KTM TRILINE User manual

MANUAL 72183162(R01)
TRILINE™
DIRECT DRIVE PUMP
OPERATION AND MAINTENANCE MANUAL

72183261
8-2016/Rev 01
ORIGINAL INSTRUCTIONS
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 2016
KMT Waterjet Systems
635 West 12th Street
PO 231
Baxter Springs, KS 66713-0231
Phone:
Fax:
[phone]
[phone]

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TABLE OF CONTENTS
Title Page
Notice
Table of Contents
Appendix
Section Page
1Introduction............................................................................................................1-1
1.1 Overview................................................................................................1-1
Operational Overview............................................................................1-2
1.2 Product Nameplate.................................................................................1-4
1.3 Intended Use of Equipment ...................................................................1-4
1.4 Safety .....................................................................................................1-5
Safety Precautions..................................................................................1-5
Training..................................................................................................1-7
Personal Protective Equipment..............................................................1-7
Additional Precautions...........................................................................1-7
Lockout/Tagout Procedure.....................................................................1-8
Emergency Medical Treatment..............................................................1-8
1.5 Worldwide Product Support ..................................................................1-9
1.6 Spare Parts .............................................................................................1-9
2Installation..............................................................................................................2-1
2.1 Overview................................................................................................2-1
2.2 Installation Summary.............................................................................2-1
2.3 Installation Requirements ......................................................................2-2
Transporting...........................................................................................2-3
2.4 Power Requirements..............................................................................2-3
2.5 Service Connections...............................................................................2-4
Inlet Water Requirements......................................................................2-5
Drain ......................................................................................................2-5
Plant Air.................................................................................................2-6
2.6 High Pressure Piping..............................................................................2-6
Measurements and Dimensions .............................................................2-8
Power Coning.........................................................................................2-9
Power Threading....................................................................................2-9
2.7 High Pressure Connections....................................................................2-10
Standard Connections ............................................................................2-10
Anti-Vibration Connections...................................................................2-11
2.8 Commissioning......................................................................................2-12
2.9 Decommissioning ..................................................................................2-13

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3Maintenance ...........................................................................................................3-1
3.1 Overview................................................................................................3-1
3.2 Maintenance...........................................................................................3-1
Daily Inspection.....................................................................................3-1
Periodic Maintenance.............................................................................3-1
Mandatory Maintenance Schedule.........................................................3-3
High Pressure System Maintenance.......................................................3-5
3.3 Maintenance Precautions.......................................................................3-5
4Operation................................................................................................................4-1
4.1 Overview................................................................................................4-1
4.2 Preparing the Pump for Startup..............................................................4-2
4.3 Starting the Pump...................................................................................4-3
5Service Procedures.................................................................................................5-1
5.1 Overview................................................................................................5-1
5.2 Service and Maintenance Overview ......................................................5-2
Specialized Maintenance Tools .............................................................5-3
Mandatory Maintenance Schedule.........................................................5-3
5.3 High and Low Pressure Connections.....................................................5-4
5.4 Loading and Unloading the Tie Rods....................................................5-5
Unloading the Tie Rods.........................................................................5-6
Loading the Tie Rods.............................................................................5-8
5.5 Minor Maintenance Kit..........................................................................5-11
Lapping the Discharge Check Valve Body............................................5-15
Discharge Check Valve Assembly Installation......................................5-16
End Cap Assembly.................................................................................5-16
Plunger Torque Verification..................................................................5-17
Subplate Adapter Installation.................................................................5-17
Dynamic Seal Installation......................................................................5-17
High Pressure Cylinder Installation.......................................................5-19
Inlet Check Valve Assembly Installation ..............................................5-19
End Cap Installation...............................................................................5-20
Pressure Control Valve Maintenance.....................................................5-21
5.6 Major Maintenance Kit..........................................................................5-23
Discharge Check Valve Assembly Installation......................................5-27
End Cap Assembly.................................................................................5-28
Plunger Removal and Installation..........................................................5-28
Subplate Adapter Installation.................................................................5-29
Dynamic Seal Installation......................................................................5-29
High Pressure Cylinder Installation.......................................................5-30
Inlet Check Valve Assembly Installation ..............................................5-31
End Cap Installation...............................................................................5-32
Pressure Control Valve Maintenance.....................................................5-32
Replacing the Belts ................................................................................5-34
5-7 Pressure Control Valve Maintenance Kit ..............................................5-35

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5.8 Low Pressure Filter Maintenance ..........................................................5-39
5.9 Servicing the Crankcase.........................................................................5-40
Lubricating the Pump.............................................................................5-40
Tensioning and Aligning the Belt Drive................................................5-40
Replacing the Belts ................................................................................5-43
5-10 Pressure Loading Tool Maintenance Kit ...............................................5-43
Bleeding the Pressure Loading Tool......................................................5-46
6Troubleshooting .....................................................................................................6-1
6.1 Overview................................................................................................6-1
6.2 Troubleshooting Guide ..........................................................................6-2
Short Component Life............................................................................6-9
Troubleshooting Illustration...................................................................6-11
7Specifications..........................................................................................................7-1
7.1 Overview................................................................................................7-1
7.2 Installation Specifications......................................................................7-1
7.3 Pump Specifications...............................................................................7-2
Plant Air.................................................................................................7-2
7.4 Water Quality Standards........................................................................7-3
8Parts List.................................................................................................................8-1
8.1 Overview................................................................................................8-1
8.2 Index ......................................................................................................8-2
APPENDIX
Exhibit
Electrical Schematic
Material Safety Data Sheets

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SECTION 1
INTRODUCTION
1.1 Overview
The TRILINE™direct drive pump is a powerful, high pressure waterjet cutting tool designed for
minimum maintenance and reliable performance.
Table 1-1
TRILINE™Direct Drive Pump
Motor
Horsepower
Rating
Maximum Operating
Pressure
Water Volume
Maximum Single
Orifice Diameter
(at full pressure)
Motor
Speed
HP
Kw
30
22
55,000 psi (3,792 bar)*
0.84 gpm (3.18 L/min)
0.012” (0.30 mm)
720 rpm
*Note: Maximum pressure with cutting head valve open is 55,000 psi (3,792 bar). Maximum pressure
with cutting head valve closed is 60,000 psi (4,137 bar).
The pump is available in three configurations, with covers, without covers and free standing with
wall mounted electrical, display and filter assembly. All configurations feature single or dual
pressure operation.

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Introduction
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Operational Overview
Supply water is introduced through the 1/2-inch NPT connection on the bulkhead of the pump
and is routed to the normally closed solenoid valve.
When the pump is started, the solenoid valve opens and allows water to flow through the valve.
The inlet water pressure is displayed on the pre-filter pressure gauge on the control panel.
The water passes through the coarse filter assembly and is routed to the subplate to cool the high
pressure cylinders. When the water returns from the subplate, it passes through a fine filter and is
sent to the low pressure manifold.

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Introduction
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Water pressure can be observed on the post-filter pressure gauge on the control panel. Water
pressure is monitored by a 15 psi (1 bar) pressure switch on the low pressure manifold. If the
pressure falls below 15 psi (1 bar) the red indicator light on the control panel will illuminate
indicating low inlet water pressure.
From the manifold, supply water is sent to each of the end caps in the high pressure assembly.
The motor turns the crankcase causing the three plungers in the high pressure system to stroke.
On the inlet stroke, the plunger retracts
creating a low pressure area and allowing the
inlet poppet to open. Inlet water fills the high
pressure cylinder, forcing the discharge
poppet to close.
On the pressure stroke, the plunger extends
pressurizing and compressing the water. The
inlet poppet is forced to close, sealing the
passage. As the water is pushed through the
discharge check valve, the discharge poppet
opens. The water enters the end cap and is
routed to the high pressure manifold.

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Introduction
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High pressure water exits the high pressure manifold and is routed to the cutting head. The
pressure control valve regulates the outlet pressure. Excess pressure, above the requested
pressure, passes through the drain on the pressure control valve.
1.2 Product Nameplate
The product nameplate contains the pump model, serial, identification and part numbers for each
individual machine.
Figure 1-1: Product Nameplate
1.3 Intended Use of Equipment
The TRILINE™ pump has been designed solely for the generation of high pressure cutting water
for industrial and commercial applications in non-explosive atmospheres, such as cutting parts
from raw material on an x-y table.
The intended working liquid is potable water. The use of any other liquid should only be
considered after consulting with KMT Waterjet. Use of the pumps for hydrostatic testing
purposes should also only be considered after consulting with KMT.
The intended use further includes compliance with the operating, maintenance and repair
conditions prescribed by the manufacturer as detailed in this manual.
This machine is intended solely for the purpose described above. Use of
the machine for a different purpose or conversion of the machine
without the written agreement of the manufacturer shall not be
considered as intended use. The manufacturer shall not be liable for
damage incurred as a result in such cases. The risk shall be borne solely
by the owner.

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Introduction
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1.4 Safety
The high pressure waterjet cutting system is a high energy cutting tool capable of cutting many
dense or strong materials. Do not touch or be exposed to high pressure water. High pressure
water will penetrate all parts of the human body. The liquid stream and the material ejected by
the extreme pressure can result in severe injury.
Safety Precautions
The operator and service personnel shall pay particular attention to the safety precautions detailed
in Table 1-2.
Table 1-2
Safety Precautions
The electrical enclosure and motor junction box can present an
electrical shock hazard. Always disconnect and lockout the main
power before opening the enclosure.
Always disconnect and lockout the main power and the circuit
breaker/disconnect on the enclosure door before performing any type
of maintenance.
Never open or perform maintenance on the unit with the main power
disconnect on. Before any maintenance or repairs are performed, the
machine shall be isolated, and rendered inoperative.
The lockout/tagout procedure applies to any employee who operates
and/or performs service or maintenance on the machine.
The surface of high pressure water components become hot during
normal operation. Failed, or failing components, can become
extremely hot during operation.
High pressure water can remain in the system even when the pump has
been shut off. All pressure can be safely bled from the system by
opening the high pressure cutting water valve for a few seconds after
shutting off the pump.
Pressing the emergency stop button turns the control power to the
pump off, stops the pump and bleeds the high pressure water.

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Introduction
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Table 1-2
Safety Precautions
The work area around the equipment shall be clean and free of debris
and oil spills.
To reduce the likelihood of slip, trip and fall hazards, it is the
responsibility of the user of this equipment to clean up spills near the
pump.
All personnel involved in the installation, operation and/or service of
the pump must carefully read, understand and follow the procedures in
this manual to avoid creating unsafe conditions, risking damage to the
equipment, or personal injury.
The weight of the machine is not evenly distributed from one end to
the other. The machine can be safely lifted from either end or either
side.
When the machine is removed from the crate, note the position of the
fork pockets on the bottom of the machine. The pockets are positioned
in relationship to the center of gravity to balance the weight on the
pallet jack or forklift.
Safety precautions and warnings for specific procedures are emphasized throughout this manual
as illustrated in the following examples. These precautions must be reviewed and understood by
operating and maintenance personnel prior to installing, operating or servicing the machine.
Adherence to all Warnings, Cautions and Notes is essential to safe and efficient service and
operation.
Warnings emphasize operating or service procedures, or conditions that can result
in serious personal injury or death.

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Introduction
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Cautions emphasize operating or service procedures, or conditions that can result in
equipment damage or impairment of system operation.
Notes provide additional information that can expedite or improve operating or
service procedures.
Training
All personnel operating, servicing or working near the waterjet cutting equipment shall adhere to
all safety precautions described in this manual, as well as the applicable plant safety precautions.
Only KMT factory trained, qualified personnel shall service, maintain and operate the equipment.
Personal Protective Equipment
All maintenance and operating personnel shall practice and promote safety at all times to avoid
potential injury and unnecessary downtime. Maintenance procedures should be performed in a
well-ventilated area.
Any personnel in proximity of the equipment are to wear proper personal
protective equipment to include at a minimum, safety glasses with side shields
and hearing protection.
In addition to safety glasses with side shields, it is recommended that maintenance
personnel wear chemical resistant gloves.
Additional Precautions
Once the pump is integrated into a system (i.e. with an x-y table), a risk assessment must be
completed for the combined system to determine any additional hazards that require additional
guarding or protective devices.
A risk assessment in accordance with EN12100 is recommended. Isolation of personnel from the
cutting area, such as light curtains and/or warning beacons should be considered.

Section 1
Introduction
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Lockout/Tagout Procedure
This lockout/tagout procedure is designed to protect all employees from injuries
caused by the unexpected energizing or startup of the machine, or the release of
stored energy during service and maintenance.
This is accomplished with energy isolating devices that prevent the transmission or release of
energy. An energy source is any source of electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, or other energy source that could cause injury to personnel.
A lockout device utilizes a lock and key to hold an energy isolating device in the safe position
and prevents the machine from being energized. A tagout device is a prominent warning device
that can be securely attached to the machine warning personnel not to operate the energy isolating
device. This procedure requires the combination of a lockout device and a tagout device.
The lockout/tagout procedure applies to any employee who operates and/or performs service or
maintenance on the machine. Before any maintenance or repairs are performed, the machine
shall be isolated, and rendered inoperative as follows.
1. Shut down the machine by pressing the stop button, and open the high pressure cutting
water valve to bleed the water pressure from the system.
2. Disconnect, lockout and tag the main, customer supplied, power source.
3. Lockout and tag the circuit breaker/disconnect on the electrical enclosure door.
4. Close, lockout and tag the manual shutoff valves for the supply water and air service
connections.
Emergency Medical Treatment
An emergency medical card is included in the binder of this manual. This information should be
used to aid in the treatment of a waterjet injury. Additional cards may be obtained by contacting
KMT Waterjet Systems using the address or telephone number shown on the card.
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
635 West 12th Street
Baxter Springs, KS 66713
[phone]
This person has been working with water jetting
at pressures to 60,000 psi (374MPa, 4,137 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.

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Introduction
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1.5 Worldwide Product Support
The KMT Waterjet Customer Service Department is available to answer your questions regarding
equipment installation and service. Technical assistance is available by phone and on-site support
is available on request.
On-site technical assistance is available during equipment installation and startup. Additionally,
technical support for service and maintenance issues and training of operators and maintenance
personnel is available. Also; periodic training sessions are conducted at KMT Waterjet and
customer facilities.
Contact the KMT Waterjet Customer Service Department for additional information.
USA
Customer Service Department
Europe
Technical Manager
KMT Waterjet Systems
PO Box 231
635 West 12th Street
Baxter Springs, KS 66713
USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Email: [e-mail]
KMT Waterjet Systems GmbH
Hohe Strasse 4-6
D-61231 Bad Nauheim
Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
1.6 Spare Parts
KMT Waterjet maintains a well-stocked Spare Parts Department, staffed by trained,
knowledgeable personnel. If required, emergency shipment is available. Contact the Customer
Service Department to order spare parts, or for additional information.

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SECTION 2
INSTALLATION
2.1 Overview
This section details equipment installation, and commissioning
requirements and procedures. These procedures require a thorough
understanding of the individual components and systems, safety
issues, and the overall operation of the pump.
All personnel involved in the installation, operation and/or service of
the pump must carefully review this manual prior to installing and
commissioning the machine.
The Technical Service Department at KMT Waterjet Systems is available to assist in the
installation and commissioning process. Service and repair training for maintenance personnel is
also available.
2.2 Installation Summary
The following summary lists the procedures required for the installation and commissioning of
the pump. A discussion of the details and requirements for each item will follow in this section.
Upon receipt, the machine must be uncrated and moved into position on a level surface.
Properly sized power drops with fused disconnects must be installed.
A pneumatic drop with a manual shutoff valve and regulator for the air connection must
be installed.
Plumbing and a manual shutoff valve for the inlet supply water.
Incoming source water must meet specific water quality standards detailed in Section 7,
flow rates and pressure requirements. It may be necessary to install water conditioning
and/or pressure boosting equipment to meet these water purity and pressure requirements.
Drain water plumbing must be suitably located and installed for the proper disposal of
wastewater.
High pressure tubing runs from the pump to the cutting station are installed with the
appropriate mountings, support brackets and hardware.
Wiring must be installed and connected between the pump and the cutting station control
system.
The machine must be commissioned and tested.

Section 2
Installation
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2.3 Installation Requirements
The pump must be installed indoors where air borne dust and contaminants are minimal. The
ambient temperature should be between 45F (7C) and 104F (40C) to ensure proper
operation of the pump.
Water temperatures exceeding this range will result in seal life degradation. If seal
life becomes unacceptable, the addition of a chiller is recommended
Refer to Table 2-1, Equipment Dimensions and Weight, to establish a suitable installation site. A
minimum clearance of 39 inches (990 mm) is required on all sides of the machine to facilitate
service.
An anti-vibration mat is essential for the stability
of the pump and the reduction of pump vibration.
The pump should be centered on the mat with no
part of the pump touching the floor beneath. With
the mat placed flat on the floor, use a forklift to
lower the pump onto the center of the mat.
If a pallet jack is used to locate the pump, set the anti-
vibration mat in place and roll the pump over the mat
and into position. Properly positioning the pump
may require two people.
Do not trim the mat or bolt the pump to the floor through the mat material.

Section 2
Installation
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Figure 2-1: Equipment Dimensions
Table 2-1
Equipment Dimensions
Horsepower
Length (A)
Width (B)
Height (C)
Weight
30 HP
41.0” (1041 mm)
43.0” (1092 mm)
50.0” (1270 mm)
1125 lbs (510 Kg)
Transporting
The weight of the machine is not evenly distributed from one end to the other. The machine can
be safely lifted from either end or either side. Lifting from the front or rear with a pallet jack is
the best means of transport.
When the machine is removed from the crate, note the position of the fork pockets on the bottom
of the machine. The pockets are positioned in relationship to the center of gravity to balance the
weight on the pallet jack or forklift.
2.4 Power Requirements
Power supplied to the pump, including overload protection, and wiring for remote control must
comply with local, regional and national electrical codes. Service voltage and ampacity must
meet the requirements of the specific model. Voltage fluctuations in excess of +/- 10 percent of
nominal voltage may damage the machine and void the warranty.

Section 2
Installation
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Refer to the nameplate for machine specific ampacity and power voltage
requirements.
2.5 Service Connections
The pump requires an incoming water source, a drain line, a high pressure discharge line and an
air supply line.
Thoroughly purge all supply plumbing prior to connection to remove any residue
that could contaminate the system.
All service connections are made on the bulkhead of the machine as shown in Figure 2-2, Service
Connections. All piping must comply with local, regional and national codes.
Manual shutoff valves should be installed for the supply water and air connections. To facilitate
service, the valves should be located as close as practical to the interface connection.
Figure 2-2: Service Connections

Section 2
Installation
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Table 2-2
Service Connections
Connection
1
Supply water in
1/2” NPT
2
HP cutting water out
3/8” HP
3
Drain
1/2” NPT
4
Air in
1/4” NPT
Inlet Water Requirements
The supply water must meet the minimum water quality standards outlined in Section 7,
Specifications. Poor water quality will drastically shorten component life and void the warranty.
Supply water piping must be sized for 150% of the pump capacity and should match the intended
maximum duty cycle.
The inlet water must be maintained at a temperature between 55 and 70º F (12.7 and 21º C) for
proper pump performance. Premature component failure is common if water temperatures are
outside this range. Inlet water chillers should be used if the inlet water temperature is above this
range.
Only PVC, copper or rubber hoses should be used between the inlet water source and the
machine.
Drain
Cutting water is discharged from the pressure control valve through the drain port. The discharge
is considered wastewater and must be piped to an appropriate location, i.e. a sewer line.
High pressure plumbing is not required; however, piping must comply with local, regional and
national codes. The discharged water is extremely hot, with temperatures in excess of 150º F (66º
C).

Section 2
Installation
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To ensure the pressure control valve does not suffer damage due to siphoned
catcher tank water, connect the valve drain line directly to an outlet drain above the
water line, or suspend the line above the catcher tank water level.
Plant Air
The facility compressed air connection should provide clean, dry air between 90 and 120 psi (6.2
and 8.3 bar). The manual air regulator should be adjusted and set at the point where 55,000 psi
(3,792 bar) water pressure is achieved with the orifice installed and the nozzle open.
The following table provides specifications for each ISO air quality classification. KMT
recommends adherence to Quality Class 4.
Table 2-3
ISO Air Quality Classifications
ISO Quality
Class
Maximum
Particle Size
(microns)
Maximum Pressure
Dew Point
(water @ 100 psi)
Maximum Oil Content
(Mg/m3)
1
0.1
-94° F (-60° C)
0.01
2
1
-40° F (-40° C)
0.1
3
5
-4° F (-20° C)
1
4
15
+38° F (+3° C)
5
5
40
+45° F (+7° C)
25
6
--
+50° F (+10° C)
--
2.6 High Pressure Piping
High pressure piping is used to transport high pressure cutting water from the machine to the
cutting station. High pressure piping and fittings must be properly rated and sized. When
transporting high pressure water over long distances, tubing and fittings with an outside diameter
of 9/16-inch are recommended. The large tubing size reduces vibration, strain and motion; as
well as reducing pressure drop and pulsation.