Flow HYPERJET 94i-S User manual

HYPERJET™ 94i-S & 94i-D
M-390 | REV. C | APRIL 2010

Due to continuing product improvement, the information contained in this document is subject to change without
notice. Flow International Corporation shall not be held liable for technical or editorial omissions made herein, nor
for any incidental or consequential damage resulting from the use of this material.
This document contains information protected by copyright. No part of this document shall be reproduced in any
manner without prior written consent from Flow International Corporation.
HyperPressure™, HyperJet™ and WaterVeyor™ are trademarks of Flow International Corporation. Dynamic
Waterjet®, HyPlex®, and Paser®ECL Plus are registered trademarks of Flow International Corporation.
© 2006–2010 Flow International Corporation. All rights reserved.
2 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Introduction
HyperJet™ 94i-S & 94i-D Pumps
Chapter 1. Equipment Description
Features 7
Specifications 8
Water requirements 9
Drain requirements 9
Water interface connections 10
Pump startup sequence 11
Operating an integrated HyperJet pump 12
Running the pump 12
Using dual pressure 12
Running the HyperJet 94i-D on one motor 13
Changing pump operation mode 13
Shipping or storing the intensifier pump 14
Chapter 2. Safety
Safety precautions 15
Warnings, cautions, and notes 15
Safety tips 16
Protective clothing 18
Emergency medical information 19
Chapter 3. Operating the Standalone Pump
Basics of pump control 21
Units 21
Main control screens 22
Start screen 22
Main Run Screen 22
Change Pressure Setpoints 23
Dual Pressure Control 23
Boost Pump Control 24
Pump Status screens 25
Pump Status 1 25
Pump Status 2 25
Analog Input Status 25
Pump shutdowns 26
Pump warnings 26
Configuration screens 27
Configuration Screen 1 27
Configuration Screen 2 27
Configuration Screen 3 28
Configuring the clock 28
Defaults 29
Display Services 29
Chapter 4. Maintenance and Troubleshooting
Periodic maintenance 31
Maintenance tips 31
Maintenance precautions 31
General precautions 31
Hydraulic oil 32
Inspection and maintenance schedule 33
Every day 33
Troubleshooting tips 34
Weep holes 34
Troubleshooting the high-pressure components 34
Using the troubleshooting table 34
Troubleshooting the intensifier pump 35
Troubleshooting the pump using FlowSense 38
Warning conditions 38
Shutdown conditions 38
Warning and shutdown conditions 39
Chapter 5. Servicing the pump
Service tips 41
Service notes 42
Torque specifications 42
Servicing the hydraulic system
Hydraulic oil pump 43
Replacing the hydraulic pump 44
Cleaning a contaminated hydraulic system 46
Checking the hydraulic oil 48
Changing the hydraulic oil 49
Replacing the kidney loop oil filter 51
Servicing the heat exchanger 52
Servicing the bleed-down valve 53
Replacing the booster pump 55
Replacing the filter elements 56
Servicing the shift valve manifold assembly 58
How it works 58
Replacing a complete intensifier assembly 59
Intensifier shift module 60
Pilot valve 62
Shift valve 64
© Flow International Corporation M-390 | 3

4 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS
Main system relief valve 66
Replacing the main system relief valve 66
Shift sensor assembly 67
How it works 67
Service tips 67
Replacing a shift sensor assembly 68
MS-2258, Maintenance Log
Chapter 5. Parts Lists
Pump drawings 69
Spares 70
Kits 70
Service kits 72
Tools 73
Label kits 73
Miscellaneous service parts 74
Chapter 6. Customer Support
MS-2266, Customer Support

Introduction
The information in this manual will help you become familiar with your new Flow International (FLOW) equipment.
It was compiled from the most current information available at the time of publication and is intended to cover the
most common configurations.
Safety
All operating personnel and service technicians must read and follow the procedures in this manual to avoid creat-
ing unsafe conditions, or risking damage to the equipment.
The comprehensive list of safety precautions in Chapter 2 of this manual must be followed to ensure safe operation
of the equipment. These precautions must be reviewed and understood by operating and maintenance personnel
before installing, operating, or servicing the equipment. The high-pressure waterjet system is a powerful cutting tool
and must always be treated with respect.
Warnings, cautions, & notes
Before operating the equipment, please read, thoroughly understand, and follow all warnings, cautions, and notes
that appear in this manual. They are defined as follows:
WARNING
Highlights an operating or service procedure or condition that
can result in death or serious injury to personnel.
CAUTION
Highlights an operating or service procedure or condition that
can lead to impaired system operation or equipment damage.
Note: Highlights an operating or service procedure or condition that is essential for efficient operation and
service.
© Flow International Corporation M-390 | 5
Introduction

Notes
6 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

CHAPTER 1
Equipment Description
The HyperJet™ 94i-S & 94i-D Pumps are powerful,
ultrahigh-pressure waterjet cutting tools.
Features
•The pumps have an output water pressure rating of
87,000 psi (6000 bar)
•UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT®
•Dual filter system removes particles larger than
0.5 microns absolute
•Controlled with FlowMaster® software
•FlowSense®, an early warning system for critical
parts
•Available in two versions: a single-motor 50 hp
(HyperJet 94i-S) or dual-motor 100 hp (HyperJet
94i-D)
HyperJet 94i-S
HyperJet 94i-D
© Flow International Corporation M-390 | 7

Specifications
Contact Flow Technical Service for further information. Also
see the system drawings in Chapter 5.
Dimensions
HyperJet94i-S .......... 54in.x40in.x45in.
HyperJet94i-D.......57.4in.x55.3in.x44.1in.
Oil ................................240SSU
Flow recommends the following oils, but other manufac-
turer’s equivalents can be used:
Shell Turbo T 46
Chevron Turbine Oil GST 46
Mobil DTE Medium
Texaco Regal R&O 46
Reservoir
HyperJet94i-S..............25gallons(95liters)
HyperJet94i-D ............37gallons(140liters)
Outputpressure.............87,000psi(6000 bar)
Filtrationprovided.........0.5micronand1micron
Cooling water in
HyperJet94i-S.......3gpm@50psi,60°Forless
HyperJet94i-D...5gpmmin@50psi,60°Forless
Filtered water in
HyperJet94i-S ....1gpm@30-35psi,80°Forless
HyperJet94i-D....3gpm@30-35psi,80°Forless
Air..................15SCFM@90psi(6.2bar)
Voltage
HyperJet94i-S.........460VAC/125A/60Hz,3ø
HyperJet94i-D ........460VAC/200A/60Hz,3ø
8 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Water requirements
The HyperJet intensifier pumps each require one water
source. Also required are three water drain lines: cool-
ant drain, leakage drain, and bleed-down water. The
leakage drain must be separate where local regulations
do not permit oil in drains. Specific requirements are
defined in the following descriptions.
Cutting water
CAUTION
A high concentration of dissolved solids (especially
silicates and calcium) in the inlet water can reduce
waterjet nozzle life. If water quality is poor and filtra-
tion will not correct it, the customer must add
additional water treatment equipment. Contact
FLOW Technical Service for more information.
Flow recommends the use of a water softener to
pre-treat the cutting water. Systems should be sized for
150% of your pump capacity, and should match your
intended maximum duty cycle.
Water pressure
Water pressure to the intensifier pump must stay be-
tween 50 and 100 psi (3.4 and 6.9 bar) at all times.
Water flow rate
The minimum inlet water flow rate must be equal to
1.5 times the maximum output flow rate.
Cooling water (to heat exchanger)
A heat exchanger regulates heat build-up in the hydraulic
oil. Optimum hydraulic oil temperature is 105°F (40.5°C).
Tap water is routed to the heat exchanger in the hydraulic
reservoir.
A thermostatically controlled cooling water flow control
valve designed for partially open operation is installed
in the line to regulate the water flow for maximum
water conservation.
Waterflowmustbesufficienttoensurethatthehydraulic
oil reservoir temperature is always maintained below
110°F (43°C). Cooling water flow rate is typically 3 gpm
(11 lpm) per 50 hp at an inlet water temperature of
60°F (15°C).
Water with low levels of minerals and acid will maximize
heat transfer efficiency and heat exchanger life.
•Waterjet systems perform better with soft water.
Drain requirements
Cooling water drain
Cooling water leaving the intensifier pump is considered
waste water. This water can be routed to a waste water
recovery system, a recirculation system, or a drain—
whichever is most applicable for the installation. If the
water is reused for cooling, a commercial water cooling
system can be used.
If the cooling water is routed directly to a waste water
drain, you must have a minimum drain capacity of
9 gpm (34 lpm).
Leakage drain (oil or water)
The pump has a drip pan to collect oil or water leakage
from the intensifier seals. Leakage is usually negligible;
however, the drain line is sized to accommodate the
worst case (if the high-pressure seals fail) of 10 gpm
(38 lpm).
Do not connect the leakage water drain to the coolant
water drain line or any other pressurized drain system.
Bleed-down water
The bleed-down valve exhausts water through the
BLEED DOWN WATER port on the bulkhead.
© Flow International Corporation M-390 | 9
CHAPTER 1
Equipment Description

Water interface connections
Please note the following:
•Flow recommends that you install manual on/off
valves in the inlet water and cooling water lines. Lo-
cate valves as close as possible to the pump interface
connection to make them easier to service.
•Coolant water lines must be made from non-corrosive
pipe or rubber hose. Rubber hose per SAE Standard
20R1, 30R1, or equivalent is recommended.
•Cutting water lines (from the filtering system to the
intensifier pump) must be as short as possible and
must be constructed of PVC, copper, or equivalent.
Do not use galvanized iron piping—it will introduce
minerals to the water, which will shorten orifice life.
Making the interface connections
•Connect inlet water line to FILTERED WATER IN.
•Connect LEAKAGE WATER to the appropriate drain or
bucket (can contain oil).
•Connect BLEED-DOWN WATER to the appropriate
drain.
Note: Purge the inlet water lines of debris before com-
pleting the connection to the pump.
10 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Pump startup sequence
After initial installation, and whenever you perform major
service on the intensifier pump, you must follow this
startup procedure when putting the equipment back
into service. This procedure provides checks to make
sure the pump is correctly reassembled.
Before starting the equipment:
•Be sure you know how to stop it.
•Read the manuals, get training from an experienced
operator, and review the safety precautions.
•Follow a written checklist that includes an inspection
for needed or ongoing service, damaged or missing
parts, leaks, and anything that could make equipment
unsafe to operate.
•Make sure doors are closed and covers are in place.
•Call out “START-UP” to let anyone in the area know
the equipment will be starting up.
WARNING
NEVER operate the pump or intensifier with uncertified
parts—this can cause explosive separation of
parts and serious bodily injury. Contact FLOW
or seek professional installation assistance.
•All operators and service personnel must review the
safety precautions in all manuals provided with this
equipment before operating the equipment.
•Cutting equipment and nozzle must be installed and
working before operating the pump. Operating the
pump without proper line restriction will damage
high-pressure components.
Starting the pump
CAUTION
Debris in the water supply line can cause
extensive damage to high-pressure components.
Such damage IS NOT covered by warranty.
1. Flush debris from all water supply hoses before
connecting them to the pump.
CAUTION
Never operate the pump without oil—this can cause
extensive damage and IS NOT covered by warranty.
2. Fill the pump case(s) with one of the recommended
oils (see the list on Page 8).
3. Make sure water lines, air lines, and drain lines are
correctly connected and routed.
4. Clear all tools, parts, and rags from around the pump.
Check areas in and around the pump for foreign
objects and debris.
CAUTION
The inlet water valve must be open before
operating the pump. Operating the pump with
the inlet water valve closed will cause damage.
5. Open the inlet water valve and check all connections
for leaks.
CAUTION
Cutting equipment and nozzles must be installed
when operating the pump. Operating the pump
without proper line restriction can cause damage.
6. Place the main electrical disconnect in the ON
position.
7. Release the E-stop button.
8. Activate FlowCUT and open a part program. Select
Run Machine. The screen will display the pump
on/off control.
CAUTION
Do not try to tighten any loose or leaking connections
while the pump is operating or while the line is pressurized.
9. Turn the pump on by clicking on the pump ON
button.
10. When the pump reaches the low-pressure setting,
allow it to run 5-10 minutes while checking for leaks
or other problems. Correct as required.
11. Click on the high-pressure icon.
12. When the pump reaches 87,000 psi (6000 bar),
operate the pump at this pressure for additional
5-10 minutes while checking for leaks. Correct as
required.
13. Turn the pump off, exit FlowCUT, and press the
E-stop button.
© Flow International Corporation M-390 | 11
CHAPTER 1
Equipment Description

Operating an integrated HyperJet pump
All integrated Flow intensifier pumps are operated using
the FlowMaster software controller. See manual M-322,
FlowCUT User's Guide, for more detailed information
on running the machine. A pump operation button on
the FlowMaster Run Machine screen is used for starting
and stopping the pump. Select HIGH PRESSURE or
LOW PRESSURE for the dual- pressure feature.
IMPORTANT
If you are running a standalone HyperJet intensifier
pump, it will have its own control panel. Turn to Chap-
ter 3 of this manual for details.
Running the pump
When the machine is in position to start a cut, click on
the ON pump button. The intensifier pump will not start
immediately; first the water booster pump turns on to
charge the system. After approximately 5 seconds, the
intensifier pump starts and begins ramping up pressure.
The pump uses an electronic proportional control valve
to automatically ramp up high-pressure water. The digi-
tal high-pressure gauge on the FlowCUT screen indi-
cates the amount of water pressure in the system.
When the system reaches the desired operating pres-
sure, you can begin cutting. Click the OFF pump but-
ton to turn off the pump. All system pressure is bled to
0 psi within one second of shutting down the pump.
Using dual pressure
Brittle materials, such as glass, stone, or composites,
should be pierced at a lower operating pressure (such
as 20,000 psi/1379 bar). To select high or low pres-
sure, highlight either the HIGH PRESSURE or LOW
PRESSURE box to the right of the pump on/off button.
•The default setting is HIGH PRESSURE, which is
normally set for an operating pressure of 87,000 psi
(6000 bar).
•Selecting LOW PRESSURE will lower the pressure,
usually to between 15,000–20,000 psi (1034–
1379 bar).
Use the LOW PRESSURE setting together with the
FlowMaster PIERCE ALL HOLES FIRST function to
pierce holes in a given program before cutting.
12 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Running the HyperJet 94i-D on one motor
The HyperJet 94i-D can be run in three modes: 100 hp (default
mode), 50 hp A, and 50 hp B.
100 hp mode
•In 100 hp mode, the first motor is started, followed by the
second motor, and then the system is brought up to pressure.
•Each motor powers one of the intensifiers. Follow the plumb-
ing connecting the motors and intensifiers to determine which
motor powers which intensifier.
50 hp A mode
•In 50 hp A mode, only the first motor is used.
•This mode should be used only if there is a problem with the
equipment that prevents normal 100 hp operation of the
pump, such as malfunction of a single intensifier or motor.
50 hp B mode
•In 50 hp B mode, only the second motor is used.
•This mode should be used only if there is a problem with the
equipment that prevents normal 100 hp operation of the
pump, such as malfunction of a single intensifier or motor.
Changing pump operation mode
1. Shut down the pump.
2. Open the OPCPump.ini file in the FlowMaster\System directory.
3. Make sure the following line in the header of the file reads:
INIT_WRITE,1 // 1=ENABLE, 0 = DISABLE
4. Locate the pump size variable line. The pump size line of a
HyperJet 100 pump operating in default mode will read:
Pump_Size,MicroWin.S-0264.USER1.Pump_Size,,1,P100
5. You can change this line to switch the pump’s mode to 50 hp A
or 50 hp B.
•To change the pump to 50 hp A mode, change the
pump size line to read:
Pump_Size,MicroWin.S-0264.USER1.Pump_Size,,0,P100
•To change the pump to 50 hp B mode, change the
pump size line to read:
Pump_Size,MicroWin.S-0264.USER1.Pump_Size,,2,P100
6. If FlowMaster was running while you were making the
changes to the OPCPump.ini file, you must close the program
and restart it in order to activate the changes.
7. Follow the Pump startup sequence on page 11 to restart the
pump.
© Flow International Corporation M-390 | 13
CHAPTER 1
Equipment Description

Shipping or storing the HyperJet pump
Whenever moving, storing, or shipping a Flow pump,
following these guidelines will help prevent damage
caused by movement or environmental conditions. These
instructions comply with transportation regulations.
Note: U.S. Department of Transportation regulations
require that hydraulic fluid be transported only in sealed
containers. Before shipping, remove all hydraulic fluid
from the oil reservoir.
Service steps
1. Disconnect power and turn off inlet water.
2. Disconnect main motor lead terminations from the
motor starter in the machine power enclosure. DO
NOT CUT LEADS.
Note: Motor leads are terminated with eye lugs and
bolted to terminations from the motor starter primary
conductors.
3. Remove water filters from housings. Empty and
clean the housings, then reinstall without filters.
4. Disconnect the plumbing from the water leakage
line.
5. Disconnect customer plumbing from the FILTERED
WATER IN bulkhead connection.
Install antifreeze
Notes:
•Use Dow Chemical Dowfrost Propylene Glycol
food-grade antifreeze (or equivalent). Antifreeze,
container, pump, and hoses must be clean to prevent
contamination.
•Antifreeze MUST NOT be introduced into an 87K
intensifier.
6. Use a small pump to force clean antifreeze through
the cooling water circuit. To ensure that the flow
control valve is open, run the pump until the oil is at
operating temperature. Otherwise, bypass the flow
control valve. A drill-motor operated transfer pump
is often adequate. Continue to pump antifreeze until
it exits the COOLING WATER OUT connection, then
disconnect the hose from the inlet water connection.
7. Remove water from the intensifier inlet water circuit
by emptying the filter housings and blowing out the
hoses and booster pump using compressed air.
Water in the intensifiers and high-pressure tubing
does not need to be removed.
Plug fittings
8. Plug all bulkhead connections. Tie wrap the inlet
water line and drain line.
Crating
9. The pump must be shipped on a framed and rein-
forced wooden pallet designed to isolate and sup-
port its weight and load characteristics.
10. Secure the filter bracket so it cannot vibrate.
11. Wrap a plastic band around the horizontal circum-
ference of the pump, protecting all corners with
cardboard between the strap and the cover corner.
Wrap an additional plastic band around the top and
under the frame, also protecting corners with card-
board.
12. The pump cover package must also be fully enclosed
in a rigid wooden crate for shipment.
14 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

CHAPTER 2
Safety
This chapter contains a comprehensive list of safety pre-
cautions that must be followed to ensure safe operation
of the equipment. These precautions must be read and
understood by everyone operating and maintaining the
equipment—before they start working with the equip-
ment. Note that OSHA and state safety agency rules
must be complied with in addition to those given in this
chapter and elsewhere in this manual. Applicable plant
general safety precautions must also be followed.
Safety precautions
FLOW designed your high-pressure waterjet cutting
system and related equipment with safety in mind.
Throughout the manual, safety precautions and warn-
ings for specific operations are highlighted. Safety pre-
cautions are also posted on the equipment. The opera-
tor and service personnel shall pay particular attention
to these precautions at all times.
Operators of a high-pressure waterjet cutting system
must treat the system as they would treat any high-
speed cutting tool. Although the waterjet may appear
harmless, it is a high-energy cutting tool capable of cut-
ting many non-metallic materials such as composites,
plastics, and wood products. Misuse of this equipment
or carelessness in its application can be extremely haz-
ardous to operating personnel. Always treat the waterjet
cutting system with respect.
Warnings, cautions, and notes
Service procedures in the waterjet manuals include
safety warnings, cautions, and notes that must be read,
understood, and adhered to. These are specific categories
of safety notices, and are defined as follows:
WARNING
Highlights an operating condition or service
procedure that can result in death or
serious injury to personnel.
CAUTION
Highlights an operating condition or service
procedure that can lead to impaired system
operation or equipment damage.
Note: Highlights an operating condition or service
procedure that is considered essential for efficient
operation and service.
Replacement labels
•Part # 006317-1
3.75 x 6 in.
•Part # 009837-1
1.8 x 3 in.
© Flow International Corporation M-390 | 15

Safety tips
•Do not allow the waterjet stream to touch any part
of your body—it will cause serious injury.
•Do not point the waterjet at anyone.
•During equipment maintenance, take the system out
of service. The controls must be properly locked and
marked with a warning sign.
•All personnel required to perform any system operating
or service function must pay particular attention to
all warning signs and notices posted in the plant and
on the equipment.
•All protective guards, shields, and covers must be in
place on the equipment at all times.
•Use cleaning solvents only in well-ventilated areas.
Avoid prolonged breathing fumes and contact with
skin or eyes.
•First aid facilities must be provided in convenient
locations throughout the plant. These locations must
be known by all personnel.
•Always keep the work area around the equipment
clean and free of debris. Oil spillage results in slip-
pery floors and must be cleaned up immediately.
•Any unfavorable conditions that may result in inju-
ries must be reported to the plant supervisor without
delay.
•As a general practice, it is recommended that safety
shoes, glasses, and hearing protection be worn by all
personnel working around the equipment. Do not
wear rings, watches, or necklaces when working
around any equipment that has moving parts.
Mechanical system
•Don’t start the system unless you know how to stop
it.
•Never maintain, service, or clean around the equip-
ment while it is operating.
•Use only the correct tools—wrong tools can cause
injury or costly damage to equipment.
•Never climb on or around the equipment on make-
shift devices. Use only approved catwalks, ladders,
or platforms.
•Do not exceed specified pressure setting limits for
pneumatic or hydraulic components. Exceeding
these limits may result in serious injury to personnel
or damage to the equipment.
•Shield and bundle equipment hoses and cables so
they do not obstruct the operator’s freedom of
movement.
•Be alert at all times when working around the
equipment.
•Clear all tools, parts, and rags from moving parts
after servicing the equipment.
Electrical system
•Only properly trained personnel shall perform elec-
trical and/or electronic troubleshooting and servicing
of electrical devices.
•Always assume that power is ON in all electrical
systems. Always check and lock out the main power
switches before servicing the equipment. Post a sign,
"Maintenance in Progress — Do Not Energize."
•Be aware that live electrical circuits are present in
the control console whenever the master disconnect
is on, regardless of whether the E-Stop is engaged.
•Disconnect circuit breakers and lock them in the OFF
position before servicing the electrical system. If this
isn’t possible, have someone stand by to prevent
someone from powering up the system.
•Take extra precautions when servicing the power
system in a damp environment.
•Never alter or bypass protective interlocks or devices
unless specifically instructed to do so, and only if all
precautions are followed.
•You must give capacitors sufficient time for discharge.
If this is not possible, discharging should be done
manually and with care.
•Do not use jumper wires across fuses, fuse holders,
or breakers.
•Make sure all tools are properly insulated for the job.
•Use only proper test apparatus; check regularly to
make sure it is working correctly.
•Use caution when connecting a test probe to test
points.
•All replacement wires must conform to the manufac-
turer’s specifications, including color coding, wire
numbers, and size.
•Close the control panel doors or junction box covers
after servicing.
16 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Waterjet system
•High-pressure water can remain in the system for an
extended time after shutting down the water source.
Always bleed down system pressure before servicing
any part of the system.
•Do not touch weep holes with your bare hands or
try to stop water by plugging the holes.
•Remember that the waterjet stream is a knife. Do
not introduce anything into its path that you do not
intend to cut.
•Wear a face shield when required by the operating
instructions.
•Do not remove protective shields from high-pressure
tubing. If shields are removed for servicing, they
must be replaced before starting the system.
•Torque all fittings to the manufacturer’s torque
specifications.
•Stepping or leaning on high-pressure tubing can
break connections, causing leakage.
•Use only high-pressure fittings, valves, and tubing
certified for 87,000 psi (6000 bar) when making
alterations or additions to the high-pressure water
system.
•Do not alter or eliminate stress relief tubing coils.
•Follow the tubing manufacturer’s recommendations
for high-pressure tube bending radii.
•Do not exceed specified operating pressures for
high-pressure water system components.
•Do not over-torque fittings or bend swivels excessively.
•Follow the manufacturer’s recommendations for
servicing the equipment, and use only original
manufacturer replacement parts.
•Follow the manufacturer’s system startup procedure
to ensure safe operation.
•Use care when lifting equipment covers during
operation.
© Flow International Corporation M-390 | 17
CHAPTER 2
Safety

Protective clothing
Personnel operating hand-held, high-pressure water cut-
ting or cleaning equipment and those working nearby
should wear the protective clothing and safety devices
described in this chapter.
FLOW recommends that work-site safety personnel ap-
prove all safety equipment and clothing for everyone
working around waterjet equipment.
Eye protection
•At a minimum, operators must
wear safety glasses with side
shields and a visor, or goggles and
a visor, to guard against spray and
flying debris.
•All eye protection shall meet ap-
propriate ANSI requirements for
that type of eye protection.
•Some states and countries have
their own eye protection rules
that must be followed.
Head protection
•Helmets must be worn at all
times by all personnel within the
work area.
•Helmet material must withstand
mechanical shock to 10 G in 8 ms
without fracturing.
Hand protection
•The operator must wear gloves
at all times. Leather gloves are
preferred.
Foot protection
•Safety footwear with steel
toe-caps 0.02-in. (5 mm) thick
(minimum) must be worn. The
toe cap must cover at least 30%
of the footwear length.
•For some applications, footwear
must be equipped with metatar-
sal guards to provide instep pro-
tection.
Hearing protection
•Operators and other personnel
exposed to noise levels of more
than 90 dBa for more than
1 hour must wear suitable ear
protection. Ear plugs and muffs
are usually adequate.
Body protection
•Waterproof garments only protect
the operator from spray and flying
debris. They DO NOT provide any
protection from direct jet impact.
WARNING
NEVER point a waterjet cutting or cleaning tool
at yourself or at any person. Do not aim any
waterjet tool at anything you do not want to cut.
18 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS

Emergency medical information
Anyone who receives equipment-related injuries while
operating high-pressure water equipment should be
given immediate hospital attention. It is vital that medi-
cal personnel have information about this type of injury.
Therefore, all waterjet operating personnel should carry
a waterproof emergency medical tag or card that de-
scribes their work and the nature of injuries inherent in
using waterjet cutting devices. The card illustrated below
can be purchased from Flow (A-8466).
The tag or card should contain the following standard
information:
© Flow International Corporation M-390 | 19
CHAPTER 2
Safety
MEDICAL ALERT
This card is to be carried by personnel working
with high-pressure waterjet equipment. Obtain
medical treatment immediately for ANY
high-pressure waterjet injuries.
FLOW INTERNATIONAL CORPORATION
23500 64th Avenue South
Kent, Washington 98032 USA
[phone]
This person has been working with water jetting at pressures to
92,000 psi (634 MPa, 6345 bar) with a jet velocity of 3900 fps
(1190 mps). This should be taken into account during diagnosis.
Unusual infections with microaerophilic organisms occurring at
lower temperatures have been reported. These may be
gram-negative pathogens, such as those found in sewage. Bac-
terial swabs and blood cultures may therefore be helpful. A lo-
cal poison control center should be contacted for additional
treatment information.

Notes
20 | M-390 © Flow International Corporation
HYPERJET™ 94i-S AND 94i-D PUMPS