figure 9 2 High Pressure Water System 7N DR C fg mA _ Gq ET bt M om Soft Seal End Cap 5 High Pressure Cylinder 2 Hydraulic Cylinder Head 6 Safety Dump Valve 3 Hydraulic Cylinder 7 Attenuator 4 Proximity Switch The green light on the proximity switch indicates there is power to the switch The red light illuminates when the switch is activated The proximity switches are magnetically activated by the presence of the metallic surface of the piston When the switch is activated it sends a signal to the PLC to change the flow of the directional control valve and reverse direction As the pressurized ol pushes the piston in one direc
84. erly cleaned prior to assembly and tightened to the correct torque specifications Maintain a clean dust and dirt free work area for maintenance Use only clean dry air and clean filtered solvent when flushing parts Use lint free cloths for cleaning Use extreme care when aligning close tolerance parts for assembly Do not force the parts together If parts bind during assembly they must be disassembled and re aligned Use only original KMT Waterjet replacement parts for consistent performance and reliability and to protect equipment warranty To avoid unsafe conditions and the risk of equipment damage operating personnel and service technicians must carefully read and follow the procedures in this manual High Pressure System Maintenance All high pressure service components are readily accessible and can be removed from the unit easily for maintenance and service High pressure fittings valves and tubing must be rated for 60 000 psi 4 137 bar Failure to use properly rated components may result in component failure equipment damage and personal injury Do not over torque fittings to stop leakage Ensure all components are clean free of burrs metal particles dirt and dust prior to assembly After servicing high pressure components the high pressure water system must be thoroughly flushed to remove any debris or contaminates l 20480285 7 201 1 Rev 03 Operate the intensifier for a short period with the nozzle
85. flow rate JL 1 30 JL 1 50 55 000 psi 3 792 bar 0 60 gpm 2 3 L min 1 0 gpm 3 8 L min Plunger diameter 0 875 22 mm Piston diameter 4 03 102 4 mm Intensification ratio 20 1 Minimum outlet pressure 6 000 psi 414 bar Maximum outlet pressure 55 000 psi 3 792 bar Pneumatic Control Valve Maximum water pressure 60 000 psi 4 137 bar Regulated air pressure 85 psi 5 9 bar Maximum flow rate 1 0 cfm 0 028 m min Orifice Capacity The following tables provide horsepower requirements for some of the more popular orifices Table 11 5 Single Orifice Diameter Motor Horsepower Maximum Maximum Single Pe Operating Orifice Diameter Model Pressure at full pressure JL 1 30 as 55 000 psi 3 792 bar 0 011 inch 0 28 mm JL 1 50 55 000 psi 3 792 bar 0 014 inch 0 36 mm 20480327 7 2011 Rev 03 Section 11 Specifications Table 11 6 Horsepower Requirements Orifice Size 45 000 psi 50 000 psi 55 000 psi inches mm 3 103 bar 3 447 bar 3 792 bar 0 003 0 076 2 3 1 7 2 0 0 004 0 102 4 0 0 005 0 127 62 0 006 0 152 9 0 0 007 0 178 10 6 12 2 0 008 0 203 16 0 0 009 0 229 202 0 010 0 254 25 0 0 011 0 279 302 0 012 0 305 36 0 0 013 0 330 422 0 014 0 356 48 9 0 015 0 381 562 0 016 0 406 639 The horsepower requirements for operating multiple orifices are determined by adding the requirements in Table 11 6 for each orifice Examples are shown below
86. fore performing any type of maintenance The surface of high pressure water and hydraulic components becomes hot during normal operation Failed or failing components can become extremely hot during operation Ensure all protective guards shields or covers are in place on the equipment at all times Never operate the pump with the guards removed 1 5 Section 1 Introduction Table 1 2 Warning Label Precautions High pressure water and or hydraulic pressure can remain in the system even when the pump has been shut off All pressure can be safely bled from the system by opening the high pressure cutting water valve for a few seconds after shutting off the pump Pressing the EMERGENCY STOP button turns the control power to the intensifier off stops the pump and bleeds the high pressure water through the safety dump valve P N 05098017 o Depressurization of the high pressure system creates a loud hissing sound when the dump valve opens The sound fades quickly as the pressure drops All personnel involved in the installation operation and or service of the intensifier must carefully read understand and follow the procedures in this manual to avoid creating unsafe conditions risking damage to the equipment or personal injury P N 20415794 Safety precautions and warnings for specific procedures are emphasized throughout this manual as illustrated in the following examples These precautions must be reviewed and
87. gland nut and the sealing head No threads should show If the gap exceeds 0 20 inch 5 mm the poppet or seat has slipped out of position The parts must be removed inspected and re assembled Use a crowfoot torque wrench combination and tighten the gland nut to the torque specifications in Table 9 1 Low Pressure Inlet Check Valve The need for inlet check valve service is indicated by unbalanced shifting or if the inlet ring 1s warm to the touch The high pressure cylinder assembly components must be disassembled to service the inlet check valve Follow the procedure High Pressure Cylinder Assembly Removal When the components have been removed proceed with Step 1 below Figure 9 11 Low Pressure Inlet Check Valve 1 Poppet Retainer 3 Inlet Poppet Check Valve 2 Compression Spring 20480314 7 2011 Rev 02 Use a 1 2 inch flat blade screwdriver to remove the poppet retainer from the sealing head Inspect the sealing head for scratches or wear on the sealing head seal contact surface and on the inlet poppet valve contact surface If defects are detected the surfaces must be refinished See the procedure Sealing Head Maintenance Inspect both faces on the inlet poppet valve The poppet valve can be installed with either face toward the sealing head If one face is worn but the opposite is not the poppet can be reversed placing the best surface toward the sealing head If both faces are worn the poppet valve must be replaced
88. he input and output of the 24 volt DC power supply 20480318 2 2009 Rev 0 10 3 Malfunction Pump quits running No control power Indication A system fault has been detected Electrical power has been interrupted Motor overload relay has been tripped Circuit breaker has been tripped Power supply fault Emergency stop button is depressed Master control relay is not energized Contact set failure on the master control relay Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Comments Check the display panel for fault messages Check the power supply circuit for a tripped breaker Check the input and output of the 24 volt DC power supply Verify that power is available at the main power source Check for a tripped main circuit breaker Check the Q 0 0 relay Identify the source of the overload and remedy the problem Reset the overload relay Check the input and output of all circuit breakers Check the input and output voltages at the power supply Pull the E STOP button out Check all remote E STOP buttons Verify that the contactor coil 1s pulling in on the master control relay Verify that the contact sets on the master control relay are changing states when the relay is energized 20480318 2 2009 Rev 0 10 4 20480318 2 2009 Rev 0 Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction Red light on operator
89. ication 17 Water leaking from the weep hole in the sealing head gland nut High pressure piping gland nut is not tight and is not sealing properly Improper high pressure piping connection Damaged sealing head gland nut 18 Water leaking from the weep holes in the soft seal end cap Worn sealing head seal assembly Damaged high pressure cylinder External crack in sealing head Damaged sealing head 20480318 2 2009 Rev 0 Comments Tighten the gland nut to the proper torque specification Check the number of exposed threads past the collar on the high pressure piping Only 1 1 2 to 2 1 2 threads should be exposed Check high pressure piping for damage cracks or deformation Inspect the gland nut for deformation of the threads Check the gland nut for cracks due to fatigue If cracks are detected replace the gland nut Replace seal assembly Check for scratches or grooves on the sealing surface If detected polish to remove following the procedure High Pressure Cylinder Maintenance detailed in Section 9 High Pressure Water System Replace the high pressure cylinder Replace the sealing head Check for scratches or grooves on the sealing surface of the sealing head If detected polish the surface following the procedure Sealing Head Maintenance detailed in Section 9 High Pressure Water System 10 8 20480318 2 2009 Rev 0 Section 10 Troubleshooting Jetlin
90. igh pressure or remains in low pressure depending on the previous pressure setting 43 Keypad and Screen Functions The keypad allows you to navigate and select functions on the screen return to a previous screen and acknowledge alarms Table 4 1 Keypad Functions Function Comments Use the arrows to highlight the desired function on the screen When a fault condition occurs an alarm message will appear over the screen and a small triangle will flash in the corner of the screen Pressing ESC will clear the message allowing you to navigate the screen but it will not clear the fault Press ESC twice to return to the previous screen To clear a fault press the A arrow to highlight the flashing triangle and press ENTER to display the alarm message Press the ACK button to acknowledge the fault Press ENTER to initiate a function Icon displays above the F1 button on the System Information Settings and Maintenance Screens Press Fl on these screens to return to the Run Screen 20480289 2 2009 Rev 0 4 2 4 4 20480289 Operation E Run Screen The Run Screen is the only screen where the pump can be started to create pressure and a normal motor stop can be performed Figure 4 2 Run Screen Jetline AN 3 N 0000000 10 59 59 AM Capacity 000 000 On the Run Screen the state of the function buttons F1 F2 F3 and F4 changes according to the current status of the pump The avail
91. igure 9 6 Hydraulic Piston Plunger 3 High Pressure Cylinder Assembly 2 Hydraulic Piston Assembly 20480314 7 2011 Rev 02 9 5 High Pressure Water System ms 0 4 Service and Maintenance Overview Never perform any type of maintenance on the high pressure water system while it IS pressurized Always turn the power off and bleed the high pressure water before servicing Pressing the emergency stop button turns the control power off to the intensifier and bleeds high pressure water through the dump valve Improper assembly can lead to the premature failure of components Maintenance procedures must be followed carefully components must be properly cleaned prior to assembly and tightened to the correct torque specifications Some high pressure components are not serviceable at the customer level others require precise refinishing KMT Waterjet Systems offers maintenance and refinishing services for these components NOTE Refer to Section 12 Parts List for a complete listing of replacement parts and part numbers 20480314 7 2011 Rev 02 9 6 High Pressure Water System ms Torque Specifications Table 9 1 Torque Specifications details the torque specifications and tightening sequences for the high pressure components and connections Table 9 1 Torque Specifications High Pressure Water System Hydraulic Cylinder Head Socket Head Screws 8 M14 each Torque 75 80 ft lbs 102 108 Nm Hex Key M12 Proximi
92. ill only flex in a single plane without being subjected to torsional stress The use of high pressure swivels is strongly recommended 2 9 Commissioning When the machine has been positioned all service connections installed and the high pressure plumbing has been installed to the cutting area the machine is ready to be commissioned The following procedure is used for the initial startup and testing of the machine l 20480282 8 2010 Rev 02 Check all areas in and around the pump for foreign objects and debris Remove all tools parts etc from the area Check the hydraulic fluid level The hydraulic system is pre filled prior to shipping If the hydraulic fluid is low or empty due to leakage during transit the system must be filled Follow the instructions and specifications in Section 6 Recirculation System Open the shutoff valves on the service connections and check for leaks Check the connection between the customer supplied main power disconnect and the disconnect circuit breaker on the enclosure door Verify the proper voltage supply Close the enclosure door and turn the control power on To activate control power pull the EMERGENCY STOP button out and press the RESET button Refer to Section 4 Operation for additional information regarding control panel functions 1 Emergency Stop 2 Reset Button Installation 6 On the Run Screen press the F3 button to select low pressure operation Jetline 30 S
93. injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance on the high pressure system components Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance Turn the cutting water supply off Loosen and remove the high pressure gland fitting connected to the discharge high pressure check valve Move the tubing to clear the work area Loosen and remove the low pressure piping connected to the inlet water port on the sealing head collar When the required maintenance has been completed and the components reassembled connect the low pressure water piping to the inlet water port on the sealing head collar Apply Pure Goop to the threads on the high pressure gland fitting Before installing the high pressure fitting ensure proper collar position 1 1 2 to 2 1 2 threads should be exposed Install and tighten the fitting to the torque specifications in Table 9 1 Turn the cutting water supply on and check for low pressure leaks Remove the cutting orifice and start the machine Operate in low pressure mode to flush the high pressure passages Install the orifice and operate at high pressure to check for leaks High Pressure Cylinder Assembly The high pressure cylinder assembly must be disassembled to service the inlet check valves sealing head seal assembly plunger high pressure seals hydraulic pis
94. intensifier following the procedure High Pressure Cylinder Assembly Removal Figure 9 18 Hydraulic Piston Removal 1 O Ring 5 Hydraulic Seal Cartridge 9 Hydraulic Piston 2 Backup Ring 6 Bushing Retainer Flange 10 Hydraulic Cylinder 3 Hydraulic Cylinder Head 7 Retaining Ring 11 Proximity Switch 4 Socket Head Screw 8 Plunger 12 O Ring Spacer 4 Remove both of the proximity switches to prevent interference and to allow the hydraulic oil to drain back to the reservoir minimizing oil spillage It will take approximately five minutes for the oil to drain 5 Remove the retaining rings bushing retainer flanges and the hydraulic cartridge seals 6 Loosen and remove the socket head screws in the hydraulic cylinder heads 7 Remove the hydraulic cylinder heads with the o rings and backup rings The mounting flat for the proximity switch provides a small lip for loosening the cylinder head 8 Grasp the plunger firmly and pull the piston out of the hydraulic cylinder 9 Place the piston in a vice and remove the retaining ring on each end of the piston 20480314 7 2011 Rev 02 9 24 High Pressure Water System ms 10 Pull each plunger to remove it from the piston The plunger retainer will remain with the plunger when it is removed 11 Remove the o ring and the backup ring from each side of the piston Bearing Rings and Seal Assembly l Use a smooth dull edged blade made from brass or similar soft metal material to remove the t
95. l failure on the directional Check the coils on the control valve directional valve with a volt meter to verify if they are good or bad PLC failure If there are inputs from the proximity switches but no outputs contact the KMT Customer Service Department for a logic review and verification of PLC failure 20480318 2 2009 Rev 0 10 2 Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction Indication Comments No hydraulic oil pressure The high and low limit Disassemble the compensators compensators on the clean and inspect the hydraulic pump are blocked components following the with debris and are not maintenance procedure in controlling the swashplate Section 7 Hydraulic System The flexible coupling has Replace the flexible coupling failed 5 Pump will not start Emergency stop button is Pull the E STOP button out and depressed press the RESET button Check all remote E STOP buttons Output signal has been Check the Q 0 0 relay Interrupted A protection fault has been Check the display panel for activated fault messages Motor overload relay has Identify the source of the been tripped overload and remedy the problem Resetthe overload relay Console display and lights Main power is disconnected Check the main power and do not illuminate verify that the main power disconnect 1s on Control power 1s not Check the power supply circuit available for a tripped breaker Check t
96. let Water Groove 7 High Pressure Cylinder 4 Sealing Head 8 Hydraulic Cylinder Head 4 Position a pin spanner wrench on the soft seal end cap to turn counter clockwise Position a cylinder wrench on the high pressure cylinder to turn clockwise Break the end loose It may be necessary to tap the spanner wrench with a plastic hammer 5 Unscrew the end cap until it is flush with the inlet water groove on the sealing head With a screwdriver in the groove supported by the end cap gently pry the sealing head out as far as possible Repeat this process until the sealing head is loose from the high pressure cylinder 20480314 7 2011 Rev 02 9 10 KMT Section 9 A High Pressure Water System 6 Unscrew and remove the end cap and sealing head from the cylinder 7 Use the seal removal tool to remove the sealing head seal components from the cylinder To service the high pressure seals plunger hydraulic piston or hydraulic seal cartridge continue with Step 8 8 Remove the cylinder liner 9 Position the vee block cradle under the high pressure cylinder to support the weight Unthread and remove the cylinder from the hydraulic cylinder head and plunger The cylinder can be rotated with the cylinder wrench or by hand VAN CAUTION Due to the weight of the high pressure cylinder adequate support must be provided to prevent damage to the plunger or seals during removal and installation NOTE If thread or metal surface g
97. local regional and national codes Plant Air The facility compressed air connection should provide clean dry air regulated to 85 psi 5 9 bar Air usage is minimal normally less than 1 scf m The following table provides specifications for each ISO air quality classification KMT recommends adherence to Quality Class 4 8 2010 Rev 02 2 6 KMT EE ISO Quality Class I 2 3 4 5 6 ISO Air Quality Classifications Maximum Particle Size microns 0 1 a Contaminated Waste Drain Table 2 6 Maximum Pressure Dew Point water 100 psi 94 F 60 C 40 F 40 C 4 F 20 C 38 F 43 C 45 F 7 C 50 F 10 C Section 2 Installation Maximum Oil Content Mg m 0 01 0 1 l 5 25 Oil and water that can accumulate on the drip pans is disposed of through the contaminated waste drain on each pan This oil and water mixture is considered contaminated and disposal must comply with local regional and national codes The volume of waste will be minimal and can be collected in a container of some appropriate type 2 6 Flow Requirements Figure 2 4 Pressure Drop Values illustrates the pressure drop for four different pipe sizes The graph can be used to calculate the minimum source water pressure 1 Enter the graph at the required GPM and note the pressure drop figures for the different pipe sizes 2 Multiply the pressure drop PSI FT by the length in feet of
98. m the die and body of the tool before threading the next tube Power Threading 1 Secure the coned tubing in a tube vise No more than the recommended length of tubing should extend beyond the face of the vice See Table 2 10 Recommended Extension Length 2 Mount the threading tool in a 3 8 inch or 1 2 inch variable speed power drill Apply cutting oil to the end of the tube and slide the threading tool on the tubing 3 Make sure the drill is set to turn counter clockwise Apply steady pressure against the end of the tubing while the threads are being cut Apply cutting oil frequently and liberally throughout the cutting operation A medium weight cutting oil with high sulfur content is recommended 4 Continue threading until the proper thread length 1s reached See Table 2 9 Column L Reverse the direction of the drill and remove the threading tool 20480282 8 2010 Rev 02 2 13 Section 2 Installation NOTE Clean the machining chips from the die and body of the tool before threading the next tube 2 8 High Pressure Connections When installing high pressure discharge piping it is essential that all burrs are carefully removed and the tubing sections purged with clean compressed air prior to assembly Lightly spraying the inside of the tube with a carrier fluid such as WD 40 before purging with air will help carry the burrs High pressure piping must be installed without torsional or bending stresses and proper suppo
99. n the intensifier and the cutting station control system e The machine must be commissioned and tested 8 2010 Rev 02 2 1 Installation P 72727 7 7 CU w 2 5 20480282 Site Requirements The intensifier must be installed indoors where air borne dust and contaminants are minimal The ambient temperature should be between 40 F 5 C and 104 F 40 C with a maximum relative humidity of 95 percent Refer to Table 2 1 Equipment Dimensions and Weight to establish a suitable installation site A minimum clearance of 36 inches 914 mm should be provided on all sides of the machine to facilitate service Figure 2 1 Equipment Dimensions E ie FOS O G 5 e e o Table 2 1 Equipment Dimensions and Weight Model 1 Length 2 Width 3 Height Weight JL 130 78 98 2 006 mm 36 00 914 mm 46 58 1 183 mm 2 450 lbs 1 111 kg JL 150 78 98 2 006 mm 36 00 914 mm 46 58 1 183 mm 2 650 lbs 1 202 kg Transporting The weight of the machine is not evenly distributed from one end to the other Do not attempt to lift the machine from either end Note the warnings stamped on the crate The center of gravity is clearly identified on the sides of the
100. ng pressure making disassembly difficult If the attenuator develops a high pressure water leak it should be replaced 20480314 7 2011 Rev 02 9 27 High Pressure Water System KMT Section 9 A 9 13 High Pressure Dump Valve The high pressure dump valve assembly includes a normally open high pressure water valve and a solenoid operated pneumatic actuator The following procedure is recommended for servicing the high pressure dump valve Failure to follow this procedure will cause damage to the stem valve seat or both x The high pressure dump valve is a safety device designed to instantly release high pressure from the system Proper maintenance is imperative to prevent potential personal injury Figure 9 22 Pneumatic Valve Seal Tools illustrates the special tools recommended for this procedure Figure 9 22 Pneumatic Valve Seal Tools O 20470475 9500671950 49835114 204 0415 1 Seal Tool Kit 20470475 4 Seal Positioning Tool 05067350 2 Seal Installation Tool 20470417 NO NC Pneumatic Valves 3 Seal Push Tool 20470413 2 Port Pneumatic Dump Valves 5 Seal Positioning Tool 49833114 Quick Release Valves 3 Port Pneumatic Dump Valves Pneumatic Control Dump Valve For reliable operation the valve seat seal assembly brass backup ring and stem shall always be replaced at the same time The SST backup ring can be reused Before proceeding
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102. nt should be changed when the gauge reads 40 psi 2 8 bar at normal operating temperature If the element is not replaced and fills with debris the bypass relief in the filter head will open to prevent over pressurization The relief valve opens at 50 psi 3 4 bar When the valve opens the oil bypasses the filter and unfiltered oil is allowed to return to the reservoir The temperature low level switch monitors the oil temperature and level in the reservoir An automatic shutdown will occur if the operating oil temperature exceeds 145 F 63 C An automatic shutdown will also occur if the oil level falls below 30 gal 114 L NOTE To conserve water usage it is recommended that the cooling water be shut off at the end of the day A sensor bulb from the modulating valve is submerged in the reservoir Even when the control power is off the valve will remain open allowing water to flow until the oil is cooled ae i ne Service and Maintenance Procedures To ensure the supply of properly conditioned oil to the main hydraulic system the components will require routine servicing and maintenance The procedures for servicing these components are detailed below NOTE p 5 0 a a ee ee ee x Refer to Section 12 Parts List for a complete listing of replacement parts and part x numbe
103. ole in the sealing head 20480318 2 2009 Rev 0 Damaged plunger Seal material buildup on plunger Damaged high pressure cylinder Seat in the discharge check valve is not sealing properly Improper torque on gland nut Erosion or scratches on the contact surface of the sealing head or on the gland nut where the seat makes contact Check the plunger for longitudinal scratches or flaws If detected replace the plunger or return to KMT Waterjet for evaluation and rework Polish the plunger surface following the procedure Plunger Maintenance detailed in Section 9 High Pressure Water System Check for scratches grooves or material buildup on the inside diameter of the cylinder If detected polish the bore following the procedure High Pressure Cylinder Maintenance detailed in Section 9 High Pressure Water System Check the inside diameter of the cylinder for expansion where the high pressure seal assembly is located If detected replace the cylinder Make sure the gland nut is tightened to the proper torque specification Inspect the seat sealing head and gland nut for scratches erosion or cracks Tighten the gland nut to the proper torque specification Polish the surfaces following the procedure Sealing Head Maintenance detailed in Section 9 High Pressure Water System 10 7 KMT Eessen Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction Ind
104. ooting Guide Listen to the machine and observe it in operation Learn to recognize the normal sounds and operating conditions of the system Carefully define the symptom of the problem Locate the symptom on the troubleshooting guide that most closely corresponds to the problem 2 2009 Rev 0 If the symptoms in the guide do not correspond to the malfunction or if the problem is not resolved by the recommended corrective action contact the KMT Customer Service Department for assistance 10 1 Section 10 Troubleshooting Jetline JL 1 Troubleshooting Guide Malfunction Indication Comments High oil temperature Cooling water flow is Check cooling water source resulting in shutdown restricted for proper temperature and flow rate The water pressure delivered to the heat exchanger requires a minimum of 35 psi 2 4 bar for flow through the exchanger Water modulating valve is Replace the valve stuck open or closed or is out of adjustment Adjust the valve Scale build up in the heat The heat exchanger will need exchanger has restricted the to be flushed or replaced flow Low oil level resulting in Check the level gauge shutdown Check for hydraulic leaks Check the level switch Hydraulic pressure but no Proximity switch failure From the Maintenance Screen high pressure water on the control panel jog the pressure intensifier left and right and verify that the red light comes on at both proximity switches Coi
105. ousing 2 2009 Rev 0 5 4 KIMT eem Section 5 Low Pressure Water System Figure 5 4 Strainer 1 Plug Unscrew and remove the strainer plug and seal ring Remove and clean the mesh liner Install the liner Ensure the seal ring is properly positioned replace the plug and hand tighten Turn the cutting water supply on Press the red bleed valve to remove any air inside the filter housing Start the machine and verify satisfactory pressure readings Booster Pump Adjustment If the discharge pressure from the booster pump stays below 90 psi 6 bar while the intensifier 1s shifting the relief valve on the booster pump should be adjusted Figure 5 5 Booster Pump 20480293 2 2009 Rev 0 1 Booster Pump 2 Relief Valve Acorn Nut Turn the cutting water supply on Start the machine and initiate normal shifting operation Observe the discharge pressure from the booster pump If the pressure stays below 90 psi 6 bar continue with Step 4 Stop the intensifier and remove the acorn nut on the side of the pump to access the adjustment screw It is normal for water to leak out when the acorn nut is removed Use a flat screwdriver and turn the adjustment screw clockwise to increase the discharge pressure or counter clockwise to decrease the pressure Adjust the pressure to the highest desired pressure within normal booster pump range 5 5 Section 5 Low Pressure Water System If the adjustment screw is
106. peration Electrical power from the utility grid enters the main circuit breaker disconnect on the electrical enclosure door as 3 phase alternating current The power is then distributed in two directions The 3 phase AC at the voltage provided from the grid is routed to the motor starter contactor s and then to the main motor Single phase AC is routed to the transformer The transformer converts the incoming voltage to 230 volt AC that is routed to both the motor starter contactor s and to the power supply The power supply then provides 24 volt direct current to the control circuits including the emergency stop logic the PLC and the display panel 2 2009 Rev 0 R 1 KIMT pr Figure 8 1 Electrical Control Power Section 8 Electrical System 1 Line Customer Supplied Line Voltage 3 Phase Line Power Wall Disconnect Circuit Breaker Disconnect NH tn N Transformer 8 Power Supply 12 Display Panel 13 Motor Control Relay 14 Contactor Coil 230V AC 15 Motor Starter Contactor 16 Motor The motor starter contactors are solenoid operated by 230 volt AC control power The contactors are arranged in a wye delta starter circuit Wye delta starter circuits are typically installed in all low voltage machines that require high curren
107. quently for water content Sound Level Sound level with optional side panels 75 0 dB A 20480327 7 201 1 Rev 03 Specifications ms Equipment Dimensions and Weights geg JL 1 30 78 98 2 006 mm 36 00 914 mm 46 58 1 183 mm 2 450 Ibs 1 111 kg JL 1 50 78 98 2 006 mm 36 00 914 mm 46 58 1 183 mm 2 650 Ibs 1 202 kg Service Connections x x Connection x Height 1 2 BSPT 12 51 318 mm 16 26 413 mm 20 01 508 mm 23 76 604 mm 28 76 730 mm 36 26 921 mm 40 26 1 023 mm Drain 1 2 BSPT Cooling Water In 1 2 BSPT A B C D Cooling WaterOut 12 BSPT E open F G Cutting Water In Contaminated Waste Drain 1 2 BSPT Cutting Water Out 9 16 HP 1 4 BSPT Plant Air In Plant Air The facility compressed air connection should provide clean dry air regulated to 85 psi 5 9 bar Air usage is minimal normally less than 1 scf m The following table provides specifications for each ISO air quality classification KMT recommends adherence to Quality Class 4 Table 11 2 ISO Air Quality Classifications Maximum Maximum Pressure ISO Quality Particle Size Dew Point Maximum Oil Content Class microns water 100 psi Mg m 94 F 60 C 001 7 2011 Rev 03 2 40 F 40 C 0 1 3 4 F 20 C 4 38 F 43 C 5 5 45 F 7 C 25 6 yea 50 F 10 C Specifications A 11 3 Water Specifications
108. r and turn counter clockwise to compress the spring slowing water flow and increasing temperature Or turn clockwise to reduce spring tension increasing water flow and decreasing the temperature 7 Monitor the sight gauge on the side of the reservoir until the adjusted temperature can be determined It will take some time for the temperature in the oil reservoir to change 8 Repeat steps 2 and 3 if necessary 20480302 8 2010 Rev 01 6 7 KIMT r SECTION 7 HYDRAULIC SYSTEM 7 1 Overview The main hydraulic power circuit supplies the intensifier assembly with the hydraulic oil required to produce high pressure water High pressure cutting water is generated from the oil pressure In the hydraulic cylinder System components include the electric motor hydraulic pump 4 way directional control valve and the hydraulic manifold The manifold houses the high and low pressure control valves hydraulic gauge two pressure solenoid valve and the main system relief valve The system relief valve monitors hydraulic ol pressure and provides system protection by limiting excess pressure Figure 7 1 Main Hydraulic Power Circuit SAA 1 Hydraulic Pump Electric Motor Hydraulic Manifold T N System Relief Valve 20480306 2 2009 Rev 0 OO I O Un Solenoid Valve 9 Pressure Gauge Low Pressure Control 10 Intensifier High Pressure Control Directional Control Valve 7 1 Hydraulic System PC 72 Opera
109. re 1s reached The high pressure setting 1s increased by turning the high pressure control valve on the hydraulic manifold clockwise NOTE It 1s strongly recommended that the high pressure plumbing be purged under high pressure operating conditions using a large inexpensive orifice Contamination can be released when the tubing expands under pressure Early orifice failures could be experienced if the piping is not adequately purged 2 10 Decommissioning All local regulations must be adhered to when the intensifier is decommissioned and taken out of service for any reason 20480282 8 2010 Rev 02 2 18 KIMT r SECTION 3 MAINTENANCE 3 1 3 2 20480285 Overview The Jetlline series has been designed to fail safely Systems fail gradually seals and connections can begin to leak slowly or suddenly through specially designed weep holes Water or oil dripping from a weep hole indicates internal seals or valves are beginning to fail a warning that maintenance will be required The comprehensive fault detection and troubleshooting logic built into the programmable logic controller PLC monitors crucial temperature and fluid levels Warning and shutdown sensors guard against potential injury and equipment damage Maintenance The waterjet system has been designed for ease of maintenance and long reliable operation In order to keep the equipment in optimum operating condition routine and preventive maintenance i
110. roduction ETT 1 6 1 7 1 8 20480273 Spare Parts KMT Waterjet maintains a well stocked Spare Parts Department staffed by trained knowledgeable personnel If required emergency shipment is available Contact the Customer Service Department to order spare parts or for additional information Manual Organization This manual contains operating and maintenance procedures for the Jetline Series Information is organized as follows e Section 1 Introduction provides an overview of equipment features and options a brief operational overview details regarding safety issues and contact information for product support e Section 2 Installation details installation requirements and procedures Systematic guidelines for commissioning the intensifier are also provided e Section 3 Maintenance highlights routine and preventive maintenance requirements Precautions associated with high pressure cutting equipment are also reviewed e Section 4 Operation explains the control functions and the display panel where operating parameters are set and monitored e Sections 5 through 9 are specific to each individual system Each section contains a detailed description of the principles of operation and the function of each system Routine maintenance procedures associated with the system are also detailed e Section 10 Troubleshooting is a comprehensive guide containing the information required to diagnose problems and repair th
111. rom one solenoid to b Te EI Sa the other LEDs are alternately illuminated A AA 1 P 3 4 When low pressure is selected a normally closed solenoid valve is activated The valve remains closed while operating in high pressure and 1s held open electrically during low pressure operation An illuminated LED on the solenoid indicates low pressure operation 20480310 2 2009 Rev 0 8 5 KIMT HA 20480310 2 2009 Rev 0 Component Hydraulic Cylinder High Pressure Safety Dump Valve 6 NS Section 8 Electrical System Table 8 1 Sensors and Solenoids Function As pressurized hydraulic oil is sent to one side of the hydraulic cylinder it pushes against the piston moving it in one direction until it activates the proximity switch at the end of the stroke The hydraulic flow is then sent to the opposite side of the cylinder and the piston reverses direction until it activates the proximity switch at the opposite end of the stroke The green light on the proximity switch indicates there is power to the switch The light turns red when the switch is activated The proximity switches are magnetically activated by the presence of the metallic surface of the piston When the switch 1s activated it sends a signal to the PLC to change the flow of the directional control valve and reverse direction The safety dump valve releases the stored pressure in the intensifier and high pressure delivery lines The high pressur
112. rs Hydraulic Oil Maintenance The hydraulic oil should be replaced after 3 000 hours or one year of service whichever comes first The oil should be replaced sooner if a fluid sample indicates contamination that cannot be rectified by filtering An air breather and filter are located on the top of the reservoir The air breather prevents dirt from being sucked into the reservoir when the oil level drops and allows air to escape when the level rises The air breather must not be used as a fill point Oil must only be replaced at the fill port on the filter head Do not attempt to fill the reservoir from the air breather The oil will not be filtered and will not conform to the cleanliness requirements of the system 8 2010 Rev 01 6 3 Recirculation System KMT Section 6 FC Figure 6 3 Hydraulic Reservoir 1 Breather 3 Drain 2 Oil Fill Port Before proceeding disconnect and lockout the main power supply and the electrical enclosure and ensure that all high pressure water and hydraulic pressure has been bled from the system Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before performing maintenance Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before performing maintenance 1 Drain the oil reservoir by connecting the inlet hose from an oil
113. rts and guides must be provided Torsional stress will cause premature component failure Pure Goop anti seize compound must be applied to the threads and contact surfaces of all stainless steel components prior to assembly Failure to lubricate components with Pure Goop will result in galling rendering the components useless VAN CAUTION Do not use any other anti seize compound Apply Pure Goop only to stainless steel components Standard Connections Standard connections are used for general applications where internal pressure 1s the only load on the tubing Figure 2 8 Standard High Pressure Connections 1 Gland Nut 3 Exposed Threads 2 Collar 4 Tubing 1 Deburr the tubing ID and thoroughly clean the tubing threads 2 Slip the gland nut onto the tubing 20480282 8 2010 Rev 02 2 14 Section 2 Installation 3 Apply Pure Goop to the threads on the tubing Screw the collar onto the threaded end of the tubing leaving 1 1 2 to 2 1 2 threads exposed on the tubing between the collar and the coned tubing 4 Apply Pure Goop to the male threads on the gland nut and insert the tubing into the connection Engage the gland nut and tighten finger tight 5 Tighten the gland nut to the torque specifications in Table 2 11 Proper piping supports and guides must be provided End connections will not support the tubing load alone Table 2 11 Torque Specifications High Pressure Connections 1 4
114. s Figure 4 9 Program Information Screen Program Into PLG 00000000F ev HMI 20468473R ev Settings Screen Operating parameters and equipment options are established on the settings screens The A or V arrow in the top left hand corner of the screen indicates additional options Use the A or V arrow on the keypad to view all information options All settings screens are password protected and some screens are not accessible at the customer level Customer available screens require a login and password to access Figure 4 10 Settings Screen 2 2009 Rev 0 4 7 20480289 Section 4 Operation Stroke Rate Screen The overstroke setpoint is increased or decreased from the Stroke Rate Screen Stroke rate should be set slightly higher than the desired operating rate to shutdown the machine quickly in the event of an overstroke condition The upper limit stroke rate is preset according to the horsepower rating of the machine The JL 1 30 is preset at 37 strokes per minute and the JL 1 50 is preset at 60 strokes per minute Before setting the stroke rate monitor the actual strokes minute during normal operation The overstroke setpoint should then be set 20 above that rate Figure 4 11 Stroke Rate Screen JLI ONG Kote Setpoint ont strokes min 00 To increase or decrease the stroke rate use the arrows on the keypad to highlight the desired A or V button on the screen Continue to press ENTER until the desired
115. s essential Detailed maintenance procedures for specific systems are provided in subsequent sections of this manual Daily Inspection The following inspection procedures should be performed each day If problems are detected they should be remedied before placing the machine in service e Prior to startup inspect the area around the machine the high pressure piping and connections for indications of leaks e Make sure there is no maintenance work in process e Check the hydraulic oil level e As the machine is started and water pressure increases listen for unusual sounds e Check for water or oil leakage e Check the condition of the hydraulic oil filter e Check the condition of the low pressure water filter Periodic Maintenance A number of factors can contribute to component failure poor water quality operating conditions or improper maintenance procedures Maintaining a service log can be a useful method of tracking component life and maintenance trends Analyzing service intervals will assist in preparing a preventive maintenance schedule tailored to your specific application and production requirements Periodic maintenance at regularly scheduled intervals will minimize unscheduled downtime and premature component failure 7 201 1 Rev 03 3 1 KIMT A Section 3 Maintenance Improper assembly can lead to the premature failure of components Maintenance procedures must be followed carefully components must be prop
116. stroke rate is displayed Configuration Screen The configuration screen is used at initial startup to set the horsepower and equipment parameters for the specific pump The Configuration Screen is not accessible at the customer level 2 2009 Rev 0 4 8 Operation o Language Screen The Language Screen lists the available display languages Use the arrows on the keypad to highlight the desired language and press ENTER to select Or Press F4 to toggle through the languages Figure 4 12 Language Screen Language Serial Number Screen The Serial Number Screen is password protected and used to record the serial number for the specific pump The Serial Number Screen is not accessible at the customer level Date Time Screen The date and time are changed from the Date Time Screen Use the arrows on the keypad to highlight the value to be changed month day year etc Press ENTER until the desired value is displayed Figure 4 13 Date Time Screen Date lime 12131 20060 10 59 59 RM rr HMI Screen The HMI Screen is used to load a new operating program and is not accessible at the customer level 20480289 2 2009 Rev 0 4 9 4 8 20480289 Operation HB sss Maintenance Screen The Maintenance Screen is used to facilitate maintenance procedures and reset maintenance hours and strokes When started from the Maintenance Screen the pump starts in maintenance mode Figure 4 14 Maintenance Screen
117. t draw Three 3 phase contactors are used to start the motor slowly minimizing the initial current draw 20480310 2 2009 Rev 0 8 2 Electrical System A Figure 8 2 Wye Delta Configuration Three 3 Phase Contactors The circuit breaker door disconnect provides the primary over current protection for the machine All power is automatically disconnected from the machine when the main disconnect on the enclosure door is opened However power is still present on the input side of the circuit breaker door disconnect The only way to isolate all power to the machine is to turn the customer installed main power disconnect off Figure 8 3 Electrical Enclosure Door 1 Circuit Breaker Disconnect 20480310 2 2009 Rev 0 8 3 Section 8 Electrical System NOTE x See Section 2 Installation regarding specifications for the customer installed main power disconnect Sensors and Solenoids Warning and shutdown sensors monitor operating conditions and electronically operated solenoids provide basic intensifier shift control The harness cable connects these sensors and solenoids to the PLC Figure 8 4 Sensors and Solenoids
118. tandards Constituent Minimum mg l Requirement Better Best Note Do not reduce the TDS beyond this amount or the water will be too aggressive Table 11 4 Water Impurities Constituent Alkalinity Calcium Chloride Free Chlorine Iron Magnesium as Mg Manganese as Mn Nitrate Silica Sodium Sulfate TDS Total Hardness Chemical Formula Bicarbonate HCO Carbonate CO3 Hydrate OH expressed as CaCO Ca Cl Cl Fe ferrous Fe ferric Mn NO S10 SO CaCO Comments Acid neutralizing capacity of water Foaming and carryover of solids causes embrittlement of steel can produce CO a source of corrosion When dissolved makes water hard contributes to the formation of scale Adds to solid content and increases corrosive character of water in relative percentage presence with oxygen induces stress corrosion cracking Oxidizing agent can attack elastomeric seals and damage reverse osmosis RO membranes Discolors water or precipitation source of scale and erosion When dissolved makes water hard contributes to the formation of scale Discolors water or precipitation source of scale and erosion Adds to solid content effect is not generally significant industrially Causes scale Found naturally introduced to water in the ion exchange water softening process Adds to solid content combines with calcium to form calci
119. ter Motor STOD ioter t eaa ehe etn Sx dre axe Sena e Rond 4 Startup aber Emergency OP 4 1 4 3 Keypad and Screen FOE 4 2 4 4 re EE 4 3 4 5 D VSLC CT CC EE 4 4 4 6 TATORMMATIOME Cte 4 4 In EE 4 5 Capacite SCLC EE 4 5 SMOKER MED CE NEE 4 6 DAS is NETT TT 4 6 Program ege ee EE 4 7 4 7 SELLES Oia 4 7 SOKE Ee EE 4 8 CONTOUR AUIOM SCHOOLS se orsi ote onse stvent bs a 4 8 Language E cto sodio metes histo uta ecu sa 4 9 Seral Number Sle ei eee teen ak adn 4 9 Date Time e EE 4 9 A b aa ili pa likaa shashpa 4 9 4 8 Maintenance Os 4 10 Maintenance Tours SCECOD add 4 10 Maintenance STORES CIN EE 4 1 4 9 TEE eet 4 11 Low Pressure Water System 5 1 5 1 EE 5 1 32 Cutting Water supply Quality uu y it 5 2 5 3 LP pasan asum qam miss ah masta aS Gana as 5 2 5 4 Service and Maintenance Procedures 5 4 Filter Assembly and Strainer Maintenance 5 4 Booster Pump A serenite E 5 5 11 20480338 8 2010 Rev 02 Recirculation SY RE 6 1 6 1 e yu nent latte 6 1 6 2 E aaa ana 6 2 6 3 Service and Maintenance Procedur s U a ua En 6 3 Hydraulic Oil NMaintondnee a 6 3 Bereet BUM 6 5 Oil Fiter Maintenance EE 6 6 Operating Temperature Adjustment 6 6 Hydraalhe Systemi E 7 1 7 1 O A A A A 7 1 1 2 ie EE 7 2 7 3 Service and Maintenance Procedures
120. the cylinder Do not install the pneumatic cylinder in a vise to remove the cylinder head This may distort the body and seize the piston preventing proper operation 2 Remove the o ring on the cylinder head Apply FML 2 grease to a new o ring and install 3 Remove the two o rings on the piston Apply FML 2 grease to two new o rings and install 4 Install the piston in the pneumatic cylinder Apply anti seize compound to the threads on the cylinder head and screw it into the pneumatic cylinder 20480314 7 2011 Rev 02 9 33 Section 9 High Pressure Water System KMT PR 9 14 Weep Holes High pressure seals and connections fail gradually and begin leaking slowly Weep holes are located at every threaded high pressure connection to provide a vent for internal leaks Water or oil dripping from a weep hole indicates one or more internal components are beginning to fail Table 9 3 lists the location of the weep hole the possible source of the leak and the corrective action required Table 9 3 Weep Holes High Pressure Water System Location Indication Comments Hydraulic Cylinder Head Hydraulic oil leaking from the weep hole in the hydraulic cylinder head Failed hydraulic cartridge seal Replace the cartridge seal If the leak persists check the plunger for linear scratches or scoring Water leaking from the weep hole on the hydraulic cylinder head flange Failed high pressure seal assembly Replace
121. the high pressure seal assembly Damaged plunger Check the plunger for longitudinal scratches or flaws If detected replace the plunger or return to KMT for evaluation Seal material buildup on plunger Polish the plunger surface following the procedure Plunger Maintenance Damaged high pressure cylinder Check for scratches grooves or material buildup on the inside diameter of the cylinder If detected polish the bore following the procedure High Pressure Cylinder Maintenance Check the inside diameter of the cylinder for expansion where the high pressure seal assembly is located If detected replace the cylinder 204803 14 7 201 1 Rev 02 9 34 KMT Eessen Location Sealing Head Water leaking from the weep hole in the sealing head Water leaking from the weep hole in the gland nut 20480314 7 2011 Rev 02 Table 9 3 Weep Holes High Pressure Water System Indication Seat in the discharge check valve is not sealing properly Internal crack in sealing head Improper torque on gland nut Erosion or scratches on the contact surface of the sealing head or on the gland nut where the seat makes contact High pressure piping gland nut is not tight and is not sealing properly Improper high pressure piping connection Damaged sealing head gland nut Section 9 High Pressure Water System Comments Make sure the gland nut is tightened to the proper torque specification Insp
122. the piston and the inside diameter of the hydraulic cylinder On each end of the piston a plunger retainer and retaining ring hold the plungers in position Figure 9 17 Hydraulic Piston Components 1 Piston Seal Assembly 5 Plunger 2 Bearing Ring 6 Retaining Ring 3 Ram Piston 7 Backup Ring 4 Plunger Retainer 8 O Ring Hydraulic Piston and Plunger Removal The following procedure is used to remove the hydraulic piston and plungers It is necessary to remove the components from both ends of the intensifier Prior to removing electrical power or any high or low pressure piping bring the hydraulic piston in the left or right stop position to facilitate maintenance The plunger will extend in the selected direction allowing full exposure when the unit is disassembled Refer to Section 4 Operation 1 Turn the machine off and observe the appropriate Lockout Tagout procedures Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before proceeding Ensure all pressure 1s relieved or blocked from the hydraulic and high pressure circuits before proceeding 20480314 7 2011 Rev 02 9 23 Section 9 High Pressure Water System 2 Disconnect the high and low pressure water piping from both ends of the intensifier following the procedure High and Low Pressure Water Piping 3 Remove the high pressure cylinder assembly components on each end of the
123. the seal components are properly installed apply FML 2 grease to the exposed surfaces of the seals and slide the hydraulic cartridge seal over the plunger into the cavity of the hydraulic cylinder head KIMT pr 20480314 7 2011 Rev 02 8 10 11 Section 9 High Pressure Water System Thoroughly clean the bushing retainer flange including the cross drilled weep holes Install the retainer flange over the plunger Install the retaining ring ensuring the retaining ring fully seats inside the groove in the hydraulic cylinder head The o rings on the hydraulic cartridge will take up clearance Tap lightly on the bushing retainer flange with the cartridge removal tool to compress the o rings enough to start the retaining ring in the groove Use a flat blade screwdriver to push on the outer edge of the retainer flange while working one end of the retaining ring into the groove The retainer flange should tilt or tip enough to allow the retaining ring to move into the groove Continue working the ring into the groove while tilting the retainer flange until the ring is fully seated Install the high pressure cylinder into the hydraulic cylinder head following the procedure High Pressure Cylinder Assembly Installation Connect the high and low pressure water piping and turn the low pressure water supply on High Pressure Water System ms 9 10 Hydraulic Piston and Plungers Two bearing rings provide wear contact between
124. the seal installation tool inserting the o ring end of the seal first so the tapered end of the seal wedge ring end faces the actuator The tapered end of the seal must face the actuator See Figure 9 25 Valve Seal Installation Use the seal push tool to push the seal assembly into the bore of the valve body until the seal makes light contact with the seal positioning tool Remove the push tool and the installation tool from the valve body Install the existing SST backup ring and a new brass backup ring on a new stem The vee groove on the SST backup ring must face toward the brass backup ring The small OD of the brass backup ring must face toward the seal assembly See Figure 9 24 Dump Valve Components Apply FML 2 grease to the tip of the stem and insert the stem with the backup rings into the top of the valve body so the stem enters the ID of the seal assembly Insert the stem until the chamfer on the stem is seated against the SST backup ring See Figure 9 26 Valve Stem Placement Section 9 High Pressure Water System VAN CAUTION Do not push the o ring on the seal assembly past the inlet port on the valve wn This will damage the seal o ring ZL 7 CN WZ 7 gt 1 SST Backup Ring 4 Seal O Ring 2 Inlet Port 5 Stem Chamfer 3 Seal Positioning Tool 18 Remove the high pressure adapter and the seal positioning tool 19 Apply Pure Goop anti seize compound to the
125. therefore KMT Waterjet Systems be helpful This injury must be treated as an acute surgical emergency and be evaluated by a qualified 635 West 12th Street surgeon Circulation may be compromised Baxter Springs KS 66713 therefore DO NOT APPLY HEAT TO INJURED 620 856 2151 PART For first aid 1 Elevate injured part 2 Antibiotics 3 Keep injured person NPO 15 Worldwide Product Support The KMT Waterjet Customer Service Department is available to answer your questions regarding equipment installation and service Technical assistance is available by phone and on site support 1s available on request On site technical assistance is available during equipment installation and startup Additionally technical support for service and maintenance issues and training of operators and maintenance personnel is available Periodic training sessions are also conducted at KMT Waterjet and customer facilities Contact the KMT Waterjet Customer Service Department for additional information USA Customer Service Manager Europe Technical Manager KMT Waterjet Systems KMT Waterjet Systems GmbH PO Box 231 Wasserstrahl Schneidetechnik 635 West 12th Street Auf der Laukert 11 Baxter Springs KS 66713 D 61231 Bad Nauheim USA Germany Phone 800 826 9274 Phone 49 6032 997 117 Fax 620 856 2242 Fax 49 6032 997 270 Email Email w service kmtwaterjet com order service kmt waterjet com w parts kmtwaterjet com 20480273 9 2009 Rev 01 1 7 Int
126. threads of the actuator and carefully thread it into the valve body guiding the stem head into the hole in the actuator Turn the actuator clockwise until resistance is felt Reverse the actuator 1 4 turn and give it a quick spin clockwise to seat it Hand tighten only 5 ft lbs 7 Nm 20 Apply Pure Goop anti seize compound to all surfaces except the ID of a new valve seat Install the seat into the valve body inserting the small OD first 21 Apply anti seize compound to the threads on the high pressure adapter Install the adapter and torque to 25 ft lbs 34 Nm 22 Replace the 1 4 inch drain gland nut and collar and torque to 25 ft lbs 34 Nm 23 Apply anti seize compound to the threads on the 3 8 inch high pressure gland fittings Install the collar and the gland fittings and torque to 50 ft lbs 68 Nm 24 Install the air supply hose and the electrical connection to the solenoid valve Turn the air pressure to the actuator on and test the valve for leaks and proper operation 20480314 7 2011 Rev 02 9 32 High Pressure Water System ms Pneumatic Actuator The following procedure is used to service the pneumatic actuator Figure 9 27 Pneumatic Actuator 1 Cylinder Head 7 Cylinder Head 2 O Ring 8 O Ring 3 O Ring 9 O Ring 4 Piston 10 Pneumatic Cylinder 5 Pneumatic Cylinder 11 Piston 6 Control Air 1 Unscrew and remove the cylinder head using a strap wrench and a pin spanner Remove the piston from
127. tion The electric motor drives three pumps mounted in tandem the main hydraulic pump the recirculation pump and the booster pump The motor drives the variable displacement pressure compensated hydraulic pump by means of a flexible coupling Hydraulic fluid from the reservoir is drawn into the inlet low pressure side of the hydraulic pump Oil delivered to the pump should be maintained at 110 115 F 43 46 C Hydraulic fluid then enters the bottom of the manifold through an internal anti rotation check valve After a shutdown the anti rotation check valve prevents the pump from running backwards Figure 7 2 Hydraulic System Components 1 High Low Limit Compensators 6 Low Pressure Control 2 Hydraulic Pump 7 High Pressure Control 3 Electric Motor 8 Directional Control Valve 4 Pressure Gauge 9 Relief Valve 5 High Low Solenoid Valve 20480306 2 2009 Rev 0 7 2 Hydraulic System A 13 20480306 The main system relief valve provides system protection by monitoring the oil pressure entering the manifold If the hydraulic pressure exceeds 3 408 psi 235 bar the valve opens to limit the pressure The valve is factory calibrated and is not serviceable A drain line from the valve prevents oil from collecting behind the relief valve to ensure a constant pressure under all operating conditions The hydraulic system operates at high or low pressure se
128. tion the plunger on that end extends and pushes against the water in the high pressure cylinder increasing the pressure up to 55 000 psi 3 792 bar When the piston reverses direction the plunger retracts and the plunger in the opposite cylinder extends to deliver the high pressure water Low pressure water is routed through the inlet water ports to the inlet passages in the sealing heads When the plunger retracts the inlet check valve opens to allow water to fill the high pressure cylinder When the plunger extends to create high pressure water the inlet valve closes to seal the inlet passage and the discharge check valve opens to allow the high pressure water to exit the cylinder As the plunger retracts the discharge check valve closes 7 201 1 Rev 02 9 2 20480314 High Pressure Water System KMT Section 9 FC Figure 9 3 High Pressure Cylinder bie 1 2 aH 1 Discharge Check Valve 5 Hydraulic Piston 9 High Pressure Cylinder 2 Sealing Head 6 Retracted Plunger 10 Inlet Water Passage 3 Inlet Check Valve 7 Hydraulic Cylinder 11 Inlet Water Port 4 Extended Plunger 8 Hydraulic Oil In 12 Outlet Water Passage The intensifier is a reciprocating pump As the piston and plungers move from one side to the other high pressure water exits one side of the intensifier as low pressure water fills the opposite side The high pressure water is then routed to the attenuator The
129. tion 2 A 10 Activate the control power and press the F1 button on the Run Screen to start the motor The dump valve will open for a short time to allow trapped air to bleed from the high pressure cylinders Run the machine in low pressure for approximately five minutes with the orifice removed to purge the system 11 Check for any leaks in the plumbing or around the high pressure cylinders If leaks are detected stop the machine and correct any problems 12 Observe the pressure gauge on the outlet manifold to ensure the discharge cutting water pressure 1s between 90 120 psi 6 8 bar If not the booster pump pressure must be adjusted Refer to Section 5 Low Pressure Water System for additional information Remove the acorn nut on the side of the booster pump and use a flat blade screwdriver to turn the adjustment screw Turn the screw clockwise to increase the pressure or counter clockwise to decrease the pressure 13 Check the safety circuits by pushing the EMERGENCY STOP button In and verifying that the power goes off and high pressure water is drained from the system If applicable check all remote start and emergency stop functions 14 Install a large inexpensive orifice and start the machine 15 Press the F3 button from the Run Screen to select high pressure operation Increase the high pressure setting in gradual increments checking for leaks at each interval Continue increasing the pressure until the operating pressu
130. tion on the rear bulkhead of the machine A water modulating valve in the outlet line regulates the cooling flow through the heat exchanger The valve is factory set but may require adjustment to maintain the operating oil temperature at 115 F 46 C Oil temperature can be visually monitored from a dual scale level temperature sight gauge on the side of the hydraulic oil reservoir Figure 6 2 Recirculation System Components 1 Hydraulic Oil Reservoir 7 Oil Fill Port 2 Air Breather 8 Filter Element 3 Temperature Low Level Switch H Water Modulating Valve 4 Level Temperature Sight Gauge 10 Heat Exchanger 5 Filter Head 11 Recirculation Pump 6 Pressure Gauge 12 Case Drain The recirculation pump pulls oil from the reservoir and sends it to the heat exchanger The oil to water heat exchanger controls heat build up in the hydraulic oil The plate style design allows cooling water and oil to flow side by side through alternating plates The cooled oil then passes through the filter element and returns to the reservoir The cooling water either 1s discharged to the drain on the rear bulkhead or is routed to a customer supplied water chiller 8 2010 Rev 01 6 Recirculation System A 6 3 20480302 The hydraulic oil filter assembly consists of the filter head with bypass relief valve pressure gauge filter element and the oil fill port The filter eleme
131. tional control valve sends flow to the hydraulic cylinder in one direction until the hydraulic piston activates the proximity switch at the end of the stroke The activated switch sends a signal to the PLC to reverse the direction of flow The piston then moves in the opposite direction until it activates the proximity switch at the opposite end of the stroke Service and Maintenance Procedures The extreme duty cycles demanded of the hydraulic system make routine inspection and maintenance acutely important Leaks must be detected and remedied as soon as possible The operating pressure settings must be checked daily and the electric motor must be inspected at regular intervals It is also possible for the flexible coupling to fail and require replacement NOTE ee Refer to Section 12 Parts List for a complete listing of replacement parts and part numbers 2 2009 Rev 0 7 3 KMT pr Section 7 Hydraulic System Hydraulic Operating Pressure Hydraulic operating pressure settings should be checked daily and adjusted as necessary High and low operating pressure is adjusted at the high and low pressure control valves per the specifications in Table 7 1 Table 7 1 Hydraulic Operating Pressure Limits Adjustment Pressure Limits Increase Decrease Minimum Maximum High Pressure Clockwise Counter clockwise 290 psi 20 bar 3 000 psi 207 bar Low Pressure Clockwise Counter clockwise 290 psi 20 bar 800 psi 55 bar
132. ton and hydraulic seal cartridge Disassembly is not required when servicing the discharge check valves 9 9 High Pressure Water System ms High Pressure Cylinder Assembly Removal Prior to removing electrical power or any high or low pressure piping bring the hydraulic piston in the left or right stop position to facilitate maintenance The plunger will extend in the selected direction allowing full exposure when the unit is disassembled Refer to Section 4 Operation l Turn the machine off and observe the appropriate Lockout Tagout procedures Severe injury can result if the machine is not properly locked out Observe electrical Lockout Tagout procedures before proceeding Ensure all pressure is relieved or blocked from the hydraulic and high pressure circuits before proceeding mnnn xY a ee a nn mem 5 5 5 TT TF ox r ann ons mm mm s n res EE 2 Disconnect the high and low pressure water piping following the procedure High and Low Pressure Water Piping 3 Gently pry the sealing head collar off of the sealing head Figure 9 8 High Pressure Cylinder Assembly Removal WY C lt 7 K M Wl gt s lt E th lt Ds ADA De et NY et ie 7 1 Lid dil S n 4 S J N Sealing Head Collar 5 Sealing Head Seal Assembly 2 Soft Seal End Cap 6 Cylinder Liner 3 In
133. ttings up to the maximum flow capacity of the hydraulic pump The high and low limit compensators mounted on the pump regulate the flow of hydraulic fluid to maintain constant operating pressures Operating pressures are set and adjusted at the high and low pressure control valves on the manifold The high and low limit compensators regulate the flow of hydraulic fluid to the system by controlling the angle of the swashplate If the oil is not properly maintained the compensators can become blocked with debris As a result pump control will be lost and you will not be able to create hydraulic oil pressure 3 The normally closed two pressure solenoid valve is controlled by the operator s selection of high or low pressure The valve is closed while operating in high pressure and is open during low pressure operation A light on the solenoid connector indicates low pressure operation A reference gauge on the top of the manifold displays hydraulic pressure to the intensifier When the intensifier shifts it is normal for the pressure to quickly fall and then rise again The 4 way directional control valve directs pressurized oil to one end the hydraulic cylinder and returns fluid to the reservoir from the opposite end causing the intensifier to stroke The movement is controlled hydraulically by a pilot valve that is electronically operated by two solenoids energized by the PLC Indicators light up as each solenoid is energized The direc
134. tubing while the cone is being cut Apply cutting oil frequently and liberally throughout the cutting operation A medium weight cutting oil with high sulfur content is recommended 4 The tool will stop cutting when the tube angle and facing is complete NOTE Clean the machining chips from the blade and body of the tool before coning the next tube 20480282 8 2010 Rev 02 2 12 Section 2 Installation Table 2 10 Recommended Extension Length 1 4 Tubing 1 25 1 50 31 8 38 1 mm 3 8 Tubing 1 25 1 50 31 8 38 1 mm 9 16 Tubing 1 75 2 00 44 5 50 8 mm Hand Threading l Secure the coned tubing in a tube vise No more than the recommended length of tubing should extend beyond the face of the vice See Table 2 10 Recommended Extension Length 2 Apply cutting oil to the end of the tube and slide the threading tool on the tubing 3 Grip the handles of the tool firmly apply steady pressure and turn the tool counter clockwise Approximately every half turn reverse direction to break off and remove the chips Apply cutting oil frequently and liberally throughout the cutting operation A medium weight cutting oil with high sulfur content is recommended 4 Continue threading until the proper thread length is reached see Table 2 9 Column L Remove the tool from the end of the tubing NOTE PAR AA AA AA A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A AA ee A E A mg Clean the machining chips fro
135. turned too far out counter clockwise an internal spring and relief will fall down inside the pump If this occurs the pump must be removed and the parts must be reinstalled to avoid component damage 6 Replace the acorn nut resume normal operation and observe the booster discharge pressure Peak pressure should be in the range of 90 to 120 psi 6 to 8 bar If it is not repeat the adjustment procedure 20480293 2 2009 Rev 0 5 6 KIMT r SECTION 6 RECIRCULATION SYSTEM 6 1 20480302 Overview The oil recirculation circuit is a cooling and filtration system that provides properly conditioned oil to the main hydraulic system Hydraulic oil is maintained at the proper operating temperature and condition by continuous recirculation System components include the water modulating valve recirculation pump heat exchanger oil filter assembly and the hydraulic oil reservoir A temperature low level switch connected to the PLC monitors temperature and oil level conditions in the hydraulic oil reservoir and provides automatic shutdown protection Figure 6 1 Oil Recirculation Circuit 1 Cooling Water Out 4 Water Modulating Valve 7 Pressure Gauge 2 Recirculation Pump 5 Oil Filter Assembly 8 Heat Exchanger 3 Hydraulic Oil Reservoir 6 Bypass Relief Valve 9 Cooling Water In 8 2010 Rev 01 6 1 Recirculation System A 6 2 20480302 Operation Cooling water is introduced through the 1 2 inch BSPT connec
136. ty Switch Socket Head Screws 2 M6 each Torque 140 160 in Ibs 16 18 Nm Hex Key M5 Sealing Head Discharge Gland Nut 130 ft Ibs 176 Nm Poppet Retainer 25 30 in Ibs 2 8 3 4 Nm Pneumatic Control Valve HP Adapter 25 ft Ibs 34 Nm 1 4 inch Outlet to Drain 25 ft Ibs 34 Nm Pneumatic Actuator 5 ft Ibs 7 Nm 3 8 inch HP Gland Nut 50 ft Ibs 68 Nm High Pressure Fittings 1 4 HP Gland Nut 25 ft Ibs 34 Nm 3 8 HP Gland Nut 50 ft Ibs 68 Nm 9 16 HP Gland Nut 110 ft Ibs 149 Nm 20480314 7 2011 Rev 02 9 7 High Pressure Water System ms Specialized Maintenance Tools KMT Waterjet has designed tools to facilitate the removal and installation of specialized system components These tools are illustrated in Figure 9 7 Specialized Maintenance Tools and part numbers are provided in Table 9 2 Figure 9 7 Specialized Maintenance Tools Table 9 2 Specialized Maintenance Tools High Pressure Water System Part Number 1 Cartridge Removal Tool 72113886 2 Seal Removal Tool 10148674 3 Cylinder Wrench 05066139 4 Vee Block Cradle 20494488 20480314 7 2011 Rev 02 9 8 KIMT A 9 5 9 6 20480314 7 2011 Rev 02 Section 9 High Pressure Water System High and Low Pressure Water Piping Before performing any maintenance on the high pressure components it is necessary to remove the high and low pressure water piping The following procedure should be used to remove and install the piping Severe
137. ugh a tiny hole in the orifice water pressure is converted to water velocity capable of cutting most any material 20480273 9 2009 Rev 01 129 Introduction The major components include the high pressure cylinder assemblies hydraulic cylinder hydraulic piston attenuator and the safety dump valve Figure 1 3 High Pressure System Components 1 High Pressure Cylinder Assembly 4 Safety Dump Valve 2 Hydraulic Cylinder Assembly 5 Attenuator 3 Hydraulic Piston Operating System A programmable logic controller PLC provides basic intensifier shift control and monitors out of limit conditions Operator interface is through the function button control panel Figure 1 4 Control Panel ECE da S N 0000000 10 59 59 AM Canale DDD 20480273 9 2009 Rev 01 124 Introduction ETT 1 4 20480273 Safety The high pressure waterjet cutting system 1s a high energy cutting tool capable of cutting many dense or strong materials Do not touch or be exposed to high pressure water High pressure water will penetrate all parts of the human body The liquid stream and the material ejected by the extreme pressure can result in severe injury All personnel operating servicing or working near the waterjet cutting equipment sh
138. um sulfate scale Measure of the total amount of dissolved matter in water Sum of all hardness constituents in water typically expressed as their equivalent concentration of calcium carbonate primarily due to calcium and magnesium in solution but may include small amounts of metal Carbonate hardness is usually due to magnesium and calcium bicarbonate non carbonate hardness is due to sulfates and chlorides 20480327 7 201 1 Rev 03 1 1 5 Specifications hs Table 11 4 Water Impurities Constituent Chemical Formula Comments pH Intensity of the acidic or alkaline solids in water pH scale runs from 0 highly acidic to 14 highly alkaline with 7 being neutral 11 4 Electrical Specifications Electrical System Motor type TEFC Totally Enclosed Fan Cooled Controls Voltage 24 volts DC Power supply 5 amps DC Ampacity and Power Voltage Requirements Circuit Breaker Power Voltage Horsepower Amps Amps 208 3 60 mam 100 230 3 60 100 380 3 50 60 400 3 50 60 415 3 50 60 460 3 60 50 5753 60 40 200 3 50 60 175 208 3 50 60 175 240 3 60 175 380 3 50 Ugo em 100 400 3 50 OOO 415 3 50 100 480 3 60 50 575 3 60 50 20480327 7 2011 Rev 03 1 1 6 Specifications KMT Section 11 ms 11 5 Hydraulic and High Pressure Water System Specifications Hydraulic System Maximum operating pressure 2 750 psi 190 bar Main system relief valve 3 408 psi 235 bar High Pressure Water System Maximum
139. usting screw on the high limit compensator clockwise until the hydraulic reference gauge reads 3 000 psi 207 bar Select low pressure operating mode on the display panel and turn the adjusting screw on the low limit compensator clockwise until the reference gauge reads 290 psi 20 bar Lock the adjustment screw in place Select high pressure operating mode on the display panel and turn the knob on the high pressure control valve counter clockwise until the reference gauge reads 2 000 psi 138 bar Open the high pressure water control valve allowing water to flow Set the desired high operating pressure by adjusting the high pressure control valve While the machine is running and high pressure water is flowing select low pressure operating mode Set the desired low operating pressure by adjusting the low pressure control valve 7 7 KIMT DE SECTION 8 ELECTRICAL SYSTEM 8 1 8 2 20480310 Overview The Jetline series is equipped with integral motor starter and control circuitry enclosed in the electrical panel The operator controls the machine primarily through a function button control panel that communicates with the programmable logic controller PLC A series of sensors provide automatic shutdown logic and diagnostics Major system components include the electric motor control panel high voltage and control components and the wiring harness that connects the sensors and solenoid valves to the PLC O
140. v 6 6 I ST IOO dH 9cr8LO0Tl vz I ge og oqnL dH 0 0L008 L I ST PUDO dH 6Sv8L001 Z I 8 dH 9L 06S8ZL001 9 8 c e nuo4 68 8001 IZ r se PWD dH 6ZI9 001 I O c xg OQNL 4H 0601 02 r 8c OO dH SILS8LOOI r T Joyenuoyy dur E6STOITL oi I g og oqnL dH TI 0L008 r OT X SLI X TIIN Maine peH J900S BOOS SHOT I I ST mag QNL dH 8P9L9P0T T I 8 X o peoyxing Surdno gcoes6r LI I A quiossy JOIJISUQUI 809t0C I AJnuen UONDLIISOG JOQUNN maul Ajpuen uondrnosoq 4oqunw WJJ Ltd Hed 9 69LT0C A qUI9SS Y 1938 AA 9Jnssoaq USIH L CI BL JST SJADd TI UONI vi cl 0 A9Y TIOZ L OEEOSHOZ AJQuiassp 191044 AANSSIAd YSIH Z aAns1y 117 SID TI 400938 CI Cl CO A9Y TTOZ L O EO8Pr07 I A quiossy SUISNOH 191A 8L689v07 OI C OC x OS esoH LdSd depy v 689v0C 6 I 0S X0 qIegasoH pcL89v0C 81 C SL HO4 N 0L689v07 8 I 0 X 0 OIf LdSg Jodepy 6689v0c LI I SL X L diq wo0 O0 ZI9001 L I 0g X CL odig Surysng TSIS8LOOI 91 I IONO PIJOUN 9p989rv0C 9 P ON MN an ESTOLOOI SI I OC XOS LASH oqa 19689v0C I UOIOIN OT Wows Jy ZZL9OIOL pi C SL LdSH 9IddiN 9689t0C P 9 ISYSEM POT 88869001 I I DATA SOUSA S0S69r0c E C 0 X OS esoH LdSd Jodepy 6689v0C cl P 9 ISUYSEM WIA L6L69001 I ATEA IU C8689T0C IT I gc di
141. ve the adapter and valve seat 7 Remove the stem SST backup ring and brass backup ring from the valve body 8 Remove the seal assembly by pushing it with the seal push tool P N 20470413 The assembly must be pushed out through the actuator port in the top of the valve body 9 Discard the stem brass backup ring seal assembly and valve seat 10 Clean and inspect the valve body being careful not to damage or scratch the bore 20480314 7 2011 Rev 02 9 30 KIMT pr Section 9 High Pressure Water System Figure 9 25 Valve Seal Installation nA A N 20480314 7 2011 Rev 02 Pneumatic Actuator Seal Push Tool Seal Assembly Seal Installation Tool Seal Positioning Tool High Pressure Adapter O Ring Seal O 0 NY Valve Body 10 Bronze Wedge Ring 11 12 13 14 15 16 17 Place the seal positioning tool into the opposite end of the valve body as shown in Figure 9 25 Valve Seal Installation Thread the high pressure adapter into the valve body until light contact is made with the positioning tool Tighten finger tight only Apply Pure Goop anti seize compound to the threads on the seal installation tool Screw the seal installation tool into the threads of the valve body Tighten finger tight only See Figure 9 25 Valve Seal Installation Lubricate the new seal and o ring with FML 2 food grade grease Insert the seal o ring and bronze wedge ring into
142. wo bearing rings and the two piece seal assembly NOTE Do not scratch the surfaces of the piston seal groove Scratches on the sides or bottom of the groove can result in hydraulic leaks 2 Inspect the bottom of the seal grooves for marks scratches and residue buildup Clean and or repair the groove surfaces as required 3 Apply FML 2 grease to the new bearing rings and install the rings 4 The piston seal assembly consists of a seal ring and an o ring Apply FML 2 grease to both rings Use the smooth dull edged blade to install the o ring ensuring the ring is not twisted after installation Slide the outer seal ring over the metal edges and ease it into position over the inner o ring Figure 9 19 Hydraulic Piston os N I x j T d A aa NN KY SS 1 Bearing Ring 3 Inner O Ring 2 Outer Seal Ring Plunger Maintenance Plunger surfaces can become streaked with longitudinal scratches or flaws and discolored or dull in appearance If any of these conditions become severe the high pressure seal assembly and possibly the hydraulic cartridge seal will leak 20480314 7 2011 Rev 02 9 25 High Pressure Water System ms Accumulation of debris on the surface of the plunger can be removed by polishing in a radial direction with 600 grit sandpaper However plunger surface flaws usually cannot be repaired on site The plunger can

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