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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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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11-2004/Rev 0 iii
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

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11-2004/Rev 0 iv
Pneumatic Actuator...............................................................................9-34
9.15 Weep Holes...........................................................................................9-35
10 Troubleshooting ...............................................................................................10-1
10.1 Overview...............................................................................................10-1
10.2 Troubleshooting Guide .........................................................................10-2
11 Specifications....................................................................................................11-1
11.1 Overview...............................................................................................11-1
11.2 Installation Specifications.....................................................................11-1
Environment..........................................................................................11-1
Sound Level..........................................................................................11-1
Equipment Dimensions and Weights....................................................11-2
Service Connections..............................................................................11-2
11.3 Water Specifications.............................................................................11-2
Cutting Water Supply ...........................................................................11-2
Recirculation System ............................................................................11-3
Water Quality Standards.......................................................................11-3
11.4 Electrical Specifications........................................................................11-6
Electrical System ..................................................................................11-6
Ampacity and Power Voltage Requirements........................................11-6
11.5 Hydraulic and High Pressure System Specifications............................11-6
Hydraulic System..................................................................................11-6
High Pressure Water System ................................................................11-7
Orifice Capacity....................................................................................11-7
Torque Specifications ...........................................................................11-9
12 Parts List...........................................................................................................12-1
12.1 Overview...............................................................................................12-1
12.2 Part Nomenclature ................................................................................12-2
12.3 Index .....................................................................................................12-3
APPENDIX
Exhibit
System Schematic
Electrical Schematic
Material Safety Data Sheets

SECTION 1
INTRODUCTION
Page 1-1 49831878
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.

SECTION 1
INTRODUCTION
Page 1-2 49831878
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

SECTION 1
INTRODUCTION
Page 1-3 49831878
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

SECTION 1
INTRODUCTION
Page 1-4 49831878
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: [e-mail]
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.