KMT H2O JET

WATERJET
INTENSIFIER

72106161(R0)

OPERATION AND MAINTENANCE MANUAL

KMT H2O JET
WATERJET INTENSIFIER

OPERATION AND MAINTENANCE MANUAL

 KMT H2O JET
WATERJET INTENSIFIER

OPERATION AND MAINTENANCE MANUAL

MANUAL 72106161(R0)
 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

KMT Waterjet Systems

635 West 12th Street
POB 231
Baxter Springs, KS 66713-0231

Phone: (800) 826-9274

Fax: (620) 856-5050

72106161
12-2011/Rev 01
TABLE OF CONTENTS

Title Page
Notice
Table of Contents
Appendix

Section Page

1 Introduction ...................................................................................................... 1-1

1.1 Overview...............................................................................................1-1
1.2 Product Nameplate................................................................................1-1
1.3 Operational Overview...........................................................................1-1
Low Pressure Water System .................................................................1-2
Recirculation System ............................................................................1-2
Hydraulic System..................................................................................1-2
High Pressure Water System ................................................................1-3
1.4 Safety ....................................................................................................1-3
Lockout/Tagout Procedure....................................................................1-4
Warning Labels.....................................................................................1-4
Emergency Medical Treatment.............................................................1-6
1.5 Worldwide Product Support .................................................................1-6
1.6 Spare Parts ............................................................................................1-7
1.7 Equipment and Service Manual Questionnaire.....................................1-7
2 Installation ........................................................................................................ 2-1
2.1 Overview...............................................................................................2-1
2.2 Installation Summary ............................................................................2-1
2.3 Site Requirements .................................................................................2-2
Transporting..........................................................................................2-2
2.4 Power Requirements .............................................................................2-3
2.5 Service Connections..............................................................................2-3
Cooling Water.......................................................................................2-4
Cutting Water........................................................................................2-5
Drain .....................................................................................................2-5
Plant Air ................................................................................................2-5
2.6 Flow Requirements ...............................................................................2-6
2.7 High Pressure Piping.............................................................................2-7
Measurements and Dimensions ............................................................2-8
Hand Coning .........................................................................................2-9
Power Coning........................................................................................2-10
Hand Threading ....................................................................................2-11
Power Threading...................................................................................2-11

2.8 High Pressure Connections ...................................................................2-12

72106161
12-2011/Rev 01
i
 Standard Connections ...........................................................................2-12
Anti-Vibration Connections..................................................................2-13
2.9 Commissioning .....................................................................................2-14
2.10 Decommissioning .................................................................................2-16
3 Maintenance ..................................................................................................... 3-1
3.1 Overview...............................................................................................3-1
3.2 Maintenance..........................................................................................3-1
Daily Inspection ....................................................................................3-1
Periodic Maintenance............................................................................3-1
High Pressure System Maintenance......................................................3-2
3.3 Maintenance Precautions ......................................................................3-3
4 Operation .......................................................................................................... 4-1
4.1 Overview...............................................................................................4-1
4.2 Startup and Stop Sequence ...................................................................4-1
Startup Following High Pressure Maintenance ....................................4-2
Emergency Stop ....................................................................................4-2
4.3 Fault Conditions....................................................................................4-2
5 Low Pressure Water System ........................................................................... 5-1
5.1 Overview...............................................................................................5-1
5.2 Cutting Water Supply Quality ..............................................................5-1
5.3 Operation...............................................................................................5-1
5.4 Service and Maintenance Procedures ...................................................5-2
Filter Assembly Maintenance ...............................................................5-2
6 Recirculation System ....................................................................................... 6-1
6.1 Overview...............................................................................................6-1
6.2 Operation...............................................................................................6-1
6.3 Service and Maintenance Procedures ...................................................6-2
Hydraulic Oil Maintenance...................................................................6-2
Oil Filter Maintenance ..........................................................................6-4
7 Hydraulic System ............................................................................................. 7-1
7.1 Overview...............................................................................................7-1
7.2 Operation...............................................................................................7-1
7.3 Service and Maintenance Procedures ...................................................7-2
Hydraulic Operating Pressure ...............................................................7-3
Motor/Hydraulic Pump Maintenance ...................................................7-4
Shift Valve and Manifold Service.........................................................7-4
Solenoid and Pilot Valve Service .........................................................7-7
8 Electrical System .............................................................................................. 8-1
8.1 Overview...............................................................................................8-1
8.2 Sensors and Solenoids...........................................................................8-1
8.3 Service and Maintenance Procedures ...................................................8-4
Proximity Switch Maintenance.............................................................8-4

9 High Pressure Water System .......................................................................... 9-1

72106161
12-2011/Rev 01
ii
 9.1 Overview...............................................................................................9-1
9.2 Operation...............................................................................................9-1
9.3 Service and Maintenance Overview .....................................................9-3
Torque Specifications ...........................................................................9-4
9.4 High and Low Pressure Water Piping...................................................9-5
9.5 High Pressure End Caps........................................................................9-6
High Pressure End Cap Removal..........................................................9-6
High Pressure End Cap Installation ......................................................9-6
9.6 High Pressure Cylinder Assembly ........................................................9-7
High Pressure Cylinder Removal..........................................................9-7
High Pressure Cylinder Installation ......................................................9-8
High Pressure Cylinder Maintenance ...................................................9-9
9.7 Sealing Head Assembly ........................................................................9-9
High Pressure Discharge Check Valve .................................................9-10
Low Pressure Inlet Check Valve...........................................................9-11
Sealing Head Maintenance ...................................................................9-13
9.8 High Pressure Seal Assembly ...............................................................9-13
9.9 Hydraulic Seals .....................................................................................9-17
9.10 Hydraulic Piston and Plunger Service ..................................................9-19
Hydraulic Piston and Plunger Removal................................................9-19
Plunger Installation ...............................................................................9-21
Hydraulic Piston Installation.................................................................9-21
9.11 Hydraulic Cylinder Maintenance..........................................................9-23
9.12 Plunger Maintenance ............................................................................9-23
9.13 High Pressure Attenuator......................................................................9-23
9.14 High Pressure Dump Valve ..................................................................9-24
Pneumatic Control Dump Valve...........................................................9-24
Pneumatic Actuator...............................................................................9-29
10 Troubleshooting ............................................................................................... 10-1
10.1 Overview...............................................................................................10-1
10.2 Troubleshooting Guide .........................................................................10-1
11 Specifications .................................................................................................... 11-1
11.1 Overview...............................................................................................11-1
11.2 Installation Specifications.....................................................................11-1
Environment..........................................................................................11-1
Sound Level ..........................................................................................11-1
Equipment Dimensions.........................................................................11-2
Service Connections..............................................................................11-2
Plant Air ................................................................................................11-2
11.3 Water Specifications .............................................................................11-3
Cutting Water Supply ...........................................................................11-3
Cooling Water Supply...........................................................................11-3
Water Quality Standards .......................................................................11-4
11.4 Electrical Specifications........................................................................11-6
Electrical System ..................................................................................11-6
Ampacity and Power Voltage Requirements........................................11-6
11.5 Hydraulic and High Pressure System Specifications............................11-6
Hydraulic System..................................................................................11-6

72106161
12-2011/Rev 01
iii
 High Pressure Water System ................................................................11-6
Orifice Capacity ....................................................................................11-7
Torque Specifications ...........................................................................11-8
12 Parts List ........................................................................................................... 12-1
12.1 Overview...............................................................................................12-1
12.2 Index .....................................................................................................12-2

APPENDIX

Exhibit
Electrical Schematic

72106161
12-2011/Rev 01
iv
SECTION 1
INTRODUCTION

1.1 Overview
The KMT H2O Jet combines all the unique capabilities and advantages of waterjet cutting
with the reliability, ease of operation and service support that have made KMT Waterjet
Systems a leader in waterjet technology.

Table 1-1
KMT H2O Jet

Motor
Horsepower Maximum Maximum Maximum Single
Rating Operating Flow Rate Orifice Diameter
HP Kw Pressure (at full pressure) (at full pressure)
50 37 60,000 psi (4,137 bar) 1.0 gpm (3.8 L/min) 0.014 inch (0..56 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

1.3 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 specifications are provided in Section 11, Specifications.

72106161
12-2011/Rev 01
1-1
 Section 1
Introduction

Low Pressure Water System

The low pressure water system supplies the cutting water flow to the intensifier. Major
system components include the booster pump/motor assembly and the low pressure water
filter assembly.

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.

Figure 1-1: System Components

A LP Water System C Recirculation System

1 Booster Pump/Motor Assembly 6 Oil Filter Assembly
2 LP Water Filter Assembly 7 Hydraulic Oil Reservoir
B Hydraulic System 8 Heat Exchanger
3 Electric Motor 9 Recirculation Pump
4 Hydraulic Pump
5 Hydraulic Manifold

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.

72106161
12-2011/Rev 01
1-2
 Section 1
Introduction

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 through a tiny hole in the orifice,
water pressure is converted to water velocity capable of cutting most any material.

The major components include the high pressure cylinder assemblies, hydraulic cylinder
assembly, hydraulic piston, attenuator and the safety dump valve.

Figure 1-2: High Pressure System Components

1 High Pressure Cylinder 3 Safety Dump Valve

2 Hydraulic Cylinder 4 Attenuator

1.4 Safety
The high pressure waterjet cutting system is 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 shall adhere
to the following safety precautions, as well as the applicable plant safety precautions.

Only KMT factory trained, qualified personnel shall service and maintain the
equipment.

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.

72106161
12-2011/Rev 01
1-3
 Section 1
Introduction

Lockout/Tagout Procedure

This lockout/tagout procedure is designed to protect all employees from injuries caused by the
unexpected energizing or startup of the machine, or the release of stored energy during
service and maintenance.

This is accomplished with energy isolating devices that prevent the transmission or release of
energy. 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 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 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. Close, lockout and tag the manual shutoff valves for all service connections: cutting
water in, cooling water in and out, and air.

Warning Labels

Warning labels are posted on the machine to indicate potential hazards. The operator and
service personnel shall pay particular attention to these warning labels. Table 1-2 describes
the necessary precautions and provides the part number required to order replacement labels.

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 and the circuit
1 breaker/disconnect on the electrical enclosure before
performing any type of maintenance.

P/N 05114962

72106161
12-2011/Rev 01
1-4
 Section 1
Introduction

Table 1-2
Warning Label Precautions

The surface of high pressure water and hydraulic

components becomes hot during normal operation.
Failed, or failing components, can become extremely
2 hot during operation.

P/N 05114970

High pressure water and/or hydraulic pressure can

remain in the system even when the pump has been shut
off. All pressure can be safely bled from the system by
opening the high pressure cutting water valve for a few
3 seconds after shutting off the pump.

Pressing the EMERGENCY STOP button turns the control

power to the intensifier off, stops the pump and bleeds
P/N 05098017 the high pressure water through the safety dump valve.

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
4 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
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.

WARNING

Warnings emphasize operating or service procedures, or conditions that can result

in serious personal injury or death.

CAUTION

Cautions emphasize operating or service procedures, or conditions that can result in

equipment damage or impairment of system operation.

72106161
12-2011/Rev 01
1-5
 Section 1
Introduction

NOTE
Notes provide additional information that can expedite or improve operating or
service procedures.

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/cm2) 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 therefore
be helpful. This injury must be treated as an acute
KMT Waterjet Systems 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.

1.5 Worldwide Product Support

The KMT Waterjet Customer Service Department is available to answer your questions
regarding equipment installation and service. Technical assistance is available by phone and
on-site support is available on request.

On-site technical assistance is available during equipment installation and startup.

Additionally, technical support for service and maintenance issues and training of operators
and maintenance personnel is available. Periodic training sessions are also conducted at
KMT Waterjet and customer facilities.

72106161
12-2011/Rev 01
1-6
 Section 1
Introduction

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:
[email protected] [email protected]
[email protected]

1.6 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.

1.7 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.

72106161
12-2011/Rev 01
1-7
 Equipment and Service Manual Questionnaire

1. General Appearance
Was the unit received in good condition? Yes No
Comments:

Is the unit a convenient size? Yes No

2. Controls
Are the controls user friendly? Yes No
Is the unit easy to operate? Yes No
Comments:

3. Performance
Does the unit perform smoothly and meet your expectations? Yes No
Does the unit run quietly? Yes No
Comments:

4. Did the installation and startup go smoothly? Yes No

Comments:

5. What features do you consider the most significant?

Quiet operation
Appearance
Performance/Operation
Repair/Maintenance
Other

6. What areas could be improved?

Appearance
Performance
Serviceability
Other

72106161
12-2011/Rev 01
1-1
 Equipment and Service Manual Questionnaire

7. Manual Organization
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
Yes No
equipment?
Comments:
Are there paragraphs or procedures you feel need clarification? Please
Yes No
identify them by page number and add your comments.
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 No

Comments:

Name Title
Company Date
Address

72106161
12-2011/Rev 01
1-2
SECTION 2
INSTALLATION

2.1 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 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.

2.2 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.

Upon receipt, the machine must be uncrated and moved into position on a level
surface.

Properly sized power drops with fused disconnects or circuit breakers, and properly
sized starting components must be installed.

A pneumatic drop with a manual shutoff valve and regulator for the air connection
must be installed.

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.

Drain water plumbing must be suitably located and installed for the proper disposal of
wastewater.

High pressure tubing runs from the intensifier to the cutting station must be installed
with the appropriate mountings, support brackets and hardware.

Wiring must be installed and connected between the intensifier and the cutting station
control system.

The machine must be commissioned and tested.

72106187
12-2010/Rev 0
2-1
 Section 2
Installation

2.3 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, 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

Table 2-1
Equipment Dimensions and Weight

(1) Length (2) Width (3) Height Weight

58.00” (1,473 mm) 47.44” (1,205 mm) 41.64” (1,058 mm) 2,260 lbs (1,025 kg)

Transporting

The weight of the machine is not evenly distributed from one end to the other. Note the
warnings stamped on the crate. The center of gravity is clearly identified on the sides of the
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.

72106187
12-2010/Rev 0
2-2
 Section 2
Installation

Figure 2-2: Fork Pockets

1 Fork Pockets

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
detailed in Table 2-2. Voltage fluctuations in excess of +/- 10 percent of nominal voltage
may damage the machine and void the warranty.

Table 2-2
Ampacity and Power Voltage Requirements

Motor Full Load Recommended

Power Voltage Horsepower Amps Circuit Breaker Amps
380/3/50 50 69 100

2.5 Service Connections

Depending on the model, the intensifier requires one or two incoming water sources, cooling
water and cutting water; one or 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 bulkhead of the machine as shown in Figure 2-3,
Service connections. Table 2-3 lists the fittings required and the height of 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.

72106187
12-2010/Rev 0
2-3
 Section 2
Installation

CAUTION

Thoroughly purge all supply plumbing prior to connection to remove any residue
that could contaminate the system.

Figure 2-3: Service Connections

Table 2-3
Service Connections

Connection Height
A Drain 1/2” BSPT 10.26” (260 mm)
B Cutting Water In 1/2” BSPT 14.26” (362 mm)
C Cooling Water Out 1/2” BSPT 18.26” (464 mm)
D Cooling Water In 1/2” BSPT 22.26” (565 mm)
E Cutting Water Out 9/16” HP 30.26” (768 mm)
F Plant Air In 1/4” BSPT 35.39” (899 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 60 psi
(4.0 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 2-4, Chilled Water Systems.

72106187
12-2010/Rev 0
2-4
 Section 2
Installation

Table 2-4
Chilled Water Systems
Cooling Requirements at Full Capacity

Horsepower BTU/HR
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 (2.5 bar) at all
times. If the facility water pressure is below, or can fall below 35 psi (2.5 bar), a water
pressure booster pump is required.

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, i.e. a sewer line. The volume of water released will be
minimal and does not require high pressure plumbing; however, piping must comply with
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.

Table 2-5
ISO Air Quality Classifications
Maximum Maximum Pressure
ISO Quality Particle Size Dew Point Maximum Oil Content
Class (microns) (water @ 100 psi) (Mg/m3)
1 0.1 -94° F (-60° C) 0.01
2 1 -40° F (-40° C) 0.1

72106187
12-2010/Rev 0
2-5
 Section 2
Installation

Table 2-5
ISO Air Quality Classifications
3 5 -4° F (-20° C) 1
4 15 +38° F (+3° C) 5
5 40 +45° F (+7° C) 25
6 -- +50° F (+10° C) --

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 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.

Figure 2-4: Pressure Drop Values

Pipe Sizing
0.45
0.4
Pressure drop (PSI/FT)

0.35
0.3 1/2" ID
0.25 3/4" ID
0.2 1" ID
0.15 1-1/4" ID
0.1
0.05
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Required GPM

72106187
12-2010/Rev 0
2-6
 Section 2
Installation

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.

WARNING

High pressure tubing and fittings must be rated for 60,000 psi (4,136 bar). Failure
to use properly rated components may result in component failure causing
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 2-6.

Table 2-6
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
1/4” Tube Vise 05108782
3/8” Tube Vise 05108790
9/16” Tube Vise 05108774

72106187
12-2010/Rev 0
2-7
 Section 2
Installation

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 2-7. Table 2-8 lists the required cone and thread
dimensions illustrated in Figure 2-6.

Figure 2-5: Tube Length

Table 2-7
LENGTH Engagement Allowance (EA)
1/4” Tubing 0.49” (12.4 mm)
TUBE LENGTH = LENGTH + 2(EA) 3/8” Tubing 0.68” (17.3 mm)
9/16” Tubing 0.86” (21.8 mm)

Figure 2-6: Cone and Thread Dimensions

Table 2-8
Cone and Thread Dimensions
D L Thread
Tube OD Tube ID (Maximum) (Maximum) UNF-LH
1/4” (6.35 mm) 0.083” (2.11 mm) 0.125” (3.2 mm) 0.562” (14.3 mm) 1/4” - 28
3/8” (9.52 mm) 0.125” (3.18 mm 0.219” (5.6 mm) 0.750” (19.1 mm) 3/8” - 24
9/16” (14.29 mm) 0.188” (4.78 mm) 0.281” (7.1 mm) 0.938” (23.8 mm) 9/16” - 18

72106187
12-2010/Rev 0
2-8
 Section 2
Installation

Hand Coning
Figure 2-7: Hand Coning Tool

1 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 blades.

2. Turn the feed nut counter-clockwise to retract the cutting blades 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 blades. Loosely tighten the gland nut to
slightly grip the tubing.

4. Turn the feed nut counter-clockwise 1/4 turn to retract the cutting blades 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
blades and through the lubrication channel at the cutter handle.

Apply cutting oil frequently and liberally throughout the cutting operation. A medium
weight cutting oil with high sulfur content is recommended.

6. Turn the feed nut clockwise until the cutting blades contact the end of the tubing.

7. In a smooth, 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 blades should make light,
uninterrupted cuts.

72106187
12-2010/Rev 0
2-9
 Section 2
Installation

NOTE
Before interrupting the cut, back the cutter blades away from the tubing. Use
compressed air or a small brush to remove the accumulation of chips from the
blades 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 blades, 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 2-9, 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 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.

Table 2-9
Recommended Extension Length
1/4” Tubing 1.25-1.50” (31.8-38.1 mm)
3/8” Tubing 1.25-1.50” (31.8-38.1 mm)
9/16” Tubing 1.75-2.00” (44.5-50.8 mm)

72106187
12-2010/Rev 0
2-10
 Section 2
Installation

Hand 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 2-9, 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 2-8, Column L.
Remove the tool from the end of the tubing.

NOTE
Clean the machining chips from the die and body of the tool before threading the
next tube.

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 2-9, 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 is reached, see Table 2-8, Column L.
Reverse the direction of the drill and remove the threading tool.

NOTE
Clean the machining chips from the die and body of the tool before threading the
next tube.

72106187
12-2010/Rev 0
2-11
 Section 2
Installation

2.8 High Pressure Connections

When installing high pressure discharge piping it is essential that all burrs be 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
supports 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.

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 is the only
load on the tubing.

Figure 2-8: Standard High Pressure Connections

1 Gland Nut 3 Collar

2 Tubing 4 Exposed Threads

1. Deburr the tubing ID and thoroughly clean the tubing threads.

2. Slip the gland nut onto the tubing.

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

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.

72106187
12-2010/Rev 0
2-12
 Section 2
Installation

5. Tighten the gland nut to the torque specifications in Table 2-10.

WARNING

Proper piping supports and guides must be provided. End connections will not
support the tubing load alone.

Table 2-10
Torque Specifications
High Pressure Connections
1/4” 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 Tubing 4 Collet
2 Gland Nut 5 Exposed Threads
3 Collar

1. Deburr the tubing ID and thoroughly clean the tubing threads.

2. Slip the gland nut and the collet onto the tubing.

72106187
12-2010/Rev 0
2-13
 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 2-10.

When a flexible whip is used to allow cutting nozzle movement, anti-vibration fittings and
proper supports and guides must be provided to prevent failures from non-water related
stresses. The whip will only flex in a single plane without being subjected to torsional stress.
The use of high pressure swivels is strongly recommended.

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.

1. Check all areas in and around the pump for foreign objects and debris. Remove all
tools, parts, etc. from the area.

2. 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 in Section 6, Recirculation System.

3. Open the shutoff valves on the service connections and check for leaks.

4. Check the connection between the customer supplied, main power disconnect and the
machine. Verify the proper voltage supply.

5. Turn the control power on and use the customer supplied control to select low pressure
operation.

6. 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.

72106187
12-2010/Rev 0
2-14
 Section 2
Installation

1 Hydraulic Manifold 3 High Pressure Control Valve

2 Hydraulic Pressure Gauge

7. Check the motor rotation. The correct direction of rotation is marked with an arrow
on the electric motor.

CAUTION

Do not allow the motor to run backward. Incorrect motor rotation will result in
damage to the hydraulic pump.

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. The
electrical power phase must be reversed to any two motor leads. The leads must be
reversed at the electric motor, or at the main power disconnect.

8. Remove the cutting orifice and open the nozzle valve.

9. Start the motor and run the machine at a low pressure for approximately five minutes
with the orifice removed to purge the system.

10. Check for any leaks in the plumbing, or around the high pressure cylinders. If leaks
are detected, stop the machine and correct any problems.

11. 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.

12. Install a large, inexpensive orifice and start the machine.

13. Use the customer supplied control to select high pressure operation and increase the
high pressure setting in gradual increments, checking for leaks at each interval.
Continue increasing the pressure until the operating pressure is reached.

The high pressure setting is increased by turning the high pressure control valve on the
hydraulic manifold clockwise.

72106187
12-2010/Rev 0
2-15
 Section 2
Installation

NOTE
It is strongly recommended that the high pressure plumbing be purged under high
pressure operating conditions, using a large, inexpensive orifice. Contamination
can be released when the tubing expands under pressure. Early orifice failures
could be experienced if the piping is not adequately purged.

2.10 Decommissioning
All local regulations must be adhered to when the intensifier is decommissioned and taken out
of service for any reason.

72106187
12-2010/Rev 0
2-16
SECTION 3
MAINTENANCE

3.1 Overview
The KMT H2O Jet 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.

3.2 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 is 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.

Prior to startup, inspect the area around the machine, the high pressure piping and
connections for indications of leaks.

Make sure there is no maintenance work in process.

Check the hydraulic oil level.

As the machine is started and water pressure increases, listen for unusual sounds.

Check for water or oil leakage.

Check the condition of the hydraulic oil 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.

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.

72106161
12-2010/Rev 0
3-1
 Section 3
Maintenance

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

The high pressure system is conveniently mounted on a drip pan. All 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.

1. Operate the intensifier for a short period with the nozzle valve open and the orifice
removed.

2. Turn the intensifier off and install an orifice.

3. Turn the machine on and increase the operating pressure in gradual increments.
Check all high pressure connections for leaks.

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
Blue Goop, 2 ounce Stainless steel threads 20460486
FML-2 Grease, 14-1/2 ounce O-rings, backup rings, bearing 10087385
rings, seal components
JL-M Grease, 16 ounce Non-stainless steel threads 49832199

72106161
12-2010/Rev 0
3-2
 Section 3
Maintenance

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.

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.

Never service or maintain the equipment while it is operating.

All high pressure leaks must be repaired immediately. 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. 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.

72106161
12-2010/Rev 0
3-3
SECTION 4
OPERATION

4.1 Overview
The operator interface on the KMT H2O Jet is through the control panel or an optional,
remote control panel. Figure 4-1 identifies the control panel components and functions.

Figure 4-1: Control Panel

1 Start Pump 3 Emergency Stop

2 Stop Pump

EMERGENCY STOP button turns the control power off. The electric motor, hydraulic
pump and intensifier stop, the dump valve opens and high pressure is bled from the
system. Pull the EMERGENCY STOP button out to reset.

START button starts the pump and generates high pressure. This green button is
illuminated during normal operation.

STOP button turns the electric motor and hydraulic pump off. Control power remains
on. This red button flashes during abnormal operation and remains on if the pump
stops due to an abnormal condition.

4.2 Startup and Stop Sequence

The following procedure is used to start and stop the pump under normal operating conditions.

1. Pull the EMERGENCY STOP button out.

2. Press the START button. The green button will illuminate, the motor will start and
after a brief delay, the hydraulic pump will start.

3. To stop the pump, press the STOP button. The green light will go off, the pump will
stop, and the red light will illuminate.

Startup Following High Pressure Maintenance

The following startup procedure should be used following maintenance on any high pressure
components.

72106161
12-2010/Rev 0
4-1
 Section 4
Operation

1. Disconnect the electrical power cable from the solenoid valve on the dump valve.

2. Press the START button.

The intensifier will cycle and discharge water through the dump valve, purging the air
from the high pressure cylinders and filling them with water.

CAUTION

Failure to purge the air from the high pressure system following maintenance will
damage the high pressure seals.

3. Connect the electrical power cable to the solenoid valve on the dump valve.

4. Check for any leaks in the plumbing, or around the high pressure cylinders.

Emergency Stop
When the EMERGENCY STOP button is pressed, all electrical power is immediately terminated.
The dump valve opens and high pressure is relieved in the system. The emergency stop
function can be wired to a remote control panel.

4.3 Fault Conditions

Automatic shutdown will occur as a result of the faults listed in Table 4-1. The red, STOP
button will blink and the number of blinks will indicate the type of fault.

Table 4-1
Fault Conditions

Number of Blinks Indication Comments

1 Left Overstroke Abnormally high stroke rate caused
A left overstroke condition has by an external or internal leak.
occurred Shutdown will occur if condition
persists.

2 Right Overstroke Abnormally high stroke rate caused

A right overstroke condition has by an external or internal leak.
occurred Shutdown will occur if condition
persists.

3 Topworks Overstroke Abnormally high stroke rate in both

An intensifier overstroke condition directions caused by an external or
has occurred. internal leak. Shutdown will occur
if condition persists.

4 Motor Overload Fault The motor overload relay is

monitored and displayed when the
overloads trip. Overloads are set on
automatic reset.

72106161
12-2010/Rev 0
4-2
 Section 4
Operation

Table 4-1
Fault Conditions

Number of Blinks Indication Comments

5 High Oil Temperature The red light will illuminate and
High hydraulic oil temperature, in shutdown will occur. When the
excess of 144 F (62 C) temperature returns to normal, the
red light will go off.

6 Low Oil Level The red light will illuminate and

Oil level is below 21 gallons (79 shutdown will occur. When the fault
liters) has been corrected, the red light will
go off.

72106161
12-2010/Rev 0
4-3
SECTION 5
LOW PRESSURE WATER SYSTEM

5.1 Overview
The low pressure water system, cutting water supply circuit, supplies the intensifier with the
required cutting water flow and pressure.

5.2 Cutting Water Supply Quality

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 bulkhead of the
machine and passes 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. If the pressure drops below
30 psi (2 bar) the switch activates an automatic shutdown.

Figure 5-1: Low Pressure Water System

1 Inlet Water Solenoid Valve 3 Booster Pump/Motor Assembly

2 30 psi Pressure Switch 4 LP Water Filter Assembly

72106161
12-2011/Rev 01
5-1
 Section 5
Low Pressure Water System

Cutting water is then routed to booster pump. The booster pump increases the pressure to the
relief valve setting to ensure proper supply to the intensifier assembly.

Pressurized water passes through the filter assembly where debris is removed to prevent
contaminates from damaging the check valves and seals in the intensifier. The filter assembly
consists of a filter head, housing and a filter element. A bleed valve on the top of filter head
is used to release pressure or air inside the housing.

From the filter assembly, cutting water is routed to the inlet check valves in the sealing heads
on each end of the intensifier.

5.4 Service and Maintenance Procedures

To ensure water quality and supply to the high pressure system, the filter element, strainer and
booster pump will require routine servicing and maintenance. The procedures for servicing
these components are detailed below.

NOTE
Refer to Section 12, Parts List for a complete listing of replacement parts and part
numbers.

Filter Assembly 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 assembly.
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.

The following procedure is used to replace the filter element and clean the strainer.

Figure 5-3: Filter Element

20492256
12-2011/Rev 01
5-2
 Section 5
Low Pressure Water System

1 Pressure Gauge 4 Filter Element

2 Bleed Valve 5 Filter Housing
3 Filter Element

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 housing.

5. Turn the cutting water supply on.

6. Press the red bleed valve to remove any air inside the filter housing.

7. Start the machine and verify satisfactory pressure readings.

20492256
12-2011/Rev 01
5-3
SECTION 6
RECIRCULATION SYSTEM

6.1 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 recirculation pump, oil-to-water heat exchanger, oil filter
assembly and the hydraulic oil reservoir.

6.2 Operation
Cooling water is introduced through the 1/2-inch BSPT connection on the bulkhead and
routed to the ball valve mounted on the heat exchanger. The ball valve is used to manually
regulate the cooling flow to the heat exchanger. Oil temperature can be visually monitored
from a dual scale level/temperature sight gauge on the side of the hydraulic oil reservoir.

Figure 6-1: Recirculation System Components

1 Temperature/Low Level Switch 7 Heat Exchanger

2 Hydraulic Oil Reservoir 8 Pressure Gauge
3 Air Breather 9 Filter Head
4 Recirculation Pump 10 Oil Fill Port
5 Level/Temperature Sight Gauge 11 Filter Element
6 Manual Ball Valve

72106161
12-2011/Rev 01
6-1
 Section 6
Recirculation System

The recirculation pump pulls oil from the reservoir and sends it to the heat exchanger where
heat buildup is controlled in the hydraulic oil.

The cooled oil then passes through the filter element and returns to the reservoir. The cooling
water either is discharged to the 1/2-inch BSPT drain on the bulkhead or is routed to a
customer supplied water chiller.

The hydraulic oil filter assembly consists of the filter head with a bypass relief valve and
pressure gauge, a filter element and the oil fill port. The filter element should be changed
when the gauge reads 30 psi (2.1 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.

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.

6.3 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
Refer to Section 12, Parts List for a complete listing of replacement parts and part
numbers.

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 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 added at the
fill port on the filter head and removed at the drain valve.

72106161
12-2011/Rev 01
6-2
 Section 6
Recirculation System

CAUTION

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.

Figure 6-2: Hydraulic Oil Reservoir

1 Drain 4 Level/Temperature Sight Gauge

2 Temperature/Low Level Switch 5 Oil Fill Port
3 Breather

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

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.

2. Drain the oil reservoir by connecting the inlet hose from an oil transfer pump to the
drain on the reservoir.

3. Pump the used oil out to a container and remove the inlet hose from the drain.

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.

72106161
12-2011/Rev 01
6-3
 Section 6
Recirculation System

4. Connect the discharge hose from the oil transfer pump to the fill port on the oil filter
and pump the fresh oil into the reservoir.

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. Check the oil sight gauge on the reservoir to ensure proper fill level.

6. Remove the hose from the case drain on the 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.

CAUTION

Oil in the pump case provides internal lubrication for the main hydraulic pump.
Failure to the fill the pump case with oil will allow air to become trapped inside,
damaging the pump.

7. Disconnect the discharge hose from the fill port.

8. Check the sight gauge again and follow the same procedure to add additional oil if
necessary.

Oil Filter Maintenance

If the filter element is not properly serviced and is allowed to fill 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 30 psi (2.1 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 6-3: Oil Filter Assembly

1 Filter Head
2 Filter Element
3 Pressure Gauge

72106161
12-2011/Rev 01
6-4
 Section 6
Recirculation System

1. Use a filter wrench to unscrew the filter element from the filter head. Ensure the old
gasket is removed with the filter.

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.

Section deleted – Water Modulating Valve

72106161
12-2011/Rev 01
6-5
SECTION 7
HYDRAULIC SYSTEM

7.1 Overview
The main hydraulic power circuit supplies the intensifier assembly with the hydraulic flow
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, and the hydraulic manifold.
The manifold houses the 4-way directional control valve and the system relief valve. The
relief valve monitors hydraulic oil pressure and provides system protection by limiting excess
pressure.

7.2 Operation
The electric motor drives two pumps mounted in tandem; the main hydraulic pump and the
recirculation pump.

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 7-1: Hydraulic System Components

72106161
12-2010/Rev 0
7-1
 Section 7
Hydraulic System

1 Hydraulic Pump 5 Low Pressure Control

2 Electric Motor 6 High Pressure Control
3 Pressure Gauge 7 Directional Control Valve
4 High/Low Solenoid Valve 8 System Relief Valve

The main system relief valve provides system protection by monitoring the oil pressure
entering the manifold. If the hydraulic pressure exceeds 3,400 psi (234 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 settings up to the maximum flow
capacity of the hydraulic pump. The high and low limit compensators mounted on the pump
regulate the flow of hydraulic fluid to maintain constant operating pressures. Operating
pressures are set and adjusted at the high and low pressure control valves on the manifold.

CAUTION

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.

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 hydraulic pump 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 directional valve consists of a spool with internal passages that direct hydraulic flow to
one end of the hydraulic cylinder while returning fluid to the reservoir through the opposite
end. Spool position is solenoid operated. The solenoids are alternately energized in response
to the position of the hydraulic piston as the proximity switch detects the end of the stroke.

7.3 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 setting must be checked daily, and the electric motor must be
inspected at regular intervals.

NOTE
Refer to Section 12, Parts List for a complete listing of replacement parts and part
numbers.

72106161
12-2010/Rev 0
7-2
 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)

Figure 7-2: High/Low Pressure Controls

1 High Pressure Control 2 Low Pressure Control

1. Check the operating pressure to determine if adjustment is necessary.

2. If high pressure adjustment is required, loosen the locking thumbscrew on the high
pressure control valve by turning counter-clockwise.

3. Turn the knob on the control valve clockwise to increase operating pressure. Turn the
knob counter-clockwise to decrease pressure.

4. Tighten the locking nut and verify the high pressure setting.

5. If low pressure adjustment is required, loosen the locking nut on the low pressure
control valve by turning counter-clockwise.

6. Turn the hex clockwise to increase operating pressure. Turn the hex counter-
clockwise to decrease pressure.

7. Tighten the locking nut and verify the low pressure setting.

72106161
12-2010/Rev 0
7-3
 Section 7
Hydraulic System

Motor/Hydraulic Pump 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.

NOTE
Motor bearings are sealed for life and require no periodic maintenance.

The hydraulic pump is mounted to the electric motor by means of a keyed shaft, close
coupling. If the pump and motor are separated, the shaft and coupling must be lubricated
with anti-seize grease prior to re-assembly.

Shift Valve and Manifold Service

As oil flows in and out of the hydraulic cylinder it flows through the shift valve. The valve
spool opens and closes passageways to direct pressurized oil into one end of the cylinder, and
bleeds the oil from the opposite end, causing the cylinder to stroke. The spool movement is
controlled hydraulically by a pilot valve mounted directly on the shift valve. The shift valve
and manifold require no routine maintenance.

Figure 7-3: Shift Valve

Problems associated with a faulty shift valve are usually limited to an uneven, slow, or non-
cycling intensifier. Uneven stroking can also be caused by check valve problems.

A cracked manifold or leaking o-rings are usually the result of misaligned end bells, i.e., one
end bell is rotated in relation to the other.

Figure 7-4: End Bell Misalignment

72106161
12-2010/Rev 0
7-4
 Section 7
Hydraulic System

Whenever the tie rods are removed, the intensifier assembly fixture must be used to ensure
that the end bells are aligned during the assembly process.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

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.

2. Remove the cap screws securing the end covers on the shift valve and remove the
covers.

3. Using your fingers, check the shift valve spool for freedom of movement. The spool
must move with light pressure through the full stroke. If the spool is jammed, the
valve must be replaced.

4. Remove the spool and check that all grooves in the spool are clean and all polished
surfaces are undamaged. Check the inside of the shift valve body for any damage or
foreign material. If everything is satisfactory, insert the spool into the shift valve.

5. If the shift valve and manifold are satisfactory, replace the end cap.

Shift Valve Replacement

WARNING

The shift valve is a specially modified unit designed for use in this application.
Using a substitute shift valve may create a potential safety hazard, lower
performance of the pump and will void the warranty.

1. If the shift valve or port o-rings must be replaced, remove the shift cable and pilot
valve and set them aside. See the Solenoid and Pilot Valve Service for the correct
procedure.

2. Loosen the fasteners in one-eighth turn increments until all torque has been removed.
Remove the shift valve and discard it if faulty.

3. Check the manifold and o-rings. If they are not in need of service, proceed to Step 18.
If the manifold or o-rings need service continue with Step 4.

4. Disconnect the oil supply and return lines from the manifold; cap the lines with the
plugs supplied with the pump.

5. Disconnect the water supply lines at the quick-disconnects.

6. Remove the pressure relief valve and set aside. Use a spanner wrench (20460162) to
make removal easier.

72106161
12-2010/Rev 0
7-5
 Section 7
Hydraulic System

7. Disconnect the small diameter, hydraulic high pressure line connected to the manifold.
Move the high pressure lines out of the way.

8. Loosen the screws mounting the manifold to the intensifier in one-eighth turn
increments.

9. Remove the screws mounting the manifold to the frame and remove the manifold.

10. If the manifold is cracked, check that the end bells are in alignment with each other
using a steel straight edge. If any misalignment is noted, mount the intensifier on the
intensifier assembly fixture and loosen the tie rod nuts. Torque the four cap screws
mounting the end bells to the assembly fixture to 35 ft-lbs (48 Nm), then back off one-
eighth to one-quarter turn until more than finger tight. The bolts must hold the end
bells tight against the fixture to prevent any misalignment but not interfere with the
tightening of the tie rod nuts.

11. Using a figure-eight pattern, torque all tie rod nuts to 40 ft-lbs (54 Nm)], then 60 ft-lbs
(81 Nm)], then 80 ft-lbs (108 Nm)], then 100 ft-lbs (135 Nm), then 120 ft-lbs (163
Nm). Remove the intensifier from the intensifier assembly fixture and place it back in
the pump.

12. Clean and inspect all parts to be reused.

13. Lubricate the new o-rings with Parker Super O-Lube and place in the port cavity’s end
bell. If any oil is lost in the process, refill with fresh oil.

14. Align the manifold ports with the intensifier ports and thread in the fasteners.

15. Torque all cap screws to 25 ft-lbs (34 Nm) in one-eighth to one-quarter turn
increments using a figure-eight pattern.

16. Install the cap screws mounting the manifold to the pump frame and torque to 110 ft-
lbs (149 Nm).

17. Connect the oil supply and return lines to the manifold.

18. Lubricate the o-rings with Parker Super O Lube and place the o-rings in the port
grooves of the shift valve to be installed.

19. Place the shift valve onto the manifold and install the fasteners. Torque the fasteners
in one-eighth turn increments in a two-step process.

Torque screws 1 and 2 to 11.5 ft-lbs (15.5 Nm). Torque the outer screws (3-6)
incrementally to 55 ft-lbs (75Nm) in a crisscross pattern. Verify screws 1 and 2 are at
11.5 ft-lbs (15.5 Nm).

72106161
12-2010/Rev 0
7-6
 Section 7
Hydraulic System

Figure 7-5: Torque Sequence

3 2 6

5 1 4

CAUTION

Failure to correctly follow torque sequence when installing the shift valve may
sufficiently warp the body, preventing spool movement. Such damage is usually
not reversible.

20. Using your fingers, make sure the spool moves freely.

21. Lubricate the end cover o-rings with Parker Super O-Lube and mount the end cover to
the shift valve housing. Torque the cap screws to 10 ft-lbs (14Nm).

22. Install the pilot valve and the solenoid cables.

23. Attach the water supply lines at the quick-disconnect fittings. Attach the high pressure
tubing at both ends, and then torque the gland nuts.

24. Check the intensifier for incomplete work, tools, parts and rags. Start the pump and
operate at idle oil pressure.

25. Slowly increase the pressure to the rated output while checking for leaks.

26. Stop the pump and inspect for any leakage and correct as required.

Solenoid and Pilot Valve Service

The pilot valve spool and solenoid plunger can be checked for freedom of movement without
disassembling the pilot valve.

1. With the machine turned off, depress the small center ring on the end of the solenoid
with a small wooden dowel. It will initially depress about .25” (6 mm) and then the
movement of the valve spool can be felt. If movement is not felt, repeat this process
on the other side. The spool itself will only move .13” (3 mm). If no movement is felt
the entire assembly will probably require replacement.

72106161
12-2010/Rev 0
7-7
 Section 7
Hydraulic System

Figure 7-6: Solenoid

2. While the intensifier is off, apply 24 volts across the front and rear contacts (not the
side one) on the solenoid connection to check for solenoid movement.

3. The black plastic nut on each solenoid can be unscrewed and the electro-magnet
portion of the solenoid removed.

4. Inside there is a silver shaft that houses the solenoid plunger and a spring to absorb
shock from the movement of the pilot valve spool. This shaft has a set of notches on it
to receive a wrench for removal.

5. When the assemblies are removed from each side the pilot valve spool can be
manually pushed from side to side to check the movement.

6. The pilot valve spool should then be removed at this point to check for burrs and other
signs of wear and leakage. If there is any wear or leakage across the valve, the entire
assembly must be replaced.

Figure 7-7: Pilot Valve

3 4 5 7
6

1 Pilot Valve 5 Solenoid Electro Magnet

2 Pilot Valve Spool 6 O-Ring
3 Spool Stop 7 Plastic Nut
4 Solenoid Plunger Housing

72106161
12-2010/Rev 0
7-8
 Section 7
Hydraulic System

Pilot Valve Assembly Replacement

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

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.

2. Unplug the connections at the solenoid where the shift lights are located.

3. Remove the screws on top of the pilot valve assembly.

4. Make sure there is a slight film of oil on the o-rings and face of the new pilot.

5. Clean any debris that may be on the joining surface on the top of the shift valve and
check for scratches or other marks.

6. Mount the new pilot valve assembly in place so the wire connections on the solenoids
face the back of the cabinet.

7. The screws only have to be hand tight at about 15 ft- lbs (20 Nm).

8. Reconnect the cables to the solenoids. Notice they are labeled for front left (FL), front
right (FR) and so on.

72106161
12-2010/Rev 0
7-9
SECTION 8
ELECTRICAL SYSTEM

8.1 Overview
Major components of the electrical system for the KMT H2O Jet include the electric motors
and the wiring harness that connects the sensors and solenoid valves to the customer supplied
controller.

The 12-lead electric motor can be wired for either wye-delta or across-the-line starting. The
motor includes a 9-post terminal block for the junction of motor and starter wire leads.

8.2 Sensors and Solenoids

Sensors monitor operating conditions and electronically operated solenoids provide basic
intensifier shift control. The cables connected to these sensors and solenoids are bundled into
a wiring harness. Table 8-1 lists the recommended shutdown settings.

Table 8-1
Recommended Shutdown Settings

Label Sensor Shutdown Setting

1 Low hydraulic oil level 21 gal (79 L)

1 High hydraulic oil temperature 144 F (62 C)

Figure 8-1: Sensors and Solenoids

72106161
12-2011/Rev 01
8-1
 Section 8
Electrical System

1 Oil Level/Temperature Switch (1) 5 Right Proximity Switch (3)

2 Inlet Water Solenoid (6) 6 4-Way Valve ‘A’ Solenoid (4)
3 Safety Dump Valve (7) 7 4-Way Valve ‘B’ Solenoid (5)
4 Left Proximity Switch (2) 8 Inlet Water Pressure Switch

Table 7-2
Sensors and Solenoids

Component Function

Hydraulic Reservoir
1 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.

Inlet Water Solenoid Valve

2 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.

Safety Dump Valve

3 When control power is removed, 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 a
solenoid operated air valve.

The normally open pneumatic dump valve is held

closed by air pressure. When the air supply is
interrupted, 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.

72106161
12-2011/Rev 01
8-2
 Section 8
Electrical System

Table 7-2
Sensors and Solenoids

Component Function

Hydraulic Cylinder
4 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 proximity switches are activated when the

piston makes contact with the shift pin and the
movement is transferred to the magnet in the
actuator assembly. When the switch is activated,
it sends a signal to the controller to change the
flow of the directional control valve and reverse
direction.

Hydraulic Manifold
5 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
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.

Inlet Water
6 The 30 psi pressure switch 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.

72106161
12-2011/Rev 01
8-3
 Section 8
Electrical System

8.3 Service and Maintenance Procedures

Electrical components require minimal service. The proximity switches on the hydraulic
cylinder may require replacement.

NOTE
Refer to Section 12, Parts List for a complete listing of replacement parts and part
numbers.

Proximity Switch Maintenance

A proximity switch has failed and needs to be replaced if the LEDs do not change state,
indicating they are not sensing the piston, or if an LED flashes continuously.

Figure 8-2: Proximity Switch

1 Proximity Switch 3 Firing Pin

2 Proximity Switch Screw 4 Actuator Assembly

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

WARNING

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.

2. Disconnect the proximity switch cable.

3. Remove the proximity switch screws and carefully remove the proximity switch.
Some force may be required due to the resistance created by the o-rings.

72106161
12-2011/Rev 01
8-4
 Section 8
Electrical System

4. Remove the actuator assembly and inspect for ease of movement and to ensure the
springs and magnet are intact.

5. To remove the firing pin, lubricate the o-ring in the firing pin tool and insert the tool
into the actuator assembly bore in the end bell, o-ring end first. This creates a suction
that extracts the pin.

Figure 8-3: Firing Pin Removal

1 Actuator Assembly Bore 3 Firing Pin Bore

2 Actuator Assembly Bore 4 End Bell

6. Inspect the firing pin. It should be approximately 1.150” (29.20 mm) long, with a
shaft OD of approximately 0.082” (2.08 mm) and have no measurable bend.

7. Inspect the firing pin bore in the end bell. It must be polished and have no gouges,
burrs or other surface disruptions. It must not be elongated or egg shaped.

8. Use the firing pin tool and a small Allen wrench to replace the firing pin. Position the
firing pin in the groove of the tool with the head toward the o-ring. Insert the tool into
the actuator assembly bore using the Allen wrench to apply pressure against the firing
pin. Rotate the tool until the pin lines up with the firing pin bore. The pressure
applied will force the firing pin into the bore. Visually inspect the pin to ensure it is
correctly installed.

9. Install the actuator assembly, large end first, so the magnet faces the proximity switch.

10. Install the new proximity switch. Apply JL-M grease to the threads on the screws and
tighten to 140-160 in-lbs (16-18 Nm).

CAUTION

Ensure that the proximity switch is properly installed and secured prior to starting
the machine. Failure to tighten the hold down screws on each switch will result in
the spray of hydraulic oil.

11. Reconnect the proximity switch cable.

72106161
12-2011/Rev 01
8-5
SECTION 9
HIGH PRESSURE WATER SYSTEM

9.1 Overview
The high pressure water system is supported by both the cutting water supply circuit and the
hydraulic circuit. Cutting water of sufficient flow and pressure is routed from the cutting
water supply circuit to the intensifier where it is pressurized up to 60,000 psi (4,137 bar) and
delivered to the cutting head.

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.

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 end caps; and a .41 liter capacity attenuator. Sophisticated check valves and seal
assemblies ensure hydraulic oil, and the low pressure and high pressure water travel in the
appropriate direction.

9.2 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.

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 magnet in the actuator assembly. When the switch is activated, the
flow of the directional control valve is changed and the direction is reversed.

As the pressurized oil pushes the piston in one direction, the plunger on that end extends and
pushes against the water in the high pressure cylinder, increasing the pressure up to 60,000 psi
(4,137 bar). When the piston reverses direction, the plunger retracts and the plunger in the
opposite cylinder extends to deliver the high pressure water.

72106161
12-2010/Rev 0
9-1
 Section 9
High Pressure Water System

Figure 9-1: High Pressure Cylinder

1 Discharge Check Valve 5 Retracted Plunger 8 Extended Plunger

2 Sealing Head 6 Hydraulic Cylinder 9 Inlet Water Passage
3 Inlet Check Valve 7 High Pressure Cylinder 10 Outlet Water Passage
4 Hydraulic Piston

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.

Figure 9-2: High Pressure Water System

1 High Pressure Cylinder 5 High Pressure End Cap

2 Proximity Switch 6 Safety Dump Valve
3 Hydraulic Cylinder 7 Attenuator
4 End Bell

72106161
12-2010/Rev 0
9-2
 Section 9
High Pressure Water System

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 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 high pressure 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, 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.

9.3 Service and Maintenance Overview

Never perform any type of maintenance on the high pressure water system while it is
pressurized. Always turn the main control power off and bleed the high pressure water before
servicing.

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.

72106161
12-2010/Rev 0
9-3
 Section 9
High Pressure Water System

Torque Specifications

Table 9-1, Torque Specifications, details the torque specifications and tightening sequences
for the high pressure components and connections.

Table 9-1
Torque Specifications
High Pressure Water System

End Bell Lock Nuts

1st Stage Finger-tight
2nd Stage 40 ft-lbs (27 Nm)
Crossing Pattern
3rd Stage 60 ft-lbs (43-47 Nm)
Crossing Pattern
4th Stage 80 ft-lbs (43-47 Nm)
Crossing Pattern
5th Stage 100 ft-lbs
Crossing Pattern
6th Stage 120 ft-lbs
Crossing Pattern

Crossing Pattern

Proximity Switch
Torque 140-160 in-lbs (16-18 Nm)

Sealing Head
Discharge Gland Nut 30-50 ft-lbs (41-67 Nm)

Pneumatic Control Valve

3/8-inch HP Gland 50 ft-lbs (68 Nm)
1/4-inch HP Gland 25 ft-lbs (34 Nm)
Pneumatic Actuator 5 ft-lbs (7 Nm)
HP Adapter 25 ft-lbs (34 Nm)

72106161
12-2010/Rev 0
9-4
 Section 9
High Pressure Water System

Table 9-1
Torque Specifications
High Pressure Water System

High Pressure Fittings

1/4” HP Gland Nut 25 ft-lbs (34 Nm)
3/8” HP Gland Nut 50 ft-lbs (68 Nm)
9/16” HP Gland Nut 110 ft-lbs (149 Nm)

9.4 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.

WARNING

Severe 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.

1. Turn the cutting water supply off.

2. Loosen and remove the high pressure gland fitting connected to the discharge high
pressure check valve. Move the tubing to clear the work area.

3. Remove the low pressure water quick disconnect from the inlet water port on the end
cap.

4. When the required maintenance has been completed and the components reassembled,
connect the low pressure water connection to the inlet water port on the end cap.

5. 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 8-1.

6. Turn the cutting water supply on and check for low pressure leaks.

7. Remove the cutting orifice and start the machine. Operate at low pressure to flush the
high pressure passages.

8. Install the orifice and operate at high pressure to check for leaks.

72106161
12-2010/Rev 0
9-5
 Section 9
High Pressure Water System

9.5 High Pressure End Caps

High Pressure End Cap Removal

Prior to removing electrical power or any high or low pressure piping, start the machine and
retract the plunger on the opposite end to be serviced to allow full exposure when the unit is
disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

3. Use a pin spanner wrench (P/N 20460162) to turn the end cap counter-clockwise to
break the end cap loose. It may be necessary to tap the spanner wrench with a plastic
mallet. Continue to unscrew the end cap until it is removed. Removing the sealing
head assembly at the same time is recommended.

Figure 9-3: High Pressure End Cap

1
2

1 High Pressure Cylinder 3 Sealing Head Assembly

2 High Pressure End Cap

High Pressure End Cap Installation

1. Apply Blue Goop to the flat end of the high pressure cylinder and the shoulders on the
sealing head. Apply FML-2 grease to the o-rings on the sealing head.

72106161
12-2010/Rev 0
9-6
 Section 9
High Pressure Water System

2. Install the sealing head in the high pressure cylinder and thread the end cap onto the
cylinder. Turn the end cap clockwise until it bottoms out and then tighten with a
spanner wrench using only your hands. Any additional torque could cause problems
the next time the end bell is removed.

3. Connect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

9.6 High Pressure Cylinder Assembly

The high pressure cylinder can be removed from the end bell with the end cap and sealing
head assembly installed. However, due to the combined weight of these components,
removing the end cap and sealing head first is recommended.

High Pressure Cylinder Removal

Prior to removing electrical power or any high or low pressure piping, start the machine and
extend the plunger on the end to be serviced to allow full exposure when the unit is
disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Use a girth grip wrench to unthread the high pressure cylinder from the end bell.
Support the weight of the cylinder until it completely clears the plunger.

CAUTION

The high pressure cylinder is heavy and can damage the plunger or cause injury if
it not supported correctly.

72106161
12-2010/Rev 0
9-7
 Section 9
High Pressure Water System

Figure 9-4: High Pressure Cylinder Assembly Removal

2 1

1 High Pressure Cylinder 3 Plunger

2 End Bell

NOTE
If thread or metal surface galling is detected during removal, galled surfaces and
threads must be filed, sanded and lubricated prior to reassembly. See the
procedure, High Pressure Cylinder Maintenance.

High Pressure Cylinder Installation

1. Inspect and clean the high pressure cylinder threads and alignment surfaces.

2. Apply Pure Goop the high pressure cylinder threads and shoulder guides. Thread the
cylinder into the end bell. Supporting the weight of the cylinder, use caution to not
slam the cylinder against the end bell, damaging the threads.

NOTE
The shoulder guides are close fitting, smooth diameters located at either end of the
cylinder threads. As the plunger goes into the cylinder, the cylinder will become
difficult to rotate. If necessary, use the cylinder wrench to assist.

3. Use the cylinder wrench (P/N 20459001) to tighten the high pressure cylinder hand-
tight. Then tap the wrench with the palm of your hand to tighten.

4. Install the end cap and sealing head assembly, following the procedure, End Cap
Installation.

5. Connect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

6. Start the machine at low pressure 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.

72106161
12-2010/Rev 0
9-8
 Section 9
High Pressure Water System

If leaks are detected, turn the machine off and remedy the problem. When the
problem has been remedied, repeat the startup 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 is replaced.

1. 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.

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 seal 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.

9.7 Sealing Head Assembly

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 9-5: Sealing Head

1 Discharge Check Valve 4 High Pressure Cylinder

2 End Cap 5 Inlet Check Valve
3 Sealing Head

72106161
12-2010/Rev 0
9-9
 Section 9
High Pressure Water System

High Pressure Discharge Check Valve

The discharge check valve can only be serviced with the end cap removed from the high
pressure cylinder.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high pressure water piping, following the procedure, High and Low
Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Remove the gland nut. The poppet pin, spring and discharge poppet will normally
remain in the gland nut when it is removed. Remove the components from the gland
nut.

5. Use a magnet to remove the poppet seat from the sealing head.

6. Inspect the poppet pin, spring and discharge poppet for wear. If any component is
worn, replace all components.

NOTE
The spring and discharge poppet should be replaced as a set. If one component
requires replacement, replace all components.

7. Inspect both faces of the seat for damage or cracking. A cracked or damaged seat
must be replaced. The seat is not symmetrical; the rounded side must face the sealing
head body.

72106161
12-2010/Rev 0
9-10
 Section 9
High Pressure Water System

Figure 9-6: High Pressure Discharge Check Valve

3
1

4
2

1 Gland Nut 4 Discharge Poppet

2 Poppet Pin 5 Seat
3 Compression Spring

8. Apply a thin film of Blue Goop to the rounded face of the seat and insert the seat into
the sealing head body. Do not apply Goop to the flat face.

9. Install the poppet pin, spring and discharge poppet in the gland nut.

10. Apply Blue Goop to the threads on the gland nut and thread the gland nut into the
sealing head. Do not apply Goop to the sealing face of the gland.

11. Use a torque wrench to tighten the gland nut to the torque specifications in Table 8-1.

12. Install the end cap and sealing head assembly, following the procedure, End Cap
Removal.

13. Connect the high pressure water piping, following the procedure, High and Low
Pressure Water Piping.

14. Start the pump and operate at low pressure, without a cutting orifice, to flush the high
pressure passages, and then operate the pump at high pressure with orifice installed to
check for leaks. Verify that the high pressure fittings do not leak, and that the high
pressure water signal is normal, indicative of the normal check valve operation.

Low Pressure Inlet Check Valve

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

72106161
12-2010/Rev 0
9-11
 Section 9
High Pressure Water System

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.

2. Disconnect the high pressure water piping, following the procedure, High and Low
Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Remove the poppet retainer screw and then remove the poppet retainer and inlet
poppet.

Figure 9-7: Low Pressure Inlet Check Valve

3 4

2
1

1 Inlet Poppet 3 Poppet Retainer Screw

2 Poppet Retainer 4 Inlet Water Passage

5. Inspect the sealing head for pits, scratches jetting erosion on the sealing surface. If
defects are detected, the surface must be refinished. See the procedure, Sealing Head
Maintenance.

6. Inspect the inlet water port in the sealing head of cracking.

7. Inspect the sealing surface of the inlet poppet. If the surface is marred it can be re-
lapped. If the poppet will not be within the required limits after re-lapping it must be
replaced. See the procedure, Sealing Head Maintenance.

8. Install the inlet poppet assembly

9. Inspect the assembled unit to ensure the poppet moves freely and the poppet retainer
screw is seated.

72106161
12-2010/Rev 0
9-12
 Section 9
High Pressure Water System

Sealing Head Maintenance

The sealing head should be inspected for scratches, excessive sealing damage or erosion
marking on the contact surface, and on the inlet poppet valve contact surface. If defects are
detected, the surfaces must be refinished. The sealing head can be returned to KMT Waterjet
for refinishing.

Place a piece of 600-grit wet/dry abrasive strip on the granite lapping block. Make sure there
are no air bubbles between the abrasive sheet and the lapping block.

1. Lap the discharge poppet and gland nut as necessary. A minimum allowable thickness
of 0.350” (8.890 mm) must be maintained on the insert. The minimum allowable
length of the discharge poppet is 0.607” (15.418 mm).

NOTE
The discharge poppet requires only the use of a 600 grit wet/dry abrasive strip.
Use of above 600 grit and lapping to a mirror-like surface may cause check valve
sticking problems.

2. Use a figure eight pattern when lapping the inlet poppet and sealing head body. Finish
with one straight pass, then rotate 90-degrees and do one more pass. This will give a
crosshatch appearance.

A minimum height of 0.365” (9.271 mm) must be retained on the shoulder of the inlet
poppet face. A radius of 0.035” (0.889 mm) and a minimum thickness of 0.120:
(3.048 mm) must also be maintained.

9.8 High Pressure Seal Assembly

The following procedure should be used to replace the high pressure seal assembly. The high
pressure seal tool kit (P/N 20458926) will be required for this procedure.

Prior to removing electrical power or any high or low pressure piping, start the machine and
extend the plunger on the end to be serviced to allow full exposure when the unit is
disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

72106161
12-2010/Rev 0
9-13
 Section 9
High Pressure Water System

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder
Removal.

5. Remove the seal buttress from the end bell. Wipe and clean surfaces, weep holes and
grooves and check for cracks.

Figure 9-8: Seal Buttress Removal

2
3

1 Seal Buttress 3 High Pressure Seal Assembly

2 Plunger

6. Use the seal removal tool and a plastic faced mallet to remove the high pressure seal
assembly and backup sleeve from both ends of the high pressure cylinder. Be careful
not to scratch the cylinder bore.

Figure 9-9: High Pressure Seal Removal

4
2

3
1

1 High Pressure Seal Assembly 3 High Pressure Cylinder

2 Backup Sleeve 4 Seal Removal Tool

72106161
12-2010/Rev 0
9-14
 Section 9
High Pressure Water System

7. Inspect the backup sleeve for wear. Polish is necessary.

8. Clean and inspect the cylinder bore for obvious ridges or grooves. If seal debris is
present, follow the procedure, High Pressure Cylinder Maintenance.

NOTE
The ends of the high pressure cylinder often show a ‘step’ between the backup
sleeve and the high pressure seal where the two overlap by a small amount. This is
normal and does not indicate a flaw in the cylinder.

9. Inspect the exposed surface of the plunger for scratches, surface discoloration or
unusual contact markings. Replace the plunger if necessary.

10. Screw the adapter flange onto the flat end of the high pressure cylinder and place the
tapered sleeve compressor into the flange with the largest ID facing out.

Figure 9-10: High Pressure Seal Installation, Flat End

1 5
2

3 4
4

1 High Pressure Seal Assembly 4 High Pressure Cylinder

2 Tapered Sleeve Compressor 5 Seal Removal Tool
3 Adapter Flange

11. Apply food grade grease to the high pressure seal assembly and insert the assembly
into the tapered sleeve with the o-ring facing in.

12. Use the seal plunger tool to push the seal assembly into the high pressure cylinder
until it is flush with the end of the cylinder. A rubber mallet may be required to
position the seal assembly correctly.

72106161
12-2010/Rev 0
9-15
 Section 9
High Pressure Water System

13. Unscrew the adapter flange from the high pressure cylinder, turn the cylinder over and
place the flat end on the large aluminum spacer.

Figure 9-11: High Pressure Seal Installation, Opposite End

5
7

6
1 4

1 High Pressure Seal Assembly 5 Seal Removal Tool

2 Tapered Sleeve Compressor 6 Spacer
3 Adapter Flange 7 Backup Sleeve
4 High Pressure Cylinder

14. Apply food grade grease to the backup sleeve and slide the sleeve into the high
pressure cylinder.

15. Screw the adapter flange onto the end of the high pressure cylinder and place the
tapered sleeve compressor into the flange with the largest ID facing out.

16. Apply food grade grease to the high pressure seal assembly and to the inside of the
sleeve and insert the assembly into the tapered sleeve with the o-ring facing in.

17. Use the seal plunger tool to push the seal assembly into the high pressure cylinder
until it is flush with the end of the cylinder.

18. Install the seal buttress.

19. Install the high pressure cylinder, following the procedure, High Pressure Cylinder
Assembly Installation.

20. Install the end cap and sealing head assembly, following the procedure, End Cap
Installation.

72106161
12-2010/Rev 0
9-16
 Section 9
High Pressure Water System

21. Reconnect the high and low pressure water piping and turn the low pressure water
supply on.

9.9 Hydraulic Seals

The intensifier assembly fixture is required for this procedure. The fixture is used during the
reassembly process to square the end bells with each other and to minimize the possibility of
o-ring damage as the cylinder is being drawn onto the end bells. When the end bells are
assembled out of alignment, oil manifold leakage and breakage may occur.

Prior to removing electrical power or any high or low pressure piping, start the machine and
extend the plunger on the end to be serviced to allow full exposure when the unit is
disassembled.

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder
Removal.

5. Remove the proximity switch on the end of the hydraulic cylinder to be serviced.
Remove the opposite proximity switch to drain hydraulic oil into the reservoir if both
ends of the hydraulic cylinder are to be serviced.

6. Remove the lock nuts and then remove the tie rods retaining the end bells to the
hydraulic cylinder. Remove the end bell.

NOTE
The bore of the hydraulic cylinder should be inspected for wear grooves and
surface finished whenever the end bells are removed. Excessive grooving on the
bore is indicative of piston seal wear.

72106161
12-2010/Rev 0
9-17
 Section 9
High Pressure Water System

Figure 9-12: Hydraulic Seal Installation

1 2

4 3

1 Low Pressure Seal Assembly 3 Hydraulic Seal Assembly

2 Snap Ring 4 Hydraulic Seal Spacer

7. Remove the snap ring and the hydraulic seal spacer from the end bell.

8. Remove the hydraulic seal assembly from the inside of the end bell and remove the
low pressure seal assembly from the outside.

9. Apply FML-2 food grade grease to the new hydraulic and low pressure seal
assemblies and install.

10. Position the end bell, apply JL-M grease to the threads on the tie rods and install the
tie rods and lock nuts. Torque the nuts to the specifications in Table 8-1.

11. Apply JL-M grease to the screw threads and install the proximity switch(s). Torque
the screws to the specifications in Table 8-1.

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.

72106161
12-2010/Rev 0
9-18
 Section 9
High Pressure Water System

9.10 Hydraulic Piston and Plunger Service

The following procedures are used to remove, repair and install the hydraulic piston and
plunger.

Hydraulic Piston and Plunger Removal

1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.

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.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.

3. Remove the end cap and sealing head assembly, following the procedure, End Cap
Removal.

4. Remove the high pressure cylinder, following the procedure, High Pressure Cylinder
Removal.

5. Remove the proximity switches on the each end of the hydraulic cylinder to drain the
hydraulic oil into the reservoir.

6. Remove the lock nuts and then remove the tie rods retaining the end bells to the
hydraulic cylinder. Remove both end bells.

NOTE
The bore of the hydraulic cylinder should be inspected for wear grooves and
surface finished whenever the end bells are removed. Excessive grooving on the
bore is indicative of piston seal wear.

7. Remove the hydraulic piston and plungers from the hydraulic cylinder. If the piston
must be driven out of the cylinder due to seal squeeze and friction, us a plastic headed
hammer to avoid striking the assembly with a metal object.

72106161
12-2010/Rev 0
9-19
 Section 9
High Pressure Water System

Figure 9-13: Plunger Removal

1 Hydraulic Piston 5 Plunger Retainer

2 Plunger 6 Backup Ring
3 Hydraulic Cylinder 7 Plunger Seal
4 Snap Ring

8. Remove the snap ring and the plunger retainer. The retainer can be loosened by
blowing air into one of the four openings in the retainer. Remove the plunger by hand.

9. Repeat Step 8 to remove the other plunger.

10. Remove the backup rings from each side of the piston using a non-metallic tool to
prevent scratching or scoring the piston.

11. Remove the plunger seals from each side of the piston.

12. Clean off parts of the piston assembly. Ensure all oil, dirt and burrs are removed from
all surfaces.

72106161
12-2010/Rev 0
9-20
 Section 9
High Pressure Water System

Plunger Installation

1. Apply Parker O-Lube to the backup rings and plunger seals. Install two backup rings
and one plunger seal in each piston groove. The plunger seal must be positioned
between the backup rings.

Figure 9-14: Plunger Seal Installation

1 4

5 6
3 3

1 Plunger 4 Plunger Seal

2 Grooves 5 Correct
3 Backup Ring 6 Incorrect

2. Install the plungers in the counter-bores in the piston with a turning motion. Ensure
the plunger seal and backup rings do not get nicked or rolled.

3. Slide the plunger retainers over the plungers with the large end facing the piston.
Install the snap rings to secure the plungers.

Hydraulic Piston Installation

The center band on the piston consists of four parts. There are two nylon backup rings, an
inner energized ring and an outer Teflon cap ring. Two bearing rings are installed in the outer
band on the piston.

1. Remove the old piston seals.

CAUTION

Do not scratch the bottom surface of the piston seal groove. Scratches to the seal
groove sides and/or bottom can result in hydraulic leaks.

2. Inspect the seal groove bottom for marks or scratches and residue buildup. Clean
and/or repair the groove surfaces as required.

72106161
12-2010/Rev 0
9-21
 Section 9
High Pressure Water System

3. Carefully slide inner energized ring over the piston until it rest in the center slot. Use
a mandrel and finger sleeve to stretch the Teflon cap ring over the piston. The Teflon
cap ring must be centered on top of the energized ring.

NOTE
Heating the Teflon cap ring in 150-200° F (65-90° C) water for 2-3 minutes will
soften the ring enough to facilitate installation.

The Teflon cap ring must be resized using a ring compressor for at least three minutes
so it will fit in the hydraulic cylinder.

4. Install the nylon backup rings on each side of the Teflon cap ring with the curved
inside edge facing the cap.

Figure 9-15: Center Band Component Installation

3 3

1 2

1 Energized Ring 3 Nylon Backup Ring

2 Teflon Cap Ring

5. Install the bearing rings in the outside slots in the piston. Rotate the bearing rings so
the end joints do not line up.

6. Inspect the hydraulic cylinder for scratches, burrs or gouges to ensure it is suitable for
use.

7. Lubricate the cylinder bore and the piston assembly with hydraulic oil.

8. Use a ring compressor to contain the bearing rings and plunger seal assemblies.

9. Push the piston assembly into the hydraulic cylinder bore.

10. Remove the ring compressor and continue to drive the piston assembly into the
cylinder until it is approximately centered in the cylinder.

11. Install the plungers, following the procedure, Plunger Installation.

12. Position the end bells, apply JL-M grease to the threads on the tie rods and install the
tie rods and lock nuts. Torque the nuts to the specifications in Table 8-1.

72106161
12-2010/Rev 0
9-22
 Section 9
High Pressure Water System

CAUTION

The intensifier assembly fixture must be used to ensure the end bells are aligned
during the assembly process.

13. Apply JL-M grease to the screw threads and install the proximity switches. Torque
the screws to the specifications in Table 8-1.

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.

14. Install the high pressure cylinder, following the procedure, High Pressure Cylinder
Assembly Installation.

15. Install the end cap and sealing head assembly, following the procedure, End Cap
Installation.

16. Reconnect 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 end bells are removed. Excessive grooving is indicative of
piston seal wear.

9.12 Plunger Maintenance

Plunger surfaces can become streaked with longitudinal scratches or flaws, and discolored or
dull in appearance; or the outboard end can become smeared with stainless steel due to
contact with the backup sleeve. If any of these conditions become severe, the high pressure
seal assembly and possibly the hydraulic seals will leak.

Plunger surface flaws usually cannot be repaired on site. The plunger can be returned to
KMT Waterjet for reconditioning.

9.13 High Pressure Attenuator

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

72106161
12-2010/Rev 0
9-23
 Section 9
High Pressure Water System

9.14 High Pressure Dump Valve

The high pressure dump valve assembly includes a normally open high pressure water valve
and a solenoid operated air valve. The following procedures are recommended for servicing
the high pressure dump valve. Failure to follow these procedures will cause damage to the
stem, valve seat, or both.

WARNING

The high pressure dump valve is a safety device designed to instantly release high
pressure in the system. Proper maintenance is imperative to prevent potential
personal injury.

Figure 9-16, Pneumatic Valve Seal Tools, illustrates the special tools recommended for this
procedure.

Figure 9-16: Pneumatic Valve Seal Tools

1 Seal Installation Tool (20470417) 3 Seal Push Tool (20470413)

2 Seal Positioning Tool (05067350) Seal Tool Kit (20470475)
2-Port Dump Valve
3 Seal Positioning Tool (49833114)
3-Port Dump Valve

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, 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.

72106161
12-2010/Rev 0
9-24
 Section 9
High Pressure Water System

WARNING

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 9-17: High Pressure Dump Valve

1 Pneumatic Actuator 5 Signal

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.

72106161
12-2010/Rev 0
9-25
 Section 9
High Pressure Water System

Figure 9-18: Dump Valve Components

1 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 remove 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.

72106161
12-2010/Rev 0
9-26
 Section 9
High Pressure Water System

Figure 9-19: Valve Seal Installation

1 Pneumatic Actuator 6 Seal Positioning Tool

2 Seal Push Tool 7 High Pressure Adapter
3 Seal Assembly 8 O-Ring
4 Seal Installation Tool 9 Seal
5 Valve Body 10 Bronze Wedge Ring

11. Place the seal positioning tool into the opposite end of the valve body as shown in
Figure 9-19, Valve Seal Installation. Thread the high pressure adapter into the valve
body until light contact is made with the positioning tool. Tighten finger-tight only.

12. 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 9-19, Valve Seal Installation.

13. Lubricate the new seal and o-ring with FML-2 food grade grease. Insert the seal, o-
ring and bronze wedge ring into 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 9-19, Valve Seal Installation.

14. 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.

15. Remove the push tool and the installation tool from the valve body.

16. 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 9-18,
Dump Valve Components.

17. 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 9-20, Valve Stem Placement.

72106161
12-2010/Rev 0
9-27
 Section 9
High Pressure Water System

CAUTION

Do not push the o-ring on the seal assembly past the inlet port on the valve body.
This will damage the seal o-ring.

Figure 9-20: Valve Stem Placement

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 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.

72106161
12-2010/Rev 0
9-28
 Section 9
High Pressure Water System

Pneumatic Actuator

The following procedure is used to service the pneumatic actuator.

Figure 9-21: Pneumatic Actuator

Normally Open Actuator - Air Pressure to Close

1 Cylinder Head 7 Control Air 1/8 Female NPT
2 O-Ring 8 Cylinder Head
3 O-Ring 9 Piston
4 Piston 10 O-Ring
5 O-Ring 11 O-Ring
6 Pneumatic Cylinder 12 Pneumatic Cylinder

1. Unscrew and remove the cylinder head. Remove the piston from the cylinder.

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.

72106161
12-2010/Rev 0
9-29
SECTION 10
TROUBLESHOOTING

10.1 Overview
The troubleshooting guide will help identify the probable cause of a system malfunction and
assist in providing corrective action. The following symptoms are discussed in this section:

1. High oil temperature

2. Low oil level
3. Restricted or no cooling flow
4. Hydraulic pressure but no high pressure water pressure
5. No hydraulic oil pressure
6. Pump shaft will not turn
7. Pump will not start
8. Pump quits running
9. Abnormal fluctuations in high pressure water signal
10. Hot surfaces on the high pressure cylinder components
11. Low cutting water supply pressure
12. Oil pressure is satisfactory, but cutting water flow or pressure is low
13. Hydraulic oil leaking from the weep hole at the intensifier
14. Water leaking from the weep hole at the high pressure plunger seal
15. Water leaking from the weep hole at the high pressure sealing head seal

10.2 Troubleshooting 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.

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.

72106161
12-2010/Rev 0
10-1
 Section 10
Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction Indication Comments

1. High oil temperature Cooling water flow is Check cooling water source
restricted for proper temperature and
flow rate.

Water modulating valve is Replace the valve.

stuck open or closed

Scale build up in the heat The heat exchanger will need

exchanger has restricted the to be flushed or replaced.
flow

2. Low oil level Check the level gauge.

Check for hydraulic leaks.

Check the level switch.

3. Restricted or no cooling Check cooling water flow to The water pressure

flow and from the heat exchanger differential across 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 or out of adjustment
Adjust the valve.

4. Hydraulic pressure but no Proximity switch failure Jog the intensifier left and
high pressure water right and verify that the red
pressure light comes on at both
proximity switches.

Coil 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.

5. No hydraulic oil pressure The high and low limit Disassemble the
compensators on the compensators, clean and
hydraulic pump are blocked inspect the components.
with debris

Incorrect motor rotation Check the motor rotation.

6. Pump shaft will not turn Hydraulic pump has seized Replace the hydraulic pump.

72106161
12-2010/Rev 0
10-2
 Section 10
Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction Indication Comments

7. Pump will not start Emergency stop button is Check all remote E-STOP
depressed buttons.

Main power is disconnected Check the main power and

verify that the main power
disconnect is on.

8. Pump quits running Electrical power has been Check the power supply
interrupted circuit for a tripped breaker.

Verify that power is available

at the main power source.

9. Abnormal fluctuations in Large, worn or damaged Make sure the orifice does
high pressure water signal orifice 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.

Piping leaks Check system components for

leaks, including the dump
valve connection.

Check valve leakage Inspect the discharge check

valves in the sealing heads.

Inspect the inlet check valves

in the sealing heads.

Seal leakage Inspect the high pressure seal

at the plunger.

Inspect the high pressure seal

at the sealing head.

Hydraulic control Check the operation of the

malfunction hydraulic relief valve.

Verify that the directional

control valve is shifting
properly.

Check the operation of the

proximity switches.

72106161
12-2010/Rev 0
10-3
 Section 10
Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction Indication Comments

10. Hot surfaces on the high Leaking discharge check Inspect the condition of the
pressure cylinder valve seat, poppet valve, spring,
components and guide.

Leaking inlet check valve Inspect the condition of the

poppet valve and poppet
retainer.

Worn plunger Check the high pressure seal

at the plunger and check the
plunger for wear. Replace if
necessary.

Damaged high pressure Check the high pressure

cylinder cylinder for cracks or
damage.

11. Low cutting water supply Restricted water supply Check cutting water supply
pressure flow and pressure.

Clogged strainer Check the strainer and clean

if necessary.

12. Oil pressure is satisfactory, Low hydraulic pressure If operating in low pressure,
but cutting water flow or setting switch to high pressure
pressure is low operation and check the
hydraulic pressure setting.

Restricted or no cutting water Check the cutting water

supply supply flow and pressure.

Leak in high pressure water Inspect fittings for leakage

lines and torque to the specified
values.

Worn hydraulic piston seals Replace the piston seals.

Replacing all hydraulic oil
seals at the same time is
recommended.

Excessive demand for high Reduce demand to rated

pressure water output.

Worn check valves Repair the check valves.

Leaking high pressure seals Replace the seals.

72106161
12-2010/Rev 0
10-4
 Section 10
Troubleshooting

KMT H2O Jet Troubleshooting Guide

Malfunction Indication Comments

13. Hydraulic oil leaking from Check the hydraulic cylinder
the weep hole at the o-ring for leakage.
intensifier
Check the proximity switch
area for oil leakage.

Check the hydraulic oil seal

and clean or replace as
necessary.

14. Water leaking from the Worn high pressure plunger Replace the high pressure seal
weep hole at the high seal assembly.
pressure plunger seal
Damaged plunger If the leak is greater than 1
drop in 10 strokes, check the
plunger.

Damaged high pressure Check for the scratches,

cylinder grooves or material buildup
on the inside diameter of the
high pressure cylinder.
Replace if damage is
detected.

15. Water leaking from the Worn high pressure sealing Check the seal assembly
weep hole at the high head seal
pressure sealing head seal
Damaged high pressure Check for the scratches,
cylinder grooves or material buildup
on the inside diameter of the
high pressure cylinder.
Replace if damage is
detected.

72106161
12-2010/Rev 0
10-5
 Section 10
Troubleshooting

Figure 10-1: Troubleshooting Guide

1
2 5
7
6 8 9

4
17 10
3
11
16
15
12

14 13

1. End Cap
2. End Bell
3. High Pressure Cylinder
4. Discharge Check Valve
5. Hydraulic oil Pinched or failed o-ring or incorrectly torque tie rod
6. Hydraulic oil Failed oil seal
7. Cold water Failed o-ring on high pressure plunger seal
8. Hot water Failed high pressure plunger seal or high pressure cylinder
9. Hydraulic oil Improperly torque, pinched or failed o-ring
10. Hot water Loose discharge gland
11. Pulsing warm water Leaking inlet check valve
12. Hot water Leaking discharge check valve
13. Hot water Loose gland nut or failed cone or seat
14. Cold water Failed inlet water o-ring
15. Cold water Failed o-ring on high pressure sealing head seal
16. Hydraulic oil Incorrect torque or end bell alignment, possible failed o-ring
17. Hot water Failed high pressure sealing head seal or high pressure cylinder

72106161
12-2010/Rev 0
10-6
SECTION 11
SPECIFICATIONS

11.1 Overview
Comprehensive listings of specifications for the KMT H2O Jet are provided in this section.

Table 11-1
KMT H2O Jet

Motor Horsepower
Rating
Model HP Kw
KMT H2O Jet 50 37

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 frequently for water content.

Sound Level

Sound level with optional side panels 75.0 [dB(A)]

72106161
12-2011/Rev 01
11-1
 Section 11
Specifications

Equipment Dimensions and Weights

Length Width Height Weight

58.00” (1,473 mm) 47.44” (205 mm) 41.64” (1,058 mm) 2,260 lbs (1,025 kg)

Service Connections

Connection Height
A Drain 1/2” BSPT 10.26” (260 mm)
B Cutting Water In 1/2” BSPT 14.26” (362 mm)
C Cooling Water Out 1/2” BSPT 18.26” (464 mm)
D Cooling Water In 1/2” BSPT 22.26” (565 mm)
E Cutting Water Out 9/16” HP 30.26” (768 mm)
F Plant Air In 1/4” BSPT 35.39” (899 mm)

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/m3)
1 0.1 -94° F (-60° C) 0.01
2 1 -40° F (-40° C) 0.1
3 5 -4° F (-20° C) 1
4 15 +38° F (+3° C) 5
5 40 +45° F (+7° C) 25
6 -- +50° F (+10° C) --

72106161
12-2011/Rev 01
11-2
 Section 11
Specifications

11.3 Water Specifications

Cutting Water Supply (Low Pressure Water System)

Maximum consumption 4.0 gpm (15.1 L/min)
Minimum inlet water pressure 35 psi (2.4 bar) flowing
Maximum inlet water pressure 100 psi (6.9 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)

Cooling Water Supply (Recirculation System)

Maximum consumption at 75 F (24 C) 3.0 gpm (11.4 L/min)
Total heat rejection 8.6 HP (6.4 kW)
Reservoir capacity 30 gal (114 L)
Low oil level shutdown 21 gal (79 L)
Minimum operating oil temperature 60 F (15 C)
Optimum operating oil temperature 115 F (46 C)
Hot oil shutdown (maximum operating oil temperature) 144 F (62 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) Β7≥1000*
Fluid cleanliness rating (ISO fluid cleanliness rating)) 17/14**
Nominal recirculation pressure 30 psi (2 bar)

Recommended oil type

General service Mobil DTE 26, Grade 68
TM
Conoco Hydroclear multi-purpose
R&O
Food service Fuchs/Geralyn AW68 Food Grade Oil

* 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.
**Note: Indicates ISO 4406 range numbers for maximum permissible number of particles per
milliliter, greater than 5 and 15 microns.
17 <1,300 particles per milliliter, >5 microns
14 <160 particles per milliliter, >15 microns

72106161
12-2011/Rev 01
11-3
 Section 11
Specifications

Water Quality Standards

The quality of the inlet cutting water supply is one of the most important factors affecting
component life and performance. Water treatment requirements can be determined by a water
analysis.

The cutting water supply must meet the following standards. A high concentration of
dissolved solids, especially calcium, silica and chlorides will affect high pressure component
life.

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 1
Free Chlorine 1 1 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 1
Sodium 50 10 1
Sulfate 25 25 1
TDS* 200 100 35**
Total Hardness 25 10 1

pH 6.5-8.5 6.5-8.5 6.5-8.5

Turbidity (NTU) 5 5 1

* Note: Total dissolved solids

**Note: Do not reduce the TDS beyond this amount or the water will be too aggressive.

72106161
12-2011/Rev 01
11-4
 Section 11
Specifications

Table 11-4
Water Impurities

Constituent Chemical Formula Comments

Alkalinity Bicarbonate (HCO3) Acid neutralizing capacity of water. Foaming

Carbonate (CO3) and carryover of solids, causes embrittlement of
Hydrate (OH), steel, can produce CO2, a source of corrosion.
expressed as CaCO3
Calcium Ca When dissolved makes water hard; contributes to
the formation of scale.
Chloride Cl Adds to solid content and increases corrosive
character of water; in relative percentage
presence with oxygen induces stress corrosion
cracking.
Free Chlorine Cl2 Oxidizing agent; can attack elastomeric seals and
damage reverse osmosis (RO) membranes.
Iron Fe++ (ferrous) Discolors water or precipitation; source of scale
Fe+++ (ferric) and erosion.
Magnesium as Mg When dissolved makes water hard; contributes to
the formation of scale.
Manganese as Mn Mn++ Discolors water or precipitation; source of scale
and erosion.
Nitrate NO3 Adds to solid content; effect is not generally
significant industrially.
Silica SiO2 Causes scale
Sodium Na Found naturally; introduced to water in the ion
exchange water softening process.
Sulfate SO4 Adds to solid content; combines with calcium to
form calcium sulfate scale.
TDS Measure of the total amount of dissolved matter
in water.
Total Hardness CaCO3 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.
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.

72106161
12-2011/Rev 01
11-5
 Section 11
Specifications

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

Motor Full Load Circuit Breaker

Power Voltage Horsepower Amps Amps
380/3/50 50 69 100

11.5 Hydraulic and High Pressure 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 flow rate

60,000 psi (4,137 bar) 1.0 gpm (3.8 L/min)
Plunger diameter 0.875” (22 mm)
Piston diameter 4.00” (101.64 mm)
Intensification ratio 19.9:1
Minimum outlet pressure 10,000 psi (689 bar)
Maximum outlet pressure 60,000 psi (4,137 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) m3/min

72106161
12-2011/Rev 01
11-6
 Section 11
Specifications

Orifice Capacity

The following tables provide horsepower requirements for some of the more popular orifices.

Table 11-5
Single Orifice Diameter

Motor
Horsepower Maximum Maximum Single
Rating Operating Orifice Diameter
Model HP Kw Pressure (at full pressure)
H2O Jet 50 37 60,000 psi (4,137 bar) 0.014 inch (0.36 mm)

Table 11-6
Horsepower Requirements
Orifice Size 45,000 psi 50,000 psi 55,000 psi 60,000 psi
inches (mm) (3,103 bar) (3,447 bar) (3,792 bar) (4,137 bar)

0.003 (0.076) 1.7 2.0 2.3 2.6

0.004 (0.102) 3.0 3.5 4.0 4.6
0.005 (0.127) 4.6 5.4 6.2 7.1
0.006 (0.152) 6.7 7.8 9.0 10.2
0.007 (0.178) 9.1 10.6 12.2 13.9
0.008 (0.203) 11.8 13.9 16.0 18.2
0.009 (0.229) 15.0 17.5 20.2 23.0
0.010 (0.254) 18.5 21.6 25.0 28.5
0.011 (0.279) 22.4 26.2 30.2 34.4
0.012 (0.305) 26.6 31.2 36.0 41.0
0.013 (0.330) 31.2 36.6 42.2 48.1
0.014 (0.356) 36.2 42.4 48.9 55.8
0.015 (0.381) 41.6 48.7 56.2 64.0
0.016 (0.406) 47.3 55.4 63.9 72.8
0.017 (0.432) 53.4 62.6 72.2 82.2
0.018 (0.457) 59.9 70.1 80.9 92.2

The horsepower requirements for operating multiple orifices are determined by adding the
requirements in Table 11-6 for each orifice. Examples are shown below.

72106161
12-2011/Rev 01
11-7
 Section 11
Specifications

Orifice Size Number of Operating Total

inches (mm) Orifices Pressure Calculation Horsepower

0.005 (0.127) 3 55,000 3 x 6.2 18.6

0.012 (0.305) 1
50,000 31.2 + 17.5 48.7
0.009 (0.229) 1

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.

WARNING

Excessive torque can cause component damage or failure, resulting in potential

hazards to equipment and personnel.

Torque Specifications

End Bell Lock Nuts

1st Stage Finger-tight
2nd Stage 40 ft-lbs (27 Nm)
Crossing Pattern
3rd Stage 60 ft-lbs (43-47 Nm)
Crossing Pattern
4th Stage 80 ft-lbs (43-47 Nm)
Crossing Pattern
5th Stage 100 ft-lbs
Crossing Pattern
6th Stage 120 ft-lbs
Crossing Pattern

Crossing Pattern

72106161
12-2011/Rev 01
11-8
 Section 11
Specifications

Torque Specifications

Proximity Switch
Torque 140-160 in-lbs (16-18 Nm)

Sealing Head
Discharge Gland Nut 30-50 ft-lbs (41-67 Nm)

Pneumatic Control Valve

3/8-inch HP Gland 50 ft-lbs (68 Nm)
1/4-inch Outlet to Drain 25 ft-lbs (34 Nm)
Pneumatic Actuator 5 ft-lbs (7 Nm)
HP Adapter 25 ft-lbs (34 Nm)

High Pressure Fittings

1/4” HP Gland Nut 25 ft-lbs (34 Nm)
3/8” HP Gland Nut 50 ft-lbs (68 Nm)
9/16” HP Gland Nut 110 ft-lbs (149 Nm)

72106161
12-2011/Rev 01
11-9
SECTION 12
PARTS LIST

12.1 Overview
This section contains a comprehensive list of all parts for the KMT H2O Jet 50. To facilitate the ordering of replacement parts, item numbers in each
table correspond to the identifying numbers in the accompanying figures.

Use the following information to contact the Customer Service Department at KMT Waterjet Systems.

USA Europe
Customer Service Department Spare Parts Manager
KMT Waterjet Systems KMT Waterjet Systems GmbH
PO Box 231 Wasserstrahl Schneidetechnik
635 West 12th Street Auf der Laukert 11
Baxter Springs, KS 66713-0231 D-61231 Bad Nauheim
USA Germany

Phone (800) 826-9274 Phone +49-6032-997-119

Fax (620) 856-2242 Fax +49-6032-997-271
Email [email protected] Email [email protected]
[email protected]

72106161
12-2011/Rev 01
12-1
 Section 12
Parts List

12.2 Index
Part lists are arranged in the following sequence.

Parts List Index

Part Part
Table Description Number Page Table Description Number Page

12-1 KMT H2O Jet 50 Intensifier Unit 12-3 12-8 Electronic Shift Assembly 12-16
12-2 Intensifier Assembly 20458728 12-5 12-9 Hydraulic Hose Connections 20497379 12-18
12-3 Sealing Head Assembly 20458908 12-7 12-10 Reservoir Assembly 20498197 12-21
12-4 High Pressure Piping 20497330 12-8 12-11 Bulkhead Pipe Assembly 20497372 12-23
12-5 Pneumatic Valve/Actuator Assembly 20427739 12-10 12-12 Electrical Assembly 72102411 12-26
12-6 Hydraulic Power Package 20497413 12-12 12-13 Electrical Configuration 72102429 12-28
12-7 Hydraulic Pump Assembly 20498668 12-14 12-14 Cover Assembly 20498048 12-31
12-15 LP Water Filter Assembly 72110201 12-33

72106161
12-2011/Rev 01
12-2
 Section 12
Parts List

Table 12-1
KMT H2O Jet 50 Intensifier Unit

Part
Item Number Description Quantity

1 20497330 High Pressure Piping 1

2 72102411 Electrical Assembly 1
3 20497372 Bulkhead Pipe Assembly 1
4 20498074 Frame Assembly 1
5 20498197 Reservoir Assembly 1
6 20497379 Hydraulic Hose Connections 1
7 20497413 Hydraulic Power Package 1
8 20497395 Decal Package 1

72106161
12-2011/Rev 01
12-3
 Section 12
Parts List

Figure 12-1: KMT H2O Jet 50 Intensifier Unit

72106161
12-2011/Rev 01
12-4
 Section 12
Parts List

Table 12-2
Intensifier Assembly
20458728

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20458305 End Cap 2 12 20458062 Plunger Retainer 2

2 20457399 High Pressure Cylinder 2 13 20458869 Hydraulic Piston Assembly 1
3 20458299 End Bell, LH 1 20457966 Hydraulic Piston
4 20458302 End Bell, RH 1 20458821 Rebuild Kit, Piston Rings
5 20458191 Tie Rod 4 20460216 Seal
6 20460489 Hex Nut 8 14 20458170 Spacer, Hydraulic Seal 2
7 20457414 Hydraulic Cylinder 1 15 20458908 Sealing Head Assembly 2
8 20458161 Backup Sleeve 2 16 20460252 Snap Ring 2
9 20458773 Rebuild Kit, High Pressure Seal Assembly 1 17 05202930 Snap Ring 2
20457990 Seal Buttress 18 20457267 Inlet Water Nipple 2
20458113 High Pressure Seal 20457159 Adapter, Quick Disconnect
20457393 Seal Hoop 20459025 O-Ring, Quick Disconnect
20460108 O-Ring
10 20458797 Rebuild Kit, Hydraulic Seal Assembly 1
11 20457912 Plunger 2

72106161
12-2011/Rev 01
12-5
 Section 12
Parts List

Figure 12-2: Intensifier Assembly

72106161
12-2011/Rev 01
12-6
 Section 12
Parts List

Table 12-3
Sealing Head Assembly
20458908

Part
Item Number Description Quantity

1 20458098 Body 1 Figure 12-3: Sealing Head Assembly

2 20457381 Gland 1
3 20458140 Seat 1
4 20458089 Poppet Retainer Screw 1
5 20457948 Inlet Poppet 1
6 20460048 Discharge Poppet 1
7 05116751 Poppet Pin 1
8 20458896 Poppet Retainer 1
9 80077241 O-Ring 2
10 20460033 Compression Spring 1

20458830 Repair Kit

Includes items 3, 4, 5, 6, 8, 9 and 10

72106161
12-2011/Rev 01
12-7
 Section 12
Parts List

Table 12-4
High Pressure Piping
20497330

Part Part
Item Number Description Quantity Item Number Description Quantity

2 20498314 Attenuator Assembly, .96L 1 13 20498280 U-Bolt, 3.50 2

3 49830581 Coupling, HP Bulkhead, .56 x .38 1 14 49883499 Lock Washer, M12 4
4 10094704 HP Tube, .38 x 3.0 1 15 49898729 Flat Washer, M12 4
5 10078715 HP Collar .38 4 16 10078780 Elbow, HP, .38 x .38 1
6 10078129 HP Gland, .38 4 17 20498585 HP Tube, Bent, .38 2
7 20427739 Pneumatic Valve/Actuator Assembly 1 18 20499594 Socket Head Screw, M14 x 2 x 20MM 3
8 20498577 HP Tube, Bent, .38 1 19 20499610 Lock Washer, M14 3
9 10078426 HP Collar, .25 1 20 05045497 Pressure Gauge, 0-5000 psi 1
10 10078459 HP Gland, .25 1 21 20498610 HP Tube, .38 1
11 20498652 HP Tube, Bent, .25 1 22 20498618 HP Tube, Bent, .38 1
12 10079531 Coupling, HP/HP, .56 x .38 2 23 10078590 Tee, HP, .38 1

72106161
12-2011/Rev 01
12-8
 Section 12
Parts List

Figure 12-4: High Pressure Piping

72106161
12-2011/Rev 01
12-9
 Section 12
Parts List

Table 12-5
Pneumatic Valve/Actuator Assembly, Normally Open
20427739

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20427648 Valve Body 1 10189553 Actuator Assembly, Normally Open

2 10178697 Valve Seat 1 7 BV401184 Pneumatic Cylinder 1
3 49830904 Adapter, HP Water Valve 1 8 BV601184 Cylinder Head 1
4 20435636 Valve Stem 1 9 BV501184 Piston 1
5 10188233 Backup Ring, Brass 1 10 10187250 Backup Ring, SST 1
6 20428052 Seal Assembly 11 10074714 O-Ring, 2.44 x 2.63 x .09 1
12 10074565 O-Ring, 2.25 x 2.38 x .06 2

72106161
12-2011/Rev 01
12-10
 Section 12
Parts List

Figure 12-5: Pneumatic Valve/Actuator Assembly, Normally Open

72106161
12-2011/Rev 01
12-11
 Section 12
Parts List

Table 12-6
Hydraulic Power Package
20497413

Part
Item Number Description Quantity

1 20498147 Electric Motor, 50HP 1

2 20498155 Coupling, Flexible Drive 1
3 20498173 Flange, Motor/Pump 1
4 20477284 Vibration Isolation Mount 2
5 49892375 Hex Head Screw, M16 x 2 x 60MM 6
6 49892359 Lock Washer, M16 6
7 49892342 Flat Washer, M16 6
8 49833072 Lock Washer, .63 4
9 20498660 Socket Head Screw, M16 x 2 x 25MM 4
10 20477807 Hex Nut, M18 8
11 20477803 Lock Washer, M18 8
12 20477800 Flat Washer, M18 8
13 20477758 Hex Head Screw, M18 8
Ref 1 10091510 Arrow Decal --

72106161
12-2011/Rev 01
12-12
 Section 12
Parts List

Figure 12-6: Hydraulic Power Package

72106161
12-2011/Rev 01
12-13
 Section 12
Parts List

Table 12-7
Hydraulic Pump Assembly
20498668

Part
Item Number Description Quantity

1 05045505 Piston Pump 1

2 20498626 Gear Pump 1
3 05139720 O-Ring, 85MM x 3MM 1
4 49883580 Flat Washer, M10 2
5 10064715 Lock Washer, M10 2
6 05037593 Socket Head Screw, M10 x 1.50 x 25MM 2
7 05048780 Split Flange Kit, 2.0 1
8 05048806 Adapter, Flange/Hose, 2.0 x 2.0 1

72106161
12-2011/Rev 01
12-14
 Section 12
Parts List

Figure 12-7: Hydraulic Pump Assembly

72106161
12-2011/Rev 01
12-15
 Section 12
Parts List

Table 12-8
Electronic Shift Assembly

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20457897 Firing Pin 2 4 20458290 Shift Sensor Housing and Cable Assembly 2
2 72106179 Hydraulic Manifold Assembly 20457402 Housing
2.1 20499180 Manifold 1 05202782 O-Ring
2.2 10187052 HP Relief Valve 1 05202873 O-Ring
2.3 10187060 LP Relief Valve 1 20459037 Socket Head Screw, 10-24 x 1
2.4 10185585 Solenoid Valve 1 20493669 Cable, Electronic Sensor
2.5 05122650 Plug, ORB, #8 3 20493677 Cord Connector
2.6 05104559 Plug, ORB, #4 1 5 20458941 Pilot Shift and Main Valve Assembly 1
2.7 80085756 Check Valve 1 20458173 Hydraulic Spool
2.8 72106187 Relief Valve 1 20493695 Shift Valve
2.9 72104336 Ring Spacer 1 6 20493396 Adapter, JIC/SAE, 1.0 x 1.0 2
3 20457264 Actuator Assembly, Shift Sensor 2 7 95159513 Socket Head Screw, 1/4-20 x 2 2
20458050 Magnet Retainer 8 95119038 Socket Head Screw, 3/8-16 x 2-1/4 4
20457372 Plunger, Spring Guide 9 95308508 Hex Head Screw, 3/8-16 x 2-1/4 4
20457501 Nut, Spring Guide 10 95277109 Flat Washer, .38 4
05203013 Spring, Sensor
05203021 Spring, Sensor
20493661 Magnet

72106161
12-2011/Rev 01
12-16
 Section 12
Parts List

Figure 12-8: Electronic Shift Assembly

72106161
12-2011/Rev 01
12-17
 Section 12
Parts List

Table 12-9
Hydraulic Hose Connections
20497379

Part Part
Item Number Description Quantity Item Number Description Quantity

1 10142644 Adapter, JIC/ORB, .25 x .25 3 11 20499576 Hydraulic Hose Assembly, .25 x 27.0 1
2 20497437 Hydraulic Hose Assembly, .75 x 20.50 1 12 20499644 Hydraulic Hose Assembly, .25 x 15.50 1
3 10083517 Hose Clamp 2 13 20497429 Hydraulic Hose Assembly, .75 x 28.50 1
4 10179018 Radiator Hose, 2.0 8.0" 14 20426972 Adapter, ORB/JIC, 1.0 x .75 1
5 20499618 Hydraulic Hose Assembly, 1.0 x 16.50 1 15 05122650 Plug, ORB, .63 3
6 80086192 Adapter, JIC/ORB, 1.0 x 1.0 1 16 05104559 Plug, ORB, .38 1
7 05052493 Adapter, JIC/ORB, .75 x .63 1 17 05045497 Pressure Gauge, 0-5000 psi 1
8 20499652 Hydraulic Hose Assembly, .75 x 14.0 1 18 20499626 Hydraulic Hose Assembly, .75 x 10.0 1
9 05073168 Adapter, JIC/ORB, .75 x .75 1 19 86300018 Split Flange Kit, 1.0 1
10 20497421 Hose, 1.0 x 1.0 x 33.0,FLANG/JIC,90D 1 20 10142594 Adapter, ORB/JIC, 1.0 x .75 1

72106161
12-2011/Rev 01
12-18
 Section 12
Parts List

Figure 12-9A: Hydraulic Hose Connections

72106161
12-2011/Rev 01
12-19
 Section 12
Parts List

Figure 12-9B: Hydraulic Hose Connections

72106161
12-2011/Rev 01
12-20
 Section 12
Parts List

Table 12-10
Reservoir Assembly
20498197

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20498181 Reservoir Weldment 1 17 20470406 Hose Barb, .50 x .50 2

2 20498272 Gasket, Reservoir 1 18 10070191 Hex Nut, M8 4
3 20498189 Lid, Reservoir 1 19 10069672 Lock Washer, M8 2
4 61149739 Pipe Plug, 2.0 1 20 20477570 Adapter, JIC/BSPT, .75 x .50 1
5 20468736 Air Breather 1 21 20499717 Adapter, JIC/BSPT, .75 x .50 1
6 10191484 Pan Head Screw, M5 x 10MM 3 22 20499743 Plug, BSPT, .75 1
7 72118248 Temperature/Level Switch 1 23 20468704 Adapter, BSPT/JIC, 1.0 x 1.0 1
8 49892466 Flat Washer, M10 9 24 20498264 Hex Head Screw, M12 x 1.75 x 20MM 4
9 49891948 Lock Washer, 10MM 10 25 49883499 Lock Washer, M12 4
10 80089410 Hex Head Screw, M10 x 1.50 x 30MM 10 26 49898729 Flat Washer, M12 4
11 20468655 Temperature/Level Gauge 1 27 20479720 Adapter, BSPT/JIC, .25 x .25 1
12 20468728 Adapter, BSPT/JIC, .75 x .75 2 28 20468695 Plug, BSPT, .50 1
13 20468740 Bushing, BSPT, 1.25 x .75 2 29 20499725 Adapter, BSPT/JIC, .75 x .75 1
14 20468662 Filter Head 1 30 20498205 Bracket, Door Latch 1
15 20468666 Filter Element 1 31 20499750 Magnet 2
16 20476941 Adapter, BSPT/ORB, .75 x .75 1 32 20468732 Heat Exchanger 1
33 86700007 Ball Valve 1

72106161
12-2011/Rev 01
12-21
 Section 12
Parts List

Figure 12-10: Reservoir Assembly

72106161
12-2011/Rev 01
12-22
 Section 12
Parts List

Table 12-11
Bulkhead Pipe Assembly
20497372

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20469497 Coupling, Bulkhead, BSPT, .94 x .25 1 14 20469066 Adapter, BSPT/JIC, .50 x .50 1
2 20469488 Coupling, Bulkhead, BSPT, 1.50 x .50 4 15 20468724 Hose Barb, .50 x .50 1
3 20469985 Jam Nut, 3/4-16 1 16 20470406 Hose Barb, .50 x .50 4
4 10070092 Jam Nut, 1-14 4 17 20469070 Nipple, BSPT, .50 x 3.0 1
5 20468995 Elbow, BSPT, .12 x .25 1 18 20469074 Solenoid Valve 1
6 20469007 Check Valve 1 19 20469031 Tee, BSPT, .50 x .50 1
7 20469989 Nipple, BSPT, .12 x .12 1 20 20498644 Adapter, BSPT/Pipe, .50 x .50 1
8 20469016 Solenoid Valve 1 21 49834328 Adapter, Pipe/Tube, .50 x .25 1
9 20469020 Coupling, Tube, 6MM x .12 1 22 20498569 Adapter, ORB/ipe, .50 x .38 1
10 20469023 Poly Tube, 6MM 12.0" 23 10079036 Hose Barb, .50 x .38 1
11 20469027 Adapter, Tube/Pipe, 6MM x .13 1 24 20498603 Adapter, ORB/Pipe, .50 x .38 1
12 20469031 Tee, BSPT,.50 1 25 20498676 Adapter, Hose/Pipe, .50 x .38 1
13 86200011 Pressure Switch, 30 psi 1 26 20421272 Hose, Push-on, .50 200.0"
27 86200015 Water Pump Assembly 1
28 10078152 Bushing Pipe, .75 x .50 2
29 72110201 LP Water Filter Subassembly 1
30 05013313 Hex Head Screw, M6 x 1 x 20MM 2

72106161
12-2011/Rev 01
12-23
 Section 12
Parts List

Figure 12-11A: Bulkhead Pipe Assembly

72106161
12-2011/Rev 01
12-24
 Section 12
Parts List

Figure 12-11B: Bulkhead Pipe Assembly

72106161
12-2011/Rev 01
12-25
 Section 12
Parts List

Table 12-12
Electrical Assembly
72102411

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20498230 Enclosure 1 14 10085520 Connector, Flexible Conduit, 1.50 1

2 72102429 Electrical Configuration 1 15 20470325 Terminal Lug, #14-2/0 6
3 49898729 Flat Washer, M12 4 16 72109623 Pushbutton Switch, Red 1
4 49891922 Lock Washer, M12 4 17 72109615 Pushbutton Switch, Green 1
5 20499784 Hex Nut, M12 4 18 20468378 Legend Plate, Yellow 1
6 20499816 Harness 1 19 20468391 Switch, E-Stop 1
7 10125912 Cable Tie, .87 10 20 10124279 Connector, Cable, .50 1
8 10115830 Connector, Flexible Conduit, 1.50 1 21 80079775 Cable, #18 50.0"
9 05141700 Ring Terminal, #8 2 22 10122646 Connector, Cable, .50 1
10 20469132 Flexible Conduit, 1.50 30.0" 23 10082857 Gasket Assembly 2
11 20468875 Wire, 10MM, Black 300.0" 24 10083012 Lock Nut, .50 2
12 20477288 Cable, 9MM, Green/Yellow 100.0" 25 49874191 Hole Seal, .50 4
13 20468427 Connector, Crimp Ferrule, #8 18 26 72109649 Contact Block 1
27 72109631 Contact Block 1

72106161
12-2011/Rev 01
12-26
 Section 12
Parts List

Figure 12-12: Electrical Assembly

72106161
12-2011/Rev 01
12-27
 Section 12
Parts List

Table 12-13
Electrical Configuration
72102429

Part Part
Item Number Description Quantity Item Number Description Quantity

1 20477059 Circuit Breaker 1 18 20468416 Connector, Crimp Ferrule, #14 8

2 05081955 Socket Head Screw, 8-32 x 2 4 19 20468235 Circuit Breaker 1
3 20468452 Rotary Drive, Circuit Breaker 1 20 20468875 Wire, 10MM, Black 72.0"
4 20468448 Breaker, Terminal Cover 2 21 20468427 Connector, Crimp Ferrule, #8 6
5 05141650 Ground Lug, #4-#0 4 22 72102280 Contactor 1
6 20468420 Ground Lug 2 23 72102288 Overload Relay 1
7 10167070 Pan Head Screw, 8-32 x 1 8 24 80078223 End Block 11
8 10069607 Lock Washer, #8 8 25 20468239 Transformer 1
9 95146429 Hex Nut, #8-32 4 26 20468900 Wire, 1.5MM, Red 160.0"
10 20477288 Cable, 9MM, Green/Yellow 110.0" 27 20468424 Connector, Crimp Ferrule, #16 250
11 05141700 Ring Terminal, #8 4 28 20469108 Circuit Breaker 1
12 20468313 Terminal Block 1 29 20468403 Power Supply 1
13 20468440 DIN Rail 60.0" 30 20468896 Wire, 1.5MM, Blue 1,040.0"
14 10073492 Pan Head Screw, 8-32 x 1/2 33 31 20468904 Wire, 1.5MM, Blue/White 240.0"
15 10114627 Flat Washer, #8 33 32 20468883 Wire, 1MM, Green/Yellow 80.0"
16 20468346 Wiring Duct 150.0" 33 80078207 Terminal Block 5
17 20468892 Wire, 2.5MM, Black 60.0" 34 20468395 Circuit Breaker 1

72106161
12-2011/Rev 01
12-28
 Section 12
Parts List

Table 12-13
Electrical Configuration
72102429

Part Part
Item Number Description Quantity Item Number Description Quantity
35 20468375 Terminal Block 32 39 20468305 Terminal Block 7
36 20468371 End Barrier 2 40 20498694 Subplate 1
37 20468367 Jumper, Terminal Block 2 41 20468288 PLC, S7200 1
38 20468358 Marker, Terminal Block 16 42 20468342 Battery, PLC 1
43 20468248 Relay Base 3
44 20468256 Tube Base Relay 3

72106161
12-2011/Rev 01
12-29
 Section 12
Parts List

Figure 12-13: Electrical Configuration

72106161
12-2011/Rev 01
12-30
 Section 12
Parts List

Table 12-14
Cover Assembly
20498048

Part
Item Number Description Quantity

1 20498007 Rear Cover 1

2 20497999 Front Cover 1
3 20468638 Rubber Bumper 2
4 10122067 Flat Washer, M8 5
5 10069672 Lock Washer, M8 5
6 10070191 Hex Nut, M8 2
7 05080841 Button Head Screw, M6 x 1 x 22MM 8
8 10107118 Flat Washer, M6 8
9 49892011 Lock Washer, M6 8
10 10070183 Hex Nut, M6 8
11 20498033 Latch 2
12 05014584 Hex Head Screw, M8 x 1.25 x 16MM 3

72106161
12-2011/Rev 01
12-31
 Section 12
Parts List

Figure 12-14: Cover Assembly

72106161
12-2011/Rev 01
12-32
 Section 12
Parts List

Table 12-15
LP Water Filter Assembly
72110201

Part
Item Number Description Quantity

1 20468978 Filter Housing Assembly 1

2 86800001 Filter Element, 10 Micron 1
3 72110219 Bushing, BSPT, .75 x .50 2
4 20470406 Hose Barb, .50 x .50 2
5 20469031 Tee, BSPT, .50 x .50 2
6 72110226 Bushing, BSPT, .50 x .25 1
7 20469501 Pressure Gauge 1
8 20469066 Adpater, BSPT/JIC, .50 x .50 1
9 20468724 Hose Barb, .50 x .50

72106161
12-2011/Rev 01
12-33
 Section 12
Parts List

Figure 12-15: LP Water Filter Assembly

72106161
12-2011/Rev 01
12-34