KMT STREAMLINE SL-IV 50 PLUS Operation manual

STREAMLINE HIGH PRESSURE
WATERJET PUMP
OPERATION and SERVICE MANUAL
SL-IV 50 PLUS
HSEC
Manual No. 80079650

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 Systems believes the information described
in this manual to be accurate and reliable. Much care has
been taken in its preparation, however, the Company
cannot accept any responsibility, financial or otherwise,
for any consequences arising out of the use of this
material. The information contained herein is subject to
change, and revisions may be issued to advise of such
changes and/or additions.
KMT WATERJET SYSTEMS
Fluid Products
KMT Waterjet Systems
635 West 12th Street P.O.Box 231
Baxter Springs, Kansas 66713
Tel. [phone]
FAX [phone]
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TABLE of CONTENTS
SECTION 1 INTRODUCTION
1 SL-IV Waterjet Pump General Information 1-1
1.1 Physical Description 1-1
1.1.1 Standard Equipment 1-2
1.2 Functional Description 1-3
1.2.1 Functional Features 1-3
1.3 Worldwide Product Support 1-4
1.3.1 Service Department 1-4
1.3.2 Spare Parts 1-4
1.3.3 Questionnaire 1-5
1.4 Safety 1-7
1.4.1 Labels and Abbreviations 1-7
1.4.2 Safety Procedures 1-9
1.4.3 High Pressure (HP) Piping Safety 1-11
1.4.4 Emergency Medical Treatment 1-12
SECTION 2 INSTALLATION
2 Installation 2-1
2.1 Installation Overview 2-1
2.1.1 Buyer Obligations 2-2
2.1.2 Seller Obligations 2-3
2.2 Installation Requirements (Utilities) 2-4
2.2.1 Equipment Location/ Environment 2-4
2.2.2 Service Connections 2-5
2.2.3 Tools and Equipment 2-6
SECTION 3 OPERATION
3 Operation 3-1
Main Menu 3-4
Run Screen 3-5
Run Screen 2 3-7
Hours 3-8
Alarm History Screen 3-9
Pressure Control Screen 3-10
Stroke Rate Screen 3-11
Set Up Screen (2) 3-12
Maintenance Screen 3-13
Alarm Screen 3-14
No Pressure Screen 3-15
Language 3-16
Alarm Banner (Example) 3-17
SECTION 4 MAINTENANCE
4 Maintenance 4-1
4.1 Scheduled Maintenance 4-3
4.2 General Maintenance 4-4
4.3 Service Log Data 4-6
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SECTION 5 TROUBLESHOOTING
5 Troubleshooting
5.1 Troubleshooting - Electrical 5-1
5.1.1 Pump Will Not Start 5-1
5.1.2 Console Display and Lights Fail to Illuminate 5-1
5.1.3 Pump Quit Running 5-1
5.1.4 No Control Power (24vdc) 5-1
5.1.5 Red Light, Message on Operator’s Console 5-2
5.2 Troubleshooting – HP Water 5-3
5.2.1 HP Water Signal Abnormal Fluctuation 5-3
5.2.2 Hot Surfaces on HP Cylinder Components 5-3
5.2.3 Oil or Water Leaks from HP Intensifier 5-3
5.2.4 HP Check Valve Leak 5-4
5.2.5 Normal Temperature, but Check Valve Problem 5-4
5.2.6 HP Cutting Water Too Low 5-4
5.3 Troubleshooting – LP Water 5-4
5.3.1 Low Booster Pump Pressure 5-4
5.4 Troubleshooting – Hydraulic 5-5
5.4.1 Hot Hydraulic Oil 5-5
5.4.2 Hydraulic Pressure But No High Pressure Water Pressure 5-5
5.5 Special Procedure—HP Water Check Valve 5-6
5.5.1 HP Check Valve Troubleshooting 5-6
SECTION 6 LOW PRESSURE WATER SYSTEM
6 Low Pressure Water System 6-1
6.1 Oil Cooling Water Supply 6-3
6.2 Cutting Water Supply 6-4
6.2.1 Normal Operating Condition 6-4
6.2.2 Operation 6-5
6.2.3 Booster Pump Pressure Adjustment 6-7
6.2.4 Low Pressure System Protection 6-7
6.3 Maintenance Overview 6-8
6.3.1 Water Filter Service 6-9
6.3.2 Boost Pump 6-10
SECTION 7 HIGH PRESSURE WATER SYSTEM
7 High Pressure (HP) Water 7-1
7.1 Components 7-1
7.2 Intensifier Disassembly and Reassembly 7-2
7.2.1 HP & LP Water Piping 7-4
7.2.2 HP Cylinder 7-5
7.2.3 Hard Seal End Cap 7-7
7.2.4 HP Plunger Seal Service 7-8
7.2.5 Plunger and Hydraulic Cartridge 7-13
7.2.6 Hydraulic Cylinder Head and Piston 7-14
7.3 Intensifier Subassemblies Inspection & Repair 7-16
7.3.1 Discharge HP Check Valve 7-17
7.3.2 Inlet Check Valve 7-19
7.3.3 Sealing Head 7-21
7.3.4 HP Cylinder 7-22
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7.3.5 Plunger 7-23
7.3.6 Hydraulic Seal Cartridge 7-24
7.3.7 Hydraulic Piston 7-26
7.3.8 Hydraulic Cylinder 7-30
7.4 HP Dump Valve 7-31
7.5 HP Attenuator 7-31
SECTION 8 ELECTRICAL SYSTEM
8 Electrical System 8-1
8.1 Electrical Overview 8-1
8.1.1 Motor Starter Circuit 8-3
8.1.2 Control Circuits and Logic 8-4
8.1.3 Operation 8-6
8.1.4 Control Power Circuits 8-9
8.1.5 Proportional Pressure Control (Optional) 8-9
8.1.6 Modem (Optional) 8-9
8.2 Maintenance Overview 8-10
8.2.1 Proximity Switch Service 8-10
8.2.2 Optical Relay Switch Service 8-11
SECTION 9 HYDRAULIC SYSTEM
9 Hydraulic System 9-1
9.1 Features 9-1
9.1.1 Components 9-2
9.2 Operation 9-3
9.2.1 Hydraulic Pressure Adjustment 9-3
9.2.2 Hydraulic System Pressure Protection 9-4
9.3 Motor/ Hydraulic Service Maintenance 9-5
9.3.1 Motor Service 9-6
9.3.2 Manifold Service 9-6
SECTION 10 RECIRCULATION SYSTEM
10 Recirculation System 10-1
10.1 Components 10-1
10.2 Operation 10-3
10.3 System Pressure Protection 10-4
10.4 Maintenance Overview 10-5
SECTION 11 SPECIFICATIONS
11 Specifications 11-1
11.1 Equipment Specifications 11-1
11.2 Torque Specifications 11-3
11.3 Cutting Water Specifications 11-4
11.4 Cooling Water Specifications 11-5
11.5 Orifice Support Capacity 11-5
SECTION 12 PARTS LISTS
12 Parts Lists and Drawings
Electrical Schematic Diagram
Hydraulic Schematic Diagram
ACCESSORIES

SECTION 1
INTRODUCTION
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1SL-IV Waterjet Pump General Information
The Streamline SL-IV Waterjet Pump, maintains the level of component
reliability and ease of installation and maintenance that have made the
Streamline waterjet pumps the standard of the industry for both water and
Hydrobrasive™ applications.
The SL-IV Waterjet Pump uses low pressure water, which meets certain quality
requirements, and increases the pressure up to 4,136 bar (60,000 psi) for ultra-
high–pressure waterjet cutting, hydrobrasive cutting, cleaning, surface
preparation, etc.
This manual provides information for installation, operation, and maintenance
of the SL-IV Waterjet Pump.
Basic configurations of SL-IV intensifier pumps discussed in this manual are
listed in Table 1-1 below.
TABLE 1-1. Model Data- SL-IV Waterjet Intensifier Pumps
Motor
Horsepower
Rating
Plunger Quantity
and Diameter
(inches)
Hp Kw
Intensifier
Model HP Water
Max Oper
Pressure
(psi)
7/8
(0.875”)
[22 mm]
1-1/8
(1.125”)
[29 mm]
Frame
Dim “L”
(inches)
Redundant
Option
Available?
30 22 SL-IV 30+ 2 - 67.75 Yes
50 37 SL-IV 50+ 2 - 67.75 Yes
60 45 SL-IV 60+ 2 - 77.75 Yes
75 56 SL-IV 75+ - 2 77.75 Yes
100 75 SL-IV
100D
4 - 77.75 No
100 75 SL-IV 100S
60,000
- 2 77.75 Yes
1.1 Physical Description
The waterjet pump is equipped with one or two hydraulically operated
intensifiers, one or two liters of high pressure attenuator volume, a
motor/hydraulic pump assembly, an electric starter panel, control sensors,
solenoids and logic, control interface panel, a low pressure water booster pump,
and a low pressure water filter.
The high pressure system is conveniently mounted on a drip pan. All service
components are easily accessible from at least two sides simplifying
maintenance. The entire high pressure system can be removed from the rest of
the unit quickly for maintenance and serviceability.

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INTRODUCTION
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1.1.1 Standard Equipment
Following is an overview of the standard equipment for the SL-IV Waterjet
Pump:
•Variable displacement, pressure compensated hydraulic pump
•Water pressure booster and filtration system with 10-micron double-length
filter
•High efficiency heat exchanger in independent recirculation pump circuit
•Stand-alone unit with built-in motor starter (wye delta or across the line).
•High pressure safety dump valve
•Dual pressure compensator
•1 or 2 liters of high pressure attenuator volume
•Microprocessor control with diagnostic capability
•Water inlet shut-off valve
•Booster pump
•Integral water and oil drip pans
•Electrical remote control interface

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INTRODUCTION
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1.2 Functional Description
The SL-IV Waterjet Pump meets the automotive and industrial markets needs of
low to high volume production of water jet pumps. The maximum HP water
pressure is limited by a hydraulic relief valve that is factory certified and sealed.
No HP rupture disk is required.
HP water is produced by an intensifier consisting of two HP water cylinders
mounted to a hydraulic cylinder. Ceramic plungers (2 per intensifier) attach to
the hydraulic piston and extend into each HP cylinder. With two intensifiers
mounted on one SL-IV frame, both may operate simultaneously (dual) or one
may serve as stand-by for the other (redundant). Piston travel is sensed
electronically by proximity switches which control hydraulic flow to/from the
double-acting hydraulic piston/cylinder.
Refer to Table 1-2 for HP water performance limits for various power levels of
SL-IV waterjet pumps.
TABLE 1-2 HP WATER PERFORMANCE-
SL-IV WATERJET INTENSIFIER PUMPS
55,000 psi 60,000 psi
Horsepower Orifice Size
(inches)
Flow Rate
(gpm)
Orifice Size
(inches)
Flow Rate
(gpm)
30 0.011 0.60 0.010 0.52
50 0.014 0.98 0.013 0.88
60 0.015 1.12 0.014 1.02
75 0.017 1.44 0.016 1.33
100 0.020 2.00 0.019 1.88
The recirculation hydraulic loop for cooling and filtering oil runs continuously
whenever the motor is running.
1.2.1 Functional Features
Following is a list of SL-IV Waterjet Pump features:
•4,136 bar (60,000 psi) operating pressure
•Electronic reversing
•24 vdc safety control
•Standard high pressure water leak detection
•Standard dual pressure control facilitates hole piercing and kiss cut
applications
•Exclusive long slow stroke
•Cartridge type hydraulic seal
•Low pressure water booster pump and filtration
•Reduced cooling water requirements
•Choice of English, German, Spanish, Swedish and Italian readouts as
standard
•Meets CE requirements

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INTRODUCTION
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1.3 Worldwide Product Support
The KMT Waterjet Systems Service Department serves the customer, by
providing:
•Supervision of equipment installation, start up, and training for the number
of days specified in the quotation, and per approved project. Additional time
requested will be invoiced on a per diem basis, plus travel and normal living
expenses.
•Field Services: on-site technical support is available on request. These
services are invoiced on a per diem basis, plus travel, and normal living
expenses.
•Technical Assistance: the Service Department is available for technical
assistance by phone.
•Training: the Service Department conducts periodic training sessions at
KMT Waterjet designated training locations. On-site training is also
available.
1.3.1 Service Department
To contact the KMT Waterjet Service Department:
USA: Customer Service Manager Europe: Technical Manager
KMT Waterjet Systems KMT Waterjet Systems GmbH
P.O. Box 231 Wasserstrahl–Schneidetechnik
635 West 12th Street Auf der Laukert 11
Baxter Springs, KS 66713 D–61231 Bad Nauheim
USA Germany
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected] Email: [email protected]
1.3.2 Spare Parts
KMT Waterjet maintains a well stocked Spare Parts Department staffed by well
trained knowledgeable personnel. Emergency shipment is available.
Contact the Customer Service Department of KMT Waterjet.
1.3.3 Questionnaire
The following equipment and service manual questionnaire will provide
information to allow us to serve you better. Please complete them at your
convenience and return to the applicable Customer Service Department as
shown above.

SECTION 1
INTRODUCTION
Page 1-5 49831878
EQUIPMENT AND SERVICE MANUAL QUESTIONNAIRE
We have just installed a new SL-IV Waterjet Pump at your location. We are interested
in your initial impressions of the unit and its installation. Please take a few moments
and answer the following questions.
1. General Appearance
Was unit received in good condition?
Comments:
Yes No
2. Is the unit a convenient size?
Yes No
3. Controls
a. Are the controls user friendly?
b. Is the unit easy to operate?
Comments:
Yes
Yes
No
No
4. Performance
a. Does the unit perform smoothly and meet your expectations?
Does the unit run quietly?
Comments:
Yes
Yes
No
No
5. Did installation and start-up go smoothly?
Comments:
Yes No
6. What feature(s) do you consider the most significant with this unit?
Quiet Operation
Appearance
Performance (Operation)
Repair/Maintenance
Other
7. What areas need improvement?
Appearance
Servicability
Performance ________
Other

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INTRODUCTION
Page 1-6 49831878
Manual Organization
1. Does the table of contents help you find topics easily?
Comments:
Yes No
2. Is the information well organized?
Comments:
Yes No
3. Is the page layout suitable for the material being presented?
Comments:
Yes No
Graphics
1. How do you rate the quality and quantity of the photos/illustrations?
Comments:
Yes No
Text
1. Does the information in the manual adequately explain how to
operate and service the equipment?
Comments:
Yes No
2. Are there paragraphs or procedures you feel need clarification? Please
identify them by page number and add your comments.
Comments:
Yes No
3. Is there anything you would add or delete from the manual to make it
more useful?
Comments:
Yes No
4. Is there any information that should receive more emphasis?
Comments:
Yes No
Name: Title:
Company
Address:

SECTION 1
INTRODUCTION
Page 1-7 49831878
1.4 Safety
Safety procedures and safe practices must be followed during installation,
operation, and maintenance of the waterjet pump. In this section we have
provided label and sign descriptions used in this manual, as well as
recommended safety procedures.
1.4.1 Labels and Abbreviations
The following describes hazard classifications of the waterjet pump.
Indicates the presence of a hazard, which can cause
personal injury, or property damage if the caution
instruction is ignored.
Indicates the presence of a hazard, which can cause
severe personal injury, death, or substantial property
damage if the warning instruction is ignored.
(ISO 3021)
High pressure waterjet can cause eye injury. Wear eye
protection when operating or working near machine.
Hazardous noise can cause hearing loss.
Wear ear protection when operating or working near
machine.
(ISO 6010)
Hazardous voltage within can cause injury or death.
Disconnect and lockout main power before opening
cabinet.
Start/Control Power On
Stop
(ISO 1024)
Hot Surface inside. Do not touch.
(ISO 6060)
Do not operate with guard removed. Replace Guard
before operating machine.
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CAUTION
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INTRODUCTION
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Rear of Waterjet Pump
•HP Water "OUT"
•Plant Air "IN"
•Cooling Water "IN"
•Cooling Water "OUT"
•Cutting Water "IN"
•Drain

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INTRODUCTION
Page 1-9 49831878
1.4.2 Safety Procedures
Safety procedures must be observed while working on the pump, or any high
pressure part of the installation. Service should only be performed by
qualified personnel.
•The high pressure water, 4,136 bar (60,000 psi) in waterjet cutting systems
should not be a cause for concern. Users must have due respect for these
pressures and use proper SAFETY PROCEDURES and SAFE WORK HABITS.
•Everyone associated with the waterjet cutting system must realize that the
force of the waterjet cutting stream can penetrate many dense or strong
materials.
•Keep all untrained people away from the waterjet cutting area. Use barriers
or partitions if needed.
•Safety glasses must be worn at all times in the waterjet cutting area.
•All EMERGENCY STOP buttons must be checked periodically. The normal
operating position is pulled out.
•To check: turn on power and activate the EMERGENCY STOP buttons by
pushing them in to see if the power goes off. Each device should be checked
on a specified schedule. Each time the device is checked, it must function or
be replaced before operating the system.
•Apply High Purity Goop (P/N 10084440) to all threaded high pressure
connections. All tubing, fittings and bolted connections should be torqued to
recommended values. Do NOT attempt to tighten or loosen a HP water fitting
when the circuit is pressurized, see High Pressure (HP) Piping Safety.
•All high pressure leaks must be repaired immediately.
•Inspect all equipment on a scheduled basis.
•Before performing any maintenance on the unit, MECHANICALLY LOCK
THE MAIN CONTROL POWER OFF, and assure the high pressure has been
bled off.
•If steam or fog is noticed inside the clear top cover, this indicates a high
pressure leak. Turn off intensifier and bleed pressure before lifting the cover.
•Pressing the emergency stop button turns off the control power to the
intensifier, stops the intensifier pump, and bleeds high pressure water
through the dump valve. Depressurization of the high pressure system can
be heard when the dump valve opens as a loud hissing that fades quickly as
the pressure drops.

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INTRODUCTION
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Never do any work on the unit without making sure the
electrical panel disconnect is locked out with a padlock in
the OFF position.
Never work on any high pressure component, or loosen any
high pressure fittings without first bleeding the system and
assuring there is no high pressure water present.
Make sure the safety devices are operational. To panic stop
the pump and bleed the high pressure, the EMERGENCY
STOP buttons must be pushed in. The system pressure
dump valves must be open.
Do not attempt to touch or be exposed to high pressure
water. The high pressure water will penetrate all parts of
human body without exception.
The liquid stream or material ejected by these extreme
pressures can injure or kill.
Do not operate the intensifier with any of the covers opened
or removed.
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INTRODUCTION
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1.4.3 High Pressure (HP) Piping Safety
High pressure piping must be installed without torsional or bending stresses.
Proper supports and guides must be provided. 9/16” outside diameter HP
tubing and fittings are recommended between the pump and the cutting
station. This large tubing size will reduce vibration, strain and motion between
the pump piping and the cutting area. The larger piping diameter also reduces
pressure drop, and pressure pulsation.
Do not try to repair a leak in a HP water fitting when it is
pressurized. Always shut off the power and bleed the HP
water before doing maintenance on HP components. Weep
holes are provided to release HP water if leakage occurs at a
sealing surface. If a fitting is loosened with HP water
present, a jet of HP water will exit the nearest weep hole
with possible hazardous results.
Use extreme caution when handling high pressure
equipment. Possible failure from fatigue cracking or over-
pressurization can result in a hazardous high pressure
leak, or component failure.
A flexible ¼” HP tube (whip) is frequently used on the
cutting system to allow cutting nozzle movement. Supports
and guides for the whip must be used, anti-vibration
fittings and proper support must be provided to prevent
failures from external loads (non-water related stresses).
When tightening or loosening HP connections, always use a
supporting wrench to avoid bending forces or stress on the
connection. Do not exceed recommended torque values
High pressure piping and fittings designed to 4,100 bar
(60,000 psi) must always be used. Failure to do so may lead
to catastrophic component failure, which can cause
equipment damage, injury or even death.
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INTRODUCTION
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1.4.4 Emergency Medical Treatment
An information card to aid treating a waterjet injury is included in the binder of
each manual. The card is shown below. Contact the address shown for
additional cards.
(Front Side)
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.
KMT Waterjet Systems
P.O. box 231, 635 West. 12th Street
Baxter Springs, KS 66713
[phone]
(Back Side)
This person has been working with water jetting at pressures to
55,000 psi (374MPa, 3740 bar, 3867 Kg/cm2) with a jet velocity
of 3,000 fps (914 mps). Foreign material (sand) may have been
injected with water. Unusual infections with microaerophilic
organisms occurring at lower temperatures have been reported,
such as gram negative pathogens as are found in sewage.
Bacterial swabs and blood cultures may therefore be helpful.
This injury must be treated as an acute surgical emergency and
be evaluated by a qualified surgeon. Circulation may be
compromised, therefore, DO NOT APPLY HEAT TO
INJURED PART. For first aid: (1) Elevate injured part (2)
Antibiotics (3) Keep injured person NPO.

SECTION 2
INSTALLATION
Page 2-1 49831894
2Installation
The installation, start-up, operation, and maintenance of the SL-IV Waterjet
Pump requires complete reading and study of this manual to understand the
system in detail.
2.1 Installation Overview
•Read the manual and become familiar with the operation of each component
and its nomenclature.
•Understand the complete system and its function before operating it.
•Safety procedures and safe practices must be followed during installation,
operation, and maintenance of the SL-IV Waterjet Pump.

SECTION 2
INSTALLATION
Page 2-2 49831894
2.1.1 Buyer Obligations
Equipment installation requires cooperation between the user and KMT
Waterjet. If on-site support is requested, the KMT Waterjet Service Department
will require the following tasks be accomplished before arrival at the customer
site.
•The waterjet cutting equipment should be uncrated, positioned and leveled,
with electrical and fluid services brought to the unit.
•Provide and install power drops with fused disconnects sized to the
equipment power requirements.
•Provide and install pneumatic drops with manual shutoff valves.
•Provide all mounting and support brackets and hardware for high pressure
tubing runs.
•Provide and install water conditioning equipment necessary to meet water
purity requirements. Provide and install manual shutoff valves.
•Provide and install necessary cooling water inlet/outlet, and drain water
connections to the intensifier pump, and/or cutting equipment and manual
shut-off valves.
•Provide suitably located and sized drains and proper disposal of waste
water.
•Provide, install and connect wiring between the intensifier pumps, and the
cutting station control system.
•KMT Waterjet supplies a pre-filled hydraulic system. If fluid is low or empty
due to leakage during transit, the system must be filled per specifications.

SECTION 2
INSTALLATION
Page 2-3 49831894
2.1.2 Seller Obligations
If KMT Waterjet Service is requested, the following tasks will be the
responsibility of the KMT Waterjet technician at installation.
•Insure site preparation is satisfactory.
•Remove internal strapping and blocking material.
•Insure that power is connected prior to equipment turn on.
•Insure that connections have been made for water and pneumatic service.
•Test motor rotation direction and correct if necessary.
•Check and test electrical signal connections between intensifier pump and
cutting area.
•Power up and check out pump (and cutting station, if supplied by KMT
Waterjet for proper operation.
•Set boost pump discharge pressure.
•Install and test high pressure plumbing.
•Follow the standard test procedure to insure satisfactory performance.
•Train maintenance personnel in the performance of maintenance and repair
procedures.
•Sign off the installation and testing on KMT Waterjet's standard acceptance
document.