Omax MAXJET 5i 320303 Series Instruction Manual

MAXJET® 5i Nozzle
Installation and Maintenance











OMAX Corporation
21409 72nd Avenue South
Kent, WA USA 98032
Information:
Technical Support:
E-Mail:
Web:
253-872-2300
1-800-838-0343
[e-mail]
http://www.omax.com
400715D-EN

400715D-EN
2
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 document was provided.
OMAX Corporation believes the information described in this document is accurate and reliable. From time to time,
design improvements will be made to the OMAX equipment. Photographs, text, and sketches within the body of this
document may not exactly represent your equipment. In general, this document 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 material in this document. 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 user
documentation. If you have any questions or concerns about the content of this document , please email us at tech_
[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 their equipment to bring you the best in abrasive waterjet machining
technology. For that reason, your abrasive waterjet 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 email us at [e-mail]. You can
also receive technical support online at http://www.omax.com (user name and password required for technical support
access).
Original Instructions in English
October 2020
© 2020 OMAX Corporation. All rights reserved.

3
400715D-EN
Contents
SAFETY 4
Equipment Labels 4
Safety Legend 5
REQUIRED TOOLS 6
Customer Tools 6
OMAX Tools 7
REFERENCES 7
Documents 7
Videos 8
DOCUMENT SCOPE 8
OVERVIEW 8
Nozzle Assembly 9
Filter Assembly 9
Mixing Tube 10
INSTALL THE NOZZLE 10
Install the Nozzle Body on an A-Jet 10
Install the Nozzle Body on a Motorized Z-Axis 12
Install the Nozzle Body on a Tilt-A-Jet 14
Install the Mixing Tube 16
REMOVE THE NOZZLE 18
Remove the Mixing Tube 18
Remove the Nozzle Body from an A-Jet 19
Remove the Nozzle Body from a Motorized Z-Axis 20
Remove the Nozzle Body from a Tilt-A-Jet 21
MAINTENANCE 22
Maintenance Schedule 23
Prepare For Maintenance 23
Rotate the Mixing Tube 24
Clean or Replace the Final Filter 25
Replace the Final Filter Assembly 26
Clean the Metal Screen Filter Assembly 27
Clean and Examine the Nozzle Assembly 29
Examine the Abrasive Feed Tube 30
CUSTOMER SUPPORT 31

400715D-EN
4
SAFETY
This section contains important safety information for the equipment. Careful observance of the safety information will
help prevent physical injury, damage to the equipment, and extend the equipment life.
Equipment Labels
The following safety labels may appear on the equipment. If ignored, physical injury, death, or equipment damage may
occur. Read the safety information in the equipment operation guides before installing, operating, or maintaining the
equipment.
WARNING Electrical Shock Hazard
This symbol indicates the presence of life-threatening voltages. Never access areas labeled
as such without first taking appropriate safety precautions: locking out power, verifying no
voltage is present on circuits prior to maintenance activities, etc.
WARNING Flying Debris/Loud Noise
Eye and ear protection are required during operation. Removing the abrasive feed tube from
the nozzle while under pressure will blow abrasive particles into the air, getting into eyes, and
could contaminate tools and machines.
No Open Flame
Do not allow smoking near the machine. Do not operate the equipment in an explosive
atmosphere. Make sure that no ignition source (such as open flame or electrostatic
discharge) is nearby the equipment. Do not store flammable materials near the equipment.
Do not use equipment in or around flammable gases or liquids. Do not allow explosive or
flammable vapors to accumulate in the area of the equipment. Proper ventilation in the work
area will assist in dissipating the accumulation of gas, vapor, and fumes. Be especially careful
when cutting materials that create sparks, such as titanium—these can ignite gases in the tank.
Lock Out Power
Never do maintenance on the equipment with the main AC disconnect ON, unlocked, or with
the pump in operation. Always follow standard lockout/tagout procedures.
Wear Eye Protection
Always wear approved safety glasses whenever cutting. Regular glasses do not provide
sufficient eye protection! The garnet abrasive is not a chemical irritant, but if not quickly
washed out, it can injure an eye just as any sand would. In addition, tank water could contain
particles from the material or chemical irritants. Have an eyewash station located near the
work area in the event abrasive spray splashes into the eyes.
Read the product labels and refer to product Safety Data Sheets (SDS) to identify properties
and hazards of chemical products and materials referenced in this document. Handle in
accordance with good industrial hygiene and safety practice. Use personal protective
equipment as specified in the SDS.

5
400715D-EN
Wear Gloves
Bacteria in the tank water can build up. A minor break in the skin can introduce harmful
bacteria into a wound. Always wear protective gloves if there are cuts or open wounds on the
hands. When setting up material for cutting, wear gloves that provide protection against sharp
metal edges.
Read the product labels and refer to product Safety Data Sheets (SDS) to identify properties
and hazards of chemical products and materials referenced in this document. Handle in
accordance with good industrial hygiene and safety practice. Use personal protective
equipment as specified in the SDS.
Read Manual
Read the equipment operator's guide for specific operator instructions and additional safety
requirements. Do not attempt to operate this machine until all safety precautions and
operating instructions are read and understood.
Electrostatic Discharge
Attention! Observe precautions for handling electrostatic sensitive devices.
Safety Legend
The following safety signal word panels and paragraph notifications may appear throughout this and other
documentation. Each provides safety issue identification and recommended actions to avoid the hazard. Be alert!
Follow the recommended safety actions and precautions to prevent injury or damage to the equipment.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Used to address practices not related to physical injury—property damage only.
NOTE
Used to provide supplementary information, emphasize a point or give a tip for easier operation.

400715D-EN
6
REQUIRED TOOLS
These tools are required to perform the procedures described in this document.
NOTE
Additional tools needed to install and maintain the equipment are listed in referenced documents.
Customer Tools
These tools are not provided by OMAX or included with the equipment.
Icon Tool Size(s)
Torque wrench 25 ft-lb (34 N·m)
8–15 ft-lb (11–20 N·m)
Crowfoot 11/16 in., 1 in., 1-1/4 in.
Wrench, open-end 1/2 in., 11/16 in., 1 in., 1-1/4 in.
Clean water 
Clean, dry, compressed air 

7
400715D-EN
OMAX Tools
These tools are provided by OMAX and are included with the equipment.
Icon Tool Size(s)
Blue Goop®
P/N 100271 
A-Jet link wrench
P/N 313379 
Nozzle filter seal tool
P/N 304157 
Final filter removal tool
P/N 319947 
Lubriplate®
P/N 201304 
REFERENCES
Documents
These documents and diagrams are associated with these instructions and can be found in the Dashboard at
https://support.omax.com.
Part Number Title
400565 Diagram, Exp Pict, MAXJET 5i Nozzle
400610 A-Jet Users Guide
400805 Diagram, Exploded Pictorial, MAXJET 5i Nozzle

400715D-EN
8
Videos
Videos associated with these instructions are located at https://elearning.omax.com.
lA-Jet Nozzle Removal and Installation
OMAX
lPreparing for Maintenance of your OMAX Equipment
lMAXJET 5i Nozzle Maintenance
MAXIEM
lPreparing for Maintenance of your MAXIEM Equipment
lMAXJET 5i Nozzle Maintenance
DOCUMENT SCOPE
This document contains the following instructions for the MAXJET 5i nozzle assembly and inlet body filter assemblies
on an A-Jet, Tilt-A-Jet, or Motorized Z-Axis installed on an OMAX or MAXIEM Abrasive Waterjet Systems.
OVERVIEW
The MAXJET 5i nozzle assembly has a 500-hour warranty (prorated for use) when installed, operated, and maintained
using the correct procedures. The integrated nozzle assembly's diamond orifice and carbide disc are factory aligned
and permanently installed inside the nozzle to produce an accurate jet stream while cutting. There are two styles of
nozzle, nozzle with abrasive tubing retention tube [1] or nozzle with abrasive inlet [2] (Figure 1). The style used is
dependent on nozzle availability and equipment. Both nozzles operate the same.
Replace the nozzle assembly after 500 or more hours of operation and the water jet stream quality degrades. Speak
with Customer Support when the water jet stream quality degrades prematurely (less than 500 hours of operation).
NOTICE
Do not disassemble the MAXJET 5i nozzle body. The nozzle body components are factory assembled and
aligned. Disassembling the nozzle body can damage the nozzle body and voids the warranty.
Handle the nozzle body with care to prevent damage to the abrasive tubing retention tube [1].
Figure 1

9
400715D-EN
Nozzle Assembly
Figure 2 
[1] Nozzle body [4] Mixing tube nut
[2] O-ring [5] Mixing tube
[3] Mixing tube collet and O-ring 
Filter Assembly
There are two types of filter assemblies available for the MAXJET 5i nozzle.
The metal filter screen filter assembly is used on the A-Jet and has a metal filter that can be used again.
Figure 3 
[1] O-ring [2] Ring seal [3] Metal filter screen
The final filter assembly is used on the Tilt-A-Jet and Motorized Z-Axis and has a replaceable plastic filter assembly.
Figure 4 
[1] O-ring [2] Filter and seal assembly

400715D-EN
10
Mixing Tube
Mixing tubes vary on equipment. The fusible mixing tube [2] is required on the A-Jet.
Figure 5 
[1] Mixing tube [2] Fusible mixing tube
INSTALL THE NOZZLE
NOTICE
To avoid damage to high-pressure components (such as lines, tubing, nipples, gland nuts, safety valves,
nozzle, inlet body) use two wrenches to counteract the torque when adjusting, attaching, or removing high-
pressure components. Binding and twisting of the high-pressure components may cause leaks and water
damage.
nTo install on an A-Jet, go to Install the Nozzle Body on an A-Jet.
nTo install on a Motorized Z-Axis, go to Install the Nozzle Body on a Motorized Z-Axis.
nTo install on a Tilt-A-Jet, go to Install the Nozzle Body on a Tilt-A-Jet.
Install the Nozzle Body on an A-Jet
WARNING
Do not install or remove the nozzle while the A-Jet motor on or active. Severe injury and damage to the A-
Jet may occur. Make sure the primary power, water, and air sources are turned off. Follow the lockout and
tagout procedures to notify others maintenance is in progress.
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.
1. Remove the mixing tube if it is installed in the nozzle body. See Remove the Mixing Tube.
NOTICE
Handle the nozzle carefully to prevent damage to the abrasive tubing retention tube.

11
400715D-EN
2. Install the O-rings on the nozzle body.
Figure 6 
3. Apply a light coat of Blue Goop to the top [1] and bottom [2] threads of the nozzle body.
Figure 7 
4. Install the nozzle flap splash guard on the nozzle body. Make sure the abrasive inlet or retention tube
aligns with the slot in the nozzle flap splash guard.
Figure 8 
5. Carefully install the nozzle body onto the inlet body.
Figure 9 

400715D-EN
12
NOTICE
Do not over or under tighten the nozzle body. Tighten the nozzle body to the specified torque. Under
tightening can cause leaks and equipment damage. Over tightening damages the sealing surface between
the orifice assembly and the nozzle filter assembly. Do not tighten the nozzle body to more than 25 ft-lb
(34 N·m).
6. Hold the A-Jet to counteract the torque, then tighten the nozzle body.
Figure 10 
7. Install the mixing tube. See Install the Mixing Tube.
8. Connect the abrasive feed tube to the nozzle and the abrasive hopper, if needed. Make sure the abrasive
tube is inserted through the slot in the nozzle flap splash guard.
Figure 11 
9. Recalibrate the A-Jet. See 400610 A-Jet Users Guide.
Install the Nozzle Body on a Motorized Z-Axis
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.
1. Remove the mixing tube if it is installed in the nozzle body. See Remove the Mixing Tube.
NOTICE
Handle the nozzle carefully to prevent damage to the abrasive tubing retention tube.

13
400715D-EN
2. Install the O-rings on the nozzle body.
Figure 12 
3. Apply a light coat of Blue Goop to the top [1] and bottom [2] threads of the nozzle body.
Figure 13 
4. Carefully install the nozzle body onto the inlet body.
Figure 14 
NOTICE
Do not over or under tighten the nozzle body. Tighten the nozzle body to the specified torque. Under
tightening can cause leaks and equipment damage. Over tightening damages the sealing surface between
the orifice assembly and the nozzle filter assembly. Do not tighten the nozzle body to more than 25 ft-lb
(34 N·m).

400715D-EN
14
5. Hold the inlet body to counteract the torque, then tighten the nozzle body.
Figure 15 
6. Install the mixing tube. See Install the Mixing Tube.
7. Connect the abrasive feed tube to the nozzle and the abrasive hopper, if needed.
Figure 16 
Install the Nozzle Body on a Tilt-A-Jet
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.
1. Remove the mixing tube if it is installed in the nozzle body. See Remove the Mixing Tube.
NOTICE
Handle the nozzle carefully to prevent damage to the abrasive tubing retention tube.

15
400715D-EN
2. Install the O-rings on the nozzle body.
Figure 17 
3. Apply a light coat of Blue Goop to the top [1] and bottom [2] threads of the nozzle body.
Figure 18 
4. Put the retainer ring [1] on the nozzle body.
Figure 19 
5. Carefully install the nozzle body onto the inlet body.
Figure 20 

400715D-EN
16
NOTICE
Do not over or under tighten the nozzle body. Tighten the nozzle body to the specified torque. Under
tightening can cause leaks and equipment damage. Over tightening damages the sealing surface between
the orifice assembly and the nozzle filter assembly. Do not tighten the nozzle body to more than 25 ft-lb
(34 N·m).
6. Hold the top of the inlet body to counteract the torque, then tighten the nozzle body.
Figure 21 
7. Install the mixing tube. See Install the Mixing Tube.
8. Connect the abrasive feed tube to the nozzle and the abrasive hopper, if needed.
Figure 22 
Install the Mixing Tube
Replace the mixing tube when the cutting performance degrades beyond adjustment of the tool offset. Cut a kerf check
part, then measure and examine it for dimensional differences.
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.

17
400715D-EN
1. Put the mixing tube into the nozzle body, then push the mixing tube until it sits firmly against the mixing
chamber [1].
Figure 23 
2. Hold the mixing tube in place, install the collet (tapered end toward the nozzle body), O-ring, and mixing
tube nut.
Figure 24 
3. Tighten the mixing tube nut by hand.
Figure 25 
NOTICE
Do not over or under tighten the mixing tube nut. Over tightening the mixing tube nut can cause the mixing
tube and the orifice to become misaligned and cause damage. Under tightening the mixing tube nut can
cause the mixing tube to come out of the nozzle when high-pressure water is activated.

400715D-EN
18
4. Hold the nozzle body to counteract the torque, then torque the mixing tube nut to secure the mixing tube.
Figure 26 
REMOVE THE NOZZLE
NOTICE
To avoid damage to high-pressure components (such as lines, tubing, nipples, gland nuts, safety valves,
nozzle, inlet body) use two wrenches to counteract the torque when adjusting, attaching, or removing high-
pressure components. Binding and twisting of the high-pressure components may cause leaks and water
damage.
When removing the nozzle assembly, first Remove the Mixing Tube, then remove the nozzle body.
nTo remove on an A-Jet, go to Remove the Nozzle Body from an A-Jet.
nTo remove on a Motorized Z-Axis, go to Remove the Nozzle Body from a Motorized Z-Axis.
nTo remove on a Tilt-A-Jet, go to Remove the Nozzle Body from a Tilt-A-Jet.
Remove the Mixing Tube
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.
1. Hold the nozzle body to counteract the torque and loosen the mixing tube nut.
Figure 27 

19
400715D-EN
2. Remove the mixing tube [1], mixing tube nut [4], collet [3], and O-ring [1].
Figure 28 
3. If needed, replace the O-ring and clean the mixing tube, mixing tube nut and collet. See Clean and Examine
the Nozzle Assembly.
Remove the Nozzle Body from an A-Jet
WARNING
Do not install or remove the nozzle while the A-Jet motor on or active. Severe injury and damage to the A-
Jet may occur. Make sure the primary power, water, and air sources are turned off. Follow the lockout and
tagout procedures to notify others maintenance is in progress.
NOTICE
Failure to remove power to A-Jet actuators prior to removing the nozzle could result in damage to the A-
Jet assembly.
NOTICE
Handle the nozzle carefully to prevent damage to the abrasive tubing retention tube.
1. Remove the abrasive feed tube from the nozzle and the abrasive hopper.
Figure 29 
NOTICE
Remove the mixing tube BEFORE installing or removing the nozzle to prevent damage. Large upward
forces from an installed mixing tube can misalign the internal nozzle components.
2. Remove the mixing tube. See Remove the Mixing Tube.

400715D-EN
20
3. Hold the A-Jet to counteract the torque, then loosen the nozzle body.
Figure 30 
4. Remove the nozzle body from the A-Jet.
5. Carefully remove the nozzle flap splash guard.
Figure 31 
For cleaning the nozzle assembly, go to Clean and Examine the Nozzle Assembly.
For cleaning or replacing the final filter assembly, go to Clean or Replace the Final Filter.
Remove the Nozzle Body from a Motorized Z-Axis
NOTICE
Handle the nozzle carefully to prevent damage to the abrasive tubing retention tube.
1. Remove the abrasive feed tube from the nozzle and the abrasive hopper.
Figure 32 