KMT Streamline SL-IV Operation manual

STREAMLINE HIGH PRESSURE
WATERJET PUMP
OPERATION and SERVICE MANUAL
SL-IV 15hp HSEC
208/230
Manual No. 05139142
Printed: 12/09/03 05139134.doc

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
KMT Waterjet Systems
635 West 12th Street, P.O. Box 231
Baxter Springs, Kansas 66713
Tel. [phone]
Fax [phone]

i05132543
TABLE of CONTENTS
SECTION 1 INTRODUCTION
1 SL-IV 11kW (15 hp) Waterjet Pump General Information 1-1
1.1 Physical Description 1-2
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 1-4
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 2-1
2.1.2 Seller Obligations 2-1
2.2 Installation Requirements (Utilities) 2-2
2.2.1 Equipment Location/ Environment 2-2
2.2.2 Service Connections 2-3
2.2.3 Tools and Equipment 2-5
SECTION 3 OPERATION
3 Features 3-1
3.1 Operation Overview 3-1
3.2 Operator Console 3-2
3.2.1 Component Description 3-4
3.2.2 Operating Procedures 3-4
3.2.3 Remote Operation 3-4
3.3 Special Start-Up Procedures 3-5
3.3.1 Start-Up Following HP Maintenance 3-5
3.3.2 Initial Pump Start –Up Procedure 3-5
3.3.3 Pump Operation 3-7
3.3.4 Hydraulic Pump Pressure Compensator Adjustment Procedure 3-10
3.4 Shutdown Procedure 3-11
3.4.1 Normal Shutdown Procedure 3-11
3.4.2 Emergency Shutdown Procedure 3-11
3.4.3 Remote E-Stop Provisions 3-11
3.5 Fault Messages Overview 3-11
3.5.1 High Oil Temperature Shutdown 3-11
3.5.2 Low Oil Level Shutdown 3-12
SECTION 4 MAINTENANCE
4 Maintenance 4-1

TABLE OF CONTENTS
ii 05132543
4.1 Scheduled Maintenance 4-3
4.2 General Maintenance 4-3
SECTION 5 TROUBLESHOOTING
5 Troubleshooting 5-1
SECTION 6 LOW PRESSURE WATER SYSTEM
6 Features 6-1
6.1 Oil Cooling Water Supply 6-1
6.2 Cutting Water Supply 6-2
6.2.1 Normal Operating Condition 6-2
6.2.2 Operation 6-2
6.2.4 Low Pressure System Protection 6-3
6.3 Maintenance Overview 6-3
6.3.1 Water Filter Service 6-3
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 7-3
7.2.2 HP Sealing Head 7-4
7.2.3 HP Cylinder 7-6
7.2.4 Hydraulic Seal Cartridge & Plunger 7-8
7.2.5 Hydraulic Cylinder Head & Hydraulic Piston 7-10
7.3 Intensifier Subassemblies Inspection & Repair 7-12
7.3.1 Discharge HP Check Valve 7-13
7.3.2 Inlet Check Valve 7-15
7.3.3 Sealing Head 7-16
7.3.4 HP Cylinder 7-17
7.3.5 Plunger 7-18
7.3.6 Hydraulic Seal Cartridge 7-19
7.3.7 Hydraulic Piston 7-21
7.3.8 Hydraulic Cylinder 7-15
7.4 HP Dump Valve 7-26
7.5 HP Attenuator 7-26
SECTION 8 ELECTRICAL SYSTEM
8 Features 8-1
8.1 Electrical Overview 8-1
8.1.1 Motor Starter Circuit 8-1
8.1.2 Control Circuits and Logic 8-1
8.1.3 Operation 8-2
8.2 Maintenance Overview 8-4
8.2.1 Proximity Switch Service 8-4
SECTION 9 HYDRAULIC SYSTEM
9 Hydraulic System 9-1
9.1 Overview 9-1
9.1.1 Features 9-1
9.1.2 Components 9-2
9.2 Operation 9-3
9.2.1 Hydraulic Pressure Compensation 9-3
9.2.2 Hydraulic System Pressure Protection 9-3
9.2.3 Motor Startup 9-4

TABLE OF CONTENTS
iii 05132543
9.3 Motor/ Hydraulic Service Maintenance 9-4
9.3.1 Pump Compensator Adjustment 9-4
9.3.2 Pump /Motor Coupling Service 9-6
9.4 Pump Service 9-6
9.4.1 Pump Case Prefill 9-6
9.4.2 Seal Kits 9-6
SECTION 10 RECIRCULATION SYSTEM
10 Features 10-1
10.1 Components 10-1
10.2 Operation 10-1
10.3 System Pressure Protection 10-2
10.4 Maintenance Overview 10-3
SECTION 11 SPECIFICATIONS
11 Specifications 11-1
Equipment Specifications 11-1
Torque Specifications 11-3
Cutting Water Specifications 11-4
Cooling Water Specifications 11-4
Orifice Support Capacity 11-5
SECTION 12 PARTS LISTS 12-1
12 Parts Lists
Hydraulic Schematic Diagram
Electrical Schematic Diagram

SECTION 1
INTRODUCTION
July 2003 1-1 05130661
Section 1 INTRODUCTION
1SL-IV 11 kW (15 hp) Waterjet Pump General Information
The Streamline SL-IV 11 kW (15 hp) Waterjet Pump, maintains the level of
component reliability and ease of installation and maintenance that have made
the KMT Waterjet Streamline waterjet pumps the standard of the industry for
both water and Hydrobrasive™ applications.
The SL-IV 11 kW (15 hp) Waterjet Pump uses low pressure water, which meets
certain quality requirements, and increases the pressure up to 3,800 bar
(55,000 psi) for ultra-high–pressure waterjet cutting, hydrobrasive cutting,
cleaning, surface preparation, etc.
This manual provides information for installation, operation, and maintenance
of the KMT Waterjet SL-IV 11 kW (15 hp) Waterjet Pump.
1.1 Physical Description
The SL-IV waterjet pump is equipped with a hydraulic intensifier, a high
pressure attenuator, a motor/hydraulic pump assembly, an electric starter
panel, control sensors, solenoids and logic, control interface panel, and a low
pressure water filter.

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INTRODUCTION
July 2003 1-2 05130661
Dimension
Letter mm inch
G 140 5.50
H 203 8.00
J 267 10.50
K 419 16.50
L 400 15.75
M 483 19.00
N 554 21.82
P 33 1.31
R 832 32.78
S 1422 56.00
T 711 28.00

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INTRODUCTION
July 2003 1-3 05130661
The SL-IV11kW (15hp) Waterjet pump is enclosed in a frame with the
dimensions of 56” length, 28” width, and 32.8” height. 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.
1.1.1 Standard Equipment
Following is an overview of the standard equipment for the SL-IV 11 kW (15 hp)
waterjet Pump:
•Variable displacement, pressure compensated hydraulic pump
•Filtration system with 10-micron filter
•High efficiency heat exchanger in independent recirculation pump circuit
•Stand-alone unit with built-in Wye-Delta motor starter
•High pressure safety dump valve
•High pressure attenuator
•Microprocessor control with diagnostic capability
•Separate water and oil drip pans
•Electrical remote control interface

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INTRODUCTION
July 2003 1-4 05130661
1.2 Functional Description
The SL-IV 11 kW (15 hp) 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
certified and sealed by TUV. No HP rupture disk is required.
The HP intensifier is a reciprocating, double-ended hydraulic operated,
electrically shifted hydraulic piston type. The HP intensifier produces water
flow at high pressure, while the HP attenuator reduces the routine fluctuations
in the HP water pressure signal. The compression ratio is 20:1 with a
maximum hydraulic pressure set at 214 bar (3,100 psi).
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 11 kW (15 hp) Waterjet Pump features:
•4,150 bar (60,000 psi) design pressure
•3,800 bar (55,000 psi) operating pressure
•Electronic reversing of intensifier piston
•24vdc control wiring
•Exclusive long slow stroke
•Cartridge type hydraulic seal for easy plunger service
•Low pressure filtration
•Reduced cooling water requirements
•Meets CE requirements

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INTRODUCTION
July 2003 1-5 05130661
1.3 Worldwide Product Support
The KMT Waterjet 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:Service Manager Europe:Technical Manager
KMT KMT Waterjet GmbH
Waterjet Systems 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]
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 Service Department of KMT Waterjet Systems.
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 Service Department as shown above.

SECTION 1
INTRODUCTION
July 2003 1-6 05130661
EQUIPMENT AND SERVICE MANUAL QUESTIONNAIRE
We have just installed a new SL-IV 11 kW (15 hp) 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.
General Appearance
Was unit received in good condition?
Comments: _________________________________________________________
Yes No
Is the unit a convenient size? Yes No
1. Controls
a. Are the controls user friendly?
b. Is the unit easy to operate?
Comments:
Yes
Yes
No
No
2. Performance
a. Does the unit perform smoothly and meet your expectations?
b. Does the unit run quietly?
Comments:
Yes
Yes
No
No
3. Did installation and start-up go smoothly?
Comments:
Yes No
4. What feature(s) do you consider the most significant with this unit?
Quiet Operation
Appearance
Performance (Operation)
Repair/Maintenance
Other
5. What areas need improvement?
Appearance
Servicability
Performance _________
Other

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INTRODUCTION
July 2003 1-7 05130661
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
July 2003 1-8 05130661
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.
CAUTION
Indicates the presence of a hazard that can cause
personal injury, or property damage if the caution
instruction is ignored.
WARNING
Indicates the presence of a hazard that can cause severe
personal injury, death, or substantial property damage
if the warning instruction is ignored.
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.
Hazardous voltage within can cause injury or death.
Disconnect and lockout main power before opening
cabinet.
!Malfunction
Hydraulic Intensifiers
Pressure Control
High Pressure
Low Pressure
Start/Control Power On
Stop
Run
Local/Remote Control

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INTRODUCTION
July 2003 1-9 05130661
Rear of Waterjet Pump
A HP Water "OUT"
B Plant Air "IN"
C Cooling Water "IN"
D Cooling Water "OUT
E " Cutting Water "IN"
F Drain
The following figure shows other safety labels or icons used on the SL-IV waterjet
pump. Trapped HP water or oil warning warns against the hazard of trapped HP
water or hydraulic pressure after the pump has been shut off. Typically all
pressure can be safely bled off if the operator will leave the HP cutting water valve
open for a few seconds after shutting off the pump.
Electrical shock hazard warns of electrical shock hazard when in the vicinity of the
electrical enclosure or motor junction box. Hot surface warning warns of hot
surfaces on the HP water and hydraulic components while the pump is in normal
operation.

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INTRODUCTION
July 2003 1-10 05130661
WARNING
Pumping System can remain
pressurised when pump is not
operating. Can cause injury or
death.
Disconnect pump power
source and depressurise
system before servicing
Figure 1-1. Other Safety Labels & Icons Used on the SL-IV Waterjet Pump
(a)Trapped HP Water or
Hydraulic Oil
(b) Electrical Shock Hazard (c) Hot Surface Warning
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, 3,800 bar (55,000 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.

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INTRODUCTION
July 2003 1-11 05130661
•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.
WARNING
Never do any work on the unit without making sure the
electrical panel disconnect is locked out with a padlock
in the OFF position, and that the proper tagout
procedure has been implemented.
WARNING
Never work on any high-pressure component, or loosen
any high-pressure fitting without first bleeding the
system and assuring there is no high-pressure water
present.
WARNING
Make sure the safety devices are operational. To panic
stop the pump and bleed the high-pressure, an
EMERGENCY STOP button must be pushed in while the
system is active. The intensifier high-pressure dump
valve will automatically open to bleed off the stored
pressure.
WARNING
Do not attempt to touch the waterjet stream, or contact
the high-pressure water. The high-pressure water will
penetrate all parts of human body without exception.
WARNING
The liquid stream or material ejected by these extreme
pressures can injure or kill.

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INTRODUCTION
July 2003 1-12 05130661
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.
WARNING
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.
WARNING
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.
WARNING
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). The whip will only flex in a single
plane without being subjected to torsional stress.
Torsional flexing will precipitate tubing failure. To
prevent torsional stress, the use of high-pressure
swivels is strongly recommended. To prolong swivel life
the whip must pass through rigid support bearing
blocks to prevent side-loading of the swivel spindle.
WARNING
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
WARNING
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
July 2003 1-13 05130661
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.
Medical Alert
“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
July 2003 2-1 05130661
Section 2 EQUIPMENT INSTALLATION
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.
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.

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INSTALLATION
July 2003 2-2 05130661
2.1.2 Seller Obligations
If KMT Waterjet 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.
•Power up and check out pump for proper operation.
•Set booster pump discharge pressure.
•Perform Leak check on high pressure plumbing.
•Follow the standard test procedure to insure satisfactory performance.
•Train maintenance personnel in the performance of maintenance and repair
procedures.
2.2 Installation Requirements (Utilities)
Environment: The SL-IV Waterjet Pump must be installed indoors.
Ambient conditions must not exceed maximum
specifications.
Moving: The SL-IV Waterjet Pump has provisions to be moved
with a forklift. Check weight specifications.
CAUTION
The waterjet pump is top heavy. Avoid situations that
could result in the equipment tipping or overturning.
WARNING
Electrical connections must be made by qualified
personnel, and must meet national and local electrical
codes.
2.2.1 Equipment Location/Environment
Space Requirements:
There should be a minimum of 900mm (36 inches) clearance on all sides
of the pump to facilitate service.
Electrical Wiring:
Power supplied to the pump must be in accordance with national and
local electrical codes. See specifications or requirements.
Insure that the service voltage and ampacity are proper for this SL-IV Pump.
Voltage fluctuations in excess of +/- ten percent of nominal voltage may
damage the SL-IV Pump. Refer to Section 11, “Specifications”.