Omax JetMachining Center 2626 Manual

The OMAX
JetMachining®Center
Operator’s Guide
OMAX Corporation Information: 253.872.2300
21409 72nd Avenue South Fax: [phone]
Kent, WA USA 98032 Technical Support: 800.298.4036
Web: http: //www.omax.com
E-mail: [email protected]

OMAX JetMachining® Center Operator’s Guide
ii 400433D-EN
This document contains subject matter to which OMAX Corporation has proprietary rights. Recipients of this
document shall not duplicate, use, or disclose information contained herein, in whole or in part, for any use
other than the purpose for which this manual was provided.
OMAX Corporation believes the information described in this manual is accurate and reliable. From time to
time, design improvements will be made to the JetMachining Center. Photographs, text, and sketches within
the body of this manual may not exactly represent your equipment. In general, this manual contains the most
up-to-date information available. However, OMAX Corporation 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 or additions.
OMAX strives to continually improve their user documentation. If you have any questions or concerns about
the content of this operator’s guide, we want to hear from you. Please email us at [e-mail]
or contact us by mail at:
OMAX Corporation
Technical Publications
21409 72nd Avenue South
Kent, WA, USA 98032
OMAX Corporation is continually improving the OMAX JetMachining® System to bring you the best in
abrasivejet machining technology. For that reason, your OMAX JetMachining System may differ slightly from
what is described in this document. If you have any questions, please feel free to contact us at
1 800-838-0343 or at email [email protected].
You can also receive technical support on-line at: http://www.omax.com/support (user name and password
required for access)
OMAX®, MAXJET® 5, Intelli-MAX®, Tilt-A-Jet®, MAXJET4®, and JetMachining®are registered trademarks of
OMAX Corporation.
Intelli-TRACETM is a trademark of OMAX Corporation.
Windows®is a registered trademark of Microsoft Corporation.
The OMAX Machine tool apparatus and linear motion track are covered by U.S. patent number 5,472,367.
Other patents pending.
The OMAX motion control with precompilation is covered by U.S. patent number 5,508,596.
January 2009
© 2009 OMAX Corporation

OMAX JetMachining® Center Operator’s Guide
400433D-EN iii
About this Manual
Purpose
This manual describes the OMAX®JetMachining®Center and provides instructions for the care and safe
operation of OMAX Models 2626, 2626xp, 2652, 5555, 55100, 80160, 60120, and 80X.
Audience
This manual assumes the reader has a basic understanding of the Windows operating system, can perform
simple computer operations such as launching programs, copying and moving files, etc., and has
participated in the operator training classes provided by OMAX as part of the original equipment purchase
and installation.
Supporting Documentation
In addition to this operator’s manual, the following documentation is included with your OMAX equipment:
• The OMAX JetMachining Center Service and Maintenance Guide
• Computer Manuals
• Pump Rebuild DVD
• Nozzle Rebuild DVD
Organization
This operator’s guide for the OMAX JetMachining Center provides the following information:
Chapter 1: Safety First
• Identifies equipment labels designed to support safe equipment operation, shows their location on
the equipment, and explains their meaning.
• Lists important safety “do’s and don’ts” to follow that are essential in ensuring safe equipment
operation.
• Explains the safety devices built into the OMAX equipment.
• Safety checklist form.
Chapter 2: Introduction
• Identifies the major components of the JetMachining Center and breaks each down into their
individual pieces, providing names and descriptions.
• Shows the location and explains operator control devices.
• Lists accessories currently available for your JetMachining Center.
Chapter 3: Operation
• Explains how the pump and abrasivejet system work.
• Provides instructions on starting and stopping the system, including an emergency shut-down.
• Discusses the JetMachining software.
• Explains important tasks performed in the material cutting process.
• Lists tips for effective use of your equipment.
• Provides procedures that cover the entire cutting process from equipment power-up to power-down
Note: This manual does not provide detailed information on the operation of the OMAX software, Make and
Layout. For instructions on using this software, refer to the OMAX Interactive Reference (the software help
screens), and the online training videos (http://www.omax.com/support/customers/videos.asp).
Chapter 4: Maintenance
• Lists maintenance requirements for the pump and JetMachining Center.
• Explains routine operator maintenance activities.
• Provides procedures for troubleshooting equipment problems.
• Provides nozzle repair/rebuild instructions.

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• Lists replaceable items normally consumed during equipment operation.
• Contains maintenance information for the pump dump valve.
Chapter 5: Customer Support
• Provides OMAX customer support contact information.
• Explains how to order and return parts for your JetMachining Center.
Chapter 6: OMAX Glossary
• Definitions of terms specific to OMAX and the waterjet industry.

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Contents
Page
About this Manual.......................................................................................iii
Purpose .............................................................................................................................. iii
Audience............................................................................................................................. iii
Supporting Documentation................................................................................................. iii
Organization ....................................................................................................................... iii
Contents.......................................................................................................v
Figures.........................................................................................................ix
Chapter 1
Safety First
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Placement of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Table Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Pump Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Equipment Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
OMAX JetMachining Center Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Chapter 2
Introduction
OMAX High-pressure Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Pump Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Front and Right Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Control Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Front View With Front Panel Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Top View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Side View with End Panel Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
OMAX JetMachining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Major Components of the JetMachining Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
PC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Control Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
X-Y Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Accessories for the OMAX JetMachining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Tilt-A-Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Precision Optical Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Waterjet Brick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
MaxJet® 5 MiniJet Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Solids Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
Drill Head Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Closed Loop Water Recycling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Terrain Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
Chapter 3
Operation
Operating the High-Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Starting the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Stopping the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Emergency Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Setting the Pump RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Pump Operating Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
OMAX JetMachining Center Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
About Abrasivejet Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
The OMAX Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
OMAX Layout Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
OMAX Make Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
OMAX Interactive Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Drawing the Part Using Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Setting the Tool Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Making the Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Determining Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Clamping and Positioning Materials for Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6

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Using Tabs for Holding Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Ensuring Clean and Quiet Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Keep the Abrasivejet Nozzle Under Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Place a Muff on the Abrasivejet Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Keep Extra Sponges on Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Washing Heavy Garnet Deposits from Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Tips for Effective Cutting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Setting Soft Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Auto Homing Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Operating the JetMachining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Configuring Your Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Cutting Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
Setting Up the Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
Configuring the Make Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 19
Cutting the Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20
Shutting Down the JetMachining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
Startup Checkoff Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
Shutdown Checkoff Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Chapter 4
Maintenance
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Main Electric Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Changing Crankcase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Routine Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Less Frequent Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
JetMachining Center Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Table Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Rebuilding the Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Nozzle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Identifying When to Repair and Rebuild the Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Preparing for Nozzle Repair/rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Removing a MaxJet® 5 Nozzle Assembly from a Tilt-A-Jet. . . . . . . . . . . . . . . . . . . . 4 - 5
Removing the Nozzle Mixing Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Removing the Nozzle Body from the Inlet Body . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Removing the Filter Seal Assembly from the Inlet Body. . . . . . . . . . . . . . . . . . . 4 - 7
Removing the Orifice Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Removing the Mixing Chamber Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Removing the Mixing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Removing the Nozzle Body O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Cleaning and Inspecting Nozzle Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Reassembling the Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Nozzle Filter Seal Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Mixing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Mixing Chamber Disc and Orifice Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Mixing Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Nozzle Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Maximizing Nozzle Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Removing and Reinstalling the Inlet Body on a Tilt-A-Jet. . . . . . . . . . . . . . . . . . . . . . 4 - 22
Removing a Stuck Inlet Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Cleaning the Inlet Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
Reinstalling the Inlet Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Removing and Reinstalling a Mini-MaxJet 5 Nozzle Assembly . . . . . . . . . . . . . . . . . 4 - 28
Disassembling a MiniJet Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Step 2: Remove the MiniJet Nozzle Body from the Inlet Body Extension . . . . . 4 - 29
Step 3: Remove the Inlet Body Extension from the Inlet Body. . . . . . . . . . . . . . 4 - 29
Step 4: Remove the MiniJet Dummy Orifice from the Inlet Body . . . . . . . . . . . . 4 - 30
Step 9: Remove Ring Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
Reassembling the MiniJet Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
Mini-Maxjet 5 Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 33
Installing the Mini-Maxjet 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 33
Operating the Mini-MAXJET 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 33
Dump Orifice Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 34
Setting the Adjustable Dump Orifice (ADO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35
Changing the Dump Valve Orifice Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 39
Disassemble the Dump Valve and Removing the Orifice Assembly . . . . . . . . . 4 - 39
Reassembling the Dump Valve With Replacement Orifice Assembly . . . . . . . . 4 - 42
Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 43

OMAX JetMachining® Center Operator’s Guide
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Troubleshooting the OMAX Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Display Screen Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Normal Operation Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Pump Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Possible Pump Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Fault Message, “Charge Pressure Low”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
Fault Message, “Charging Pump Contactor” . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45
Fault Message, “Dead Head” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45
Fault Message “Variable Drive Fault”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45
Low Pump Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 46
No Power at the Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 46
Pump Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 46
No Keypad Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 47
Troubleshooting the OMAX JetMachining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48
Machine Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48
Machining Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48
Software Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 52
Nozzle and Abrasive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 53
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 54
Positioning Accuracy Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 55
Consumable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 57
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 59
Training Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 60
Chapter 5
Customer Support
Contacting OMAX Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Returning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Returned Material Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Parts Ordered in Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Unused Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Parts Shipped in Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Parts Returned for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Parts Returned for Warranty Repair or Replacement. . . . . . . . . . . . . . . . . . . . . 5 - 3
Two-year Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Chapter 6
OMAX Glossary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
Index.............................................................................................................Index - 1

OMAX JetMachining® Center Operator’s Guide
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OMAX JetMachining® Center Operator’s Guide
400433D-EN ix
Figures
Page
Figure 1-1: Safety Labels for the OMAX Models 2626, 2626|xp, 2652, 5555, and 55100............................ 1-3
Figure 1-2: Safety Labels for the OMAX 80160............................................................................................. 1-3
Figure 1-3: Safety Labels for the OMAX 60120............................................................................................. 1-4
Figure 1-4: Safety Labels for the OMAX 80X................................................................................................ 1-4
Figure 1-5: Safety Labels for the OMAX High-pressure Pump...................................................................... 1-5
Figure 1-6: Sound Level Map of OMAX JetMachining Center...................................................................... 1-7
Figure 2-1: OMAX High-Pressure Water Pump............................................................................................. 2-1
Figure 2-2: OMAX Variable Speed High-Pressure Pump Front View........................................................... 2-2
Figure 2-3: Pump Control Panel Components................................................................................................. 2-2
Figure 2-4: Front Panel Keypad and Display Screen ...................................................................................... 2-3
Figure 2-5: Pump Control Switches ................................................................................................................ 2-4
Figure 2-6: Pump with Top Lid Open and Front Panel Removed................................................................... 2-5
Figure 2-7: Pump Top View with Lid Open.................................................................................................... 2-6
Figure 2-8: Pump Internal Components on Right Side ................................................................................... 2-6
Figure 2-9: OMAX 80160 JetMachining Center............................................................................................. 2-7
Figure 2-10: The Model 55100 OMAX JetMachining® Center..................................................................... 2-8
Figure 2-11: The JetMachining Center PC Controller .................................................................................... 2-8
Figure 2-12: Control Panel Operator Switches................................................................................................ 2-9
Figure 2-13: The OMAX 80X JetMachining Center..................................................................................... 2-10
Figure 2-14: OMAX Tilt-A-Jet ..................................................................................................................... 2-10
Figure 2-15: OMAX Precision Optical Locator............................................................................................ 2-11
Figure 2-16: Waterjet Brick........................................................................................................................... 2-11
Figure 2-17: OMAX Solids Removal System............................................................................................... 2-12
Figure 2-18: OMAX Inlet Water Chiller....................................................................................................... 2-12
Figure 2-19: OMAX Drill Head Attachment................................................................................................. 2-13
Figure 2-20: Closed Loop Water Recycling System..................................................................................... 2-13
Figure 2-21: OMAX Terrain Follower Attached to a Tilt-A-Jet................................................................... 2-14
Figure 3-1: The Abrasivejet Nozzle ................................................................................................................ 3-4
Figure 3-2: The Abrasive Waterjet System..................................................................................................... 3-5
Figure 3-3: Quality Examples.......................................................................................................................... 3-6
Figure 3-4: Using Tabs Prevents Small Parts from Falling in the Tank.......................................................... 3-7
Figure 3-5: Cutting Nozzle with a Muff Attached........................................................................................... 3-8
Figure 3-6: Selecting Auto Home in OMAX Make...................................................................................... 3-11
Figure 3-7: White Water Tank Internal View................................................................................................ 3-12
Figure 3-8: White Water Tank Location in OMAX Pump............................................................................ 3-13
Figure 3-9: Verify Correct Mixing Tube Placement ..................................................................................... 3-14
Figure 3-10: Use the Homes Menu Option to Initiate an Auto Home........................................................... 3-14
Figure 3-11: Use Setup to Enable the Soft Limits......................................................................................... 3-15
Figure 3-12: Pump and Nozzle Test Options ................................................................................................ 3-15
Figure 3-13: Example of Both Good and Poor Quality Jet Streams.............................................................. 3-15
Figure 3-14: Comparison of Jet Streams with Different Jewel and Mixing Tube Conditions...................... 3-16
Figure 3-15: Comparison Spread of Waterjets and Abrasive-waterjets at Different Health States .............. 3-16
Figure 3-16: Nozzle Pressure Test Stop Button ............................................................................................ 3-17
Figure 3-17: Bimba Valve Abrasive Feed Block .......................................................................................... 3-18
Figure 3-18: Setup Menu for Pump and Nozzle Settings.............................................................................. 3-18
Figure 3-19: Settings for Pump and Nozzle .................................................................................................. 3-18
Figure 3-20: Event and Relay Timing Displayed Values.............................................................................. 3-19
Figure 3-21: Material Setup Example............................................................................................................ 3-19
Figure 3-22: Cut, Pierce, and Terrain Follower Setting Options................................................................... 3-20
Figure 3-23: Nozzle Position Functions........................................................................................................ 3-20
Figure 3-24: Z-axis Height ........................................................................................................................... 3-21
Figure 3-25: Pump and Nozzle Test Options ................................................................................................ 3-22
Figure 4-1: Changing the Pump’s Crankcase Oil............................................................................................ 4-2
Figure 4-2: Remove the Abrasive Hose from the Nozzle................................................................................ 4-6

OMAX JetMachining® Center Operator’s Guide
x400433D-EN
Figure 4-3: Removing the Nozzle Mixing Tube.............................................................................................. 4-6
Figure 4-4: Removing the Nozzle Body from the Inlet Body.......................................................................... 4-7
Figure 4-5: Screwing the Removal Tool into the Filter Seal ........................................................................... 4-7
Figure 4-6: Removing the Orifice Assembly from the Nozzle Body .............................................................. 4-7
Figure 4-7: Removed Orifice Assembly and Mixing Chamber Disc............................................................... 4-8
Figure 4-8: Pressing the Mixing Chamber from the Nozzle Body .................................................................. 4-8
Figure 4-9: Removing the O-ring from the Nozzle Body................................................................................ 4-9
Figure 4-10: Rinsing Parts with Clean Water .................................................................................................. 4-9
Figure 4-11: Cleaning Parts in Ultrasonic Cleaner with White Vinegar........................................................ 4-10
Figure 4-12: The Four Primary Nozzle Assembly Components Requiring Inspection................................. 4-10
Figure 4-13: Good Jewel Orifice.................................................................................................................... 4-10
Figure 4-14: Chipped Orifice Assembly Jewel.............................................................................................. 4-11
Figure 4-15: Plugged Jewel Orifice ............................................................................................................... 4-11
Figure 4-16: Worn Mixing Chamber Discs.................................................................................................... 4-12
Figure 4-17: Worn Mixing Tubes .................................................................................................................. 4-12
Figure 4-18: Pump and Nozzle Test Options................................................................................................. 4-13
Figure 4-19: Installing the Mixing Tube Upside Down to Dislodge a Clogged Opening ............................. 4-13
Figure 4-20: Worn Mixing Chamber ............................................................................................................. 4-14
Figure 4-21: Purging the High-pressure System of Contaminates with the Nozzle Removed...................... 4-14
Figure 4-22: Nozzle Filter Seal Assembly..................................................................................................... 4-14
Figure 4-23: Filter Seal Assembly Inserted into Inlet Body .......................................................................... 4-15
Figure 4-24: Locating the Mixing Chamber Groove and Abrasive Inlet Hole for Alignment ...................... 4-15
Figure 4-25: Using the Push Tool and Arbor Press to Insert the Mixing Chamber into the Nozzle Body.... 4-15
Figure 4-26: Installing the O-ring on the Nozzle Body ................................................................................. 4-16
Figure 4-27: Placing the Mixing Chamber Disc in the Center Bore of the Nozzle Body.............................. 4-16
Figure 4-28: Inserting the Orifice Assembly in the Nozzle Body with the Jewel Side Facing Up................ 4-16
Figure 4-29: Applying Blue Goop to the Nozzle Body Inlet Threads ........................................................... 4-17
Figure 4-30: Installing the Nozzle Body onto the Nozzle Inlet Body............................................................ 4-17
Figure 4-31: Aligning the Nozzle’s Abrasive Inlet Hole............................................................................... 4-17
Figure 4-32: Damage Caused by an Off-center Orifice................................................................................. 4-18
Figure 4-33: Tightening the Nozzle’s Brass Retainer Nut............................................................................. 4-18
Figure 4-34: Tightening the Nozzle Body to the Inlet Body.......................................................................... 4-18
Figure 4-35: Inserting the Mixing Tube into the Nozzle Body...................................................................... 4-19
Figure 4-36: Placing the Mixing Tube Collet and Nut onto the Mixing Tube............................................... 4-19
Figure 4-37: Tightening the Mixing Tube onto the Nozzle Body.................................................................. 4-19
Figure 4-38: Abrasive Damage from Not Using a Nozzle Muff.................................................................... 4-21
Figure 4-39: Removing the Air Hose from the Air Canister Fitting Ring..................................................... 4-22
Figure 4-40: Using a 1-1/8" open-end Wrench to Remove the Air Canister................................................. 4-22
Figure 4-41: Removing the Coil Nipple From the On/Off Valve Body Adapter Fitting............................... 4-22
Figure 4-42: Removing the 5mm Allen Screws that Secure the On/Off Valve Body ................................... 4-23
Figure 4-43: Removing the On/Off Valve Body with Seat from the Tilting Plate........................................ 4-23
Figure 4-44: Removing the Inlet Body from the Tilting Plate....................................................................... 4-23
Figure 4-45: Installing the Body Removal Tool Post to Remove a Stuck Inlet Body................................... 4-24
Figure 4-46: Placing the Tube over the Tool Post and Tightening the Flange Nut ....................................... 4-24
Figure 4-47: Removing the Brass Inlet Body Retaining Nut with the Spanner Wrench ............................... 4-24
Figure 4-48: Using White Vinegar to Loosen a Stuck Inlet Body................................................................. 4-25
Figure 4-49: Tightening Flange Nut to Detach the Inlet Body ...................................................................... 4-25
Figure 4-50: Cleaning the Inlet Body Hole with Brush and Soapy Water..................................................... 4-25
Figure 4-51: Applying Blue Goop to the Inlet Body Male Threads and Bore Diameter............................... 4-26
Figure 4-52: Hand Tightening the Inlet Body and Aligning to Tilting Plate Hole........................................ 4-26
Figure 4-53: Applying Blue Goop and Anti-seize Compounds to Valve Body Components ....................... 4-26
Figure 4-54: Correct Placement of the Valve Body Seat into the Valve Body.............................................. 4-27
Figure 4-55: Placing the On/Off Valve Body Against the Cutting Head Inlet Body..................................... 4-27
Figure 4-56: Tightening the Four Valve Body Screws and Applying Blue Goop to the Gland Nut Threads 4-27
Figure 4-57: Tightening the Coil Nipple to the On/Off Valve Body Adapter Fitting ................................... 4-28
Figure 4-58: Installing the On/Off Valve Air Canister .................................................................................. 4-28
Figure 4-59: Removing the MiniJet Nozzle Body from the Inlet Body Extension........................................ 4-29
Figure 4-60: Removing the Inlet Body Extension from the Inlet Body......................................................... 4-29