KTM STREAMLINE L-IV 50 Operation manual

Printed: 12/02/04 80081573.doc
STREAMLINE HIGH PRESSURE
WATERJET PUMP
OPERATION and SERVICE MANUAL
SL-IV 50
HSEC
230V
Manual No. 80082837

20417320
11-2004/Rev 0
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 2004
KMT Waterjet Systems
635 West 12th Street
POB 231
Baxter Springs, KS 66713-0231
Phone:
Fax: [phone] [phone]

20417320
11-2004/Rev 0 i
TABLE OF CONTENTS
Title Page
Notice
Table of Contents
Appendix
Section Page
1Introduction......................................................................................................1-1
1.1 Overview...............................................................................................1-1
1.2 Performance Features and Options.......................................................1-1
1.3 Product Nameplate................................................................................1-2
1.4 Operational Overview...........................................................................1-2
Low Pressure Water System.................................................................1-2
Recirculation System ............................................................................1-3
Hydraulic System..................................................................................1-3
High Pressure Water System ................................................................1-3
Operating System..................................................................................1-4
1.5 Safety ....................................................................................................1-5
Lockout/Tagout Procedure....................................................................1-5
Warning Labels.....................................................................................1-6
Emergency Medical Treatment.............................................................1-8
1.6 Worldwide Product Support .................................................................1-9
1.7 Spare Parts ............................................................................................1-9
1.8 Manual Organization ............................................................................1-9
1.9 Equipment and Service Manual Questionnaire.....................................1-10
2Installation........................................................................................................2-1
2.1 Overview...............................................................................................2-1
2.2 Installation Summary............................................................................2-1
2.3 Site Requirements.................................................................................2-2
Transporting..........................................................................................2-3
2.4 Power Requirements.............................................................................2-3
2.5 Service Connections..............................................................................2-4
Cooling Water.......................................................................................2-5
Cutting Water........................................................................................2-6
Drain .....................................................................................................2-6
Plant Air................................................................................................2-6
2.6 Flow Requirements...............................................................................2-6
2.7 High Pressure Piping.............................................................................2-7
Measurements and Dimensions ............................................................2-9
Hand Coning.........................................................................................2-10
Power Coning........................................................................................2-11
Hand Threading ....................................................................................2-12

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11-2004/Rev 0 ii
Power Threading...................................................................................2-12
2.8 High Pressure Connections...................................................................2-13
Standard Connections ...........................................................................2-13
Anti-Vibration Connections..................................................................2-14
2.9 Commissioning.....................................................................................2-15
2.10 Decommissioning .................................................................................2-18
3Maintenance .....................................................................................................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
4Operation..........................................................................................................4-1
4.1 Overview...............................................................................................4-1
4.2 Startup Sequence...................................................................................4-1
Startup after Motor Stop .......................................................................4-1
Startup after Emergency Stop...............................................................4-1
4.3 Main Menu............................................................................................4-2
4.4 Run Screen............................................................................................4-2
4.5 Run Screen Alarms...............................................................................4-3
4.6 Alarm Banners......................................................................................4-5
4.7 Alarm History .......................................................................................4-7
Changing the Date and Time ................................................................4-7
4.8 Set-Up Screen .......................................................................................4-8
4.9 Stroke Rate Screen................................................................................4-8
4.10 Hours Screen.........................................................................................4-9
4.11 Maintenance Screen..............................................................................4-10
4.12 Language Screen...................................................................................4-11
5Low 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 System Options.....................................................................................5-2
Operation with Optional Booster Pump and Water Filter ....................5-2
5.5 Service and Maintenance Procedures ...................................................5-4
Filter Assembly and Strainer Maintenance...........................................5-4
Booster Pump Adjustment....................................................................5-5
6Recirculation System .......................................................................................6-1
6.1 Overview...............................................................................................6-1
6.2 Operation...............................................................................................6-2
6.3 Service and Maintenance Procedures ...................................................6-3
Hydraulic Oil Maintenance...................................................................6-3
Oil Filter Maintenance..........................................................................6-6
Operating Temperature Adjustment .....................................................6-6

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7Hydraulic System.............................................................................................7-1
7.1 Overview...............................................................................................7-1
7.2 Operation...............................................................................................7-2
7.3 Service and Maintenance Procedures ...................................................7-3
Hydraulic Operating Pressure...............................................................7-4
Motor Maintenance...............................................................................7-5
Flexible Coupling Replacement............................................................7-6
Hydraulic Compensator Maintenance...................................................7-8
Hydraulic Pump or Electric Motor Replacement..................................7-11
8Electrical System..............................................................................................8-1
8.1 Overview...............................................................................................8-1
8.2 Operation...............................................................................................8-1
Sensors and Solenoids...........................................................................8-4
8.3 Service and Maintenance Procedures ...................................................8-8
Proximity Switch Maintenance.............................................................8-8
Optical Relay Maintenance...................................................................8-9
9High Pressure Water System ..........................................................................9-1
9.1 Overview...............................................................................................9-1
9.2 Operation...............................................................................................9-2
9.3 System Components..............................................................................9-4
9.4 Service and Maintenance Overview .....................................................9-5
Torque Specifications ...........................................................................9-6
Specialized Maintenance Tools ............................................................9-8
9.5 High and Low Pressure Water Piping...................................................9-9
9.6 High Pressure Cylinder Assembly........................................................9-9
High Pressure Cylinder Assembly Removal.........................................9-10
High Pressure Cylinder Assembly Installation.....................................9-12
High Pressure Cylinder Maintenance ...................................................9-13
9.7 Hard Seal End Caps ..............................................................................9-13
Hard Seal End Cap Removal ................................................................9-13
Hard Seal End Cap Installation.............................................................9-14
9.8 Sealing Head.........................................................................................9-15
High Pressure Discharge Check Valve.................................................9-15
Low Pressure Inlet Check Valve...........................................................9-17
Sealing Head Maintenance ...................................................................9-18
9.9 High Pressure Seal Assembly...............................................................9-19
9.10 Hydraulic Cartridge Seal Replacement.................................................9-21
Hydraulic Cartridge Seal.......................................................................9-22
9.11 Hydraulic Piston and Plungers..............................................................9-24
Hydraulic Piston and Plunger Removal................................................9-25
Bearing Rings and Seal Assembly........................................................9-26
Plunger Maintenance ............................................................................9-27
Hydraulic Piston and Plunger Installation ............................................9-28
9.12 Hydraulic Cylinder Maintenance..........................................................9-29
9.13 High Pressure Attenuator......................................................................9-29
9.14 High Pressure Dump Valve ..................................................................9-29
Pneumatic Control Valve......................................................................9-31