KMT SL-VI 50 72159007 (r01) PDF

STREAMLINE SL-VI 50
WATERJET INTENSIFIER
OPERATION AND MAINTENANCE MANUAL
MANUAL 72159007(R01)
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 2015
KMT Waterjet Systems

635 West 12th Street
PO 231
Baxter Springs, KS 66713-0231
Phone: (800) 826-9274

Fax: (620) 856-5050
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ORIGINAL INSTRUCTIONS
TABLE OF CONTENTS
Title Page
Notice
Table of Contents
Appendix
Section Page
1 Introduction ............................................................................................................ 1-1
1.1 Overview ................................................................................................ 1-2
1.2 Performance Features and Options ........................................................ 1-2
1.3 Product Nameplate ................................................................................. 1-4
1.4 Operational Overview ............................................................................ 1-4
Low Pressure Water System .................................................................. 1-4
Recirculation System ............................................................................. 1-5
Hydraulic System ................................................................................... 1-5
High Pressure Water System ................................................................. 1-5
Operating System ................................................................................... 1-6
1.5 Misuse of Equipment ............................................................................. 1-6
1.6 Safety ..................................................................................................... 1-6
Lockout/Tagout Procedure..................................................................... 1-7
Warning Labels ...................................................................................... 1-8
Emergency Medical Treatment .............................................................. 1-11
1.7 Worldwide Product Support .................................................................. 1-11
1.8 Spare Parts ............................................................................................. 1-12
1.9 Manual Organization ............................................................................. 1-12
2 Installation .............................................................................................................. 2-1
2.1 Overview ................................................................................................ 2-2
2.2 Installation Summary ............................................................................. 2-2
2.3 Site Requirements .................................................................................. 2-3
Transporting ........................................................................................... 2-4
2.4 Power Requirements .............................................................................. 2-5
2.5 Service Connections............................................................................... 2-6
Cooling Water (Oil-to-Water Models)................................................... 2-7
Cutting Water ......................................................................................... 2-8
Drain ...................................................................................................... 2-8
Plant Air ................................................................................................. 2-8
Contaminated Waste Drain .................................................................... 2-9
2.6 Flow Requirements ................................................................................ 2-9
2.7 High Pressure Piping.............................................................................. 2-10
Measurements and Dimensions ............................................................. 2-11
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Hand Coning .......................................................................................... 2-12
Power Coning......................................................................................... 2-13
Hand Threading ..................................................................................... 2-14
Power Threading .................................................................................... 2-14
2.8 High Pressure Connections .................................................................... 2-15
Standard Connections ............................................................................ 2-15
Anti-Vibration Connections ................................................................... 2-15
2.9 Commissioning ...................................................................................... 2-16
2.10 Decommissioning .................................................................................. 2-19
3 Maintenance ........................................................................................................... 3-1
3.1 Overview ................................................................................................ 3-2
3.2 Maintenance ........................................................................................... 3-2
Daily Inspection ..................................................................................... 3-2
Periodic Maintenance............................................................................. 3-2
High Pressure System Maintenance....................................................... 3-5
3.3 Maintenance Precautions ....................................................................... 3-5
3.4 Tool Kits ................................................................................................ 3-6
4 Operation ................................................................................................................ 4-1
4.1 Overview ................................................................................................ 4-2
4.2 Home Screen .......................................................................................... 4-2
4.3 Operating Overview ............................................................................... 4-3
Standard Units ........................................................................................ 4-3
Units Equipped with a Pressure Transducer .......................................... 4-5
Units Equipped with Proportional Pressure Control.............................. 4-6
Units Equipped with a Pressure Transducer and Proportional Pressure 4-8
4.4 Intensifier Control Screen ...................................................................... 4-8
4.5 General Pump Data Screen .................................................................... 4-10
4.6 Machine Setup ....................................................................................... 4-11
Pressure Limit and Calibration Screen .................................................. 4-13
Operator Configuration Screen .............................................................. 4-15
4.7 Service and Maintenance ....................................................................... 4-16
4-8 Alarms .................................................................................................... 4-18
5 Low Pressure Water System ................................................................................. 5-1
5.1 Overview ................................................................................................ 5-2
5.2 Cutting Water Supply ............................................................................ 5-2
5.3 Operation................................................................................................ 5-2
5.4 Service and Maintenance Procedures .................................................... 5-4
Filter Assembly and Strainer Maintenance ............................................ 5-4
Booster Pump Adjustment ..................................................................... 5-5
6 Recirculation System ............................................................................................. 6-1
6.1 Overview ................................................................................................ 6-2
6.2 Operation (Oil-to-Water Cooling System)............................................. 6-2
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6.3 Operation (External Oil-to-Air Cooling System) .................................. 6-3
6.4 Operation (Onboard Oil-to-Air Cooling System) .................................. 6-4
6.5 Operation (Onboard Water/Air Combination Cooling System) ............ 6-5
Hydraulic Oil Maintenance .................................................................... 6-6
Pump Priming ........................................................................................ 6-9
Oil Filter Maintenance ........................................................................... 6-9
7 Hydraulic System ................................................................................................... 7-1
7.1 Overview ................................................................................................ 7-2
7.2 Operation................................................................................................ 7-2
Hydraulic Operating Pressure ................................................................ 7-4
Proportional Valve Maintenance ........................................................... 7-5
Motor Maintenance ................................................................................ 7-6
Hydraulic Compensator Maintenance.................................................... 7-6
Compensator Calibration (Manual Adjustment) .................................... 7-8
Compensator Calibration (Proportional Control Adjustment)............... 7-9
8 Electrical System .................................................................................................... 8-1
8.1 Overview ................................................................................................ 8-2
8.2 Operation................................................................................................ 8-2
Switch Gear ............................................................................................ 8-4
Sensors and Solenoids............................................................................ 8-6
Proximity Switch Maintenance .............................................................. 8-11
9 High Pressure Water System ................................................................................ 9-1
9.1 Overview ................................................................................................ 9-2
9.2 Operation................................................................................................ 9-2
Redundant Intensifiers ........................................................................... 9-3
9.3 System Components............................................................................... 9-6
9.4 Service and Maintenance Overview ...................................................... 9-7
Specialized Maintenance Tools ............................................................. 9-7
Torque Specifications ............................................................................ 9-8
9.5 High and Low Pressure Water Piping .................................................... 9-10
9.6 High Pressure Cylinder Assembly ......................................................... 9-11
High Pressure Cylinder Assembly Removal.......................................... 9-11
High Pressure Cylinder Assembly Installation ...................................... 9-13
High Pressure Cylinder Maintenance .................................................... 9-13
9.7 Hard Seal End Caps ............................................................................... 9-14
Hard Seal End Cap Removal ................................................................. 9-14
Hard Seal End Cap Installation .............................................................. 9-15
9.8 Sealing Head .......................................................................................... 9-16
High Pressure Discharge Check Valve .................................................. 9-16
Low Pressure Inlet Check Valve............................................................ 9-18
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Sealing Head Maintenance .................................................................... 9-19
9.9 High Pressure Seal Assembly ................................................................ 9-20
9.10 Hydraulic Seal Cartridge and Plunger Removal .................................... 9-22
Plunger Maintenance ............................................................................. 9-24
Plunger Installation ................................................................................ 9-24
Hydraulic Seal Cartridge Installation..................................................... 9-25
9.11 Hydraulic Piston..................................................................................... 9-26
Hydraulic Piston Removal ..................................................................... 9-27
Bearing Rings and Seal Assembly ......................................................... 9-28
Plunger Button Sockets, Seals and Retainer Pins .................................. 9-29
Internal Check Valves ............................................................................ 9-29
Hydraulic Piston Installation.................................................................. 9-30
9.12 Hydraulic Cylinder Maintenance ........................................................... 9-31
9.13 High Pressure Attenuator ....................................................................... 9-31
9.14 High Pressure Dump Valve ................................................................... 9-31
3-Port Pneumatic Control Dump Valve ................................................. 9-32
2-Port Pneumatic Control Dump Valve ................................................. 9-35
Pneumatic Actuator ................................................................................ 9-39
9.15 Weep Holes ............................................................................................ 9-40
10 Troubleshooting ..................................................................................................... 10-1
10.1 Overview ................................................................................................ 10-2
10.2 Troubleshooting Guide .......................................................................... 10-3
10.3 Soft Starter ............................................................................................. 10-12
11 Specifications .......................................................................................................... 11-1
11.1 Overview ................................................................................................ 11-2
11.2 Installation Specifications ...................................................................... 11-2
Environment ........................................................................................... 11-2
Sound Level ........................................................................................... 11-2
Equipment Dimensions and Weights ..................................................... 11-3
Service Connections............................................................................... 11-3
Plant Air ................................................................................................. 11-3
11.3 Water Specifications .............................................................................. 11-4
Cutting Water Supply ............................................................................ 11-4
Cooling Water Supply............................................................................ 11-5
Water Quality Standards ........................................................................ 11-6
11.4 Electrical Specifications......................................................................... 11-8
Electrical System ................................................................................... 11-8
11.5 Hydraulic and High Pressure Water System Specifications .................. 11-8
Hydraulic System ................................................................................... 11-8
High Pressure Water System ................................................................. 11-8
Orifice Capacity ..................................................................................... 11-9
11.6 Torque Specifications ............................................................................ 11-9
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12 Parts List ................................................................................................................. 12-1
12.1 Overview ................................................................................................ 12-2
12.2 Index ...................................................................................................... 12-3
APPENDIX
Exhibit
System Schematic
Electrical Schematic(s)
Material Safety Data Sheets
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ORIGINAL INSTRUCTIONS v
SECTION 1
INTRODUCTION
The Introduction highlights:

§ Equipment features and options
§ Operational overview
§ Equipment safety
§ Contact information
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Section 1
Introduction
1.1 Overview
The Streamline SL-VI series combines all the unique capabilities and advantages of waterjet
cutting systems with the reliability, ease of operation and service support that have made KMT
Waterjet Systems a leader in waterjet technology.
With 30, 40, 50 and 100 horsepower single and redundant models, the SL-VI series
accommodates a wide range of applications.
Table 1-1
Streamline SL-VI Models
Motor
Horsepower
Rating Maximum Maximum Single
Operating Maximum Flow Rate Orifice Diameter
Model HP Kw Pressure (at full pressure) (at full pressure)
SL-VI 30 30 22 0.69 gpm @ 60 Hz 0.011” @ 60 Hz
(2.61 L/min) @ 50 Hz 0.28 mm @ 50 Hz
SL-VI 40 40 30 0.88 gpm @ 60 Hz 0.013” @ 60 Hz
60,000 psi (2.76 L/min) @ 50 Hz 0.28 mm @ 50 Hz
SL-VI 50 50 37 (4,137 bar)* 1.09 gpm @ 60 Hz 0.014” @ 60 Hz
(4.13 L/min) @ 50 Hz 0.36 mm @ 50 Hz
SL-VI 100 100 75 1.72 gpm @ 60 Hz 0.018” @ 60 Hz
(6.51 L/min) @ 50 Hz 0.46 mm @ 50 Hz
*Note: Maximum pressure with cutting head valve open is 60,000 psi (4,137 bar). Maximum pressure
with cutting head valve closed is 66,000 psi (4,550 bar).
1.2 Features and Options

The modular design of the SL-VI series
allows the customer to build a pump that
maximizes efficiencies and enhances
production for their specific cutting
requirements.
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Table 1-2
Standard Equipment and Optional Modules
SL-VI
S-Series Series
Electrical enclosure and controls ●
Color touch screen display ●
Ethernet/Profinet ●
Isolated high voltage components meet IEC 60204 standards ●
Remote interface plug ●
IE3 and NEMA premium motor design optimizes efficiency and ● ●
reduces electrical consumption
Patented topworks design ● ●
Dual solenoid controlled dump valve ● ●
Oil-to-water cooling circuit ● ●
Onboard air-to-water cooling circuit ○ ○
External air-to-water cooling circuit ○ ○
Combination air/water cooling circuit ○ ○
Doors ○ ○
Top cover ○ ○
Interlock top cover meets EN ISO13849-1 Safety Performance ○ ○
Standard PLa rating
Redundant intensifier ○ ○
Additional attenuator volume ○ ○
Proportional pressure control ○ ○
High pressure transducer ○ ○
Remoteline ○
Power factor correction reduces electrical demand ○
Note: Optional modules are available at the time of purchase, or as upgrades for existing equipment.
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1.3 Product Nameplate

The product nameplate contains the pump model, serial, identification and part numbers for each
individual machine.
Figure 1-1: Product Nameplate
1.4 Operational Overview

The following provides a brief overview of the function and primary components associated with
the individual systems. A detailed discussion of each system is provided in Sections 4 through 9.
Low Pressure Water System

The low pressure water system supplies the cutting water flow to the intensifier. Major system
components include the water filter assembly and the booster pump.
Figure 1-2: System Components
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Recirculation System
The recirculation system is a cooling and filtration system that provides properly conditioned oil
to the main hydraulic system. Major system components include the recirculation pump, heat
exchanger, oil filter assembly and the hydraulic oil reservoir.
Hydraulic System
The hydraulic system supplies the intensifier with the hydraulic oil required to produce high
pressure water. Major system components include the electric motor, hydraulic pump and a 4-
way directional control valve mounted on the hydraulic manifold.
High Pressure Water System

The high pressure water system is the heart of the waterjet system. Water is pressurized and
continuously delivered to the cutting head. As water passes through a tiny hole in the orifice,
water pressure is converted to water velocity capable of cutting most any material.
The major components include the high pressure cylinder assemblies, hydraulic cylinder
assembly, hydraulic piston, attenuator and the dump valve.
Figure 1-3: High Pressure Water System Components
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Operating System
A programmable logic controller (PLC) provides basic intensifier shift control and monitors out
of limit conditions. Operator interface is through the control panel display where operating
parameters are set and monitored.
Figure 1-4: Main Screen
1.5 Misuse of Equipment

The Streamline SL-VI series of waterjet pumps have been designed solely for the generation of
high pressure cutting water for industrial and commercial applications. The intended use further
includes compliance with the operating, maintenance and repair conditions precribed 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.
1.6 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.
All personnel operating, servicing or working near the waterjet cutting equipment shall adhere to
the following safety precautions, as well as the applicable plant safety precautions.
§ Only KMT factory trained, qualified personnel shall service and maintain the equipment.
§ The operator shall practice and promote safety at all times to avoid potential injury and
unnecessary downtime.
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§ 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
§ All protective guards, shields or covers shall be in place on the

equipment at all times.
§ Safety glasses and ear protection shall be worn when operating or

working near the equipment.
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 and hydraulic 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 all service connections: cutting water
in, cooling water in and out, and air.
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Warning Labels
Warning labels are posted on the machine to indicate potential hazards. The operator and service
personnel shall pay particular attention to these warning labels. Table 1-3 describes the necessary
precautions and provides the part number required to order replacement labels.
Table 1-3
Warning Label Precautions
1 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 electrical enclosure
door before performing any type of maintenance.
P/N 05114962
2 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.
P/N 72164268
3 The surface of high pressure water and hydraulic

components becomes hot during normal operation.
Failed, or failing components, can become extremely
hot during operation.
P/N 05114970
4 Ensure that all protective guards, shields or covers are

in place on the equipment at all times. Never operate
the pump with the guards removed.
P/N 80082209
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Table 1-3
Warning Label Precautions
5 High pressure water and/or hydraulic pressure 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 intensifier off, stops the pump and bleeds
P/N 05098017 the high pressure water through the dump valve.
Depressurization of the high pressure system creates a
loud hissing sound when the dump valve opens. The
sound fades quickly as the pressure drops.
6 All personnel involved in the installation, operation

and/or service of the intensifier must carefully read,
understand and follow the procedures in this manual to
avoid creating unsafe conditions, risking damage to the
equipment, or personal injury.
P/N 20415794
7 The weight of the machine is not evenly distributed

from one end to the other, particularly on the larger
horsepower models. The center of gravity is clearly
identified on the sides of the crate. Position the forklift
accordingly.
When the machine is removed from the crate, note the
position of the fork pockets on the bottom of the
P/N 72164242 machine. The pockets are positioned in relationship to
the center of gravity to balance the weight on the
8
forklift.
P/N 72164250
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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.
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.
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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.
This person has been working with water jetting

Medical Alert at pressures to 60,000 psi (374MPa, 4,137 bar,
3867 Kg/cm2) with a jet velocity of 3,000 fps
This card is to be carried by personnel (914 mps). Foreign material (sand) may have
working with high pressure waterjet been injected with water. Unusual infections
equipment. Obtain medical treatment with microaerophilic organisms occurring at
immediately for ANY high pressure waterjet lower temperatures have been reported, such as
injuries. gram negative pathogens as are found in
sewage. Bacterial swabs and blood cultures
KMT Waterjet Systems may therefore be helpful. This injury must be
635 West 12th Street treated as an acute surgical emergency and be
Baxter Springs, KS 66713 evaluated by a qualified surgeon. Circulation
(620) 856-2151 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.
1.7 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 KMT Waterjet Systems GmbH
PO Box 231 Hohe Strasse 4-6
635 West 12th Street D-61231 Bad Nauheim
Baxter Springs, KS 66713 Germany
USA
Phone: +49-6032-997-0
Phone: (800) 826-9274 Fax: +49-6032-997-270
Fax: (620) 856-2242 Email: [email protected]
Email: [email protected]
Email: [email protected]
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1.8 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.
1.9 Manual Organization

This manual contains operating and maintenance procedures for the complete SL-VI series.
Information is organized as follows:
§ Section 1, Introduction, provides equipment features and optional modules, a brief
operational overview, details regarding safety issues and contact information for product
support.
§ Section 2, Installation, details installation requirements and procedures. Also provided are
systematic guidelines for commissioning the intensifier.
§ Section 3, Maintenance, highlights routine and preventive maintenance requirements and
scheduling. Precautions associated with ultra-high pressure cutting equipment are also
reviewed.
§ Section 4, Operation, explains the control functions and the display panel where operating
parameters are set and monitored.
§ Sections 5 through 9 are specific to each individual system. Each section contains a
detailed description of the principles of operation and the function of each system.
Routine maintenance procedures associated with the system are also included.
§ Section 10, Troubleshooting, is a comprehensive guide containing the information
required to diagnose problems and repair the machine.
§ Section 11, Specifications, contains a comprehensive list of equipment specifications; a
detailed discussion of water quality standards and treatment guidelines; as well as
horsepower requirements for various orifice sizes.
§ Section 12, Parts List, contains part numbers, descriptions and drawings to facilitate the
ordering of replacement parts.
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SECTION 2
INSTALLATION
The Installation section details:

§ Installation requirements and procedures
§ Commissioning and decommissioning guidelines
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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 intensifier.
All personnel involved in the installation, operation and/or service of
the intensifier 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 intensifier system. 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.
The incoming cooling water source and cooling water drain are not required on
models equipped with an air-to-oil cooling system.
§ A pneumatic drop with a manual shutoff valve and regulator for the air connection must
be installed.
§ Plumbing and manual shutoff valves for the inlet and discharge cooling water (oil-to-
water models), and the inlet and discharge cutting water must be installed.
Incoming source water must meet specific water quality standards, 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 intensifier to the cutting station are installed with the
appropriate mountings, support brackets and hardware.
§ Wiring must be installed and connected between the intensifier and the cutting station
control system.
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§ The machine must be commissioned and tested.
2.3 Site Requirements

The intensifier must be installed indoors where air borne dust and contaminants are minimal. The
ambient temperature should be between 40° F (5° C) and 104° F (40° C), with a maximum
relative humidity of 95 percent.
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.
Figure 2-1: Equipment Dimensions
Table 2-1
Equipment Dimensions
Horsepower Length Width Height Weight
30 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.37” (1,508 mm) 2,443 lbs (1/108 kg)
40 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.37” (1,508 mm) 2,542 lbs (1,153 kg)
50 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.37” (1,508 mm) 2,870 lbs (1,302 kg)
100 HP 82.50” (2,095 mm) 52.00” (1,320 mm) 59.38” (1,508 mm) 4,691 lbs (2,128 kg)
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Table 2-1
Equipment Dimensions
Redundant Models (same dimensions as above)

30 HP 2,743 lbs (1,244 kg)
40 HP 2,842 lbs (1,289 kg)
50 HP 3,170 lbs (1,438 kg)
100 HP 5,036 lbs (2,284 kg)
Transporting
The weight of the machine is not evenly distributed from one end to the other, particularly on the
larger horsepower models. Do not attempt to lift the machine from either end. Note the warnings
stamped on the crate. The center of gravity is clearly identified on the sides of the crate. The
forklift should be positioned accordingly.
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 forklift.
Figure 2-2: Fork Pockets
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Table 2-2
Fork Pockets
Units with Optional
Onboard Cooling
30/40/50 HP 100 HP System
A Fork Pocket Dimensions
Height 2.90” (74 mm) 2.90” (74 mm) 2.90” (74 mm)
Width 8.0” (203 mm) 8.0” (203 mm) 8.0” (203 mm)
Length 43.86” (1,114 mm) 52.00” (1,320 mm) 52.00” (1,320 mm)
B Distance Between Pockets 25.0” (635 mm) 25.0” (635 mm) 25.0” (635 mm)
If the machine will be installed in an overhead location, a forklift or crane can be used to position
the pump. Heavy straps or chains, properly rated for the weight requirements, should be placed
through each fork pocket, and wrapped around the sides of the machine so they meet on the top.
The straps can then be attached to a crane or forklift to lift the machine.
The machine must be lifted from the bottom. Do not attempt to lift the machine
from the intensifier.
2.4 Power Requirements

Power supplied to the pump 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.
Refer to the nameplate for machine specific ampacity and power voltage
requirements.
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2.5 Service Connections

The intensifier requires two incoming water sources, cooling water and cutting water; two drain
lines, cooling water and wastewater; a high pressure discharge line, and an air supply line. All
piping must comply with local, regional and national codes.
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 2-3, Service
Connections. Table 2-3 lists the fittings required and the height of each interface connection.
With the exception of the wastewater and contaminated waste drain lines, manual shutoff valves
should be installed for all connections. To facilitate service, the valves should be located as close
as practical to the interface connection.
Figure 2-3: Service Connections
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Table 2-3
Service Connections
Connection Height
A Drain 1/2” NPT 8.75” (222 mm)
B Cutting Water In 1/2” NPT 11.47” (298 mm)
C Cooling Water In 1/2” NPT 14.74” (374 mm)
Hydraulic Oil Out (oil-to-air models) 3/4” JIC 14.74” (374 mm)
D Cooling Water Out 1/2” NPT 17.74” (450 mm)
Hydraulic Oil In (oil-to-air models) 3/4” JIC 14.74” (374 mm)
E Plant Air In 1/4” NPT 27.74” (705 mm)
F Cutting Water Out 9/16” HP 30.74” (780 mm)
G Contaminated Waste Drain 1/2” NPT 33.74” (857 mm)
Cooling Water (Oil-to-Water Models)

Inlet cooling water flows through the oil-to-water heat exchanger in the hydraulic system to
control heat build-up in the hydraulic oil. The cooling water is then discharged through the
cooling water out port to either the drain or routed to a customer supplied water chiller.
Cooling water supply piping must be sized to meet the flow and pressure requirements of the
specific equipment. If municipal or well water is used for cooling, ensure the supply flow and
pressure meet the requirements in Section 11, Specifications.
If a facility-wide chilled water system is used for cooling, ensure there is a minimum of 35 psi
(2.4 bar) pressure differential between the facility supply and discharge plumbing. Installation of
an in-line pressure boosting pump may be necessary to provide adequate cooling flow. Dedicated
chilled water systems should be sized according to pump horsepower as illustrated in Table 2-4,
Chilled Water Systems.
Table 2-4
Chilled Water Systems
Cooling Requirements at Full Capacity
Horsepower BTU/HR
30 13,400
40 18,000
50 22,000
100 45,000
Note: Coolant flow to the heat exchanger is regulated by the
temperature of the contents in the hydraulic reservoir and
will be shut off at times.
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Cutting Water
Inlet cutting water is filtered and then routed to the intensifier where it is pressurized and
delivered to the cutting head. The cutting water supply must meet the minimum water quality
standards outlined in Section 11, Specifications. Poor water quality will drastically shorten
component life and void the warranty.
Cutting water supply piping must be sized to meet the flow and pressure requirements listed in
Section 11, Specifications. Only PVC, copper or rubber hoses should be used between the cutting
water source and the machine.
The inlet water must be maintained at a minimum pressure of 35 psi (2.4 bar) at all times. If the
facility water pressure is below, or can fall below 35 psi (2.4 bar), a water pressure booster pump
is required.
The machine will not start if inlet cutting water pressure is below 30 psi (2 bar).
To avoid pressure spikes and premature component wear, adequate and consistent
inlet water pressure is critical.
Drain
Cutting water released through the dump valve when the emergency stop button is initiated is
discharged from the drain port. The discharge is considered wastewater and must be piped to an
appropriate location, i.e. a sewer line. The volume of water released will be minimal and does
not require high pressure plumbing; however, piping must comply with local, regional and
national codes.
Plant Air
The facility compressed air connection should provide clean, dry air regulated to 85 psi (5.9 bar).
Air usage is minimal, normally less than 1 scf/min.
The reaction time of the pneumatic valve on the cutting head is a function of air
and operating pressure. To achieve a consistent reaction time, when operating
pressure is changed, the air pressure should also be changed accordingly.
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The following table provides specifications for each ISO air quality classification. KMT
recommends adherence to Quality Class 4.
Table 2-5
ISO Air Quality Classifications
Maximum Maximum Pressure
ISO Quality Particle Size Dew Point Maximum Oil Content
Class (microns) (water @ 100 psi) (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) --
Contaminated Waste Drain

Oil and water that can accumulate on the top pan is disposed of through the contaminated waste
drain. This oil and water mixture is considered contaminated and disposal must comply with
local, regional and national codes. The volume of waste will be minimal and can be collected in a
container of some appropriate type.
2.6 Flow Requirements

Figure 2-4, Pressure Drop Values, illustrates the pressure drop for four different pipe sizes. The
graph can be used to calculate the minimum source water pressure.
2. Enter the graph at the required GPM and note the pressure drop figures for the different
pipe sizes.
3. Multiply the pressure drop (PSI/FT) by the length in feet of each pipe size used from the
water source to the intensifier. Add the values together for a total pressure drop value.
4. Add 30 to the total pressure drop to determine the minimum flowing, source water
pressure required to provide adequate supply to the intensifier.
Cutting water and cooling water capacity should be calculated separately. Note that the cutting
water requirements represent instantaneous, not average, demand. The machine will not start if
the inlet cutting water pressure drops below 30 psi (2 bar).
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Figure 2-4: Pressure Drop Values
Pipe Sizing
0.45
Pressure drop (PSI/FT)
0.4
0.35
0.3 1/2" ID
0.25 3/4" ID
0.2 1" ID
0.15 1-1/4" ID
0.1
0.05
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Required GPM
2.7 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.
High pressure tubing and fittings must be rated for 60,000 psi (4,136 bar). Failure
to use properly rated components may result in component failure causing
equipment damage, personal injury or death.
High pressure tubing lengths are coned and threaded prior to installation. KMT Waterjet
provides both hand and power tools for coning and threading high pressure tubing. See Table 2-
6, Coning and Threading Tools, for descriptions and part numbers.
Table 2-6
Coning and Threading Tools
Part Number
Hand Tools Power Tools
1/4” Coning Tool 05108832 05109897
3/8” Coning Tool 05108857 05109889
9/16” Coning Tool 05108840 05109871
1/4” Threading Tool 05108865 05122742
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Table 2-6
Coning and Threading Tools
Part Number
Hand Tools Power Tools
3/8” Threading Tool 05108873 05120258
9/16” Threading Tool 05108881 05122759
1/4” Tube Vise 05108782
3/8” Tube Vise 05108790
9/16” Tube Vise 05108774
Measurements and Dimensions

Tubing must be cut to the proper length, both ends of the tubing must then be coned, threaded and
deburred.
To determine the tube length, measure the distance between the fittings, and add two times the
engagement allowance shown in Table 2-7. Table 2-8 lists the required cone and thread
dimensions illustrated in Figure 2-6.
Table 2-7
Engagement Allowance (EA)
1/4” Tubing 0.49” (12.4 mm) Figure 2-5: Tube Length
3/8” Tubing 0.68” (17.3 mm)
9/16” Tubing 0.86” (21.8 mm)
Figure 2-6: Cone and Thread Dimensions
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Table 2-8
Cone and Thread Dimensions
D L Thread
Tube OD Tube ID (Maximum) (Maximum) UNF-LH
1/4” (6.35 mm) 0.083” (2.11 mm) 0.125” (3.2 mm) 0.562” (14.3 mm) 1/4” - 28
3/8” (9.52 mm) 0.125” (3.18 mm 0.219” (5.6 mm) 0.750” (19.1 mm) 3/8” - 24
9/16” (14.29 mm) 0.188” (4.78 mm) 0.281” (7.1 mm) 0.938” (23.8 mm) 9/16” - 18
Hand Coning
1. Place the body of the coning tool in a vise allowing adequate clearance for the rotation of
the cutter handle. Position the tool so the cutter handle is elevated slightly so the lubricant
will flow to the cutting blade.
Figure 2-7: Hand Coning Tool
2. Turn the feed nut counter-clockwise to retract the cutting blade past the access window.
3. Loosen the gland nut and insert the tubing through the collet. The end of the tubing
should just make contact with the cutting blade. Loosely tighten the gland nut to grip the
tubing slightly.
4. Turn the feed nut counter-clockwise 1/4 turn to retract the cutting blade away from the
tubing, and tighten the gland nut with a wrench.
5. Apply a liberal amount of cutting oil to the exposed end of the tubing, the cutting blade
and through the lubrication channel at the cutter handle.
6. Apply cutting oil frequently and liberally throughout the cutting operation. Medium
weight cutting oil with high sulfur content is recommended.
7. Turn the feed nut clockwise until the cutting blade contacts the end of the tubing.
8. In a smooth, continuous motion, turn the cutter handle in a clockwise direction.
Simultaneously turn the feed nut in a clockwise direction to establish a constant feed. Do
not remove too much material at once; the cutting blade should make light, uninterrupted
cuts.
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Before interrupting the cut, back the cutter blade away from the tubing. Use
compressed air or a small brush to remove the accumulation of chips from the
blade and the tubing throughout the coning operation.
9. Continue the operation until the feed nut bottoms on the housing. Turn the cutter handle
several more rotations to face-off the end of the cone.
10. Retract the cutter blade, loosen the gland nut and remove the tubing. Inspect the cone for
surface finish and completeness.
Clean the machining chips from the blade and from the collet before coning the
next tube.
Power Coning
1. Secure the tubing in a tube vise. No more than the recommended length of tubing should
extend beyond the face of the vice. See Table 2-9, Recommended Extension Length.
2. Mount the coning tool in a 3/8-inch or 1/2-inch, variable speed power drill. Apply cutting
oil to the end of the tube and slide the coning tool on the tubing.
3. While the cone is being cut, apply steady pressure against the end of the tubing.
5. The tool will stop cutting when the tube angle and facing is complete.
Clean the machining chips from the blade and body of the tool before coning the
next tube.
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Table 2-9
Recommended Extension Length
1/4” Tubing 1.25-1.50” (31.8-38.1 mm)
3/8” Tubing 1.25-1.50” (31.8-38.1 mm)
9/16” Tubing 1.75-2.00” (44.5-50.8 mm)
Hand Threading
1. Secure the coned tubing in a tube vise. No more than the recommended length of tubing
should extend beyond the face of the vice. See Table 2-9, Recommended Extension
Length.
2. Apply cutting oil to the end of the tube and slide the threading tool on the tubing.
3. Grip the handle of the tool firmly, apply steady pressure and turn the tool counter-
clockwise. Approximately every half turn, reverse direction to break off and remove the
chips.
5. Continue threading until the proper thread length is reached, see Table 2-8, Column L.
Remove the tool from the end of the tubing.
Clean the machining chips from the die and body of the tool before threading the
next tube.
Power Threading
1. Secure the coned tubing in a tube vise. No more than the recommended length of tubing
should extend beyond the face of the vice. See Table 2-9, Recommended Extension
Length.
2. Mount the threading tool in a 3/8-inch or 1/2-inch, variable speed power drill. Apply
cutting oil to the end of the tube and slide the threading tool on the tubing.
3. Make sure the drill is set to turn counter-clockwise. Apply steady pressure against the end
of the tubing while the threads are being cut.
5. Continue threading until the proper thread length is achieved, see Table 2-8, Column L.
Reverse the direction of the drill and remove the threading tool.
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Clean the machining chips from the die and body of the tool before threading the
next tube.
2.8 High Pressure Connections

When installing high pressure discharge piping it is essential that all burrs are carefully removed
and the tubing sections purged with clean compressed air prior to assembly. Lightly spraying the
inside of the tube with a carrier fluid, such as WD-40, before purging with air will help carry the
burrs.
High pressure piping must be installed without torsional or bending stresses and proper supports
and guides must be provided. Torsional stress will cause premature component failure.
Pure Goop anti-seize compound must be applied to the threads and contact surfaces of all
stainless steel components prior to assembly. Failure to lubricate components with Pure Goop
will result in galling, rendering the components useless.
Do not use any other anti-seize compound. Apply Pure Goop only to stainless
steel components.
Standard Connections
Use standard connections for general applications where internal pressure is the only load on the
tubing.
1. Deburr the tubing ID and thoroughly clean

the tubing threads.
2. Slip the gland nut onto the tubing.
3. Apply Pure Goop to the threads on the
tubing. Screw the collar onto the threaded
end of the tubing leaving 1-1/2 to 2-1/2
threads exposed on the tubing between the
collar and the coned tubing.
4. Apply Pure Goop to the male threads on the gland nut and insert the tubing into the
connection. Engage the gland nut and tighten finger tight.
5. Tighten the gland nut to the torque specifications in Table 2-10.
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Proper piping supports and guides must be provided. End connections will not
support the tubing load alone.
Anti-Vibration Connections
The bending stresses resulting from excessive vibration or shock on the threaded area of the
tubing can cause premature failure at the back of the thread. Anti-vibration connections must be
used when tubing will be subjected to vibration, rotation and movement.
The anti-vibration collet gland transfers the stress to the unthreaded section of the tubing, and the
gripping action of the collet strengthens the entire assembly.
1. Deburr the tubing ID and thoroughly clean

the tubing threads.
2. Slip the gland nut and the collet onto the
tubing.
3. Apply Pure Goop to the threads on the
tubing. Screw the collar onto the threaded
end of the tubing leaving 1-1/2 to 2-1/2
threads exposed on the tubing between the
collar and the coned tubing.
4. Apply Pure Goop to the male threads on
the gland nut and insert the tubing into the
connection. Engage the gland nut and
tighten finger tight.
5. Tighten the gland nut to the torque specifications in Table 2-10.

When a flexible whip is used to allow cutting nozzle movement, anti-vibration fittings and proper
supports and guides must be provided to prevent failures from non-water related stresses. The
whip will only flex in a single plane without being subjected to torsional stress. The use of high
pressure swivels is strongly recommended.
Table 2-10
Torque Specifications
High Pressure Connections
1/4” Tubing 25 ft-lb (34 Nm)
3/8” Tubing 50 ft-lb (68 Nm)
9/16” Tubing 110 ft-lb (149 Nm)
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2.9 Commissioning
When the machine has been positioned, all service connections installed, and the high pressure
plumbing has been installed to the cutting area, the machine is ready to be commissioned.
The following procedure is used for the initial startup and testing of the machine.
1. Check all areas in and around the pump for foreign objects and debris. Remove all tools,
parts, etc. from the area.
2. Check the hydraulic fluid level. The hydraulic system is pre-filled prior to shipping. If
the hydraulic fluid is low or empty due to leakage during transit, the system must be filled.
Follow the instructions and specifications in Section 6, Recirculation System.
Prior to shipping, the breather was removed from the reservoir, placed in a plastic
bag and attached to the pump. The breather must be installed on the reservoir prior
to operation.
3. Open the shutoff valves on the service connections and check for leaks.
4. Check the connection between the main power disconnect and the disconnect/circuit
breaker on the enclosure door. Verify the proper voltage supply. Close the enclosure
door and turn the control power on.
5. To activate the control panel display, close the electrical enclosure and engage the circuit
breaker/disconnect on the door. The control panel will go through a series of diagnostics,
and the Main Screen will display. Refer to Section 4, Operation, for additional
information regarding control panel functions.
6. On the Run Screen, press the PRESSURE switch for low pressure operation.
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7. To avoid a sudden increase in pressure, it is necessary to adjust the high pressure setting.
On standard machines, the high pressure adjustment is made at the high pressure control
valve on the hydraulic manifold. Refer to Section 7, Hydraulic System, for additional
information.
Loosen the locking nut on the high pressure

control valve by turning counter-clockwise. Turn
the high pressure control valve counter-
clockwise, decreasing the pressure to the lowest
setting.
If the machine is equipped with proportional pressure control, the pressure is

automatically set to the minimum operating pressure of 10,000 psi (689 bar) when the
PRESSURE switch on the Run Screen is set to low pressure operation.
8. Check the motor rotation. On the Main Service Screen, press the motor START button.
Observe the pressure gauge on the hydraulic manifold. If the motor rotation is correct,
pressure will begin to build in just a few seconds. If the rotation is not correct, the gauge
will not move.
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If the motor shaft is rotating in the wrong direction, press the motor STOP button and turn
the control power off by pressing the EMERGENCY STOP button.
The electrical power phase must be reversed to any two motor leads. The leads can be
reversed at the disconnect/circuit breaker on the enclosure door, or at the main power
disconnect.
Do not allow the motor to run backward. Incorrect motor rotation will result in
damage to the hydraulic pump.
9. If the unit is equipped with an oil-to-air or a combination cooling system, check the fan
motor rotation. When viewed from the motor end, the fan should rotate clockwise. If the
rotation is not correct, the electrical power phase must be reversed to any two motor leads.
The leads can be reversed at the junction box on the fan motor or at the electrical
enclosure.
10. Remove the cutting orifice and open the nozzle valve.
11. Activate the control power and press the START button on the Run Screen to start the
motor. The dump valve will open for a short time to allow trapped air to bleed from the
high pressure cylinders. Run the machine in low pressure for approximately two minutes
with the orifice removed to purge the system.
12. Install a large, inexpensive orifice and start the machine.
13. Check for any leaks in the plumbing, or around the high pressure cylinders. If leaks are
detected, stop the machine and correct any problems.
14. Observe the Booster Pressure Gauge on the front of the machine to ensure the boosted
cutting water pressure is 180 psi (12.4 bar). If not, the booster pump pressure must be
adjusted. Refer to Section 5, Low Pressure Water System, for additional information.
Locate the adjustment screw in the acorn nut on the side of

the booster pump and use a flat blade screwdriver to turn the
screw. Turn the screw clockwise to increase the pressure or
counter-clockwise to decrease the pressure.
15. Check the safety circuits by pushing the EMERGENCY STOP button in and verifying the
alarms activate and the high pressure water drains from the system. If applicable, check
all remote start and emergency stop functions.
16. On the Run Screen, press the PRESSURE switch for high pressure operation. Increase the
high pressure setting in gradual increments, checking for leaks at each interval. Continue
increasing the pressure until the operating pressure is reached.
On standard units the high pressure setting is increased by turning the high pressure
control valve on the hydraulic manifold clockwise.
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17. If the machine is equipped with proportional pressure control, press the PRESSURE switch
on the Run Screen for high pressure operation.
18. From the Run Screen select the Dashboard. Press the pressure icon
on the Dashboard to display the keypad. Enter the desired operating
pressure and press ENTER.
It is strongly recommended that the high pressure plumbing be purged under high
pressure operating conditions, using a large, inexpensive orifice. Contamination
can be released when the tubing expands under pressure. Early orifice failures
could be experienced if the piping is not adequately purged.
2.10 Decommissioning
When the intensifier is decommissioned and taken out of service for any reason all local
regulations must be adhered to.
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SECTION 3
MAINTENANCE
The Maintenance section highlights:

§ Routine and preventive maintenance requirements
§ Precautions associated with high pressure cutting equipment
§ Equipment tool kits
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3.1 Overview
The entire SL-VI series has been designed to fail safely. Systems fail gradually; seals and
connections begin to leak slowly or suddenly through specially designed weep holes. Water or
oil dripping from a weep hole indicates internal seals or valves are beginning to fail, a warning
that maintenance will be required.
The comprehensive fault detection and troubleshooting logic built into the programmable logic
controller (PLC) monitors crucial pressure, temperature and fluid levels. Warning and shutdown
sensors guard against potential injury and equipment damage.
3.2 Maintenance
The waterjet system is designed for ease of maintenance and long, reliable operation. In order to
keep the equipment in optimum operating condition, routine and preventive maintenance is
essential, see Table 3-1, Routine Maintenance Schedule.
Detailed maintenance and troubleshooting procedures for specific systems are provided in
subsequent sections of this manual.
Daily Inspection
The following inspection procedures should be performed each shift. If problems are detected,
they should be remedied before placing the machine in service.
§ Prior to startup, inspect the area around the machine, the high pressure piping and
connections for indications of leaks.
§ Make sure there is no maintenance work in process.
§ Check the hydraulic oil level.
§ As the machine is started and water pressure increases, listen for unusual sounds.
§ Check for water or oil leakage.
§ Check the condition of the water filter and the oil filter.
Periodic Maintenance
A number of factors can contribute to component failure; poor water quality, operating
conditions, or improper maintenance procedures. Maintaining a service log can be a useful
method of tracking component life and maintenance trends. Analyzing service intervals will
assist in preparing a preventive maintenance schedule tailored to your specific application and
production requirements. Periodic maintenance, at regularly scheduled intervals, will minimize
unscheduled downtime and premature component failure.
Improper assembly can lead to the premature failure of components. Follow maintenance
procedures carefully; properly clean components prior to assembly and tightened to the correct
torque specifications.
§ Maintain a clean, dust and dirt free work area for maintenance.
§ Use only clean, dry air and clean, filtered solvent when flushing parts.
§ Use lint free cloths for cleaning.
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§ Use extreme care when aligning close tolerance parts for assembly. Do not force the parts
together. If parts bind during assembly, they must be disassembled and realigned.
§ Use only original KMT Waterjet replacement parts for consistent performance and
reliability; and to protect equipment warranty.
To avoid unsafe conditions and the risk of equipment damage,

operating personnel and service technicians must carefully read and
follow the procedures in this manual.
Table 3-1
Routine Maintenance Schedule
6,000 hours
Per Shift
3-Month
6-Month
Monthly
Weekly
Yearly/
Description
Inspection for leakage and High pressure system X
abnormal conditions
Low pressure system X
Hydraulic system X
Recirculation system X
Pressure checks Discharge cutting water X
Inlet cutting water X
Booster water X
Inlet cooling water X
Hydraulic operating oil X
Compressed air X
Temperature checks Sealing head X
High pressure cylinder X
Hydraulic cylinder X
Hydraulic oil X
Inlet cooling water X
Discharge cooling water X
Dump valve X
Electric motor X
Hydraulic pump(s) X
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Table 3-1
Routine Maintenance Schedule
6,000 hours
Per Shift
3-Month
6-Month
Monthly
Weekly
Yearly/
Description
Filter units Low pressure water filter [1] X
Hydraulic oil filter [2] X
Rotating equipment vibrations Electric motor X
Hydraulic pump(s) X
Supply requirements Hydraulic oil in reservoir [3] X R
Control panel checks Lights X
Safety functions X
Note: X = to be observed
R = to be replaced
[1] When the filter element is new, document the pressure reading from the gauge on the front of the
machine. The element should be replaced when the pressure drops to 15 psi (1 bar) below the
original value. When the element is replaced, the strainer should also be cleaned.
[2] All 30, 40 and 50 horsepower machines are equipped with a numeric pressure gauge that indicates
inlet pressure. The filter element should be changed when the gauge reads 40 psi (2.8 bar) at normal
operating temperature or after 3,000 hours whichever comes first.
The 100 horsepower machines, and units equipped with an optional onboard cooling system utilize a
differential pressure indicator. Change the filter element on these machines when the indicator enters
the red zone at normal operating temperature or after 3,000 hours whichever comes first.
[3] Change the hydraulic oil at intervals required to maintain ISO 4406 cleanliness level 18/15/13, not to
exceed 6,000 hours.
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High Pressure System Maintenance

The high pressure system is conveniently mounted on a drip pan. All service components are
readily accessible, and can easily be removed from the unit for maintenance and service.
§ High pressure fittings, valves and tubing must be rated for 60,000 psi (4,137 bar). Failure
to use properly rated components may result in component failure, equipment damage and
personal injury.
§ Do not over-torque fittings to stop leakage.
§ Ensure all components are clean, free of burrs, metal particles, dirt and dust prior to
assembly.
After servicing high pressure components the high pressure water system must be thoroughly
flushed to remove any debris or contaminates.
1. Operate the intensifier for a short period with the nozzle valve open and the orifice
removed.
2. Turn the intensifier off and install an orifice.
3. Turn the machine on and increase the operating pressure in gradual increments. Check all
high pressure connections for leaks.
Many components are lubricated prior to assembly. Table 3-2 lists the recommended lubricants
and their applications. Substitutions are not recommended.
Table 3-2
Lubrication Specifications
Description Application Part Number
Pure Goop, 1 ounce Stainless steel threads and metal-to- 10084440
metal joints
FML-2 Grease, 14-1/2 ounce O-rings, backup rings, bearing rings, 10087385
seal components
JL-M Grease, 16 ounce Non-stainless steel threads 49832199
3.3 Maintenance Precautions

Make sure all safety devices are operational. Check each device on a specified schedule. If the
device does not function, replace it before operating the machine.
Check the EMERGENCY STOP button. The normal operating position is pulled out. Turn the
power on and activate the emergency stop button by pushing it in to verify the power goes off and
the safety dump valve opens to bleed the high pressure from the system.
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Before performing any maintenance on the equipment, take the system

out of service and make sure the controls are properly locked and
marked. Never perform any maintenance on the equipment without
making sure the main control power is locked out in the OFF position.
§ Never service or maintain the equipment while it is operating.

§ Steam or fog inside the top cover is an indication of a high
pressure leak. All high pressure leaks must be repaired
immediately. Press the EMERGENCY STOP button to turn the
control power off and bleed off the high pressure water from
the intensifier before lifting the cover.
§ Never service or maintain any high pressure component, or
loosen any high pressure fitting when it is pressurized. Press
the EMERGENCY STOP button to turn the control power off and
bleed off the high pressure water from the intensifier before
servicing.
§ If leakage occurs at a sealing surface, high pressure water is
released through weep holes. If a pressurized fitting is
loosened, a jet of high pressure water will exit the nearest weep
hole with possible hazardous results.
3.4 Tools Kits

Table 3-3 provides a list of the spare parts and maintenance tools included in standard tool kits
for SL-VI series pumps. Components can also be ordered individually.
Table 3-3
Tool Kits
Tool Kit Tool Kit
05072731 80075930
Part Number Description 7/8” Plunger 1-1/8” Plunger
10087385 FM-L Grease, 14-1/2 ounce 1 1
80078330 Seal Removal Tool Stand 1 1
10079986 Strap Wrench 1 1
10081370 Spanner Wrench 1 1
05053871 Combination Wrench, Box/Open 1 1
10084440 Pure Goop, 1 ounce 3 3
10087609 Crescent Wrench 1 1
20484961 Vee Block 1 1
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Table 3-3
Tool Kits
Tool Kit Tool Kit
05072731 80075930
Part Number Description 7/8” Plunger 1-1/8” Plunger
05066139 Cylinder Wrench 1 1
10148674 HP Seal Installation Tool 1
05146618 HP Seal Installation Tool 1
10149029 Emery Cloth, 320 Grit 2 2
10149037 Emory Cloth, 400 Grit 4 6
10149045 Emory Cloth, 600 Grit 6 6
10149052 Glass Pane 1 1
20477460 Plunger Removal Tool 1
20477469 Plunger Removal Tool 1
80078256 Torque Wrench, 5-75 ft/lbs 1 1
05103957 Hex Driver, 12MM 1
20470475 Seal Installation Tool Kit, Pneumatic Valve 1 1
10079523 HP Plug, .38 1
10078772 HP Plug, .56 1
10078129 HP Gland, .38 1
10078608 HP Gland, .56 1
80082191 JL-M Grease, 15 milliliter pack 2 2
80079239 End Cap Wrench 1 1
80078249 Socket Wrench, .38 1 1
72132282 Threadlocker 248 Adhesive, 19 gram tube 1 1
20494983 Threadlocker Primer, 1-3/4 ounce 1 1
20473684 Socket Driver, .63 1
20454198 Hand Coning and Threading Tools

20454201 Power Coning and Threading Tools
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SECTION 4
OPERATION
The Operation section details:

§ Principles of operation and function of the system
§ Warnings and faults, along with possible remedies
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4.1 Overview
The SL-VI series utilizes a programmable logic controller (PLC) to provide comprehensive fault
detection and troubleshooting logic. The operator functions and warnings offer a comprehensive
view of operating conditions, impending faults, shutdown faults and suggested remedies.
The operator interface is through a touch sensitive control display where operating parameters are
set and monitored. Optional proportional pressure control allows the operator to select or vary
the operating pressure from the control display or from a remote console. When the machine is
equipped with an optional pressure transducer the operating pressure can be viewed from the
display.
4.2 Home Screen

The Home Screen displays the operating status of the machine and provides access to a series of
setup and monitoring screens. The pump serial number and the PLC and HMI versions are
shown at the top of the screen.
Figure 4-1: Home Screen
A red light indicates a fault.
A flashing yellow light indicates the machine is in service mode.

A steady yellow light indicates a warning.
The green light flashes while the machine is starting.
When the intensifier is generating pressure, the green light is steady.
Press to exit to Windows operation system.
Press to display the Run Screen.
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Factory Configuration Screen

The Factory Configuration Screen is used to set the initial pump parameters at the
factory. It is password protected and is not intended for customer access.
Customer Configuration Screen
Password protected area where operating parameters are set and optional modules
purchased as upgrades are configured.
Operator Configuration Screen
The Operator Configuration Screen allows the operator to set the display language
and restore saved settings and parameters.
Main Service Screen
All maintenance and service activities are performed
from the Main Service Screen.
Before the Main Service Screen displays, the pump
will shut down. When the shutdown warning is
issued, press OK to continue or press CANCEL to
abort the request
4.3 Operating Overview
Standard Units
A standard unit is defined as any unit that is not equipped with an optional high pressure
transducer or proportional pressure control module.
The Run Screen is the only location where the machine can be started to create pressure.
Figure 4-2: Run Screen, Standard Units
The temperature gauge on the Run Screen displays the hydraulic oil temperature in the reservoir.
The following functions are also displayed:
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IDLE TIME
Press the up or down arrow to select an idle time from 0-60 minutes. The
selected interval displays above the arrows.
Idle shutdown automatically stops the motor after a deadhead condition
occurs. If the idle time is set to zero, motor shutdown is disabled.
The default idle time is set on the Customer Configuration Screen.
However, it can be changed on the Run Screen during operation.
CONTROL STATION
Press to select local or remote control. When

the shutdown warning is issued, press OK to
change control station or press CANCEL to
abort the request.
Remote control functions include, start, stop,
alarm reset, high/low pressure and a pause
function.
HIGH/LOW PRESSURE
Press the pressure switch to select high or low pressure operation. In the
current state, high pressure is selected.
When low pressure is selected, the low pressure indicator illuminates.
When the machine is stopped and restarted, it will always start in low
pressure. When the machine reaches production mode, it will go to high
pressure or remain in low pressure, depending on the previous high/low
pressure setting.
START
The start button indicates when the machine is ready to start, designated by a
green check mark next to the start button.
After the machine has been stopped, there is a delay before it can be started,
designated by a red X next to the start button.
STOP
Press the stop button to stop the machine. After the five-second delay, the
machine can be started, designated by a green check mark next to the start
button.
ALARM RESET
Press to reset an active alarm. The icon is only visible if there is an active
alarm.
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E-STOP RESET
Press to reset the emergency stop. The icon is only visible if there is an
active alarm and the e-stop was initiated. The icon will flash indicating it
must be reset before the alarm can be reset.
Press to display the Home Screen.
Press to display Intensifier Control Screen.
Press to view the Active Alarms Screen.
Press to display the Alarm History Screen.
Units Equipped with a Pressure Transducer

If the machine is equipped with an optional high pressure transducer, the Run Screen in Figure 4-
3 will display. All standard unit functions are available with the addition of a pressure gauge
indicating the operating pressure.
Figure 4-3: Run Screen with Pressure Transducer
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Units Equipped with Proportional Pressure Control

If the machine is equipped with an optional proportional pressure control, the Run Screen in
Figure 4-4 will display. All standard unit functions are available with the addition of a Pressure
Limit and Calibration Screen and a Dashboard.
The Pressure Limit and Calibration Screen is used to set the maximum and minimum pressure
limits and to calibrate the remote signal. See Section 4.6, Machine Setup, Pressure Limit and
Calibration Screen.
Figure 4-4: Run Screen with Proportional Pressure Control
Press to display the Dashboard shown in Figure 4-5.

The pressure signal source and the desired operating pressure are set on the
Dashboard.
The display provides monitoring gauges for the commanded pressure within the
limits set on the Pressure Limit and Calibration Screen. The gauges include the
pressure signal from the transducer, hydraulic oil temperature, percent of
strokerate to machine capacity and the commanded pressure to the proportional
pressure control.
Note: If the unit is not equipped with a transducer, the transducer gauge will not
display.
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Figure 4-5: Dashboard
1. Use the drop-down on the top left to select the pressure signal source, local or remote.
2. Press the pressure icon to display the keypad. Enter the desired operating pressure and
press ENTER.
The maximum and minimum pressure limits are set on the Pressure Limit and
Calibration Screen. See Section 4.6, Machine Setup, Pressure Limit and
Calibration Screen.
If the operating pressure is set outside these limits, the pressure will default to the
minimum pressure, 10,000 psi (689 bar).
Press the switch to change the setting from zero to one to display a digital readout for each gauge.
Figure 4-6: Dashboard with Digital Readout
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Units Equipped with a Pressure Transducer and Proportional Pressure

If the machine is equipped with an optional proportional pressure control and a pressure
transducer, the Run Screen in Figure 4-7 will display. All standard unit functions and all
functions available with the addition of a pressure transducer and proportional pressure control
are available.
Figure 4-7: Run Screen with Pressure Transducer and Proportional Pressure Control
4.4 Intensifier Control Screen

From the Intensifier Control Screen the operator can monitor the percent of stroke rate to the
alarm setting and percent of machine capacity.
Figure 4-8: Intensifier Control Screen, Standard Units
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The ALARM CONTROL automatically increases or decreases the alarm stroke

rate.
Open the cutting head and run the pump until it reaches desired pressure and
flow rate. Press the up arrow to set the alarm stroke rate to 100%. A warning
is issued if the stroke rate reaches 105%. A pending shutdown will occur at
110% with a 30 second delay before shutdown.
If the operating pressure is changed, the alarm stroke rate should be reset. If it not
reset, the reading on the Intensifier Control Screen will not be correct.
Press to display the General Pump Data Screen
If the machine is equipped with an optional redundant topworks, the Intensifier Control Screen in
Figure 4-9 will display. The same functions are displayed with the addition of a switch to select
topworks 1 and 2.
Figure 4-9: Intensifier Control Screen with Redundant Topworks
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4.5 General Pump Data Screen

The General Pump Data Screen provides cycle count and/or total hours for maintenance and duty
components on the pump. The indicator for the hydraulic oil filter and the hydraulic oil reservoir
are color-coded to indicate when they are approaching the recommended replacement time, see
Table 4-1, Indicator Status.
Figure 4-10: General Pump Data Screen
Press to return to the previous screen.
Press to save the current data displayed.
Table 4-1
Indicator Status
Hydraulic Oil Filter

0-2,960 hours Green
2,960-2,990 Yellow
2,990-3,000 Red
3,000 and above Flashing Red
Hydraulic Oil Reservoir

0-5,980 Green
5,980-5,990 Yellow
5,990-6,000 Red
6,000 and above Flashing Red
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The hydraulic oil filter should be replaced at 3,000 hours. The hydraulic oil should be replaced at
6,000 hours. The oil should be replaced sooner if a fluid sample indicates contamination that
cannot be rectified by filtering.
4.6 Machine Setup

The Customer Configuration Screen is a password protected screen. It allows
the customer to set operating parameters during the initial commissioning of the
pump. It also allows the customer to set up optional modules purchased as
upgrades for existing equipment.
Enter the username, user, and the password 111320 when the prompt displays.
Figure 4-11: Customer Configuration Screen
§ IDLE TIME
Use the up or down arrows to set the desired idle time from 0-60 minutes in five (5)
minute increments. The selected interval displays above the arrows. The default setting is
ten (10) minutes.
Note: When the idle time is set at zero, the function is disabled.
§ LOW WATER PRESSURE DELAY
Inlet cutting water pressure is monitored by a 30 psi pressure switch. If the inlet water
falls below 30 psi for a certain time interval, the pump will shut down. The default setting
is two (2) seconds.
Use the up and down arrows to select an interval between two (2) and five (5) seconds for
shut down. The selected interval displays above the arrows.
§ UHP PRESSURE RELIEF
When transferring from a high pressure to a low pressure, the dump valve will open to
relieve pressure and then close.
Use the up and down arrows to select a time between zero and one (1) second to open the
dump valve, release the pressure in the line and then close the dump valve. The time is set
in 50 millisecond increments. The default setting is zero.
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§ DUMP VALVE AT MOTOR OFF
Press the switch to select open or closed to set the dump valve condition when the motor
stops. The default is closed.
§ RMT PRESSURE SIGNAL CONFIG
Press the switch to select 1 or 0 to configure the remote pressure signal. Table 4-2,
Remote Pressure Signal Configuration, illustrates the result of each selection.
Table 4-2
Remote Pressure Signal Configuration
Switch Remote Pressure Pump

Setting Command Pressure
0 Low Low
0 High High
1 Low High
1 High Low
Press to save the settings to the accompanying folder. The

contents of the folder represent the current or default settings
and can be restored at any time by pressing the folder icon.
HIGH PRESSURE TRANSDUCER
Press the switch to indicate a high pressure transducer is installed on the unit.
The switch will turn green.
POWER FACTOR CORRECTION
Press the switch if power factor correction is installed on the unit. The switch
will turn green.
REDUNDANT INTENSIFIER
Press the switch if a redundant intensifier is installed on the unit. The switch
will turn green.
OIL-TO-AIR OR COMBINATION COOLING
Press the switch if an oil-to-air or combination cooling system is installed on

the unit. The switch will turn green.
Press to save the settings to the accompanying folder. The

contents of the folder represent the current or default settings
and can be restored at any time by pressing the folder icon.
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Press to display the Pressure Limit and Calibration Screen. This

function is only available on units equipped with optional
proportional pressure control.
Pressure Limit and Calibration Screen

The Pressure Limit and Calibration Screen is only available on units equipped with optional
proportional pressure control. The function is used to set the pressure limits and to calibrate the
remote signal. All input signals are regulated through this screen before going to the pump.
Figure 4-12: Pressure Limit and Calibration Screen
Although the maximum pressure limit is 60,000 psi (4,317 bar) and the minimum pressure limit is
10,000 psi (689 bar), the limits can be changed as required.
1. Press the high limit icon to display the keypad. Enter the desired high limit and press
ENTER. Pressure can be entered in either psi or bar.
2. Press the low limit icon to display the keypad. Enter the desired low limit and press
ENTER.
3. The new setpoints display on the screen and become the maximum and minimum pressure
limits for operation.
The remote calibration section is used to calibrate the high and low signal coming from the
remote controls. For example, the machine is programmed to receive a signal from 0-10 volts. If
the remote control is sending a 1.2-9.2 volt signal, the result will be a minimum pressure of
12,000 psi (827 bar) and a maximum of 55,200 psi (3,806 bar).
1. When the signal is received, press the up arrow to calibrate the maximum pressure limit,
converting the 9.2 volt signal to 60,000 psi (4,317 bar).
2. Press the down arrow to calibrate the minimum pressure limit, converting the 1.2 volt
signal to 10,000 psi (689 bar).
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These operations must be performed during commissioning and if the pressure

changes.
If the machine is also equipped with an optional high pressure transducer, the Pressure Limit and
Calibration Screen in Figure 4-11 will display. In addition to setting pressure limits and
calibrating the remote control signal, the pressure transducer must be calibrated.
Figure 4-13: Pressure Limit and Calibration Screen with Pressure Transducer
1. Run the pump until the operating pressure and oil temperature stabilize.
2. Stop the pump and relieve all pressure from the system.
3. Press the UHP ZERO button to zero the pressure transducer.
The transducer must be calibrated during commissioning and on a monthly basis

thereafter.
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Operator Configuration Screen

The Operator Configuration Screen allows the operator to set the display
language and restore saved settings and parameters.
Figure 4-14: Operator Configuration Screen
LANGUAGE
Press the flag designating the desired language.
Press to restore the factory configuration settings.
Press to restore the operator selected settings and options to the last saved
values.
Press to restore the operator selected operating parameters to the last saved
values.
Press to restore the intensifier and pump information to the last saved values.
Press to display the PLC Screen.

The PLC Screen allows the operator to monitor the PLC inputs and outputs.
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Figure 4-15: PLC Screen
4.7 Service and Maintenance

All maintenance and service activities are
performed from the Main Service Screen. When
selected, an automatic pump shut down is initiated.
When the shutdown warning is issued, press OK to
continue or press CANCEL to abort the request.
Only qualified personnel should perform
maintenance on the machine.
Figure 4-16: Main Service Screen
When the left or right arrow is pressed, the piston on the selected end will
extend, allowing full exposure to the plunger on the selected end when the
unit is disassembled.
The unit must be completely assembled to use this function.
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Press to display the General Pump Maintenance Screen.

Note: When this icon is pressed on the Intensifier Control Screen, the
General Pump Data Screen displays. The General Pump Maintenance
Screen is only available from the Main Service Screen.
Press the START button to turn the inlet cooling water on. This function can
be used to test the cooling system.
On oil-to-water systems, the solenoid valve in the discharge cooling line will
open and cooling water will flow to the heat exchanger. On oil-to-air
systems, the fan will start.
Press the START button to turn the inlet cutting water on. This function can
be used to purge the lines during commissioning or after maintenance.
Press the START button to start the motor. The motor will shut down after 10
minutes.
If the machine is equipped with an optional pressure transducer, the Main Service Screen in
Figure 4-17 will display. All standard unit functions are available with the addition of the
transducer calibration function.
Figure 4-17: Main Service Screen with Pressure Transducer
The General Pump Maintenance Data Screen displays the hours and/or cycle count for
maintenance and duty components that support the low pressure water, recirculation and
hydraulic systems.
The indicator for the hydraulic oil filter and the hydraulic oil reservoir are color-coded to indicate
when they are approaching the recommended replacement time, see Table 4-1, Indicator Status.
The hydraulic oil filter should be replaced at 3,000 hours. The hydraulic oil should be replaced at
6,000 hours. The oil should be replaced sooner if a fluid sample indicates contamination that
cannot be rectified by filtering.
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Figure 4-18: General Pump Maintenance Screen
When maintenance is performed, the operator can reset the

hydraulic filter or reservoir hours by pressing the corresponding
indicator.
When the confirmation warning is issued, press OK to continue or
press CANCEL to abort the request.
4.8 Alarms
When an alarm condition occurs, the Alarm Screen will display over the current screen. The
screen lists the type of alarm, the time and date it occurred. An ‘I’ in the status field indicates the
alarm is active.
Pressing the ACKNOWLEDGE button will temporarily clear the screen. The status
will change to ‘I A’ indicating the alarm has been acknowledged.
Figure 4-19: Alarm Screen
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When the alarm condition is corrected, press the ALARM RESET button and the E-
STOP RESET button, if applicable.
The status on the Alarm Screen will change to ‘I A O’ indicating the alarm has
been reset.
The Alarm History Screen displays the last 3,000 shutdown faults indicating the time, date and
type of alarm.
Figure 4-20: Alarm History Screen
Alarms are issued as faults, warnings or shutdowns. When a fault alarm occurs, shutdown is
immediate. The motor stops, the dump valve opens and all high pressure and hydraulic pressure
are relieved.
A warning alarm indicates a potential shutdown condition is being monitored. If the condition
persists, shutdown will occur.
A shutdown alarm will result in a shutdown after a given time interval. The interval depends on
the type of warning.
Table 4-3 lists all alarms along with the indication and possible remedies.
Table 4-3
Alarms
ID Alarm Indication and Comments Possible Remedies

1 Low Water Inlet Pressure A shutdown has occurred due to Check water supply.
Switch Fault low inlet water pressure, less than
30 psi (2 bar). Check water strainer.
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Table 4-3
Alarms

2 Low Water Inlet Pressure A shutdown has occurred due to Check water supply.
Peak Count Fault inconsistent inlet water pressure,
peaks in pressure falling below 30 Check water strainer
psi (2 bar).
The water pressure has fallen
below 30 psi (2 bar) 10 times.
3 Low Water Inlet Peak Count Inconsistent inlet water pressure, Check inlet water supply.
Warning peaks in pressure falling below 30
psi (2 bar).
Check plumbing to ensure it
A warning is issued when the is sized properly.
water pressure falls below 30 psi (2
bar) eight times. If the facility water pressure
is below, or can fall below 35
psi (2.4 bar), a water pressure
booster pump is required.
4 Low Inlet Water Pressure Cutting supply water pressure is Check water supply.
Warning inadequate for proper machine
operation, less than 30 psi (2 bar).
If the condition persists, shutdown Check water strainer.
will occur.
5 Booster Pressure Switch A shutdown has occurred due to Check booster pump
Fault low booster water pressure, less adjustment.
than 100psi (6.9 bar).
Check condition of booster
pump and replace if
necessary.
6 Oil Temperature Cold Oil temperature has dropped below Start the hydraulic motor to
Warning 68º F (20º C). If the condition warm the oil. When the oil
persists, shutdown will occur. has reached the appropriate
temperature the motor will
High pressure will not be
shut down.
generated while the oil is cold.
7 Oil Temperature Hot High hydraulic oil temperature, in Check the cooling system.
Warning excess of 144º F (62º C).
If the condition persists, shutdown
will occur.
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Table 4-3
Alarms

8 Oil Hot Pending Shutdown High hydraulic oil temperature, in Check the cooling system.
excess of 144º F (62º C).
will occur.
9 Oil Level Fault Shutdown has occurred as a result Check the level gauge.
of low hydraulic oil level.
Check for hydraulic leaks.
Check the oil level switch.
10 Oil Hot Fault Shutdown has occurred as a result Fix the cooling system
of high hydraulic oil temperature. supply and start the hydraulic
motor to cool the oil.
High pressure will not be
generated while the oil is hot.
11 QA3 Tripped, Remote The QA3 breaker has tripped. Find and fix the cause of the
Safety Function Activated, trip then reset the breaker.
Interface Plug Disconnected
The safety remote function is Reset the safety remote
activated. function.
The interface plug is disconnected. Connect the interface plug.
12 Local E-Stop Activated E-stop button on the pump has Pull the e-stop button out.
Fault been activated, resulting in Press the e-stop reset and
shutdown. fault reset buttons.
13 Local Safety Function Relay Wiring is damaged or loose. Check wiring and replace or
Fault repair as needed.
E-stop switch contacts are broken. Replace the contacts.
Defective safety relay. Replace the safety relay.
14 Remote Start PB On Fault Remote start command stayed on Check the software or
too long resulting in a shutdown. hardware source of start
Command should be a momentary command.
signal < 0.5s.
Wiring has shorted. Repair or replace the wiring.
Start pushbutton is damaged. Replace the pushbutton.
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Table 4-3
Alarms

15 Local Start PB On Fault Local start command stayed on too Train operators to not hold
long resulting in a shutdown. button on too long.
HMI touch screen is defective. Replace touch screen.
16 Safety Function Reset There is air pressure to the dump Check the pneumatic valves
Dump Valve Pneumatic valve when it should be off. for proper operation and/or
Pressure Switch (DVPPS) bypassing.
Fault
Defective dump valve pneumatic Replace the switch.
pressure switch
17 DVPPS Off Fault There is air pressure to the dump Check the pneumatic valves
valve when it should be off. for proper operation and/or
bypassing.
Defective dump valve pneumatic Replace the switch

pressure switch
18 DVPPS On Fault There is no air pressure to the Check the pneumatic valve
dump valve when it should be on. for proper operation.
Defective dump valve pneumatic Replace the switch

pressure switch
19 Motor Overload Fault The PLC monitors the motor Check incoming voltage.
overload relay and issues a fault
when the overloads trip. Check overload setting.
Check the motor amperage.
20 Remote Control Station Remote start, stop and fault reset Check the wiring.
Fault buttons are not in the correct
position for proper operation. Verify the remote interface
plug is connected.
21 Cooling Fan Overload Fault Overload has tripped on the Check incoming voltage.
cooling fan motor resulting in a
shutdown. Check overload settings.
Applies only to units equipped with
an optional cooling system. Check motor amperage.
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Table 4-3
Alarms

22 Cooling Fan Overload Overload has tripped on the Check incoming voltage.
Warning cooling fan motor. If the condition
persists, intensifier shutdown will Check overload settings.
occur.
Warning is only issued during high Check motor amperage.
pressure generation.
an optional cooling system.
23 Cooling Fan Not Operating Cooling fan motor failed to turn on Check incoming voltage.
Warning for cooling. If the condition
persists, intensifier shutdown will Check overload settings.
occur.
Warning is only issued during high Check motor amperage.
pressure generation.
an optional cooling system.
24 Idle Time Two Minute Intensifier has run in a deadhead Cycle intensifier or adjust
Shutdown Warning condition for the customer adjusted time limit.
time limit (0-60 minutes).
will occur in two (2) minutes.
25 Change Oil Filter Warning Hydraulic oil filter requires Change the oil filter and then
replacement. reset the indicator
26 Cover Interlock SSW1 Cover for intensifier 1 is open. If Close and lock the cover.
Open Warning the condition persists for two (2)
minutes, shutdown will occur.
optional cover interlock.
27 Cover Interlock SSW2 Cover for intensifier 2 is open. If Close and lock the cover.
Open Warning the condition persists, shutdown
will occur.
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Table 4-3
Alarms

28 Safety Function Interlock Cover is open. If the condition Close and lock the cover.
Relay Timer Started persists for tw0 (2) minutes,
Warning shutdown will occur in two
minutes.
29 Safety Function Interlock Shutdown has occurred as a result Close and lock the cover.
Time Expired Fault of an open cover. If the cover is
closed, but it is not locked, the two
(2) minute timer starts.
30 Cooling Fan Motor The overload has tripped.

Overload Not OK Warning
will occur.
31 Cooling Fan Motor The overload has tripped resulting

Overload Fault in a shutdown.
32 Left OS Warning A left overstroke condition has Check left high pressure seal.
occurred.
Check right discharge check
Abnormally high stroke rate
valve.
caused by an external or internal
leak. Shutdown will occur if
condition persists. Check left inlet check valve.
33 Right OS Warning A right overstroke condition has Check right high pressure
occurred. seal.
Abnormally high stroke rate
Check left discharge check
valve.
leak. Shutdown will occur if
condition persists.
Check right inlet check valve.
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Table 4-3
Alarms

34 Intensifier OS Warning A topworks overstroke condition Check plumbing for leaks.
has occurred.
Abnormally high stroke rate Check high pressure orifice.
leak. Shutdown will occur if Check incoming water
condition persists. pressure.
An intensifier overstroke warning Check inlet and discharge

indicates the intensifier is stroking check valves.
too fast in both directions.
35 Left OS Shutdown Pending A left overstroke condition has Check left high pressure seal.
occurred and shutdown will occur
in 30 seconds. Check right discharge check
valve.
Check left inlet check valve.
36 Right OS Shutdown A right overstroke condition has Check right high pressure
Pending occurred and shutdown will occur seal.
in 30 seconds.
valve.
37 Intensifier OS Shutdown An intensifier overstroke condition Check plumbing for leaks.

Pending has occurred and shutdown will
occur in 30 seconds. Check high pressure orifice.
If the machine is running near full
capacity, it is possible an Check incoming water
intensifier shutdown is actually pressure.
caused by a left or right warning.
This can be diagnosed further by Check inlet and discharge
reducing the operating pressure check valves.
and monitoring all alarm
occurrences on the Alarm Screen.
If the machine is equipped with a
pressure transducer, another level
of overstroke protection is obtained
by shutting down at the warning
level if the pressure is less than
3,000 psi (207 bar).
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Table 4-3
Alarms

38 Left OS Shutdown Fault Shutdown has occurred as a result Check left high pressure seal.
of a left overstroke.
Check right discharge check
valve.
Check left inlet check valve.
39 Right OS Shutdown Fault Shutdown has occurred as a result Check right high pressure
of a right overstroke. seal.

valve.
40 Intensifier OS Shutdown Shutdown has occurred as a result Check plumbing for leaks.
Fault of an intensifier overstroke.
Check high pressure orifice.
Check incoming water

pressure.
Check inlet and discharge

check valves.
41 Booster Pressure Warning Booster pump output pressure is Check booster pump
inadequate for proper machine adjustment.
operation, less than 100 psi (6.8
bar). Check condition of booster
pump and replace if
necessary.
will occur.
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SECTION 5
LOW PRESSURE WATER SYSTEM
The Low Pressure Water System section details:

§ Routine maintenance procedures associated with the system
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Section 5
5.1 Overview
The SL-VI series utilizes two low pressure circuits: cutting water supply and cooling water
supply. This section will discuss the cutting water supply circuit. See Section 6, Recirculation
System, for a detailed explanation of the cooling water supply circuit.
The cutting water supply circuit supplies the intensifier with the required cutting water flow and
pressure. System components include the strainer, inlet water solenoid valve, booster pump and
the low pressure filter assembly. Pressure sensors, connected to the PLC, monitor out of
tolerance conditions in the cutting water circuit and provide automatic shutdown protection.
5.2 Cutting Water Supply

The quality of the inlet cutting water supply is one of the most important factors affecting
component life and performance. Impurities in the water create grinding and corrosive effects on
all components. See Section 11, Specifications, for details regarding water quality standards.
5.3 Operation
Cutting water is introduced through the 1/2-inch NPT connection on the bulkhead of the machine.
Inlet cutting water pressure should be a minimum of 35 psi (2.4 bar) flowing, and can be
monitored from the pressure gauge located on the front of the machine.
Figure 5-1: Low Pressure Water System
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Cutting water passes through a strainer to remove debris before the water enters the normally
closed, inlet water solenoid valve. When the motor is turned on, the solenoid valve opens and
allows water to flow through the valve. The inlet water is monitored by a 30 psi pressure switch
mounted on the inlet manifold. If the pressure drops below 30 psi (2 bar) the switch activates an
automatic shutdown circuit in the PLC and the motor will not start. The inlet solenoid valve
closes 15 seconds after the motor shuts off.
The motor will not start if inlet cutting water pressure is below 30 psi (2 bar).
The booster pump increases the pressure to a maximum of 180 psi (12.4 bar) to ensure proper
supply to the intensifier assembly.
Pressurized water passes through the filter assembly where debris is removed to prevent
contaminants from damaging the check valves and seals in the intensifier. The filter assembly
consists of a filter head, housing and a 10 micron absolute filter.
As the water enters the outlet manifold, the discharge pressure is monitored by a 100 psi pressure
switch. An automatic shutdown will occur if the pressure is below 100 psi (4 bar).
If the booster pump pressure exceeds 205 psi (14 bar) a relief valve opens allowing water to exit
through the 1/2-inch drain connection on the bulkhead. It is still possible to operate the machine;
however, excess water will continue to be released through the drain.
Discharge pressure is displayed on the pressure gauge located on the front of the machine. The
gauge should read approximately 180 psi (12.4 bar) while the machine is idling. When it strokes,
the pressure drop should be no greater than 30 psi (2 bar). The water pressure range should
remain between 150-180 psi (10.3-12.4 bar) during operation.
While the intensifier assembly reverses direction, the boosted pressure will
fluctuate slightly above and below the normal setting.
A relief valve built into the filter assembly prevents excessive discharge pressure and typically
operates when the machine is in a deadhead condition. The booster pump is factory set to deliver
180 psi (12.4 bar) with an inlet pressure of 58 psi (4 bar). The pump may require adjustment to
satisfy system requirements.
To reduce overheating during a deadhead condition, water is re-circulated through the orifice in
the check valve, and routed back through the inlet of the booster pump.
From the outlet manifold, cutting water is routed to the inlet check valves in the sealing head on
each end of the intensifier. If the machine is equipped with redundant intensifiers, the cutting
water supply lines are manually connected to the active intensifier and manual hydraulic valves
are opened or closed to direct the hydraulic flow to the active intensifier. Control is switched
from one intensifier to the other from the control panel.
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Section 5
5.4 Service and Maintenance Procedures

To ensure water quality and supply to the high pressure system, the filter element, strainer and
booster pump will require routine servicing and maintenance. The procedures for servicing these
components are detailed below.
Refer to Section 12, Parts List, for a complete listing of replacement parts.
Filter Assembly and Strainer Maintenance

The life of the filter element is directly related to the quality of the inlet water. The condition of
the filter element can be monitored by observing the pressure gauge on the front of the machine.
Document the pressure reading when the filter element is new. The element should be replaced
when the pressure drops to 15 psi (1 bar) below the original value. When the filter element is
replaced, the strainer should also be cleaned.
Use the following procedure to replace the filter element and clean the strainer.
1. Turn the cutting water supply off.

2. Turn the v-clamp handle to loosen and remove the v-
clamp.
3. Slide the filter housing away from the head and remove
the old filter element.
4. Install the new element in the center of the housing.
5. Apply FML-2 grease to the o-ring in the filter head.
6. Position the housing in the filter head. Position the v-
clamp and tighten the handle.
7. Unscrew and remove the strainer body. Remove and clean the mesh liner.
8. Ensure the gasket is positioned properly in the body, install

the liner and screw the strainer body into the strainer head,
hand tighten.
9. Turn the cutting water supply on.
10. Start the machine and verify satisfactory pressure readings.
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Section 5
Booster Pump Adjustment

If the discharge pressure from the booster pump stays below 150 psi (10.3 bar) while the
intensifier is shifting, the relief valve on the booster pump should be adjusted.
1. Turn the cutting water supply on.

2. Start the machine and initiate normal, shifting operation.
3. Observe the discharge pressure from the booster pump. If the
pressure stays below 150 psi (10.3 bar), continue with Step 4.
4. Stop the intensifier and access the adjustment screw in the
acorn nut.
5. Use a flat screwdriver and turn the adjustment screw clockwise to increase the discharge
pressure or counter-clockwise to decrease the pressure. Adjust the pressure to the highest
desired pressure, within normal booster pump range.
If the adjustment screw is turned too far out (counter-clockwise) an internal spring
and relief will fall down inside the pump. If this occurs, remove the pump and
reinstall the parts to avoid component damage.
6. Resume normal operation and observe the booster discharge pressure. Peak pressure
should be 180 psi (12.4 bar). If it is not, repeat the adjustment procedure.
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SECTION 6
RECIRCULATION SYSTEM
The Recirculation System section details:

§ Principles of operation for systems equipped with optional cooling systems
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Section 6
6.1 Overview
The oil recirculation circuit is a cooling and filtration system that provides properly conditioned
oil to the main hydraulic system. Hydraulic oil is maintained at the proper operating temperature
and condition by continuous recirculation.
System components include a solenoid valve (oil-to-water models), recirculation pump, heat
exchanger, oil filter assembly and the hydraulic oil reservoir. A temperature sensor/low level
switch, connected to the PLC, monitors temperature and oil level conditions in the hydraulic oil
reservoir and provides automatic shutdown protection.
6.2 Operation (Oil-to-Water Cooling System)

Cooling water is introduced through the 1/2-inch NPT connection on the bulkhead of the
machine. A solenoid valve in the outlet line regulates the cooling water flow through the heat
exchanger. Oil temperature is monitored from a dual scale level/temperature sight gauge on the
side of the hydraulic oil reservoir.
Figure 6-1: Recirculation System (Oil-to-Water)
The recirculation pump pulls oil from the hydraulic oil reservoir and sends it to the heat
exchanger. The oil-to-water heat exchanger controls heat build-up in the hydraulic oil. The plate
style design allows cooling water and oil to flow side by side through alternating plates.
The cooled oil then passes through the filter element and returns to the reservoir. The cooling
water either is discharged to the 1/2-inch NPT drain on the bulkhead or is routed to a customer
supplied water chiller.
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Section 6
The hydraulic oil filter assembly consists of the filter head, a filter element, pressure gauge or
indicator, bypass relief valve and the oil fill port. All 30, 40 and 50 horsepower machines are
equipped with a numeric pressure gauge that indicates inlet pressure. The filter element should
be changed when the gauge reads 40 psi (2.8 bar) at normal operating temperature or after 3,000
hours whichever comes first. The 100 horsepower machines utilize a differential pressure
indicator. Change the filter element on these machines when the indicator enters the red zone at
normal operating temperature or after 3,000 hours whichever comes first.
If the element is not replaced, and fills with debris, the bypass relief in the filter head will open to
prevent over pressurization. The relief valve opens at 50 psi (3.4 bar) on 30, 40 and 50
horsepower models, 25 psi (1.7 bar) on 100 horsepower models. When the valve opens, the oil
bypasses the filter and unfiltered oil is allowed to return to the reservoir.
The temperature sensor/low level switch monitors the oil temperature and level in the reservoir.
An automatic shutdown will occur if the operating oil temperature exceeds 144° F (62° C). An
automatic shutdown will also occur if the oil level falls below the specified volume in Section 11,
Specifications.
6.3 Operation (External Oil-to-Air Cooling System)

exchanger. The temperature sensor mounted on the reservoir monitors the oil temperature and
regulates the air flow to the heat exchanger through a signal to the PLC to initiate power to the
fan. Oil temperature is monitored from a dual scale level/temperature sight gauge on the side of
the reservoir.
Figure 6-2: Recirculation System (External Oil-to-Air Cooling System)
The cooled oil returns through the bulkhead, passes through the filter element and returns to the
reservoir.
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Section 6
The hydraulic oil filter assembly consists of the filter head, a filter element, a numeric pressure
gauge, bypass relief valve and the oil fill port. Change the filter element when the gauge reads 40
psi (2.8 bar) at normal operating temperature or after 3,000 hours whichever comes first.
prevent over pressurization. The relief valve opens at 50 psi (3.4 bar). When the valve opens, the
oil bypasses the filter and unfiltered oil is allowed to return to the reservoir.
Specifications.
6.4 Operation (Onboard Oil-to-Air Cooling System)

fan. Oil temperature is monitored from a dual scale level/temperature sight gauge on the side of
the reservoir.
Figure 6-3: Recirculation System (Oil-to-Air)
The cooled oil then passes through the filter element and returns to the reservoir.
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Section 6
The hydraulic oil filter assembly consists of the filter head, a filter element, a differential pressure
indicator, bypass relief valve and the oil fill port. Change the filter element when the indicator
enters the red zone at normal operating temperature or after 3,000 hours whichever comes first.
Specifications.
6.5 Operation (Onboard Water/Air Combination Cooling System)

The recirculation pump pulls oil from the hydraulic oil reservoir and sends it to the oil-to-air heat
fan. Oil passes through the air cooling circuit and enters the oil-to-water heat exchanger.
Cooling water is introduced through the 1/2-inch NPT connection on the bulkhead of the
machine. A solenoid valve in the outlet line regulates the cooling water flow through the water
cooling circuit. Oil temperature is monitored from a dual scale level/temperature sight gauge on
the side of the hydraulic oil reservoir.
Figure 6-4: Recirculation System (Combination Water/Air)
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Section 6
The cooled oil then passes through the filter element and returns to the reservoir. The cooling
water either is discharged to the 1/2-inch NPT drain on the bulkhead or is routed to a customer
supplied water chiller.
The hydraulic oil filter assembly consists of the filter head, a filter element, a differential pressure
indicator, bypass relief valve and the oil fill port. Change the filter element when the indicator
enters the red zone at normal operating temperature or after 3,000 hours whichever comes first.
Specifications.

To ensure the supply of properly conditioned oil to the main hydraulic system, the components
will require routine servicing and maintenance. The procedures for servicing these components
are detailed below.
Hydraulic Oil Maintenance

The hydraulic oil should be changed at intervals required to maintain ISO 4406 cleanliness level
18/15/13, not to exceed 6,000 hours. The oil should be replaced sooner if a fluid sample indicates
contamination that cannot be rectified by filtering.
An air breather and filter is located on the top of the reservoir. The air breather prevents dirt from
being sucked into the reservoir when the oil level drops, and allows air to escape when the level
rises. The air breather must not be used as a fill point. Oil must only be replaced at the fill port
on the filter head.
Do not attempt to fill the reservoir from the air breather. The oil will not be
filtered and will not conform to the cleanliness requirements of the system.
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Section 6
Figure 6-5: Hydraulic Oil Reservoir
Before proceeding, disconnect and lockout the main power supply and the electrical enclosure;
and ensure that all high pressure water and hydraulic pressure has been bled from the system.
Severe injury can result if the machine is not properly locked out.
Observe electrical Lockout/Tagout procedures before performing
maintenance.
Ensure all pressure is relieved or blocked from the hydraulic and

high pressure circuits before performing maintenance.
1. Drain the oil reservoir by connecting the inlet hose from an oil transfer pump to the drain
valve on the reservoir.
2. Open the shut off valve on the drain and pump the used oil out to a container.
3. Close the shut off valve and remove the inlet hose from the drain valve.
Oil from a new drum does not meet the cleanliness requirements of the hydraulic
system. For this reason, it is important to use an oil transfer pump that will force
oil through the return filter into the reservoir.
4. Remove the cap from the fill port on the oil filter.
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Section 6
To ensure cleanliness, the oil fill port must be used to pump oil into the reservoir.
Filling at this point guarantees the hydraulic oil will pass through the oil filter
before entering the reservoir.
5. Connect the discharge hose from the oil transfer pump to the fill port and pump the fresh
oil into the reservoir.
If 3/4-inch BSPP threads are required, install the adapter located on the inside of
the frame. When filling is complete, remove the adapter and install the fill port
cap.
6. Check the oil sight gauge on the reservoir to ensure proper fill level.
7. Remove the hose from the case drain on the main hydraulic pump to make sure the pump
case fills with oil. With the hose removed, head pressure from the reservoir will force oil
into the pump case.
Oil in the pump case provides internal lubrication for the main hydraulic pump.
Failure to the fill the pump case with oil will allow air to become trapped inside,
damaging the pump.
8. Disconnect the discharge hose from the fill port and replace the fill port cap.
9. Follow the initial startup sequence in Section 4, Operation, to ensure the system is filled
with oil.
10. Check the sight gauge again and follow the same procedure to add additional oil if
necessary.
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Section 6
Pump Priming
Whenever the hydraulic reservoir is drained or the hydraulic pump is changed, bumping the
electric motor is suggested. Bumping is defined as allowing the electric motor to start rotating,
but stopping it before the motor gets up to full speed.
This procedure will ensure the hydraulic pump is full of oil and deter cavitation that will cause
the hydraulic pump to fail prematurely.
Do not perform this procedure until the correct motor rotation and the presence of
hydraulic oil in the hydraulic pump case drain line has been confirmed.
1. Disconnect the case drain to verify the presence of hydraulic oil.

2. Start the pump from the Main Service Screen, count two seconds and turn the pump off.
3. Repeat this process two times before allowing the hydraulic pump to create pressure.
Oil Filter Maintenance

If it is not properly serviced, the filter element fills with debris and the oil will be forced through
the relief valve, bypassing the filter. The bypass relief valve on 30, 40 and 50 horsepower models
opens at 50 psi (3.4 bar), it opens at 25 psi (1.7 bar) on 100 horsepower models and units
equipped with an optional onboard cooling system. Replace the filter element when the pressure
gauge or indicator meets the criteria listed in Table 6-1 or after 3,000 hours whichever comes
first.
Table 6-1
Hydraulic Oil Filter Change Criteria
Horsepower Indicator Criteria
30 Replace filter element when the pressure reading is 40
40 Numeric pressure gauge psi (2.8 bar) or greater during normal operating
50 conditions or after 3,000 hours whichever comes first.
100
Replace filter element when the indicator is in the
Units equipped Differential pressure yellow zone or entering the red zone during normal
with optional indicator operating conditions or after 3,000 hours whichever
onboard cooling comes first.
system
Note: Normal operating conditions indicate the machine is running and the oil temperature has
reached 120° F (48° C).
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Section 6
1. Use a filter wrench to unscrew the filter element from the filter head. Make sure the old
gasket is removed with the element.
2. Lubricate the gasket on the new element with

fresh oil.
3. Use the filter wrench to screw the new element
onto the filter head and hand-tighten. Do not over
tighten.
4. Start the machine and check for leaks.
If the pressure gauge reads 40 psi (2.8 bar) or greater, or the indicator is in the red
zone after the filter is changed, check the operating condition of the gauge or
indicator. These components may require replacement.
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SECTION 7
HYDRAULIC SYSTEM
The Hydraulic System section details:

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Section 7
Hydraulic System
7.1 Overview
The main hydraulic power circuit supplies the intensifier assembly with the hydraulic oil required
to produce high pressure water. High pressure cutting water is generated from the oil pressure in
the hydraulic cylinder.
System components include the electric motor, hydraulic pump, 4-way directional control valve
and the hydraulic manifold. The manifold houses the high and low pressure control valves,
hydraulic gauge, two pressure solenoid valve and the main system relief valve. The system relief
valve monitors hydraulic oil pressure and provides system protection by limiting excess pressure.
7.2 Operation
The electric motor drives three pumps mounted in tandem; the main hydraulic pump, the
recirculation pump and the booster pump.
Hydraulic fluid from the reservoir is drawn into the inlet, low pressure side of the hydraulic
pump. Oil delivered to the pump should be maintained at 110-120° F (43-49° C). Hydraulic
fluid then enters the bottom of the manifold through an internal anti-rotation check valve. After a
shutdown, the anti-rotation check valve prevents the pump from running backwards.
Figure 7-1: Hydraulic System
The main system relief valve provides system protection by monitoring the oil pressure entering
the manifold. If the hydraulic pressure exceeds 3,408 psi (235 bar) on 30, 40 and 50 horsepower
machines, the valve opens to limit the pressure. The valve opens at 2,973 psi (205 bar) on 100
horsepower machines. The valve is factory calibrated and is not serviceable. A drain line from
the valve prevents oil from collecting behind the relief valve to ensure a constant pressure under
all operating conditions.
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Section 7
Hydraulic System
The hydraulic system operates at high or low pressure settings up to the maximum flow capacity
of the hydraulic pump. The high and low limit compensators mounted on the pump regulate the
flow of hydraulic fluid to maintain constant operating pressures. Operating pressures are set and
adjusted at the high and low pressure control valves on the manifold.
If the machine is equipped with proportional pressure control, low pressure is adjusted at the
manifold, and the high pressure setting is made from the control panel or a remote console.
The high and low limit compensators regulate the flow of hydraulic fluid to the
system by controlling the angle of the swashplate. If the oil is not properly
maintained, the compensators can become blocked with debris. As a result, pump
control will be lost and you will not be able to create hydraulic oil pressure.
The normally closed, two pressure solenoid valve is controlled by the operator’s selection of high
or low pressure. The valve is closed while operating in high pressure and is open during low
pressure operation. A light on the solenoid connector indicates low pressure operation.
At startup, hydraulic pressure is automatically switched to low, limiting torque demand. The
hydraulic pressure will automatically returns to the previously selected pressure setting.
A reference gauge on the top of the manifold displays hydraulic pressure to the intensifiers.
When the intensifier shifts, it is normal for the pressure to quickly fall and then rise again.
The 4-way directional control valve directs pressurized oil to one end the hydraulic cylinder and
returns fluid to the reservoir from the opposite end, causing the intensifier to stroke. A pilot valve
that is electronically operated by two solenoids energized by the PLC controls the movement
hydraulically. Indicators light up as each solenoid is energized.
The directional control valve sends flow to the hydraulic cylinder in one direction until the
hydraulic piston activates the proximity switch at the end of the stroke. The activated switch
sends a signal to the PLC to reverse the direction of flow. The piston then moves in the opposite
direction until it activates the proximity switch at the opposite end of the stroke.
If the machine is equipped with redundant intensifiers, manual hydraulic valves are opened or
closed to direct the hydraulic flow to either intensifier.

The extreme duty cycles demanded of the hydraulic system make routine inspection and
maintenance acutely important. Leaks must be detected and remedied as soon as possible.
The operating pressure settings must be checked daily, and the electric motor must be inspected at
regular intervals. The procedures for servicing these components are detailed below.
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Section 7
Hydraulic System
Hydraulic Operating Pressure

Hydraulic operating pressure settings should be checked daily and adjusted as necessary. High
and low operating pressure on standard machines is adjusted at the high and low pressure control
valves per the specifications in Table 7-1.
For machines equipped with proportional pressure control, high pressure adjustments are made
from the Dashboard on the control panel. The following specifications and the Low Pressure
Adjustment procedure are used for low pressure adjustments.
The pressure switch on the Run Screen must be set to high pressure to enable the
proportional pressure control.
Table 7-1
Hydraulic Operating Pressure Limits
Pressure Limits
Adjustment Maximum
Increase Decrease Minimum 30/40/50HP 100HP
High Pressure Clockwise Counter- 250 psi 3,000 psi 2,600 psi
clockwise (17.2 bar) (207 bar) (179 bar)
Low Pressure Clockwise Counter- 250 psi 1,500 psi
clockwise (17.2 bar) (103 bar)
7. Check the operating pressure to determine if adjustment is necessary.
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3. If high pressure adjustment is required, loosen

the locking nut on the high pressure control valve
by turning counter-clockwise.
4. Turn the knob on the control valve clockwise to
increase operating pressure. Turn the knob
counter-clockwise to decrease pressure.
5. Tighten the locking nut and verify the high
pressure setting.
6. If low pressure adjustment is required, loosen the
locking nut on the low pressure control valve by
turning counter-clockwise.
6. Turn the hex clockwise to increase operating pressure. Turn the hex counter-clockwise to
decrease pressure.
7. Tighten the locking nut and verify the low pressure setting.
Proportional Pressure Valve Maintenance

The screen in the proportional pressure valve can become blocked with debris resulting in erratic
pressure fluctuations or the inability to reach or maintain the operating pressure.
Figure 7-2: Proportional Pressure Valve
1. Unscrew and remove the retaining nut on the proportional pressure valve.
2. Remove the coil and electronics from the valve.
3. Unscrew and remove the valve from the hydraulic manifold.
4. Use air or alcohol to clean the screen inside the valve.
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Hydraulic System
A blocked screen will appear black. Clean the screen until it is clear.
5. Screw the cleaned valve into the hydraulic manifold.

6. Replace the coil and electronics.
7. Replace the retaining nut.
Motor Maintenance
The motor should be inspected at regular intervals, approximately every 500 hours of operation or
every three months, whichever occurs first. Keep the motor clean and the ventilation openings
clear.
The zerk fittings, one at each end of the motor, must be greased at regular intervals. Refer to the
motor data plate for the grease amount and interval.
Hydraulic Compensator Maintenance

The high and low limit compensators regulate the flow of hydraulic fluid to the system. The
compensators can become blocked with debris resulting in loss of pump control.
Figure 7-3: Hydraulic Compensators
SPOOL SPRING PLUG NUT SEALING

SPRINGS
SPRING CUP COLLAR CAP
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Hydraulic System
maintenance.
Ensure all pressure is relieved or blocked from the hydraulic

and high pressure circuits before performing maintenance.
1. Remove the hydraulic hose from the low limit compensator.

2. Remove the four socket screws that attach the compensators to the pump.
3. Remove the compensators and then remove the three plugs and o-rings on the back of the
housing.
PLUG
O-RING
LOW LIMIT COMPENSATOR
ORIFICE
O-RING
HIGH LIMIT COMPENSATOR
4. Disassemble the compensators one at a time by first removing the hexagon sealing cap.
5. Loosen the lock nut, and then remove the plug nut.
6. Disassemble the plug by removing the spring collar, springs, spring cup and spool.
7. Clean the housing and all components with clean fluid and carefully dry with air.
8. Check and clean the small internal passages in the spools.
9. Check and clean the orifices in both spools.
10. Assemble in the reverse order, ensuring that the screw slot on the orifice is aligned with
the long axis of the body.
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Hydraulic System
When the compensators are removed, the machine loses adjustment. The
compensators must be reset before operation can begin.
Compensator Calibration (Manual Adjustment)
To perform this procedure, the minimum oil temperature should be 80º F (27º C).
1. Set the high and low pressure control valves on the hydraulic manifold to the minimum
setting by turning then counter-clockwise until they are all the way out.
2. Adjust the high DR compensator (the one closest to the pump) all the way out.
3. Start the pump from the Run screen and select low pressure operation. Confirm the hi/low
solenoid is on.
4. Disconnect one of the proximity switch cables from the topworks.
5. Adjust the FR compensator (low limit

compensator, farthest from pump) until the
hydraulic pressure is 250 psi (17.2 bar). Lock
the compensator with the lock nut ensuring the
reading does not change.
6. Select high pressure operation from the Run
screen. Confirm the hi-low solenoid is off.
7. Set the high pressure control valve to the
maximum setting by turning the knob
clockwise until it is all the way in.
8. Adjust the DR compensator (high limit compensator, closest to the pump) until the
hydraulic gauge reads 3,400 psi (234 bar) for 30, 40 and 50 horsepower units, 3,000 psi
(207 bar) for 100 horsepower units. At this point, the main relief valve should be opening
and further adjustment of the DR compensator should not increase the pressure.
9. Adjust the DR compensator back out until the hydraulic gauge reads 3,150 psi (217 bar)
for 30, 40 and 50 horsepower units, 2,800 psi (193 bar) for 100 horsepower units. Lock
the compensator with the lock nut ensuring the reading does not change.
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10. Adjust the low pressure control valve on the hydraulic manifold to 500 psi (34 bar) and
lock it in place.
11. Select high pressure mode from the display panel and adjust the high pressure control
valve on the hydraulic manifold to 2700 psi (186 bar) for 30, 40 and 50 horsepower units,
2,400 psi (165 bar) for 100 horsepower units..
12. Stop the pump and reconnect the proximity switch cable.
13. Mark both adjustment studs and lock nuts with tamper evident paint.
Compensator Calibration (Proportional Control Adjustment)
To perform this procedure, the minimum oil temperature should be 80º F (27º C).
1. Set the low pressure control valve on the hydraulic manifold to the minimum setting by
turning it counter-clockwise until they are all the way out.
2. Adjust the high DR compensator (the one closest to the pump) all the way out.
3. Start the pump from the Run screen and select low pressure operation. Confirm the hi/low
solenoid is on.
4. Disconnect one of the proximity switch cables from the topworks.
5. Adjust the FR compensator (low limit compensator, farthest from pump) until the
hydraulic pressure is 250 psi (17.2 bar). Lock the compensator with the lock nut ensuring
the reading does not change.
6. Remove the proportional amplifier from the proportional solenoid, disconnect the hi-low
solenoid and reconnect it to the proportional solenoid..
7. Adjust the DR compensator (high limit compensator, closest to the pump) until the
hydraulic gauge reads 3,400 psi (234 bar) for 30, 40 and 50 horsepower units, 3,000 psi
(207 bar) for 100 horsepower units. At this point, the main relief valve should be opening
and further adjustment of the DR compensator should not increase the pressure.
8. Adjust the DR compensator back out until the hydraulic gauge reads 3,150 psi (217 bar)
for 30, 40 and 50 horsepower units, 2,800 psi (193 bar) for 100 horsepower units. Lock
the compensator with the lock nut ensuring the reading does not change.
9. Reconnect the hi-low solenoid and the proportional amplifier.
10. Select the low pressure operating mode on the display panel and adjust the low pressure
control valve on the hydraulic manifold to 500 psi (34 bar) and lock it in place.
11. Stop the pump and reconnect the proximity switch cable.
12. Mark both adjustment studs and lock nuts with tamper evident paint.
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SECTION 8
ELECTRICAL SYSTEM
The Electrical System section details:

§ System operation
§ Sensor and solenoid functions
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Section 8
Electrical System
8.1 Overview
All SL-VI models are equipped with integral motor starter and control circuitry, enclosed in the
electrical panel. The operator controls the machine primarily through a touch-screen control
panel that communicates with the programmable logic controller (PLC). A series of
sensors/solenoids provide feedback and control to generate high pressure. The PLC
programming performs the machine logic and diagnostic functions to ensure the safe generation
of high pressure.
Major system components include the electric motor, control panel, high voltage and control
components, and the wiring harness that connects the sensors and solenoids to the PLC.
The Streamline SL-VI meets the requirements of the EMC Directive 2004/108/EC.
EMC characteristics may change when the SL-VI is integrated with other electrical
equipment. The finished installation, incorporating the SL-VI, should be tested
against local EMC regulations.
SL-VI models equipped with electronic controls incorporate the following:
1. Switch gear, high voltage hardware > 60VAC

Motor starter branch circuit
Motor controlled circuit breaker (MCCB) disconnect with LOTO capability
Line start or soft start (Wye-delta or electronic)
Motor overload protection
Optional cooling fan motor branch circuit
Combination motor starter, MCCB, overload protection with LOTO
Optional power factor correction capacities
Provide a reduction in KVA consumption
2. Control gear, low voltage hardware < 60VAC, designed to meet safety extra low voltage
(SELV) requirements
Programmable logic controller (PLC)
Provides the machine logic for safe operation
Human machine interface (HMI)
Provides the interface for operator inputs and machine status
Storage of machine configuration and software backups
Sensors and solenoids
Provide inputs and outputs to safely generate high pressure
Safety function monitoring
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E-stop functions to prevent or stop the generation of high pressure

Optional cover interlock system used to reduce exposure to high pressure
The switch gear is protected by a plastic barrier with electrical separation of high
voltage wiring from low voltage wiring.
8.2 Operation
Electrical supply is 3-phase, three wire plus ground (PE), connected to L1, L2 and L3 of the
MCCB of the switch gear circuit and ground (PE) to the lug labeled PE. The power is then
distributed in two directions, one to the motor control and one to the control gear.
Figure 8-1: Electrical Control Power
Some SL-VI models will use a multi-tap step down transformer to supply the signal phase power
required by the SELV DC power supply and the motor controls circuits.
When the START button is pressed, the motor control relay closes and control voltage is sent to
the contactor coil(s). The coil(s) close, sending the incoming power to the motor. When the STOP
button is pressed, the motor control relay opens, disconnecting power to the contactor coil(s),
stopping the motor.
The motor is started by either contactors or a soft starter, solenoid operated by 230 volt AC or
24V DC control power.
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Contactors are arranged in either a wye-delta or an across-the-line starter circuit. Wye-delta

starter circuits are typically installed in all low voltage, high horsepower machines that require
high current draw. Three, 3-phase contactors are used to start the motor slowly, minimizing the
initial current draw. Across-the-line or full-voltage starting requires a single 3-phase contactor
and is used on high voltage machines with low current draw.
Soft starters combine contactors, overload, timers and internal power/control wiring into a single
device. They utilize a current limit starting method to greatly reduce mechanical and electrical
shock to the system.
Switch Gear
The switch gear contains the MCCB, motor control and motor overload protection. The MCCB
is a motor rated circuit breaker that will allow high motor currents while starting. The MCCB
provides the main disconnect location for the high pressure intensifier, it is a point of LOTO.
Electrical energy will be present at the connection to the MCCB (L1, L2 and L3)
when the LOTO is applied at the intensifier. Lock out and tag out upstream
sources of electrical energy when required by governmental or company
compliance.
Motor control/motor protection will be offered in two versions, line starter with external overload
protection and soft-starter with internal overload protection. Line starters are available in
apllications when the motor full load amperage is less then 95A. Soft starter, ether wye-delta or
electronic, will be used when motor full load amperage is greater then 95A and in all european
models. Line start may be replaced with a soft starter at the customers’ request.
Figure 8-2: Motor Starter
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The circuit breaker/door disconnect provides the primary over current protection for the machine.
All power is automatically disconnected from the machine when the main disconnect on the
enclosure door is opened. However, power is still present on the input side of the circuit
breaker/door disconnect. The only way to isolate all power to the machine is to turn the customer
installed main power disconnect off.
See Section 2, Installation, regarding specifications for the customer installed main
power disconnect.
In the electrical enclosure the high voltage components are isolated from the low voltage
components. This provides an additional safety factor when maintenance is required.
Figure 8-3: Electrical Enclosure
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Sensor and Solenoids

Warning and shutdown sensors monitor operating conditions, and electronically operated
solenoids provide basic intensifier shift control. The harness cable connects these sensors and
solenoids to the PLC.
Figure 8-4: Sensors and Solenoids
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Table 8-1
Sensors and Solenoids
Component Function
Inlet Cutting Water

1 The normally closed, inlet water solenoid valve is
located at the service bulkhead. When a start
command is requested, the valve opens and the
pressure switch closes, allowing the motor to start. If
the valve opens and the pressure switch does not
close, an alarm is issued and the motor will not start.
When the motor is shut off or any alarm is present,
the valve is closed. The valve can be opened in
service mode to purge air from the system or to
pressurize the system to look for leaks.
2 The 30 psi pressure switch, mounted on the inlet

manifold, monitors the inlet cutting water. If the
pressure drops below 30 psi for the configured time
interval, an alarm will shut down the intensifier,
protecting the booster pump from damage due to
insufficient supply water pressure.
If the water pressure drops below 30 psi and then
returns, it causes a low water pressure peak. If the
machine counts eight low water pressure peaks a
warning issued. Ten low water pressure peaks will
result in an alarm that will shut down the intensifier.
Low Pressure Water Filter Assembly

3 To ensure adequate water pressure and supply to the
intensifiers, the discharge pressure is monitored by a
100 psi pressure switch.
When the booster pressure drops below 100psi a
warning is issued for 40 seconds. If the pressure
drops with in the first five seconds of the warning, an
alarm will shut down the intensifier.
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Table 8-1
Component Function
Hydraulic Reservoir
4 The temperature sensor/low level switch monitors
the oil temperature and level in the reservoir.
Although the float switch and the temperature sensor
are combined in a single unit, they function
independently.
If the operating oil temperature exceeds 144° F (62°
C) an automatic shutdown occurs. If the hydraulic
fluid level falls below specifications, a low oil level
shutdown occurs.
If the oil temperature falls below 68° F (20° C) the
intensifier will not stroke. The motor will run until
the oil reaches the minimum operating temperature,
and then the motor will shut down.
If the oil temperature is out of operating range the
intensifier will not generate high pressure. The
hydraulic motor will start to cool or heat the oil as
required.
Hydraulic Manifold
5 The 4-way directional control valve shifts the
hydraulics back and forth to the intensifier. A shift
valve directs pressurized oil to one end of the
hydraulic cylinder and returns fluid to the reservoir
from the opposite end, causing the intensifier to
stroke. The movement is controlled hydraulically by
a pilot valve that is electronically operated by two
solenoids, energized by the PLC. As power is
directed from one solenoid to the other, LEDs are
alternately illuminated.
6 When low pressure is selected, a normally closed,

solenoid valve is activated. The valve remains
closed while operating in high pressure and is held
open electrically during low pressure operation. An
illuminated LED on the solenoid indicates low
pressure operation.
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Table 8-1
Component Function
Hydraulic Cylinder
7 As pressurized hydraulic oil is sent to one side of the
hydraulic cylinder, it pushes against the piston,
moving it in one direction until it activates the
proximity switch at the end of the stroke. The
hydraulic flow is then sent to the opposite side of the
cylinder, and the piston reverses direction until it
activates the proximity switch at the opposite end of
the stroke.
The green light on the proximity switch indicates
there is power to the switch. The light turns yellow
when the switch is activated. The proximity
switches are magnetically activated by the presence
of the metallic surface of the piston. When the
switch is activated, it sends a signal to the PLC to
change the flow of the directional control valve and
reverse direction.
High Pressure Dump Valve

8/9 The normally open pneumatic dump valve is held
closed by air pressure. When the air supply is
interrupted from an emergency stop, the valve opens
and allows water to flow through the valve. Pressure
is released in the intensifier and the high pressure
water stream exits through the drain.
Redundant solenoid valves create a block and
bleed system for the air pressure used to operate
the dump valve. The first solenoid valve is
machine controlled with a safety function
override. The second solenoid is controlled by
the safety function relay.
10 A 30 psi pressure switch is used for testing and

monitoring the safety function of the block and
bleed system. If a failure is detected, a signal
from the pressure switch prevents operation to
continue.
Together, the solenoids and the pressure switch
provide redundancy and diversity to ensure all air
pressure is removed from the high pressure dump
valve when the e-stop button is pressed.
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Table 8-1
Component Function
Discharge Cooling Water

11 A solenoid valve in the discharge cooling line
regulates the cooling water flow through the heat
exchanger. The valve is controlled by the PLC to
maintain the hydraulic oil temperature within
optimum operating range.
Pressure Transducer
12 The optional pressure transducer reads the output
pressure from the attenuator in the high pressure
system. A signal is sent to the PLC module that
allows the operating pressure to be viewed from the
control panel.
Proportional Pressure Control

13 Optional proportional pressure control allows the
operator to select or vary the hydraulic operating
pressure from the control panel or from a remote
console. An electronically controlled hydraulic
cartridge valve, mounted on the hydraulic manifold,
receives a signal from the PLC and automatically
makes the operator selected adjustments.

Electrical components require minimal service. The proximity switches on the hydraulic cylinder
and the optical relay switches in the controls subassembly may require replacement.
Refer to Section 12, Parts List for a complete listing of replacement parts.
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Proximity Switch Maintenance
A proximity switch has failed and needs to be

replaced if the LEDs do not change state,
indicating they are not sensing the piston, if an
LED flashes continuously, or if the appropriate
input is not noted on the PLC processor
annunciator light panel in the electrical
enclosure.
1. Turn the machine off and observe the appropriate Lockout/Tagout procedures.
maintenance.

2. Remove the electrical cable from the failed proximity switch.

3. Remove the two socket head screws, the failed switch, the spacer and o-ring.
4. Install a new proximity switch by positioning the o-ring, spacer and the switch. Ensure
the o-ring is correctly oriented.
5. Apply JL-M grease to the threads on the screws and tighten to 140-160 in-lbs (16-18 Nm).
Ensure that the proximity switch is properly installed and secured prior to starting
the machine. Failure to tighten the two hold down screws on each switch will
result in the spray of hydraulic oil.
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SECTION 9
HIGH PRESSURE WATER SYSTEM
The High Pressure Water System section details:

§ System component overview
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9.1 Overview
The high pressure water system is supported by both the cutting water supply circuit and the
hydraulic circuit. Cutting water of sufficient flow and pressure is routed from the cutting water
supply circuit to the intensifier where it is pressurized up to a maximum of 66,000 psi (4,550 bar)
with the cutting head valve closed or 60,000 psi (4,137 bar) with the cutting head valve open.
The directional control valve in the hydraulic system creates the stroking action of the intensifier
by sending pressurized hydraulic oil to one side of the hydraulic cylinder or the other. As the
flow is sent to one side, hydraulic fluid is returned to the reservoir from the opposite side.
System components include a double-ended hydraulic cylinder; reciprocating piston assembly;
high pressure cylinders attached to each end of the hydraulic cylinder; two plungers, sealing
heads and hard seal end caps; one or two liter capacity attenuators, and a dump valve.
Sophisticated check valves and seal assemblies ensure hydraulic oil, and the low pressure and
high pressure water travel in the appropriate direction. Warning and shutdown sensors monitor
strategic pressure, temperature and fluid levels to safeguard against component damage.
9.2 Operation
The directional control valve sends pressurized hydraulic oil to one side of the hydraulic cylinder.
The pressurized oil pushes against the piston, moving it in one direction until it activates the
proximity switch at the end of the stroke. The hydraulic flow is then sent to the opposite side of
the cylinder, and the piston reverses direction until it activates the proximity switch at the
opposite end of the stroke.
Figure 9-1: High Pressure Water System
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The green light on the proximity switch indicates there is power to the switch. The red light
illuminates when the switch is activated. The proximity switches are magnetically activated by
the presence of the metallic surface of the piston. When the switch is activated, it sends a signal
to the PLC to change the flow of the directional control valve and reverse direction.
As the pressurized oil pushes the piston in one direction, the plunger on that end extends and
pushes against the water in the high pressure cylinder, increasing the pressure up to 66,000 psi
(4,550 bar) with the cutting head valve closed. When the piston reverses direction, the plunger
retracts and the plunger in the opposite cylinder extends to deliver the high pressure water.
Figure 9-2: High Pressure Cylinder
Low pressure water is routed through the inlet water ports to the inlet passages in the sealing
heads. When the plunger retracts, the inlet check valve opens to allow water to fill the high
pressure cylinder. When the plunger extends to create high pressure water, the inlet valve closes
to seal the inlet passage and the discharge check valve opens to allow the high pressure water to
exit the cylinder. As the plunger retracts, the discharge check valve closes.
The intensifier is a reciprocating pump. As the piston and plungers move from one side to the
other, high pressure water exits one side of the intensifier as low pressure water fills the opposite
side.
The high pressure water is then routed to the attenuator. The attenuator acts as a shock absorber
to dampen pressure fluctuations and ensure a steady and consistent supply of water. From the
attenuator, the high pressure water exits to the cutting head.
The dump valve releases the stored pressure in the intensifier and high pressure delivery lines.
The high pressure dump valve assembly includes a normally open high pressure water valve and
an electrically controlled air valve.
The normally open pneumatic dump valve is held closed by air pressure. When the air supply is
interrupted and exhausted from an emergency stop, the valve opens and allows water to flow
through the valve. Pressure is released in the intensifier and the high pressure water stream exits
through the drain.
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Redundant Intensifiers
If the machine is equipped with redundant intensifiers, the cutting water supply lines are
manually connected to the inlet water ports on the active intensifier. Manual hydraulic valves are
opened or closed to direct the hydraulic flow to the active intensifier. Manual high pressure water
valves are also opened or closed to direct the high pressure water flow from the active intensifier.
Control is switched from one intensifier to the other from the Intensifier Control Screen on the
control panel.
When a machine is equipped with redundant intensifiers, operation can continue on

the secondary unit if the primary unit requires maintenance. However,
maintenance must not be performed while the machine is in operation.
Maintenance must never be performed on any high pressure components while the
machine is operating. All pressure must be relieved or blocked from the hydraulic
and high pressure circuits and the electrical panel must be locked out before
performing maintenance.
Figure 9-3: Redundant Intensifiers
The following example describes the procedure for changing from one intensifier to the other. In
this example, intensifier 2 will become the active intensifier and intensifier 1 will become
inactive.
1. Turn the machine off and make sure the emergency stop button is depressed.
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3. Disconnect the low pressure water supply lines from intensifier 1 and connect them to
intensifier 2.
4. Remove the side cover to gain access to the hydraulic hand valves and close the two
hydraulic shutoff valves to intensifier 1.
5. Close the high pressure water shutoff valve to intensifier 1.
6. Open the two hydraulic shutoff valves, and the high pressure water shutoff valve to
intensifier 2.
7. Select intensifier 2 from the Intensifier Control Screen on the control display.
8. Turn the cutting water supply on and ensure all cooling water, water supply and cutting
water valves are open.
9. Ensure all hydraulic and high pressure fittings, and the proximity switches are properly
tightened on intensifier 2.
10. Start the machine in low pressure mode and inspect the hydraulic, high pressure fittings,
valves and hoses for leaks.
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9.3 System Components

The following figures illustrate the individual high pressure water system components.
The horsepower rating and/or plunger diameter determine system components,

specifications, and some maintenance procedures. The information in this section
is organized and presented accordingly.
Figure 9-4: System Components
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9.4 Service and Maintenance Overview

Never perform any type of maintenance on the high pressure water system while it is pressurized.
Always turn the power off and bleed the high pressure water before servicing. Pressing the
emergency stop button turns the control power off to the intensifier, and bleeds high pressure
water through the dump valve.
Improper assembly can lead to the premature failure of components. Follow maintenance
procedures carefully; components must be properly cleaned prior to assembly and tightened to the
correct torque specifications.
Some high pressure components are not serviceable at the customer level, others require precise
refinishing. KMT Waterjet Systems offers maintenance and refinishing services for these
components.
Refer to Section 12, Parts List for a complete listing of replacement parts.
Specialized Maintenance Tools

KMT Waterjet has designed tools to facilitate the removal and installation of specialized system
components. These tools, and their respective part numbers are illustrated in Figure 9-5,
Specialized Maintenance Tools.
Figure 9-5: Specialized Maintenance Tools
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Table 9-1, Torque Specifications, details the torque specifications and tightening sequences for
the high pressure components and connections.
Table 9-1
7/8” Diameter Plunger 1-1/8” Diameter Plunger
Hard Seal End Cap Installation

Jackbolts 6 (7/16”) each 8 (7/16”) each
1st Stage Hand Tight Hand Tight
2nd Stage 20 ft-lbs (27 Nm) 20 ft-lbs (27 Nm)
Crossing Pattern* Crossing Pattern*
3rd Stage 32-35 ft-lbs (43-47 Nm)** 32-35 ft-lbs (43-47 Nm)**
Crossing Pattern Crossing Pattern
4th Stage 32-35 ft-lbs (43-47 Nm) 32-35 ft-lbs (43-47 Nm)
Clockwise Pattern From Bolt 1 Clockwise Pattern From Bolt 1
Socket Wrench Size 3/8 inch 3/8 inch
6-Bolt Crossing Pattern 8-Bolt Crossing Pattern
* Note: Crossing Pattern: 1, 2, 3, 4, 5, 6 or 1, 2, 3, 4, 5, 6, 7, 8.

** Note: A maximum torque of 38 ft-lbs (51 Nm) is etched on the hard seal end cap. This represents
the maximum allowable torque, not the recommended torque.
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Table 9-1
Hard Seal End Cap Removal

1st Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
Clockwise pattern from Bolt 1 Clockwise pattern from Bolt 1
2nd Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
3rd Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
Clockwise pattern until all bolts Clockwise pattern until all bolts
are loose are loose
4th Stage Remove, clean and lubricate Remove, clean and lubricate
bolts prior to next use bolts prior to next use
Hydraulic Cylinder Head

Socket Head Screws 8 (M14) each 6 (3/4”) each
Torque 75-80 ft-lbs (102-108 Nm) 170-175 ft-lbs (230-237 Nm)
Hex Key M12 5/8 inch
Proximity Switch
Torque 140-160 in-lbs (16-18 Nm) 140-160 in-lbs (16-18 Nm)
Topworks Support
Torque 46 ft-lbs (62 Nm) 35-40 ft-lbs (47-54 Nm)
Hydraulic Manifold
Socket Head Screws 4 (3/8”) each 6 (1/2”) each
Torque 36 ft-lbs (49 Nm) 85 ft-lbs (115 Nm)
Socket Head Screws 2 (1/4”) each
Torque 10 ft-lbs (14Nm)
Sealing Head
Discharge Gland Nut 130 ft-lbs (176 Nm) 200 ft-lbs (271 Nm)
Poppet Retainer Screw(s) 25 in-lbs (2.8 Nm) 50 in-lbs (5.6 Nm)
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Table 9-1
3-Port Pneumatic Valve

HP Adapter 30 ft-lbs (40 Nm)
1/4-inch Outlet to Drain 25 ft-lbs (34 Nm)
Pneumatic Actuator 5 ft-lbs (7 Nm)
3/8-inch HP Gland Nut 50 ft-lbs (68 Nm)

9/16-inch/1/4-inch HP Bushing 50 ft-lbs (68 Nm)
High Pressure Fittings

1/4-inch HP Gland Nut 25 ft-lbs (34 Nm) 25 ft-lbs (34 Nm)
9.5 High and Low Pressure Water Piping

Before performing any maintenance on the high pressure components, it is necessary to remove
the high and low pressure water piping. Use the following procedure to remove and install the
piping.
maintenance.

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2. Loosen and remove the high pressure gland fitting connected to the discharge high
pressure check valve. Move the tubing to clear the work area.
3. Loosen and remove the low pressure piping connected to the inlet water port on the hard
seal end cap.
4. When the required maintenance has been completed and the components reassembled,
connect the low pressure water piping to the inlet water port on the hard seal end cap.
5. Apply Pure Goop to the threads on the high pressure gland fitting. Before installing the
high pressure fitting, ensure proper collar position, 1-1/2 to 2-1/2 threads should be
exposed. Install and tighten the fitting to the torque specifications in Table 9-1.
6. Turn the cutting water supply on and check for low pressure leaks.
7. Remove the cutting orifice and start the machine. Operate in low pressure mode to flush
the high pressure passages.
8. Install the orifice and operate at high pressure to check for leaks.
9.6 High Pressure Cylinder Assembly

KMT Waterjet recommends removing the high pressure cylinder, sealing head and end cap as an
assembly for servicing the plunger, high pressure seals, hydraulic piston and seal cartridge.
Removing the jackbolts in the hard seal end cap is not recommended except to service the inlet
check valve and cone seat on the sealing head.
High Pressure Cylinder Assembly Removal

Prior to removing electrical power or any high or low pressure piping, start the machine from the
Main Service Screen on the control panel.
Press and hold the right or left arrow until the proximity switch on the end to be serviced
illuminates. The plunger will extend in the selected direction, allowing full exposure when the
maintenance.

2. Disconnect the high and low pressure water piping, following the procedure, High and
Low Pressure Water Piping.
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Prior to removal, verify that the alignment marks on the high pressure cylinder and
on the hydraulic cylinder head are aligned. If not, check the condition of the
retaining ring and the bushing retainer flange after the cylinder assembly is
removed.
Due to the weight of the cylinder assembly, adequate support must be provided to
prevent damage to the plunger or seals during removal and installation. See Figure
9-5, Specialized Maintenance Tools for tools available to support the high pressure
assembly for this procedure.
3. Position the vee block cradle tool under the cylinder assembly. Unthread and remove the
assembly from the hydraulic cylinder head and plunger. Rotate the assembly with the
cylinder wrench or by hand.
Figure 9-6: High Pressure Cylinder Assembly Removal
If thread or metal surface galling is detected during removal, galled surfaces and
threads must be filed, sanded and lubricated prior to reassembly. See the
procedure, High Pressure Cylinder Maintenance.
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High Pressure Cylinder Assembly Installation

1. Verify the high pressure cylinder threads and alignment surfaces are adequately cleaned
and lubricated with Pure Goop, and the threads have been sanded and dressed if galling
was encountered during removal.
2. Verify the high pressure seal assembly, packing follower and cylinder liner are correctly
installed. Align the cylinder assembly with the plunger and the hydraulic cylinder head,
using the cradle tool to support the weight. Carefully push and lift the assembly into
position until the threads are ready to engage.
3. Thread the cylinder assembly into the hydraulic cylinder head.
If galling occurs during threading, remove the high pressure cylinder assembly and
inspect the mating surfaces and threads. Repair surfaces, thoroughly clean,
lubricate and thread the cylinder assembly into the hydraulic cylinder head.
An alignment mark is located on the hydraulic cylinder head under the KMT logo.
To ensure the high pressure cylinder is properly tightened and fully seated in the
hydraulic cylinder head, it is recommended that a corresponding mark be placed on
the high pressure cylinder after installation. Periodically inspect the cylinder for
movement. If movement is detected, retighten the assembly.
4. Connect the high and low pressure water piping, following the procedure, High and Low
Pressure Water Piping.
5. Start the machine in low pressure mode to flush air from the high pressure components
and to check for obvious leaks. After 5-10 strokes, switch to high pressure operation and
check for leaks.
If leaks are detected, turn the machine off and remedy the problem. When the problem
has been remedied, repeat the startup procedure, moving from low to high pressure soon
after the intensifier starts pumping water. There is no further need to flush air from the
system.
High Pressure Cylinder Maintenance

The plunger seal area in the high pressure cylinder bore should be inspected and cleaned each
time the high pressure seal assembly is replaced.
1. Clean the sealing area on the inside diameter of the high pressure cylinder and inspect the
bore for rings, scratches, pits, residue or other potential leak paths.
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2. Seal material or residue can build up, forming a ring. Running a fingernail across the
buildup will cause it to appear as a surface flaw. Grooves or ridges are typically seal
debris buildup rather than marks on the inside diameter wall of the cylinder.
3. Polish the inside diameter of the cylinder where the seal will locate with 600-grit wet/dry
sandpaper. Hold the sandpaper on the end of your finger and move in a cylindrical wiping
motion. Polish in a circumferential motion only. Do not polish or drag the sandpaper
along the length of the cylinder.
4. Clean the residue from the inside diameter of the cylinder and re-inspect for surface
defects.
9.7 Hard Seal End Caps

KMT Waterjet recommends loosening the jackbolts and removing the hard seal end caps (HSEC)
only to service the inlet check valve and the cone seat on the sealing head.
Figure 9-7: Hard Seal End Cap

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maintenance.

3. Loosen the jackbolts in the hard seal end cap following the removal procedure in Table
9-2, Torque Specifications.
4. Unscrew and remove the HSEC from the high pressure cylinder.
5. Remove the sealing head. The sealing head may be removed with the HSEC or after the
end cap has been removed.

1. Apply FML-2 grease to the two o-rings and
verify they are properly installed in the inside
diameter grooves of the HSEC. Check the high
pressure cylinder bore to verify the presence of
the cylinder liner.
2. Apply a thin film of Pure Goop to the coned-
shaped sealing surface on the sealing head.
Place the sealing head in the end cap and push
into position.
3. Apply JL-M grease to the full length of the
threads and to the ends of the jackbolts. Apply
JL-M grease to the internal threads in the
HSEC. Install the jackbolts, ensuring they are
slightly less than flush with the inner face of
the end cap.
Make sure the JL-M lube is well mixed and not dried up due to age.
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4. Position the end cap on the high pressure cylinder and fully engage the threads on the end
cap with the high pressure cylinder. The cone-shaped seal on the sealing head should be
in contact with the cylinder.
5. Unscrew the HSEC until the inlet water port is properly oriented to facilitate the low
pressure water connection. Do not unscrew the HSEC more than one full turn.
6. Hand-tighten the jackbolts until they make contact with the sealing head.
7. Tighten the jackbolts following the tightening sequence and torque specifications in Table
9-1.
8. Connect the high and low pressure water piping and turn the low pressure water supply
on.
9. Start the machine in low pressure mode to flush air from the high pressure components
and to check for obvious leaks. After 5-10 strokes, switch to high pressure operation and
check for leaks.
If leaks are detected, turn the machine off and remedy the problem. When the problem
has been remedied, repeat the startup procedure.
9.8 Sealing Head

The sealing head is sealed to the outboard end of the high pressure cylinder by a metal-to-metal
compression seal. The pre-loading jackbolts in the hard seal end cap hold the sealing head
against the end of the cylinder.
The inlet and discharge check valves in the sealing head ensure the low pressure and high
pressure water only travels in the appropriate direction.
Figure 9-8: Sealing Head
High Pressure Discharge Check Valve

The high pressure discharge check valves should be serviced on a regular, preventive
maintenance schedule. The discharge check valve can be serviced with the sealing head either
installed or removed from the high pressure cylinder.
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maintenance.

2. Disconnect the high pressure water piping, following the procedure, High and Low
Pressure Water Piping.
3. Use two wrenches to remove the discharge

gland nut. The poppet pin, spring and
discharge poppet will normally remain in the
gland nut when it is removed. Remove the
components from the gland nut.
4. Use a magnet to remove the seat from the
sealing head.
5. Inspect the poppet pin for wear and replace
the pin if worn.
6. Inspect both faces of the seat for damage or
cracking. A cracked or damaged seat must be
replaced.
Replace the seat, spring and discharge poppet as a set. If one component requires
replacement, replace all components.
7. Apply a thin film of Pure Goop to the face of the seat opposite the discharge poppet and
install the seat into the sealing head.
8. Install the poppet pin and the spring, with the larger end of the spring facing the poppet,
and then install the poppet into the gland nut.
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9. Apply Pure Goop to the sealing face and the threads on the gland nut and thread the gland
nut into the sealing head. Hand-tighten until there is a 0.20 inch (5 mm) gap between the
gland nut and the sealing head. No threads should show. If the gap exceeds 0.20 inch (5
mm), the poppet or seat has slipped out of position. Remove, inspect and reassemble the
parts.
10. Use a crowfoot/torque wrench combination and tighten the gland nut to the torque
specifications in Table 9-1.
Low Pressure Inlet Check Valve

Inlet check valve components differ, depending on the plunger diameter.
Service the inlet check valves on a regular, preventive maintenance schedule. The hard seal end
cap must be removed to service the inlet check valve. Follow the procedure, Hard Seal End Cap
Removal. With the end cap removed, proceed with Step 1 below.

1. Use a 5/16-inch wrench or socket to 1. Use a T20 star drive to remove the
remove the poppet retainer screw. poppet retainer screws and lock washers.
Remove the retainer and the inlet poppet Remove the retainer and the inlet poppet
from the sealing head. from the sealing head.
2. Inspect the sealing head for scratches or 2. Inspect the sealing head for scratches or
wear on the cone-shaped contact surface, wear on the cone-shaped contact surface,
and on the inlet poppet valve contact and on the inlet poppet valve contact
surface. If defects are detected, the surface. If defects are detected, the
surfaces must be refinished. See the surfaces must be refinished. See the
procedure, Sealing Head Maintenance. procedure, Sealing Head Maintenance.
3. Place the inlet poppet in the hole in the 3. Place the inlet poppet in the hole in the
poppet retainer as shown below. Position poppet retainer as shown below.
the inlet poppet and retainer on the Position the poppet retainer on the
sealing head, placing the dowel pin in the sealing head.
appropriate hole in the sealing head.
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4. Install the lock washers and the poppet
retainer screws.
There are two holes in the sealing head. 5. Use the T20 star drive to tighten the
The dowel pin on the poppet retainer is poppet retainer screws and torque to the
positioned in one and the inlet poppet is torque specifications in Table 9-1.
positioned over the other. Ensure that the
inlet poppet is positioned over the
through hole in the sealing head.
4. Spray Loctite 7649 on the threads of the 6 Inspect the assembled unit to ensure the
retainer screw and allow to dry. Apply poppet moves freely and the poppet
one drop of Loctite 248 on the threads retainer screws are seated.
only. Do not get any Loctite on the
poppet or any other surfaces on the inlet
check valve.
5. Use the wrench or socket to tighten the

poppet retainer screw. Tighten the poppet
retainer screw to the torque specifications
in Table 9-1.
6. Inspect the assembled unit to ensure the

poppet moves freely and the poppet
retainer screw is seated.
Sealing Head Maintenance

Inspect the sealing head for scratches, excessive sealing damage or erosion marking on the cone-
shaped contact surface, and on the inlet poppet valve contact surface. If defects are detected, the
surfaces must be refinished. The sealing head can be returned to KMT Waterjet for refinishing.
1. Clean the surface on the cone ring with 600-grit wet/dry sandpaper, using a radial motion.
It will not be possible to fully remove the main sealing marks.
2. Inspect the inlet poppet valve sealing surface for pits, scratches or jetting erosion. If
necessary, refinish the surface.
Place a piece of 1/4-1/2” thick plate glass, not window glass, on a sturdy table to provide
an absolutely flat surface. Place a piece of 400-grit wet/dry sandpaper on the glass. Use
even, deliberate strokes, rotating the sealing head approximately 10-15 degrees after each
stroke. Polish the sealing head until it is flat and smooth. Be careful not to cause
additional damage by tilting or tipping the part while polishing.
3. When the sealing head is flat and smooth, perform a final polish with 600-grit wet/dry
sandpaper.
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9.9 High Pressure Seal Assembly

The following procedure should be used to replace the high pressure seal assembly. Seal
components differ slightly, depending on the plunger diameter. See Figure 9-9, High Pressure
Seal Assembly.
Figure 9-9: High Pressure Seal Assembly
maintenance.

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2. Disconnect the high and low pressure water

piping, following the procedure, High and
3. Remove the high pressure cylinder assembly,
following the procedure, High Pressure
Cylinder Assembly Removal.
4. Apply Pure Goop to the threads on the high
pressure plug and gland fitting. Thread the
plug and gland fitting into the discharge
gland nut on the sealing head and hand
tighten.
5. Position the cylinder assembly upright in the
seal removal tool stand. If a tool stand is not
available, position the cylinder on a platform
of wooden blocks with the jackbolts resting
on the platform.
Do not stand the cylinder assembly on the top pan of the machine. The assembly
is heavy and must be properly supported to prevent it from falling.
6. Fill the cylinder with water and slide the seal removal tool or a used plunger into the
packing follower to ensure a good seal for the removal of the seal assembly.
7. Place a shop towel around the plunger or seal removal tool to avoid splash back. Use a
dead blow hammer to drive the removal tool or plunger into the cylinder until the seal
components move up and out of the cylinder.
8. Remove the cylinder liner from the bore and inspect for possible heat or wear damage, or
for debris. If scratches are detected on the tabs on the ends of the liner, the liner can be
reworked.
9. Feel approximately one inch into the cylinder bore for obvious ridges or grooves. If seal
debris is present, follow the procedure, High Pressure Cylinder Maintenance.
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10. Inspect the plunger surface for flaws. Rotate the plunger 360 degrees by hand while
viewing light reflection on the surface to detect any dullness, streaks, pits or other defects.
Run a fingernail perpendicular to the direction of the suspected flaws to determine the
severity of defects. Depending on the seal life achieved with the removed seal assembly,
make a judgment regarding plunger and/or cylinder replacement. If seal debris is present
on the plunger, polish with 600-grit wet/dry sandpaper, using a radial motion.
11. Lightly coat the new seal components with FML-2 grease and install the new components
on the plunger. Ensure the proper orientation of the backup rings as illustrated in Figure
9-9, High Pressure Seal Assembly.
12. Slide the cylinder liner over the plunger.
13. Install the high pressure cylinder assembly into the hydraulic cylinder head, following the
procedure, High Pressure Cylinder Assembly Installation.
14. Reconnect the high and low pressure water piping and turn the low pressure water supply
on.
9.10 Hydraulic Seal Cartridge and Plunger Removal

Use the following procedure to remove the hydraulic seal cartridge and the plunger.
maintenance.

3. Remove the proximity switch on the end of the hydraulic cylinder to be serviced. This
will allow the hydraulic oil to drain back to the reservoir, minimizing oil spillage. It will
take approximately five minutes for the oil to drain.
4. Remove the high pressure cylinder assembly, following the procedure, High Pressure
Cylinder Assembly Removal.
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5. Use a flat screwdriver to remove the retaining ring from the hydraulic cylinder head.
6. Remove the bushing retainer flange and clean the surfaces, weep holes and grooves.
Check the retainer flange for cracks.
7. Replace the proximity switch by positioning the o-ring, spacer and the switch. Apply
JL-M grease to the threads on the socket head screws and tighten, following the torque
Reinstall the proximity switch as soon as practical. Removal of the switch

presents the potential of an oil spray hazard.
Ensure that the proximity switch is properly installed and secured prior to starting
the machine. Failure to tighten the two hold down screws on each switch will
result in the spray of hydraulic oil.
8. Remove the collet from the plunger removal tool. Thread the large end of the tool onto
the hydraulic seal cartridge and pull the cartridge out, over the plunger.
Figure 9-10: Hydraulic Seal Cartridge Removal
9. With the cartridge removed, remove the plunger with the hydraulic cylinder head in place.
Six retainer pins hold the plunger in position. The pins close around the plunger button to
retain the plunger, and retract to release the plunger.
Clean the plunger and the ID of the collet with alcohol or a similar solvent. Partially
thread the collet into the plunger removal tool and slide the removal tool over the plunger
with the lobed end toward the plunger button. Note the orientation of the retainer pins on
the plunger button. Align the lobes on the tool with the retainer pins as shown below.
Tighten the collet and rotate the tool slightly, causing the pins to retract and release the
plunger. Remove the plunger from the hydraulic piston.
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Figure 9-11: Plunger Retainer Pins
Plunger Maintenance
Plunger surfaces can become streaked with longitudinal
scratches or flaws, and discolored or dull in appearance.
If any of these conditions become severe, the high
pressure seal assembly and possibly the hydraulic seal
cartridge will leak.
Remove accumulation of debris on the surface of the
plunger by polishing in a radial direction with 600-grit
sandpaper. However, plunger surface flaws usually
cannot be repaired on site. The plunger can be returned
to KMT Waterjet for reconditioning.
Plunger Installation
To install the plunger, slide the plunger removal tool over the plunger with the lobed end toward
the plunger button to help center the plunger in the hydraulic cylinder head. Position the plunger
in the button socket of the piston and force the plunger into place by hand. Use a flashlight to
verify that all six pins are equally extended to grip the plunger button.
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Hydraulic Seal Cartridge Installation

Seals in the hydraulic cartridge can be removed and replaced, or the complete cartridge can be
replaced. Seal components differ slightly, depending on the plunger diameter. See Figure 9-12,
Hydraulic Seal Cartridge.
Use caution during the removal and installation of the seal components to avoid scratching the
surface of the cartridge. Use the seal removal tool, a plastic or wooden dowel, or similar object
for seal removal. Do not use screwdrivers, wires or other metal objects that could damage the
cartridge. To avoid damaging the new seals, use the seal installation tool for installation.
Figure 9-12: Hydraulic Seal Cartridge
1. Carefully remove the worn seals and o-rings from the cartridge by pushing them with a
plastic or wooden dowel, or similar object. Remove the seals closest to the open ends
first, and work toward the center.
2. Inspect the seals for unusual wear, deformation or cuts. Note any unusual buildup of solid
material or debris creating possible leak paths.
3. Inspect the surface of the cartridge body for scratches, deformation, signs of metal-to-
metal contact or other unusual wear. Carefully examine the surface of the grooves on the
inside diameter. Note any scratches in the axial direction that could create a leak path.
4. Apply hydraulic oil to the inside and outside diameter of the cartridge body, and to the
individual seal components.
5. Install the seals, starting in the center and working toward the ends. See Figure 9-12 for
the proper orientation of the u-cup seals. If available, use the seal installation tool to
install the u-cup seals. See Figure 9-16, Pneumatic Valve Seal Tools.
6. Verify the proper positioning of the u-cup o-rings after installation.
7. When properly installed, apply hydraulic oil to the exposed surfaces of the seals and slide
the hydraulic seal cartridge over the plunger, into the cavity of the hydraulic cylinder
head.
8. Thoroughly clean the bushing retainer flange, including the cross-drilled weep holes.
Install the retainer flange over the plunger.
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9. Install the retaining ring, ensuring the retaining ring fully seats inside the groove in the
hydraulic cylinder head.
The o-rings on the hydraulic cartridge will take up clearance. Tap lightly on the bushing
retainer flange with the plunger removal tool to compress the o-rings enough to start the
retaining ring in the groove. Use a flat blade screwdriver to push on the outer edge of the
retainer flange while working one end of the retaining ring into the groove. The retainer
flange should tilt or tip enough to allow the retaining ring to move into the groove.
Continue working the ring into the groove while tilting the retainer flange until the ring is
fully seated.
10. Install the high pressure cylinder assembly into the hydraulic cylinder head, following the
procedure, High Pressure Cylinder Assembly Installation.
11. Connect the high and low pressure water piping and turn the low pressure water supply
on.
9.11 Hydraulic Piston

Two bearing rings provide wear contact between the piston and the inside diameter of the
hydraulic cylinder. On each end of the piston, six retainer pins hold the plunger in position. A
flat snap ring holds the plunger retainer pins in place. Two internal check valves vent unwanted
hydraulic pressure from one side of the piston to the other, preventing pressure from building
behind the plunger button.
Figure 9-13: Hydraulic Piston
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Hydraulic Piston Removal

Use the following procedure to remove the hydraulic piston.
maintenance.

2. Disconnect the high and low pressure water piping from both ends of the intensifier,
following the procedure, High and Low Pressure Water Piping.
3. Remove the high pressure cylinder assembly on each end of the intensifier, following the
procedure, High Pressure Cylinder Assembly Removal.
Figure 9-14: Hydraulic Piston Removal
4. Remove both of the proximity switches to prevent interference and to allow the hydraulic
oil to drain back to the reservoir, minimizing oil spillage. It will take approximately five
minutes for the oil to drain.
5. Remove the retaining ring, bushing retainer flange and the hydraulic seal cartridge from
both hydraulic cylinder heads. It is not necessary to remove the plunger.
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6. Loosen and remove the socket head screws in one of the hydraulic cylinder heads.
7. Remove the hydraulic cylinder head with the o-ring and backup ring. The mounting flat
for the proximity switch provides a small lip for loosening the cylinder head.
8. Grasp the plunger firmly and pull the piston out of the hydraulic cylinder.
Bearing Rings and Seal Assembly

1. Remove the plungers from the hydraulic piston.
2. Use a smooth, dull-edged blade made from brass or similar soft metal material to remove
the two bearing rings and the seal assembly.
Do not scratch the surfaces of the piston seal groove. Scratches on the sides or
bottom of the groove can result in hydraulic leaks.
3. Inspect the bottom of the seal grooves for marks, scratches and residue buildup. Clean
and/or repair the groove surfaces as required.
4. Apply FML-2 grease to the new bearing rings and install the rings.
5. The piston seal assembly consists of an inner and an outer seal ring. Apply FML-2 grease
to both rings. Use the smooth, dull-edged blade to install the inner ring. After
installation, ensure the inner ring is not twisted. Slide the outer seal ring over the metal
edges and ease it into position over the inner ring.
Figure 9-15: Bearing Rings and Seal Assembly
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Plunger Button Sockets, Seals and Retainer Pins

1. Remove the flat snap rings and plunger retainer pins on both ends of the piston.
2. Inspect the snap rings and the pins for unusual wear or deformation. Clean and inspect the
pin holes for unusual wear, deformation or enlargement.
3. Remove the plunger button o-ring and backup ring from each plunger socket. Take care
not to scratch or damage the seal groove surfaces.
4. Clean and inspect the seal grooves for residue buildup or surface marks that could cause
seal leaks.
5. Inspect the plunger button sockets for unusual wear.
Due to the high contact force between the piston and the plunger, the plunger may
make an impression in the bottom of the socket. This compression mark or
indentation is normal.
6. Apply FML-2 grease to new plunger button backup rings and o-rings. Install the rings in
the internal groove in the plunger socket. If the backup ring is not installed the plunger
can be forced out of the plunger socket.
7. Install the retainer pins, verifying that each pin moves freely without excess side play in
the pin holes.
8. Install the flat snap ring over the pins.
9. Install the plungers and check the snap-in feature of the plunger attachment. Use the
plunger removal tool to ensure the pins retract to release the plunger, and close to retain
the plunger in a uniform manner.
Internal Check Valves

It is not necessary to service the internal check valves unless a problem is suspected. If the check
valves or the internal passages in the piston require service, plunger button, seal and pin servicing
is also recommended. See Figure 9-13, Hydraulic Piston.
1. Loosen the setscrew and remove the check valves and o-

rings. Clean the internal passages.
2. Apply FML-2 grease to a new o-ring and install the o-
ring in the check valve passage. Use a blunt, pencil-like
instrument to position it in the bottom of the passage.
3. Clean and install a new check valve with the chamfered
end toward the o-ring.
4. Sparingly apply Loctite, threadlocker adhesive to the
setscrew. Thread the screw over the check valve
cartridge and tighten.
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Excess threadlocker adhesive can clog the check valve or block the internal
passage. To avoid excess adhesive, position the setscrew on an Allen wrench and
apply the adhesive. Hold the screw horizontal on a paper towel and rotate the
screw to remove excess adhesive.
Hydraulic Piston Installation

1. Ensure that the hydraulic cylinder bore is free of grit or contamination.
2. Lubricate the bearing rings and seal assembly, and lightly lubricate 2-3 inches of the
cylinder bore with FML-2 grease.
3. Install the piston into the hydraulic cylinder bore. If necessary, use a plastic head hammer
to drive the piston into position between the holes for the proximity switches.
4. Install the plungers and check the snap-in feature of the plunger attachment. Use the
plunger removal tool to ensure the pins retract to release the plunger, and close to retain
the plunger in a uniform manner.
5. Verify the proper positioning of the o-ring and backup ring in the groove on both
hydraulic cylinder heads, and they are sufficiently lubricated with FML-2 grease.
6. Position the cylinder heads on the ends of the hydraulic cylinder. Apply JL-M grease to
the threads on the socket head screws. Install the screws in each hydraulic cylinder head
and tighten, following the torque specifications in Table 9-1.
7. Replace the hydraulic seal cartridge, bushing retainer flange and retaining ring in both
hydraulic cylinder heads.
8. Replace the proximity switches by positioning the o-ring, spacers and the switches. Apply
JL-M grease to the threads on the socket head screws and tighten, following the torque
Ensure the proximity switches are properly installed and secured prior to starting
the motor. Failure to tighten the two hold down screws on each switch will result
in the spray of hydraulic oil.
9. Install the high pressure cylinder assemblies into the hydraulic cylinder heads, following
the procedure, High Pressure Cylinder Assembly Installation.
10. Connect the high and low pressure water piping, and turn the low pressure water supply
on.
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9.12 Hydraulic Cylinder Maintenance

The inside diameter surface of the hydraulic cylinder should be inspected for wear grooves and
surface finish whenever the hydraulic cylinder heads are removed. Excessive grooving is
indicative of piston seal wear.
9.13 High Pressure Attenuator

The high pressure attenuator is not serviceable at the customer level. KMT Waterjet Systems
tests the seals in the attenuator at pressures exceeding normal operating pressure, making
disassembly difficult. If the attenuator develops a high pressure water leak, it should be replaced.
9.14 High Pressure Dump Valve

The high pressure dump valve assembly includes a
normally open high pressure water valve and a
solenoid operated air valve. Redundant solenoid
valves create a block and bleed system for the air
pressure used to operate the dump valve. The first
solenoid valve is machine controlled with a safety
function override. The second solenoid is
controlled by the safety function relay.
A 30 psi pressure switch is used for testing and
monitoring the safety function of the block and
bleed system. If a failure is detected, a signal
from the pressure switch prevents operation to
continue.
Together, the solenoids and the pressure switch
provide redundancy and diversity to ensure all air
pressure is removed from the high pressure dump
valve when the e-stop button is pressed.
The SL-VI 30, 40 and 50 are equipped with a round, three-port dump valve assembly. A square,
two-port dump valve assembly is installed on the SL-VI 100 machines.
The following procedures are recommended for servicing each high pressure dump valve. Failure
to follow these procedures will cause damage to the stem, valve seat, or both.
The high pressure dump valve is designed to instantly release high pressure from
the system. Proper maintenance is imperative to prevent potential personal
injury.
Figure 9-16, Pneumatic Valve Seal Tools, illustrates the special tools recommended for this
procedure.
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Figure 9-16: Pneumatic Valve Seal Tools
3-Port Pneumatic Control Dump Valve

For reliable operation, always replace the valve seat, seal assembly, brass backup ring and stem at
the same time. The SST backup ring can be reused.
maintenance.

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Section 9
Figure 9-17: 3-Port High Pressure Dump Valve
1. Turn the air supply off.

2. Remove the air supply hose from the valve assembly.
3. Loosen and remove the high pressure gland connections and the drain connection.
4. Remove the valve and actuator assembly from the machine.
5. Loosen the cylinder head on the actuator.

Unscrew and remove the actuator from
the valve body.
6. Unscrew the high pressure adapter and
remove the adapter and valve seat.
7. Remove the stem, SST backup ring and
brass backup ring from the valve body.
8. Remove the seal assembly by pushing it
with the seal push tool (P/N 20470413).
The assembly must be pushed out
through the actuator port in the top of the
valve body.
9. Discard the stem, brass backup ring, seal
assembly and valve seat.
10. Clean and inspect the valve body, being careful not to damage or scratch the bore.
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Figure 9-18: Valve Seal Installation
11. Place the seal positioning tool into the opposite end of the valve body as shown in Figure
9-18, Valve Seal Installation. Thread the high pressure adapter into the valve body until
light contact is made with the positioning tool. Tighten finger-tight only.
12. Apply Pure Goop anti-seize compound to the threads on the seal installation tool. Screw
the seal installation tool into the threads of the valve body. Tighten finger-tight only.
13. Lubricate the o-ring in the seal assembly with silicone grease (P/N 20467543). Insert the
seal, o-ring and bronze wedge ring into the seal installation tool, inserting the o-ring end
of the seal first so the tapered end of the seal (wedge ring end) faces the actuator. The
tapered end of the seal must face the actuator.
14. Use the seal push tool to push the seal assembly into the bore of the valve body until the
seal makes light contact with the positioning tool.
15. Remove the push tool and the installation tool from the valve body.
16. Install the existing SST backup ring and a new brass backup ring on a new stem. The vee
groove on the SST backup ring must face toward the brass backup ring. The small OD of
the brass backup ring must face toward the seal assembly.
17. Insert the stem with the backup rings into the top of the valve body so the stem enters the
ID of the seal assembly. Insert the stem until the chamfer on the stem is seated
against the SST backup ring. See Figure 9-19, Valve Stem Placement.
Do not push the o-ring on the seal assembly past the inlet port on the valve body.
This will damage the seal o-ring.
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Figure 9-19: Valve Stem Placement
18. Remove the high pressure adapter and the seal positioning tool.
19. Apply Pure Goop anti-seize compound to the threads of the actuator and carefully thread it
into the valve body, guiding the stem head into the hole in the actuator. Turn the actuator
clockwise until resistance is felt. Reverse the actuator 1/4-turn, and give it a quick spin
clockwise to seat it. Hand-tighten only, 5 ft-lbs (7 Nm).
20. Apply Pure Goop anti-seize compound to all surfaces, except the ID, of a new valve seat.
Install the seat into the valve body, inserting the small OD first.
21. Apply anti-seize compound to the threads on the high pressure adapter. Install the adapter
and torque to 30 ft-lbs (40 Nm).
22. Apply anti-seize compound to the threads on 1/4-inch drain gland nut. Replace the gland
nut and collar, and torque to 25 ft-lbs (34 Nm).
23. Apply anti-seize compound to the threads on the 3/8-inch high pressure gland fittings.
Install the collar and the gland fittings and torque to 50 ft-lbs (68 Nm).
24. Install the air supply hose and the electrical connection to the solenoid valve. Turn the air
pressure to the actuator on and test the valve for leaks and proper operation.
2-Port Pneumatic Control Dump Valve

For reliable operation always replace the valve seat, seal assembly, brass backup ring and stem at
the same time. The SST backup ring can be reused.
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Section 9
maintenance.

1. Turn the air supply off.

2. Remove the air supply hose from the valve assembly.
Figure 9-20: 2-Port High Pressure Dump Valve
3. Loosen and remove the high pressure gland connections and the drain connection.
4. Remove the valve and actuator assembly from the machine.
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5. Loosen the cylinder head on the actuator.

Unscrew and remove the actuator from the
valve body.
6. Unscrew the high pressure bushing and
remove the bushing, adapter cone and
valve seat.
7. Remove the stem, SST backup ring and
brass backup ring from the valve body.
8. Remove the seal assembly by pushing it
with the seal push tool (P/N 20470413).
The assembly must be pushed out through
the actuator port in the top of the valve
body.
9. Discard the stem, brass backup ring, seal assembly and valve seat.
10. Clean and inspect the valve body, being careful not to damage or scratch the bore.
Figure 9-21: Valve Seal Installation
11. Place the seal positioning tool into the end of the valve body as shown above. Thread the
high pressure bushing into the valve body until light contact is made with the positioning
tool. Tighten finger-tight only. See Figure 9-21, Valve Seal Installation.
12. Apply Pure Goop anti-seize compound to the threads on the seal installation tool. Screw
the seal installation tool into the threads of the valve body. Tighten finger-tight only.
13. Lubricate the o-ring on the seal assembly with silicone grease (P/N 20467543). Insert the
seal and o-ring, with the bronze wedge ring, into the seal installation tool. Insert the o-
ring end of the seal first so the tapered end of the seal (wedge ring end) faces the actuator.
The tapered end of the seal must face the actuator.
14. Use the seal push tool to push the seal assembly into the bore of the valve body until the
seal makes light contact with the positioning tool.
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15. Remove the push tool and the installation tool from the valve body.
16. Install the existing SST backup ring and a new brass backup ring on a new stem. The vee
groove on the SST backup ring must face toward the brass backup ring. The small OD of
the brass backup ring must face toward the seal assembly.
17. Insert the stem with the backup rings into the top of the valve body so the stem enters the
ID of the seal assembly. Insert the stem until the chamfer on the stem is seated against the
SST backup ring. See Figure 9-22, Valve Stem Placement.
Do not push the o-ring on the seal assembly past the inlet port on the valve body.
This will damage the seal o-ring.
Figure 9-22: Valve Stem Placement
18. Remove the high pressure bushing and the seal positioning tool.
19. Apply Pure Goop anti-seize compound to the threads of the actuator and carefully thread it
into the valve body, guiding the stem head into the hole in the actuator. Turn the actuator
clockwise until resistance is felt. Reverse the actuator 1/4-turn, and give it a quick spin
clockwise to seat it. Hand-tighten only, 5 ft-lbs (7 Nm).
20. Apply Pure Goop anti-seize compound to all surfaces, except the ID, of a new valve seat.
Install the seat into the opposite end of the valve body, inserting the small OD first.
21. Apply anti-seize compound to the threads on the high pressure bushing, and on the back
side of the adapter cone. Position the adapter cone in the bushing, install the bushing and
torque to 50 ft-lbs (68 Nm).
22. Apply anti-seize compound to the threads on the 1/4-inch gland nut. Replace the gland
nut and the collar and torque to 25 ft-lbs (34 Nm).
23. Apply anti-seize compound to the threads on the 3/8-inch high pressure gland fitting.
Install the collar and the gland fitting and torque to 50 ft-lbs (68 Nm).
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Section 9
24. Install the air supply hose and the electrical connection to the solenoid valve. Turn the air
pressure to the actuator on and test the valve for leaks and proper operation.
Pneumatic Actuator
Use the following procedure to service the pneumatic actuator.
1. Unscrew and remove the cylinder head using a strap wrench and a pin spanner. Remove
the piston from the cylinder.
Do not install the pneumatic cylinder in a vise to remove the cylinder head. This
may distort the body and seize the piston, preventing proper operation.
2. Remove the o-ring on the cylinder head.

Apply FML-2 grease to a new o-ring and
install.
3. Remove the two o-rings on the piston. Apply
FML-2 grease to two new o-rings and install.
4. Install the piston in the pneumatic cylinder.
Apply anti-seize compound to the threads on
the cylinder head and screw it into the
pneumatic cylinder.
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Section 9
9.15 Weep Holes

High pressure seals and connections fail gradually and begin leaking slowly. Weep holes are
located at every threaded high pressure connection to provide a vent for internal leaks. Water or
oil dripping from a weep hole indicates one or more internal components are beginning to fail.
Table 9-2 lists the location of the weep hole, the possible source of the leak and the corrective
action required.
Table 9-2
Weep Holes
Location Indication Comments

Hydraulic oil leaking from the Failed hydraulic cartridge seal Replace the cartridge seal. If the
weep hole in the hydraulic leak persists, check the plunger
cylinder head for linear scratches or scoring.
Water leaking from the weep Failed high pressure seal Replace the high pressure seal
hole on the hydraulic cylinder assembly assembly.
head
Damaged plunger Check the plunger for
longitudinal scratches or flaws. If
detected, replace the plunger or
return to KMT for evaluation.
Seal material buildup on plunger Polish the plunger surface

following the procedure, Plunger
Maintenance.
Damaged high pressure cylinder Check for scratches, grooves or

material buildup on the inside
diameter of the cylinder. If
detected, polish the bore
following the procedure, High
Pressure Cylinder Maintenance.
Check the inside diameter of the

cylinder for expansion where the
high pressure seal assembly is
located. If detected, replace the
cylinder.
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Section 9
Table 9-2
Weep Holes
Sealing Head
Water leaking from the weep Seat in the discharge check valve Make sure the gland nut is
hole in the sealing head is not sealing properly tightened to the proper torque
specification.
Inspect the seat, sealing head and

gland nut for cracks.
Internal crack in sealing head Replace the sealing head.

A cracked sealing head can result
in water leaking from the high
pressure outlet passage to the low
pressure inlet passages.
The sealing head body can
become extremely hot.
Improper torque on gland nut Tighten the gland nut to the

proper torque specification.
Erosion or scratches on the Polish the surfaces following the

contact surface of the sealing procedure, Sealing Head
head, or on the gland nut where Maintenance.
the seat makes contact
Water leaking from the weep High pressure piping gland nut is Tighten the gland nut to the
hole in the gland nut not tight and is not sealing proper torque specification.
properly
Improper high pressure piping Check the number of exposed

connection threads past the collar on the high
pressure piping. Only 1-1/2 to 2-
1/2 threads should be exposed.
Check high pressure piping for

damage, cracks or deformation.
Inspect the gland nut for

deformation of the threads.
Damaged sealing head gland nut Check the gland nut for cracks
due to fatigue. If cracks are
detected, replace the gland nut.
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Section 9
Table 9-2
Weep Holes
Hard Seal End Cap

Water leaking from the weep Damaged high pressure cylinder Check for scratches or grooves on
holes in the hard seal end cap the cone seal surface. If detected,
polish to remove following the
procedure, High Pressure
Cylinder Maintenance.
External crack in sealing head Replace the sealing head.
Damaged sealing head Check for scratches or grooves on

the cone seal surface of the
sealing head. If detected, polish
the surface following the
procedure, Sealing Head
Maintenance.
Improper torque on jackbolts Re-torque the jackbolts to the

Damaged o-ring in the end cap Inspect the o-rings for cuts or
nicks and replace if necessary.
3-Port Dump Valve

Water leaking from the weep
holes in the 3-port dump valve
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Section 9
Table 9-2
Weep Holes
2-Port Dump Valve

Water leaking from the weep
holes in the 2-port dump valve
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SECTION 10
TROUBLESHOOTING
The Troubleshooting section contains:

§ Guide for diagnosing problems
§ Information for repairing the equipment
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Section 10
Troubleshooting
10.1 Overview
The troubleshooting guide will help identify the probable cause of a system malfunction and
assist in providing corrective action. The following symptoms are discussed in this section:
1. Inlet water pressure is falling below 30 psi (2 bar) during stroke condition
2. Outlet booster pump pressure is falling below 100 psi (6.8 bar)
3. Water is leaking around the v-clamp on the filter head
4. High oil temperature resulting in shutdown
5. Low oil level resulting in shutdown
6. Hydraulic pressure but no high pressure water pressure
7. Erratic fluctuations in the operating pressure, or inability to reach or maintain set pressure
8. No hydraulic oil pressure
9. Pump shaft will not turn
10. Pump will not start
11. Console display and lights do not illuminate
12. Pump quits running
13. No control power
14. Red light on operator’s console is on
15. Hot surfaces on the high pressure cylinder components
16. Low cutting water pressure
17. Hydraulic oil leaking from the weep hole in the hydraulic cylinder head
18. Water leaking from the weep hole in the hydraulic cylinder head
19. Water leaking from the weep hole in the sealing head
20. Water leaking from the weep hole in the sealing head gland nut
21. Water leaking from the weep holes in the hard seal end cap
22. Water leaking from the weep holes in the 3-port dump valve
23. Water leaking from the weep holes in the 2-port dump valve
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Section 10
Troubleshooting
10.2 Troubleshooting Guide

Listen to the machine and observe it in operation. Learn to recognize the normal sounds and
operating conditions of the system. Carefully define the symptom of the problem. Locate the
symptom on the troubleshooting guide that most closely corresponds to the problem.
If the symptoms in the guide do not correspond to the malfunction, or if the problem is not
resolved by the recommended corrective action, contact the KMT Customer Service Department
for assistance.
Table 10-1
SL-VI Series Troubleshooting Guide
Malfunction Indication Comments
1. Inlet water pressure is Supply water pressure or flow Check for restrictions or other
falling below 30 psi (2 bar) is low demands on the utility.
during stroke condition
Inlet solenoid valve is Replace the inlet solenoid valve.
malfunctioning
Pressure switch is bad Replace the pressure switch.
2. Outlet booster pump Supply water pressure is low Check for restrictions or other
pressure is falling below demands on the utility.
100 psi (6.8 bar)
Filter element is dirty Replace the filter element.
Mesh liner in the strainer is Clean the liner in the strainer.

clogged
Booster pump needs to be Booster pump should be

adjusted, or replaced adjusted to 150 psi (10.2 bar)
when deadheaded.
Pressure switch is bad Replace the pressure switch.
3. Water is leaking around the O-ring that closes the passage Replace or reposition the o-ring.
v-clamp on the filter head has deteriorated, been cut or
is not positioned correctly
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Section 10
Troubleshooting
Table 10-1
4. High oil temperature Oil-to-Water Models
resulting in shutdown
Cooling water flow is Check cooling water source for
restricted proper temperature and flow
rate.
Inlet solenoid valve is Replace the solenoid valve.

malfunctioning
Scale build up in the heat The heat exchanger will need to

exchanger has restricted the be flushed or replaced.
flow
A water pressure differential of
more than 35 psi (2.4 bar) may
indicate restriction.
Oil temperature sensor is not Replace the sensor.

operating properly
Oil-to-Air Models
Oil temperature sensor is not Replace the sensor.
operating properly
No power to cooler fan motor Check power supply to fan

motor.
Check the circuit breaker.
Restricted air flow to cooler There should be 36 inches (1

meter) clear space in front of the
cover.
Ambient temperature is The air cooler will not be able to

greater than 104º F maintain oil temperature at
ambient temperatures above
104º F
5. Low oil level resulting in Oil level is low due to leaks Check the level gauge.
shutdown
Check for hydraulic leaks.
Level switch is Check or replace the level

malfunctioning switch.
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Section 10
Troubleshooting
Table 10-1
6. Hydraulic pressure but no Proximity switch failure From the Maintenance Screen
high pressure water on the control panel, jog the
pressure intensifier left and right and
verify that the red light comes
on at both proximity switches.
I/O relay failure From the Maintenance Screen

on the control panel, jog the
intensifier left and right and
verify that the green light comes
on at both directional valve
solenoids.
Coil failure on the directional Check the resistance of the coils

control valve on the directional valve with a
multi- meter. The resistance
should be between 18 and 20
ohms.
PLC failure If there are inputs from the

proximity switches, but no
outputs, contact the KMT
Customer Service Department
for a logic review and
verification of PLC failure.
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Section 10
Troubleshooting
Table 10-1
7. Erratic fluctuations in the The screen in the proportional Remove the valve and clean the
operating pressure, or pressure valve is blocked with screen following the
inability to reach or debris maintenance procedure in
maintain set pressure Section 7, Hydraulic System.
Large, worn or damaged Make sure the orifice does not

orifice exceed the capacity of the pump.
Make sure the orifice is in good

working condition. Verify that
the jewel is installed in the
orifice mount.
Check valve leakage Inspect the discharge check

valves in the sealing heads.
Inspect the inlet check valves in

the sealing heads.
Seal leakage Inspect the high pressure seal on

the plunger.
Inspect the sealing head-to-

cylinder sealing surfaces.
Hydraulic control Check the operation of the

malfunction hydraulic relief valve.
Verify that the directional

control valve is shifting
properly.
Check the operation of the

proximity switches.
8. No hydraulic oil pressure The high and low limit Disassemble the compensators,
compensators on the clean and inspect the
hydraulic pump are blocked components following the
with debris and are not maintenance procedure in
controlling the swashplate Section 7, Hydraulic System.
Incorrect motor rotation Check the motor rotation.
9. Pump shaft will not turn The flexible coupling has Replace the flexible coupling.
failed
The hydraulic pump has Replace the hydraulic pump.

seized
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Section 10
Troubleshooting
Table 10-1
10. Pump will not start Emergency stop button is Pull the e-stop button out and
depressed reset safety function relay.
Check all remote safety function

relays and reset.
A protection fault has been Check the display panel for fault
activated messages.
Motor overload relay has Identify the source of the

been tripped overload and remedy the
problem. Reset the overload
relay.
Inlet water valve is turned off Turn the water valve on.
11. Console display and e-stop Control power has been Check to verify the remote
light does not illuminate interrupted interface plug is connected.
Check the input and output of

the 24 volt DC power supply.
Main power is disconnected Check the main power and

verify that the main power
disconnect is on.
12. Pump quits running Unsafe operation has been Check the display panel for fault
detected messages.
Electrical power has been Check the power supply circuit

interrupted for a tripped breaker.
Check the input and output of

the 24 volt DC power supply.
Verify that power is available at

the main power source.
Motor overload relay has Identify the source of the

been tripped overload and remedy the
problem. Reset the overload
relay.
72165890
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Section 10
Troubleshooting
Table 10-1
13. No control power Circuit breaker has been Check the input and output of all
tripped circuit breakers.
Safety function relay has been Check all safety function relays
tripped and reset.
Remote interface plug is Connect remote interface plug.

disconnected
14. Red light on operator’s An alarm condition has Check the display panel for fault
console is on occurred messages.
Refer to Section 4, Operation,
for additional information
regarding warning and alarm
conditions and recovery
procedures.
15. Hot surfaces on the high Leaking discharge check Inspect the condition of the seat,
pressure cylinder valve poppet valve, spring, poppet pin
components and sealing head surface on the
discharge end of the sealing
heads.
Leaking inlet check valve Inspect the condition of the

poppet valve, poppet retainer
and the spring, if applicable, on
the inlet end of the sealing
heads.
Damaged sealing head Check the cone flange surface of

the sealing head for scratches or
mechanical damage and replace
if necessary.
Damaged high pressure Check the high pressure cylinder

cylinder for cracks.
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Section 10
Troubleshooting
Table 10-1
16. Low discharge water Low hydraulic pressure If operating in low pressure,
pressure setting switch to high pressure
operation and check the
hydraulic pressure setting.
Clean the hydraulic relief or

proportional pressure control
valve.
Clean the compensators on the

hydraulic pump.
Collapsed element in the high Check the element in the high

pressure line filter pressure line filter, if applicable.
17. Hydraulic oil leaking from Failed hydraulic cartridge Replace the cartridge seal. If the
the weep hole in the seal leak persists, check the plunger
hydraulic cylinder head for linear scratches or scoring.
18. Water leaking from the Failed high pressure seal Replace the high pressure seal
weep hole in the hydraulic assembly assembly.
cylinder head
Damaged plunger Check the plunger for
longitudinal scratches or flaws.
If detected, replace the plunger
or return to KMT Waterjet for
evaluation and rework.
Seal material buildup on Polish the plunger surface

plunger following the procedure,
Plunger Maintenance, detailed
in Section 9, High Pressure
Water System.
Damaged high pressure Check for scratches, grooves or

cylinder material buildup on the inside
diameter of the cylinder. If
detected, polish the bore
Pressure Cylinder Maintenance,
detailed in Section 9, High
Pressure Water System.
Check the inside diameter of the

cylinder for expansion where the
high pressure seal assembly is
located. If detected, replace the
cylinder.
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Section 10
Troubleshooting
Table 10-1
19. Water leaking from the Seat in the discharge check Make sure the gland nut is
weep hole in the sealing valve is not sealing properly tightened to the proper torque
head specification.
Inspect the seat, sealing head

and gland nut for scratches,
erosion or cracks.
Improper torque on gland nut Tighten the gland nut to the

Internal crack in sealing head Replace the sealing head.

A cracked sealing head can
result in water leaking from the
high pressure outlet passages to
the low pressure inlet passages.
The sealing head body can
become extremely hot.
Erosion or scratches on the Polish the surfaces following the

contact surface of the sealing procedure, Sealing Head
head, or on the gland nut Maintenance, detailed in Section
where the seat makes contact 9, High Pressure Water System.
20. Water leaking from the High pressure piping gland Tighten the gland nut to the
weep hole in the sealing nut is not tight and is not proper torque specification.
head gland nut sealing properly
Improper high pressure Check the number of exposed

piping connection threads past the collar on the
high pressure piping. Only 1-
1/2 to 2-1/2 threads should be
exposed.
Check high pressure piping for

damage, cracks or deformation.
Inspect the gland nut for

deformation of the threads.
Damaged sealing head gland Check the gland nut for cracks
nut due to fatigue. If cracks are
detected, replace the gland nut.
72165890
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Section 10
Troubleshooting
Table 10-1
21. Water leaking from the Damaged high pressure Check for scratches or grooves
weep holes in the hard seal cylinder on the cone seal surface. If
end cap detected, polish to remove
Pressure Cylinder Maintenance,
detailed in Section 9, High
Pressure Water System.
Replace the high pressure

cylinder.
External crack in sealing head Replace the sealing head.
Damaged sealing head Check for scratches or grooves

on the cone seal surface of the
sealing head. If detected, polish
the surface following the
procedure, Sealing Head
Maintenance, detailed in Section
9, High Pressure Water System.
Improper torque on jackbolts Re-torque the jackbolts to the

Damaged o-ring in end cap Inspect the o-rings for cuts or

nicks and replace if necessary.
22. Water leaking from the

weep holes in the 3-port
dump valve
23. Water leaking from the

weep holes in the 2-port
dump valve
72165890
3-2015/Rev 0
Section 10
Troubleshooting
10.3 Soft Starter
Table 10-2
Soft Starter Troubleshooting Guide
Indication Remedy
Warning
1. Impermissible Ie CLASS The rated operational current Ie Check the rated operational
setting (control voltage set for the motor (control voltage current set for the motor,
present, no start command) present, no start command) select a lower CLASS setting,
exceeds the associated, maximum or calculate the soft starter
Device
permissible setting current with a size allowance.
(green) referred to the selected CLASS As long as the soft starter is
State/Bypassed/Failure setting. not controlled IN (0->1), this
(red) is only a status signal.
(green) However, it becomes a fault
signal if the start command is
(green)
applied.
2. Start inhibited, device too The acknowledgment and the The device cannot be started
hot motor start are inhibited for a until the temperature of the
defined time by the inherent thyristor or the heat sink has
Device
device protection following an cooled down enough to
(yellow) overload trip, to allow the soft guarantee sufficient reserve
State/Bypassed/Failure starter to cool down. for a successful startup. The
(red) time until restarting is allowed
Possible causes:
can vary but is a minimum of
§ Too many starts 30 seconds.
§ Motor ramp-up time too long Rectify the causes and
possibly retrofit the optional
§ Ambient temperature in
fan, if applicable.
switching device's
environment too high
§ Minimum installation
clearances not complied with
Fault
3. Impermissible electronics The control supply voltage does Check the control supply
supply voltage not correspond to the soft starter's voltage; could be caused by a
rated voltage. power failure, voltage dip, or
Device
incorrect control supply
(red) voltage. Use a stabilized
State/Bypassed/Failure power supply unit if due to
mains fluctuations.
(red)
72165890
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Section 10
Troubleshooting
Table 10-2
Indication Remedy
4. Impermissible Ie CLASS The rated operational current Ie Check the rated operational
setting and IN (0->1) set for the motor (control voltage current set for the motor,
(control voltage present, present, start command present) select a lower CLASS setting,
IN start command changes exceeds the associated, maximum or calculate the soft starter
from 0 to 1) permissible setting current with a size allowance.
Device referred to the selected CLASS
setting.
(green)
State/Bypassed/Failure
(red)
5. Motor protection tripping The thermal motor model has § Check whether the motor's
Overload relay/thermistor tripped. After an overload trip, rated operational current Ie
restarting is inhibited until the is set correctly.
Device
recovery time has elapsed.
(green) § Change the CLASS setting
Overload relay tripping time is 60
State/Bypassed/Failure seconds. § Possibly reduce the
(red) switching frequency.
Thermistor tripping time equals
the time for the temperature § Deactivate the motor
sensor (thermistor) in the motor protection (CLASS OFF).
to cool down. § Check the motor and the
application.
6. Thermistor protection: Temperature sensor at terminals Check the temperature sensor

wire breakage/short-circuit T11/T12/T22 is short-circuited or and the wiring.
(optional) defective, a cable is not
connected, or no sensor is
Device
connected.
(green)
(red)
7. Thermal overload on the Overload trip of the thermal Wait until the device has
device model for the power unit. cooled down again, possibly
increase the current limiting
Device Possible causes:
value set for starting, or
(yellow) § Too many starts reduce the switching
State/Bypassed/Failure frequency (too many
§ Motor ramp-up time too long consecutive starts). Possibly
(red) § Ambient temperature in retrofit the optional fan, if
switching device's applicable.
environment too high
Check the load and the motor,
§ Minimum installation check whether the ambient
clearances not complied with temperature in the soft starter's
environment is too high
(derating above 40 °C).
72165890
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Section 10
Troubleshooting
Table 10-2
Indication Remedy
8. Missing load voltage, Phase L1/L2/L3 is missing or Connect L1/L2/L3 or correct
phase failure/missing load fails/collapses when the motor is the voltage dip.
operating.
Device
(yellow) Tripped as a result of a dip in the
permissible rated operational
State/Bypassed/Failure voltage > 15 % for > 100 ms
(red) during the startup process or >
200 ms in bypass mode.
The motor that is connected is too Set the correct rated

small and the fault occurs as soon operational current for the
as it is switched to bypass mode. connected motor or set it to
the minimum value (if the
motor current is less than 10%
of the set Ie, the motor cannot
be operated with this starter).
Motor phase T1/T2/T3 is not Connect the motor properly

connected. (e.g. jumpers in the motor
terminal box, repair switch
closed etc.)
9. Device fault Soft starter is defective. Contact KMT for technical

assistance.
Device
(red)
(red)
72165890
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SECTION 11
SPECIFICATIONS
The Specifications section provides:

· Equipment specifications
· Water quality standards and treatment guidelines
· Horsepower requirements for orifice sizes
72165898
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Section 11
Specifications
11.1 Overview
Comprehensive listings of specifications for the SL-VI models listed in Table 11-1 are provided
in this section.
Table 11-1
SL-VI Models
Motor Horsepower
Rating
Model HP Kw
SL-VI 30 30 22
SL-VI 40 40 30
SL-VI 50 50 37
SL-VI 100 100 75
11.2 Installation Specifications
Environment
Installation location Indoors
Air borne dust/contaminants Minimal
Ambient temperature
Minimum storage 36° F (2° C)
Minimum operating 40° F (5° C)
Maximum operating 104° F (40° C)
Maximum relative humidity* 95%
(at maximum operating temperature)
*Note: When the relative humidity is above 50%, the oil in the reservoir
should be checked frequently for water content.
Sound Level
(with all covers in place)
30 HP 40 HP 50 HP 100 HP
Sound level [dB(A)] 74.0 75.0 76.0 TBD
72165898
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Section 11
Specifications
Equipment Dimensions and Weights

30 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.00” (1,508 mm) 2,443 lbs (1/108 kg)
40 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.00” (1,508 mm) 2,542 lbs (1,153 kg)
50 HP 66.50” (1,689 mm) 43.86” (1,114 mm) 59.00” (1,508 mm) 2,870 lbs (1,302 kg)
100 HP 82.50” (2,095 mm) 52.00” (1,320 mm) 59.00” (1,508 mm) 4,691 lbs (2,128 kg)
Redundant Models (same dimensions as above)

30 HP 2,743 lbs (1,244 kg)
40 HP 2,842 lbs (1,289 kg)
50 HP 3,170 lbs (1,438 kg)
100 HP 5,036 lbs (2,284 kg)
Service Connections
Connection Height
A Drain 1/2” NPT 8.75” (222 mm)
B Cutting Water In 1/2” NPT 11.47” (298 mm)
C Cooling Water In 1/2” NPT 14.74” (374 mm)
Hydraulic Oil Out (oil-to-air models) 3/4” JIC 14.74” (374 mm)
D Cooling Water Out 1/2” NPT 17.74” (450 mm)
Hydraulic Oil In (oil-to-air models) 3/4” JIC 14.74” (374 mm)
E Plant Air In 1/4” NPT 27.74” (705 mm)
F Cutting Water Out 9/16” HP 30.74” (780 mm)
G Contaminated Waste Drain 1/2” NPT 33.74” (857 mm)
All service connections are made on the bulkhead of the machine. The intensifier requires two
incoming water sources, cooling water and cutting water; two drain lines, cooling water and
wastewater; a high pressure discharge line, and an air supply line.
Plant Air
The facility compressed air connection should provide clean, dry air regulated to 85 psi (5.9 bar).
Air usage is minimal, normally less than 1 scf/min.
The following table provides specifications for each ISO air quality classification. KMT
recommends adherence to Quality Class 4.
72165898
6-2015/Rev 01
Section 11
Specifications
Table 11-2
ISO Air Quality Classifications
Maximum Maximum Pressure
ISO Quality Particle Size Dew Point Maximum Oil Content
Class (microns) (water @ 100 psi) (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) --
11.3 Water Specifications
Cutting Water Supply (Low Pressure Water System)

30 HP 40 HP 50 HP 100 HP
Maximum consumption 3.5 @ 60 Hz 3.5 @ 60 Hz 4.4 @ 60 Hz 8.1 @ 60 Hz
[gpm (L/min)] (11.0 @50 Hz) (11.0 @50 Hz) (16.5 @50 Hz) (30.0 @50 Hz)
Minimum inlet water pressure 35 psi (2.4 bar) flowing
Maximum inlet water pressure 80 psi (5.5 bar)
Maximum outlet water pressure 180 psi (12.4 bar)
Booster pump factory set inlet pressure 58 psi (4 bar)
Booster pump factory set outlet pressure 180 psi (12.4 bar)
Optimum inlet water temperature 65° F (18° C)
Maximum inlet water temperature 85° F (29° C)
Low inlet water pressure 30 psi (2 bar)
Low booster pressure 100 psi (6.9 bar)
72165898
6-2015/Rev 01
Section 11
Specifications
Cooling Water Supply (Recirculation System)

30 HP 40 HP 50 HP 100 HP
Reservoir capacity 39.7 gal 39.7 gal 39.7 gal 55.8 gal
(150 L) (150 L) (150 L) (211 L)
Reservoir capacity 55.8 gal 55.8 gal 55.8 gal 55.8 gal
(Units with optional onboard cooling system) (211 L) (211 L) (211 L) (211 L)
Low oil level shutdown 32.0 gal 32.0 gal 32.0 gal 41.0 gal
(121 L) (121 L) (121 L) (155 L)
Low oil level shutdown 41.0 gal 41.0 gal 41.0 gal 41.0 gal
(Units with optional onboard cooling system) (155 L) (155 L) (155 L) (155 L)
Maximum consumption at 75° F (24° C) 1.5 gpm 2.0 gpm 3.0 gpm 4.5 gpm
(5.7 L/min) (7.6 L/min) (11.4) L/min (17.0) L/min
Total heat rejection (BTU/HR) 13,400 18,000 22,000 45,000
Minimum operating oil temperature 68° F (20° C)
Optimum operating oil temperature 120° F (49° C)
Hot oil shutdown (maximum operating oil temperature) 144° F (62° C)
Minimum inlet cooling water pressure (oil-to-water models) 35 psi (2.4 bar)
Maximum inlet cooling water pressure (oil-to-water models) 100 psi (6.9 bar)
Oil filtration rating (Beta filtration rating) β10≥100*
Fluid cleanliness rating (ISO fluid cleanliness rating) 17/14**
Nominal recirculation pressure 30 psi (2 bar)
Recommended oil type

General service Conoco Phillips Megaflow AW 46
Mobil DTE 10 Excel 46
Food service Fuchs Cassida FM 46
Mobil DTE FM 46
Chevron Lubricating Oil FM 46
* Note: For each particle per milliliter downstream of the filer greater than 10 microns, there are 100
particles per milliliter larger than 10 microns upstream of the filter.
**Note: Indicates ISO 4406 range numbers for maximum permissible number of particles per milliliter,
greater than 5 and 15 microns.
17 <1,300 particles per milliliter, >5 microns
14 <160 particles per milliliter, >15 microns
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Specifications
Water Quality Standards

The quality of the inlet cutting water supply is one of the most important factors affecting
component life and performance. Water treatment requirements can be determined by a water
analysis.
Due to its aggressive nature, KMT does not recommend using deionized water in
our pumps.
The cutting water supply must meet the following standards. A high concentration of dissolved
solids, especially calcium, silica and chlorides will affect high pressure component life.
Table 11-3
Water Quality Standards
Constituent Minimum
(mg/l or ppm) Requirement Better Best
Alkalinity 50 25 10
Calcium 25 5 0.5
Chloride 100 15 1
Free Chlorine 1 1 0.05
Iron 0.2 0.1 0.01
Magnesium as Mg 0.5 0.1 0.1
Manganese as Mn 0.1 0.1 0.1
Nitrate 25 25 10
Silica 15 10 1
Sodium 50 10 1
Sulfate 25 25 1
TDS* 200 100 35**
Total Hardness 25 10 1
pH 6.5-8.5 6.5-8.5 6.5-8.5

Turbidity (NTU) 5 5 1
* Note: Total dissolved solids
**Note: Do not reduce the TDS beyond this amount or the water will be too aggressive.
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Specifications
Table 11-4
Water Impurities
Constituent Chemical Formula Comments

Alkalinity Bicarbonate (HCO3) Acid neutralizing capacity of water. Foaming
Carbonate (CO3) and carryover of solids, causes embrittlement of
Hydrate (OH), steel, can produce CO2, a source of corrosion.
expressed as CaCO3
Calcium Ca When dissolved makes water hard; contributes to
the formation of scale.
Chloride Cl Adds to solid content and increases corrosive
character of water; in relative percentage
presence with oxygen induces stress corrosion
cracking.
Free Chlorine Cl2 Oxidizing agent; can attack elastomeric seals and
damage reverse osmosis (RO) membranes.
Iron Fe++ (ferrous) Discolors water or precipitation; source of scale
Fe+++ (ferric) and erosion.
Magnesium as Mg When dissolved makes water hard; contributes to
the formation of scale.
Manganese as Mn Mn++ Discolors water or precipitation; source of scale
and erosion.
Nitrate NO3 Adds to solid content; effect is not generally
significant industrially.
Silica SiO2 Causes scale
Sodium Na Found naturally; introduced to water in the ion
exchange water softening process.
Sulfate SO4 Adds to solid content; combines with calcium to
form calcium sulfate scale.
TDS Measure of the total amount of dissolved matter
in water.
Total Hardness CaCO3 Sum of all hardness constituents in water;
typically expressed as their equivalent
concentration of calcium carbonate; primarily due
to calcium and magnesium in solution, but may
include small amounts of metal. Carbonate
hardness is usually due to magnesium and
calcium bicarbonate; non-carbonate hardness is
due to sulfates and chlorides.
pH Intensity of the acidic or alkaline solids in water;
pH scale runs from 0, highly acidic, to 14, highly
alkaline; with 7 being neutral.
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Specifications
11.4 Electrical Specifications
Electrical System
Motor type TEFC (Totally Enclosed Fan Cooled)
Controls
Voltage 24 volts DC
Power supply 5 amps DC
See nameplate for machine specific ampacity and power voltage requirements.
11.5 Hydraulic and High Pressure Water System Specifications
Hydraulic System
30 HP 40 HP 50 HP 100 HP
Maximum operating pressure 3,000 psi (207 bar) 2,600 psi (179 bar)
Main system relief valve 3,408 psi (235 bar) 2,973 psi (205 bar)

30 HP 40 HP 50 HP 100 HP
Plunger diameter [inches (mm)] 0.875 0.875 0.875 1.125
(22) (22) (22) (29)
Piston diameter [inches (mm)] 4.03 4.03 4.03 5.50
(102.40) (102.40) (102.40) (139.70)
Intensification ratio 20:1 20:1 20:1 23:1
Maximum flow rate
55,000 psi (3,792 bar) 0.75 @ 60 Hz 0.88 @ 60 Hz 1.09 @ 60 Hz 1.76 @ 60 Hz
[gpm (L/min)] (2.76 @ 50 Hz) (2.76 @ 50 Hz) (4.13 @ 50 Hz) (6.66 @ 50 Hz)
60,000 psi (4,137 bar) 0.69 @ 60 Hz 0.88 @ 60 Hz 1.09 @ 60 Hz 1.72 @ 60 Hz
[gpm (L/min)] (2.61 @ 50 Hz) (2.76 @ 50 Hz) (4.13 @ 50 Hz) (6.51 @ 50 Hz)
Minimum outlet pressure 5,100 psi 5,100 psi 5,100 psi 5,800 psi
(352 bar) (352 bar) (352 bar) (400 bar)
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Specifications

30 HP 40 HP 50 HP 100 HP
Maximum outlet pressure 60,000 psi (4,137 bar)
Pneumatic Control Valve

Maximum water pressure 60,000 psi (4,137 bar)
Minimum air pressure 85 psi (5.9 bar)
Maximum air pressure 100 psi (6.9 bar)
Maximum flow rate 1.0 cfm (0.028) m3/min
Orifice Capacity
The following table provides maximum single orifice sizes for the SL-VI series.
Table 11-5
Single Orifice Diameter
Motor
Horsepower
Rating Maximum Maximum Single
Operating Orifice Diameter
Model HP Kw Pressure (at full pressure)
SL-VI 30 30 22 0.011” @ 60 Hz
0.28 mm @ 50 Hz
SL-VI 40 40 30 0.013” @ 60 Hz
60,000 psi 0.28 mm @ 50 Hz
SL-VI 50 50 37 (4,137 bar)* 0.014” @ 60 Hz
0.36 mm @ 50 Hz
SL-VI 100 100 75 0.018” @ 60 Hz
0.46 mm @ 50 Hz
*Note: Maximum pressure with cutting head valve open is 60,000 psi (4,137 bar).
Maximum pressure with cutting head valve closed is 66,000 psi (4,550 bar).
11.6 Torque Specifications

Measurements are made with lubricated components and a certified, calibrated torque wrench.
Inconsistencies in wrench settings, lubrication and technique may not produce a leak free seal. If
leakage occurs, the torque can be increased to seal the components. However, do not exceed the
recommended torque value by more than 15 percent. If leakage persists, there is a component
problem.
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Specifications
Excessive torque can cause component damage or failure, resulting in potential

hazards to equipment and personnel.
7/8 inch (22 mm) 1-1/8 inch (29 mm)
Diameter Plunger Diameter Plunger

1st Stage Hand Tight Hand Tight
2nd Stage 20 ft-lbs (27 Nm) 20 ft-lbs (27 Nm)
Crossing Pattern* Crossing Pattern*
3rd Stage 32-35 ft-lbs (43-47 Nm)** 32-35 ft-lbs (43-47 Nm)**
Crossing Pattern Crossing Pattern
4th Stage 32-35 ft-lbs (43-47 Nm) 32-35 ft-lbs (43-47 Nm)
Clockwise Pattern From Bolt 1 Clockwise Pattern From Bolt 1
6-Bolt Crossing Pattern 8-Bolt Crossing Pattern
* Note: Crossing Pattern: 1, 2, 3, 4, 5, 6 or 1, 2, 3, 4, 5, 6, 7, 8.

** Note: A maximum torque of 38 ft-lbs (51 Nm) is etched on the hard seal end cap. This represents
the maximum allowable torque, not the recommended torque.
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Specifications
7/8 inch (22 mm) 1-1/8 inch (29 mm)

1st Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
2nd Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
3rd Stage Loosen each bolt 1/4 turn Loosen each bolt 1/4 turn
Clockwise pattern until all bolts Clockwise pattern until all bolts
are loose are loose
4th Stage Remove, clean and lubricate Remove, clean and lubricate
bolts prior to next use bolts prior to next use

Torque 75-80 ft-lbs (102-108 Nm) 170-175 ft-lbs (230-237 Nm)
Proximity Switch
Torque 140-160 in-lbs (16-18 Nm) 140-160 in-lbs (16-18 Nm)
Topworks Support
Torque 46 ft-lbs (62 Nm) 35-40 ft-lbs (47-54 Nm)
Hydraulic Manifold
Socket Head Screws 4 (3/8”) each 6 (1/2”) each
Torque 36 ft-lbs (49 Nm) 85 ft-lbs (115 Nm)
Socket Head Screws 2 (1/4”) each
Torque 10 ft-lbs (14Nm)
Sealing Head
Discharge Gland Nut 130 ft-lbs (176 Nm) 200 ft-lbs (271 Nm)
Poppet Retainer Screw(s) 25 in-lbs (2.8 Nm) 50 in-lbs (5.6 Nm)
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Section 11
Specifications
7/8 inch (22 mm) 1-1/8 inch (29 mm)

HP Adapter 30 ft-lbs (40 Nm)
1/4-inch Outlet to Drain 25 ft-lbs (34 Nm)

9/16”-1/4” HP Bushing 50 ft-lbs (68 Nm)
High Pressure Fittings

1/4-inch Gland Nut 25 ft-lbs (34 Nm) 25 ft-lbs (34 Nm)
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SECTION 12
PARTS LIST
The Parts List details:

§ Standard parts and optional modules
§ Maintenance and installation tools
§ Equipment accessories
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Section 12
Parts List
12.1 Overview
This section contains a comprehensive list of all standard and optional parts for the 50 horsepower SL-VI, maintenance tools, installation and
equipment accessories. To facilitate the ordering of replacement parts, item numbers in each table correspond to the identifying numbers in
the accompanying figures.
Use the following information to contact the Customer Service Department at KMT Waterjet Systems.
USA Europe
Customer Service Department Spare Parts Manager
KMT Waterjet Systems KMT Waterjet Systems GmbH
PO Box 231 Hohe Strasse 4-6
635 West 12th Street D-61231 Bad Nauheim
Baxter Springs, KS 66713-0231 Germany
USA
Phone (800) 826-9274 Phone +49-6032-997-0

Fax (620) 856-2242 Fax +49-6032-997-270
Email [email protected] Email [email protected]
[email protected]
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Parts List
12.2 Index
Part lists are arranged in the following sequence:
Parts List Index

Part Part
Table Description Number Page Table Description Number Page
12-1 50 HP Intensifier Unit 12-5 12-19 Electrical Kit, Motor Starter 72155215 12-42
12-2 Intensifier Assembly 72160849 12-8 12-20 Electrical Configuration, Wye-Delta Start 72164808 12-43
12-3 Hydraulic Cartridge Seal 05130091 12-10 12-21 Electrical Kit, Circuit Breaker 72155165 12-45
12-4 Sealing Head Assembly 72142526 12-11 12-22 Electrical Kit, Motor Starter 72155298 12-45
12-5 Hydraulic Piston Assembly 05132253 12-12 12-23 Electrical Kit, Hardware 72156355 12-46
12-6 Pneumatic Valve/Actuator Assembly 20427739 12-14 12-24 Electrical Kit, Low Voltage Controls 72155421 12-47
12-7 High Pressure Piping, 1L Attenuator 72162477 12-16 12-25 Electrical Kit, High Voltage Controls 72155348 12-49
12-8 High Pressure Piping, 2L Attenuator 72156222 12-18 12-26 Harness Configuration 72157172 12-51
12-9 Bulkhead Pipe Assembly 72152927 12-20 12-27 Motor Cable Assembly, 87A 72160989 12-55
12-10 Low Pressure Water Filter Assembly 72155629 12-24 12-28 Motor Cable Assembly, 48A 72159900 12-56
12-11 Hydraulic Power Package 72154447 12-26 12-29 Motor Cable Assembly, 48A 72160997 12-57
12-12 Hydraulic Manifold Assembly 72157461 12-28 12-30 High/Low Kit 72159494 12-59
12-13 Hydraulic Hose Connections 72159239 12-30 12-31 Power Factor Correction Kit 72166264 12-60
12-14 Reservoir Assembly 72152878 12-33 12-32 Cover Interlock Kit 72166272 12-62
12-15 Oil/Water Heat Exchanger Kit 72156272 12-35 12-33 Proportional Pressure Control 72158775 12-63
12-16 Oil/Air Heat Exchanger Kit, External 72163210 12-38 12-34 High Pressure Transducer 72158213 12-64
12-17 Electrical Configuration, Line Start 72158106 12-40 12-35 Redundant Kit 72155777 12-66
12-18 Electrical Kit, Circuit Breaker 72155173 12-42
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Parts List
Parts List Index

Part Part
Table Description Number Page Table Description Number Page
12-36 High Pressure Tube Coning Tools 12-68 12-45 Autoline™ Abrasive Nozzle Assembly 12-85
12-37 High Pressure Tube Threading Tools 12-69 12-46 Autoline™ II Abrasive Nozzle Assembly 12-86
12-38 Maintenance Tools and Lubricants 12-70 12-47 Autoline™ Sapphire Orifice 12-87
12-39 Focusing Tubes 12-72 12-48 Autoline™ Diamond Orifice 12-87
12-40 Standard Sapphire Orifice 12-74 12-49 Pneumatic Control Valve, NC 10138824 12-88
12-41 Standard Diamond Orifice 12-74 12-50 Pneumatic Cylinder Assembly, NC 10177855 12-89
12-42 High Pressure Filter Assemblies 12-75 12-51 Pneumatic Control Valve, NO 10184760 12-90
12-43 High Pressure Swivel Joints 12-77 12-52 Pneumatic Cylinder Assembly, NO 10189553 12-91
12-44 Nozzle Tubes 12-83 12-53 Bulk High Pressure Tubing 12-92
12-54 High Pressure Fitting and Valve Assemblies 12-93
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Parts List
Table 12-1
SL-VI 50 Horsepower Intensifier Unit
Part
Item Number Description
1 72162477 High Pressure Piping Assembly, 1L Attenuator
72156222 High Pressure Piping Assembly, 2L Attenuator
2 72158106 Electrical Configuration, Line Start
72164808 Electrical Configuration, Wye-Delta Start
3 72152927 Bulkhead Pipe Assembly
4 72152878 Reservoir Assembly
5 72154447 Hydraulic Power Package
6 05071717 System Relief Valve
7 72159239 Hydraulic Hose Connections
8 72155777 Redundant Kit (Optional)
9 72152638 Cover Assembly (Optional)
10 72152539 Door Kit (Optional)
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Figure 12-1: SL-VI 50 Horsepower Intensifier Unit
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Parts List
Figure 12-1: SL-VI 50 Horsepower Intensifier Unit
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Parts List
Table 12-2
Intensifier Assembly
72160849
Part Part
Item Number Description Quantity Item Number Description Quantity
1 72160831 High Pressure Cylinder 2 16 05034855 Backup Ring, 3.75 x 4.0 2
2 05119151 Plunger 2 17 05141106 Socket Head Screw, M14 x 60MM 16
3 72142526 Sealing Head Assembly 2 18 72146433 Proximity Switch Kit 2
4 05034772 Hydraulic Cylinder Head 2 72130929 Proximity Switch
5 20422243 High Pressure Seal Assembly 2 10183572 Socket Head Screw, M6 x 1 x 22MM
7 80073646 Cylinder Nut 2 20 05132253 Piston Assembly 1
8 05130091 Hydraulic Seal Cartridge Assembly 2 21 20427804 Intensifier Support 2
9 05007786 Bushing Retainer Flange 2 22 20427994 Socket Head Screw, M10 x 1.50 x 65MM 8
10 20497767 Liner 2 23 05061486 Lock Washer, M10 8
20491603 Liner, Brass 24 10074409 O-Ring, 1.0 x 1.25 x .13 2
11 10074920 O-Ring, 1.75 x 1.94 x .09 4 25 05144183 Spacer Assembly, Proximity Switch 2
12 80070352 Jackbolt 12 05144191 O-Ring, .69 x .88 x .09
13 05034798 Retaining Ring 2 26 05081872 Gasket, Topworks Support 2
14 05034764 Hydraulic Cylinder 1
15 10075000 O-Ring, 3.75 x 4.0 x .13 2
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Figure 12-2: Intensifier Assembly
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Parts List
Table 12-3
Hydraulic Cartridge Seal
05130091
Part
Item Number Description Quantity
1 05130109 Seal Bushing 1 Figure 12-3: Hydraulic Cartridge Seal
2 05015060 Packing Ring 2
3 10193522 O-Ring, 1.19 x 1.38 x .09 1
4 05050760 Backup Ring, 1.19 x 1.38 1
5 05129481 O-Ring, 1.0 x 1.13 x .06 1
6 05013024 O-Ring, 1.25 x 1.38 x .06 1
7 05129515 Backup Ring, .89 x 1.13 x .05 1
8 05027255 U-Cup Packing Seal 1
80084759 Rebuild Kit

Includes Items 2-8
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Parts List
Table 12-4
Sealing Head Assembly
72142526
Part
1 72142493 Sealing Head 1 Figure 12-4: Sealing Head Assembly
2 20453619 Inlet Poppet 1
3 05116777 Gland 1
4 05112768 Seat 1
5 05116561 Discharge Poppet 1
6 20474395 Screw, Poppet Retainer 1
7 05147863 Compression Spring 1
8 20474391 Poppet Retainer 1
9 05116751 Poppet Pin 1

Includes items 2, 4, 5, 6, 7 and 9
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Parts List
Table 12-5
Hydraulic Piston Assembly
05132253
Part Part
1 05132261 Ram Piston, 4.03 1 6 05049994 Backup Ring, 1.25 x 1.50 2
2 05074380 Clevis Pin 12 7 05087713 O-Ring, 1.25 x 1.50 x .13 2
3 05049887 Setscrew 2 8 05117965 Seal Assembly 1
4 10148757 Check Valve Assembly 2 9 05117940 Bearing 2
5 05088364 Retaining Ring 2

Includes Items 4, 6, 7, 8,9 and 10
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Section 12
Parts List
Figure 12-5: Hydraulic Piston Assembly
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Section 12
Parts List
Table 12-6
Pneumatic Valve/Actuator Assembly, Normally Open
20427739
Part Part
1 20427648 Valve Body 1 10189553 Actuator Assembly, Normally Open
2 10178697 Valve Seat 1 7 BV401184 Pneumatic Cylinder 1
3 49830904 Adapter, HP Water Valve 1 8 BV601184 Cylinder Head 1
4 20435636 Valve Stem 1 9 BV501184 Piston 1
5 10188233 Backup Ring, Brass 1 10 10187250 Backup Ring, SST 1
6 20428052 Seal Assembly 11 10074714 O-Ring, 2.44 x 2.63 x .09 1
12 10074565 O-Ring, 2.25 x 2.38 x .06 2
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Parts List
Figure 12-6: Pneumatic Valve/Actuator Assembly, Normally Open
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Section 12
Parts List
Table 12-7
High Pressure Piping, 1 Liter Attenuator
72162477
Part Part
1 72160849 Intensifier Topworks 1 16 72155967 HP Tube, Bent, .38 1
2 72162513 Housing, Attenuator Weldment 1 17 95670972 Lock Washer, .38 8
3 05040696 Attenuator Assembly 1 18 95375473 Socket Head Screw, 3/8-16 x 1 8
4 10079531 Coupling Assembly, HP, .56 x .38 2 19 95660957 Flat Washer, .38 8
5 10078590 Tee Assembly, HP, .38 1 20 20491892 Cup Seal 1
6 20427739 Valve/Actuator Assembly 1 21 49831480 Grommet, 3.0 x 2.25 7
7 05144837 Spacer, Attenuator Bracket 4 22 20419432 Grommet, 2.25 x 1.63 2
8 10078715 HP Collar, .38 4 23 95383790 Socket Head Screw, 1/2-13 x 1 4
9 10078129 HP Gland, .38 4 24 95413696 Lock Washer, .50 4
10 49830581 Coupling Assembly, Bulkhead, .56 x .38 1 25 10083897 Ferrule, Hose, .25 8
11 72154033 HP Tube, Bent, .38 1 26 10186153 Flexible Conduit, .38 140.0"
12 10094704 HP Tube, Bent, .38 1 27 72162495 Spacer, Attenuator 2
13 72160906 HP Tube, Bent, .38 1 28 72152547 Top Pan 1
14 72154116 HP Tube, Bent, .25 1 29 10078459 HP Gland, .25 1
15 72154075 HP Tube, Bent, .38 1 30 10078426 HP Collar, .25 1
31 49898729 Flat Washer, M12 4
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Parts List
Figure 12-7: High Pressure Piping, 1 Liter Attenuator
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Parts List
Table 12-8
High Pressure Piping, 2 Liter Attenuator
72156222
Part Part
1 72160849 Intensifier Topworks 1 16 72155967 HP Tube, Bent, .38 1
2 20424324 Housing, Attenuator Weldment 1 17 95670972 Lock Washer, .38 8
3 20413237 Attenuator Assembly 1 18 95375473 Socket Head Screw, 3/8-16 x 1 8
4 10079457 Coupling Assembly, HP, .56 x .38 2 19 95660957 Flat Washer, .38 8
5 10078590 Tee Assembly, HP, .38 1 20 20491892 Cup Seal 1
6 20427739 Valve/Actuator Assembly 1 21 49831480 Grommet, 3.0 x 2.25 7
7 05144837 Spacer, Attenuator Bracket 4 22 20419432 Grommet, 2.25 x 1.63 2
8 10078715 HP Collar, .38 4 23 95383790 Socket Head Screw, 1/2-13 x 1 4
9 10078129 HP Gland, .38 4 24 95413696 Lock Washer, .50 4
10 49830581 Coupling Assembly, Bulkhead, .56 x .38 1 25 10083897 Ferrule, Hose, .25 8
11 72154033 HP Tube, Bent, .38 1 26 10186153 Flexible Conduit, .38 140.0"
12 10094704 HP Tube, Bent, .38 1 27 72152547 Top Pan 1
13 72160906 HP Tube, Bent, .38 1 29 10078459 HP Gland, .25 1
14 72154116 HP Tube, Bent, .25 1 30 10078426 HP Collar, .25 1
15 72154075 HP Tube, Bent, .38 1 31 72170474 Foam Strip 13.0”
32 49898729 Flat Washer, M12 4
33 10112662 Neoprene 32.0”
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Parts List
Figure 12-8: High Pressure Piping, 2 Liter Attenuator
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Parts List
Table 12-9
Bulkhead Pipe Assembly
72152927
Part Part
1 72153174 Solenoid Valve 1 18 49886922 Bushing, Bulkhead, .50 x .50 3
2 10127801 Pipe Nipple, .50 x 3.0 1 19 10070092 Jam Nut, 1-14 3
3 49887011 Adapter, JIC/Pipe, .50 x .50 1 20 72155629 Filter Subassembly 1
4 05107875 Adapter, JIC/Pipe, .50 x .50 2 21 10189025 Adapter, Hose/JIC, .50 x .50 7
5 10077055 Coupling, Bulkhead, .94 x .25 1 22 05111406 Adapter, JIC/Pipe, .50 x .25 1
6 10078335 Coupling, Pipe, .25 x .13 1 23 10189025 Adapter, Hose/JIC, .50 x .50 2
7 20453730 Check Valve Assembly 1 24 05135645 Adapter, Hose/Pipe, .50 x .50 3
8 49888035 Solenoid Valve 1 25 49833882 Adapter, Hose/ORB, .50 x .50 1
9 72149291 Adapter, Tube/Pipe, .25 x .13 1 26 20448888 Adapter, JIC/Pipe, .50 x .25 1
10 05140751 Pressure Switch, 30 psi 2 27 49886989 Adapter, JIC/Pipe, .50 x .38 2
11 05139506 Pressure Gauge, 0-200 psi 1 28 20421272 Hose, Push-on, .50 200.0"
12 10127298 Elbow, Pipe, .50 x .50 1 29 10125359 Pipe Nipple, .13 x 2.0 2
13 10073823 Tee, .50 x .50 1 30 72156810 Solenoid Valve 1
14 49834328 Adapter, Pipe/Tube, .50 x .25 1 31 72156834 Tee, Pipe/Pipe, .25 x .13 1
15 20412815 Strainer 1 32 72156842 Adapter, Tube/Pipe, .25 x .25 1
16 20413789 Manifold, LP Water 1 33 05074067 Pipe Nipple, .50 x 3.0 1
17 10100436 Coupling, Pipe, .50 x .50 2 34 10119253 Elbow, Pipe, .50 x .50 1
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Parts List
Table 12-9
Bulkhead Pipe Assembly
72152927
Part Part
35 10079903 Poly Tube, .25 35.0" 43 10150449 Decal, Drain 1
36 10097624 Button Head Screw, 1/4-20 x 1/2 2 44 10192425 Hose Barb, .50 x .50 1
37 95838314 Lock Washer, .25 2 45 72124013 Pressure Gauge, 0-400 psi 1
38 95391322 Flat Washer, .25 2 46 80087828 Adapter, Hose/Pipe, .25 x .25 1
39 20456703 Decal, Contaminated Water 1 47 49830722 Adapter, Hose/Pipe, .25 x .25 2
40 10150456 Decal, HP Water Out 1 48 61126172 Hose, Push-on, .25 50.0"
41 05071808 Decal, Plant Air 1 49 49830490 Decal, Boosted Pressure 1
42 10150464 Decal, HP Water In 1 50 49830482 Decal, Pressure In 1
51 72150853 Adapter, Pipe/Solenoid Valve 2
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Parts List
Figure 12-9: Bulkhead Pipe Assembly
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Parts List
Figure 12-9: Bulkhead Pipe Assembly
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Parts List
Table 12-10
Low Pressure Water Filter Assembly
72155629
Part Part
1 72155272 Filter Housing Assembly 1 10 72131267 Pressure Switch, 100 psi 1
2 49838386 Pipe Nipple, .75 x 4.0 2 11 10187730 Elbow, Pipe, .75 x .75 1
3 49833882 Adapter, Hose/ORB, .50 x .50 2 12 80087828 Adapter, Hose/Pipe, .25 x .25 1
4 05072798 Relief Valve Assembly 1 13 20442221 Hex Nut, 1/4-20 4
5 72152951 Bracket, Filter Mount 1 15 72125264 Filter Element 1
6 10083384 U-Bolt, .75 2 16 95391322 Flat Washer, .25 4
7 20413848 Manifold, LP Water Outlet 1 17 95838314 Lock Washer, .25 4
8 10119253 Elbow- Pipe, .50 x .50 1 18 10103448 Bushing, Pipe, .75 x .50 1
9 05135652 Check Valve Assembly 1
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Parts List
Figure 12-10: Low Pressure Water Filter Assembly
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Parts List
Table 12-11
Hydraulic Power Package
72154447
Part Part
1 72153513 Electric Motor, 50 HP 1 15 72157461 Manifold Assembly 1
2 10092302 Shaft Coupling 1 16 05045364 Gear Pump 1
3 05049168 Adapter, Water Pump 1 17 10091163 Adapter, JIC/ORB, .75 x .75 1
4 10116952 Caplug, 1.04 2 18 95897294 Hex Head Screw, 5/8-11 x 1-1/2 2
5 49887094 Water Pump, Vane 1 19 49883564 Socket Head Screw, M10 x 1.50 x 30MM 2
6 95838314 Lock Washer, .25 3 20 10091510 Arrow Decal 1
7 95572897 Hex Head Screw, 1/4-20 x 5/8 3 21 72158486 Piston Pump 1
8 10069714 Flat Washer, .38 2 22 10074953 O-Ring, 1.50 x 1.75 x .13 1
9 95750394 Lock Washer, .38 2 23 95423679 Hex Head Screw, 5/8-11 x 1-3/4 4
10 95416319 Hex Head Screw, 3/8-16 x 1 2 24 05054168 Flat Washer, .63 6
11 49883580 Flat Washer, M10 2 25 95688719 Lock Washer, .63 6
12 10064715 Lock Washer, M10 2 26 72162170 Socket Head Screw, 3/8-16 x 5-1/2 4
13 72143352 Coupling, Flexible Drive 1 27 95688743 Lock Washer, .38 4
14 72137545 Flange, Motor/Pump Adapter 1 28 05045497 Pressure Gauge, 0-5,000 psi 1
05045497 O-Ring, .35 x .50 x .07
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Section 12
Parts List
Figure 12-11: Hydraulic Power Package
72165940
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Section 12
Parts List
Table 12-12
Hydraulic Manifold Assembly
72157461
Part
1 72156430 Hydraulic Manifold 1
2 72157479 Directional Control Valve 1
3 10187060 Relief Valve Assembly 1
4 10069581 Lock Washer, .25 2
5 05055017 Plug, ORB, .13 2
6 49889736 Check Valve Assembly 1
7 49889744 Retainer, Cartridge Valve 1
8 05071055 Plug, ORB, .75 1
9 49889769 Plug, ORB, .25 2
10 95688743 Lock Washer, .38 4
11 05041058 Socket Head Screw, 3/8-16 x 2-1/4 4
12 72157677 Socket Head Screw, 1/4-20 x 2-1/4 2
13 10185585 Solenoid Valve 1
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Section 12
Parts List
Figure 12-12: Hydraulic Manifold Assembly
72165940
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Section 12
Parts List
Table 12-13
Hydraulic Hose Connections
72159239
Part Part
1 95702619 Adapter, JIC/ORB, .75 x .75 3 12 72156066 Hydraulic Hose Assembly, 1.0 x 25.50 1
2 05064407 Adapter, JIC/ORB, 1.0 x .75 1 13 10128254 Hydraulic Hose Assembly, 1.0 x 19.0 1
3 05052493 Adapter, JIC/ORB, .75 x .63 3 14 49891633 Hydraulic Hose, Suction/Return, 2.0 10.0"
4 20427194 Adapter, JIC/ORB, 1.0 x 1.0 1 15 72165319 Hydraulic Hose Assembly, .25 x 16.0 1
5 05071055 Plug, ORB, .75 2 16 05071121 Hydraulic Hose Assembly, .25 x 18.0 1
6 10142644 Adapter, JIC/ORB, .25 x .25 1 17 72159280 Hydraulic Hose Assembly, .25 x 24.0 2
7 10144749 Adapter, JIC/ORB, .25 x .25 2 18 49888688 Hydraulic Hose Assembly, .75 x 24.0 1
8 80085970 Adapter, JIC/ORB, 1.0 x 1.0 2 19 10091643 Hose Clamp 4
9 05048780 Split Flange Kit, 2.0 1 20 20454519 Tee, JIC/ORB, .25 x .25 1
10 20427119 Adapter, Flange/ Hose, 2.0 x 2.0 1 21 49876089 Adapter, JIC/ORB, .25 x .25 3
11 72147664 Hydraulic Hose Assembly, .75 x 32.0 2
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Section 12
Parts List
Figure 12-13: Hydraulic Hose Connections
72165940
3-2015/Rev 0
Section 12
Parts List
Figure 12-13: Hydraulic Hose Connections
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-14
Reservoir Assembly
72152878
Part Part
1 72152885 Reservoir Weldment 1 12 72145376 Temperature/Level Sensor 1
2 20451474 Level/Temperature Gauge 1 13 72138699 Reservoir Cover 1
3 05057542 Coupling, ORB, .75 x .75 1 14 05079967 Gasket 1
4 05049697 Hydraulic Filter Head 1 15 72153711 Reservoir Weldment, Cover 1
5 05049689 Filter Element 1 16 80087687 Diffuser 1
6 05071063 Tee, JIC/ORB, .75 x .75 1 17 72118430 Gasket 78.0"
7 05079371 Adapter, BSPP/JIC, .75 x .75 1 18 95897948 Button Head Screw, 10-24 x 1/2 4
8 05069976 Cap, JIC Swivel, .75 1 19 95367207 Flat Washer, #10 4
9 20423326 Ball Valve Assembly 1 20 95367728 Lock Washer, #10 4
10 05025176 Plug, ORB, .50 1 21 10082071 Pipe Plug, .38 1
11 05092739 Air Breather 1
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Section 12
Parts List
Figure 12-14: Reservoir Assembly
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Section 12
Parts List
Table 12-15
Oil/Water Heat Exchanger Kit
72156272
Part Part
1 05145958 Heat Exchanger 1 11 20456208 Hydraulic Hose Assembly, .75 x 28.0 1
2 72153174 Solenoid Valve 1 12 20468826 Hydraulic Hose Assembly, .75 x 23.0 1
3 10084770 Pipe Nipple, .50 x 2.0 1 13 20421272 Hose, Push-on, .50 65.0"
4 95680922 Adapter, JIC/Pipe, .50 x .50 1 14 10070191 Hex Nut, M8 4
5 95157418 Adapter, JIC/Pipe, .50 x .50 1 15 10069672 Lock Washer, M8 2
6 49886922 Bushing, Bulkhead, .50 x .50 2 16 10150472 Decal, Cool In 1
7 10070092 Jam Nut, 1-14 2 17 10150480 Decal, Cool Out 1
8 05073150 Adapter, JIC/ORB, .75 x .63 2 18 72153182 Connector, DIN 1
9 10173805 Adapter, Hose/JIC, .50 x .50 2 19 72135884 Cable Assembly 1
10 10079713 Hose Barb, .50 x .50 2 20 7215853 Adapter, Pipe/Solenoid Valve 2
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Section 12
Parts List
Figure 12-15: Oil/Water Heat Exchanger Kit
72165940
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Section 12
Parts List
Figure 12-15: Oil/Water Heat Exchanger Kit
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-16
Oil/Air Heat Exchanger Kit, External
72163210
Part Part
1 20472981 Heat Exchanger, Electric 1 11 72146220 Auxiliary Contact 1
2 72164699 Hydraulic Hose Assembly, .75 x 15.0 1 12 05001698 Cable, #14 120.0"
3 05131503 Hydraulic Hose Assembly, .75 x 38.0 1 13 72171621 Connector, Cable, .50 1
4 20473026 Hydraulic Hose Assembly, .75 x 120.0 2 14 10083012 Lock Nut, .50 1
5 05085683 Decal, Hydraulic Oil Out 1 15 10082857 Gasket Assembly, Flexible Conduit, .50 1
6 05085675 Decal, Hydraulic Oil Return 1 16 20480801 Decal, Green Energy 4
7 05114962 Decal, Electrical Hazard 1 17 20436321 Coupling, JIC, .75 x .75 2
8 05114970 Decal, Burn Hazard 2 18 20436347 Bushing, JIC, .75 x .50, used for shipment 2
9 72155150 Motor Starter/Protector 1 19 10173805 Adapter, Hose/JIC, .50 x .50, used for shipment 2
10 72155033 Auxiliary Contact 1 20 20421272 Hose, Push-on, .50, used for shipment 12.0”
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Section 12
Parts List
Figure 12-16: Oil-to-Air Heat Exchanger Kit, External
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Section 12
Parts List
Table 12-17
Electrical Configuration, Line Start
72158106
Part
1 72156355 Electrical Kit, Hardware 1
2 72155173 Electrical Kit, Circuit Breaker 1
3 72155421 Electrical Kit, Low Voltage Controls 1
4 72155348 Electrical Kit, High Voltage Controls 1
5 72155215 Electrical Kit, Motor Starter 1
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Section 12
Parts List
Figure 12-17: Electrical Configuration, Line Start
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-18
Electrical Kit, Circuit Breaker, Line Start
72155173
Part
1 72154843 Circuit Breaker, 100A 1
2 72154835 Rotary Drive, Circuit Breaker 1
3 72157726 Terminal Cover 1
Table 12-19
Electrical Kit, Motor Starter, Line Start
72155215
Part
1 72154827 Contactor, 95A 1
2 72155199 Interface Relay 1
3 72154785 Overload Relay 1
4 72154918 Block, Auxiliary Contact 1
6 10118784 Wire, #0, Black 36.0”
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Parts List
Table 12-20
Electrical Configuration, Wye-Delta Start
72164808
Part
1 72156355 Electrical Kit, Hardware 1
2 72155165 Electrical Kit, Circuit Breaker 1
3 72155421 Electrical Kit, Low Voltage Controls 1
4 72155348 Electrical Kit, High Voltage Controls 1
5 72155298 Electrical Kit, Motor Starter 1
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Parts List
Figure 12-18: Electrical Configuration, Wye-Delta Start
72165940
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Section 12
Parts List
Table 12-21
Electrical Kit, Circuit Breaker, Wye-Delta Start
72155165
Part
2 72154835 Rotary Drive, Circuit Breaker 1
3 72157726 Terminal Cover, Circuit Breaker 1
Table 12-22
Electrical Kit, Motor Starter, Wye-Delta Start
72155298
Part
1 72154827 Contactor, 95A 3
2 72169184 Wiring Kit, Y-D 1
4 72154785 Overload Relay 1
7 10154821 Wire, #1, Black 36.0”
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Parts List
Table 12-23
Electrical Kit, Hardware
72156355
Part Part
1 72136298 Wiring Duct 0.416 14 10125912 Cable Tie 0.2
2 72136207 Pan Head Screw, 10-16 x 5/8 8 15 10120921 Mount, Cable Tie 6
3 72109797 DIN Rail 0.38 16 10098770 Flexible Conduit, 1.0 10.0"
4 10170132 Rivet, .187 10 17 10094563 Connector, Flexible Conduit 2
5 20430277 Ground Lug 2 18 72162461 Nut, 3/8-16 4
6 95175758 Hex Head Screw, 1/4-20 x 5/8 10 19 10174829 Lock Nut, 1.0 2
7 10069748 Flat Washer, .25 12 20 05133707 Bushing, Conduit, 1.0 x 1.0 2
8 10157659 Lock Washer, .75 10 21 72154132 Panel Insert 1
9 10073500 Pan Head Screw, 8-32 x 3/4 10 22 72136504 Connector, Plug 1
10 10114627 Flat Washer, #8 12 23 10122646 Connector, Cable, .50 1
11 10069607 Lock Washer, #8 10 24 10082857 Gasket Assembly, .50 1
12 10159143 Ring Terminal, #8 6 25 10083012 Loc4 Nut, .50 1
13 10125920 Cable Tie 0.2 26 10098812 Gasket Assembly, 1.0 2
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Section 12
Parts List
Table 12-24
Electrical Kit, Low Voltage Controls
72155421
Part Part
1 72144153 Program Controller 1 15 72149366 Connector, Dummy Module 2
2 72169075 Digital Card, I/O 1 16 72149374 Connector, Locking Element 0.2
3 72135299 Safety Relay, 24VDC 1 17 72149341 Connector, Side Entry 1
4 72140163 Module, Operator to Coupler Module 2 18 72149359 Connector, Single Lever Lock 1
5 72135166 Display 1 19 72149424 Connector, Cable Clamp 1
6 72135653 Legend Plate, E-Stop 1 20 72130028 Cable, Ethernet 1
7 72135562 Pushbutton, E-Stop 1 21 72155371 Plug, Remote Interface 1
8 72135661 Pilot Light, Red 1 22 72169210 Plug, Remote Interface 1
9 72144244 Contact Block 2 23 72155496 Plug Cover 2
10 72120528 Resistor 1 24 72155603 Memory Card 1
11 72149408 Connector, Quick Lock 2 25 20420563 End Anchor 4
12 72149416 Connector, Quick Lock 2 26 72109755 Interface Relay 1
13 72149400 Connector, Hinged Frame 1
14 72149382 Connector, Hinged Frame 1
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Parts List
Figure 12-19: Electrical Kit, Low Voltage Controls
72165940
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Section 12
Parts List
Table 12-25
Electrical Kit, High Voltage Controls
72155348
Part
2 20489290 Power Supply 1
5 72154960 Terminal Block 1
6 72144179 Safety Expansion Relay 1
7 20420563 End Anchor 2
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Section 12
Parts List
Figure 12-20: Electrical Kit, High Voltage Controls
72165940
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Section 12
Parts List
Table 12-26
Harness Configuration
72157172
Part
1 72135884 Cable Assembly, 5 Socket 8
3 72136860 Connector, DIN Form A 3
5 72136150 Cable Assembly, M12/DIN Form C 1
6 72136132 Cable Assembly, Double DIN Form A 1
7 72153182 Connector, DIN Form B 1
8 72135843 Coupling, Cable, M12 x M12 2
9 72136512 Distribution Block 1
10 10066868 Socket Head Screw, 8-32 x 1-1/2 4
11 10114627 Flat Washer, #8 8
12 10069607 Lock Washer, #8 4
13 10114510 Hex Nut, #8-32 4
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Section 12
Parts List
Figure 12-21: Harness Configuration
72165940
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Section 12
Parts List
72165940
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Section 12
Parts List
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-27
Motor Cable Assembly, 87A
72160989
Part
1 10085520 Connector, Flexible Conduit, 1.50 2
2 05081377 Bushing, Conduit, 1.50 x 1.50 1
3 10086700 Flexible Conduit, 1.50 24.0"
4 10121648 Wire, #3, Black 396.0"
5 05106398 Wire, #3, Green/Yellow 66.0"
6 05107248 Connector, Crimp Ferrule, #3 13
7 20451714 Ring Terminal 1
8 80080237 Terminal Lug 6
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Section 12
Parts List
Table 12-28
72159900
Part
1 10085520 Connector, Flexible Conduit 2
4 49877152 Wire, #8, Black 393.0"
6 05033345 Connector, Crimp Ferrule 13
8 80080237 Terminal Lug 9
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Section 12
Parts List
Table 12-29
72160997
Part
1 10085520 Connector, Flexible Conduit 2
4 49877152 Wire, #8, Black 396.0"
6 05033345 Connector, Crimp Ferrule 7
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Section 12
Parts List
Figure 12-22: Motor Cable Assembly
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-30
High/Low Kit
72159494
Part
1 10187052 Relief Valve Assembly 1
4 72135843 Coupling, Cable, M12 x M12 1
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Section 12
Parts List
Table 12-31
Power Factor Correction Kit
72166264
Part
1 72161538 Capacitor 1
2 72163444 Bracket, Capacitor 1
3 80089873 Button Head Screw, 1/4-20 x 1 3
4 95648150 Lock Washer, .25 3
5 10069748 Flat Washer, .25 3
6 72161587 Contactor, Capacitor Switch 1
7 72109797 DIN Rail .08
8 10073500 Pan Head Screw, 8-32 x 3/4 3
9 10114627 Flat Washer, #8 3
10 10069607 Lock Washer, #8 3
12 20420563 End Anchor 2
13 72146566 Wire, #18, Brown 72.0"
14 72109945 Wire, #18, Blue 60.0"
15 05020060 Wire, #10, Black 120.0"
16 10170371 Connector, Crimp Pin, #18 10
17 10170363 Connector, Crimp Pin, #10 12
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Section 12
Parts List
Figure 12-23: Power Factor Correction Kit
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-32
Cover Interlock Kit
72166272
Part
1 72163652 Bracket, Interlock 2
2 72163659 Bracket, Interlock 2
3 72161379 Relay, Safety Time Delay 1
4 72161356 Safety Switch, Door Interlock 1
5 72161364 Safety Switch, Door Interlock 1
6 10073500 Pan Head Screw, 8-32 x 3/4 8
7 10069607 Lock Washer, #8 8
8 10114627 Flat Washer, #8 8
9 72165773 Terminal Block 2
10 72165781 End Barrier 1
11 05091970 Flat Head Screw, 10-32 x 3/4 8
12 10065191 Socket Head Screw, 10-32 x 3/4 8
13 95730758 Lock Washer, #10 8
14 95367207 Flat Washer, #10 8
15 95071247 Hex Nut, #10-32 8
16 20465070 Connector, Cable, .50 2
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Section 12
Parts List
Table 12-33
Proportional Pressure Control Kit
72158775
Part
1 80071087 Proportional Pressure Control Valve 1
2 49867104 Cable, #18 96.0"
4 72109945 Wire, #18, Blue 50.0"
5 61172607 Connector, Crimp Ferrule, #18 10
8 72135405 Analog Card 1
10 10083012 Lock Nut, .50 1
11 10082857 Gasket Assembly, .50 1
12 72158140 Kit, Screen Ground 1
13 72146566 Wire, #18, Brown 50.0"
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Section 12
Parts List
Table 12-34
High Pressure Transducer Kit
72158213
Part
1 72158156 HP Tube, Bent, .38 1
2 72160914 Pressure Transducer 1
4 10094704 HP Tube, .38 x 3.0 1
5 05143631 Cable, #18 96.0"
6 10078590 Tee Assembly, HP, .38 1
7 72158164 HP Tube, Bent, .38 1
9 10078715 HP Collar, .38 1
10 10078129 HP Gland, .38 1
11 72120528 Resistor 1
12 72158140 Kit, Screen Ground 1
13 10083012 Lock Nut, .50 1
14 10082857 Gasket Assembly, Flexible Conduit, .50 1
72165940
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Section 12
Parts List
Figure 12-24: High Pressure Transducer Kit
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-35
Redundant Kit
72155777
Part Part
1 72160849 Intensifier Topworks 1 20 49898729 Flat Washer, M12 4
2 05057542 Coupling, ORB, .75 x .75 2 21 95383790 Socket Head Screw, 1/2-13 x 1 4
3 05073176 Bushing, ORB, .75 x .63 2 22 20417552 Connector, Plug 2
4 05070750 Ball Valve Assembly 4 23 20448888 Adapter, JIC/Pipe, .50 x .25 1
5 05073168 Adapter, JIC/ORB, .75 x .75 4 24 10189025 Adapter, Hose/JIC, .50 x .50 2
6 72129242 Hydraulic Hose Assembly, .75 x 30.0 2 25 72136124 Cable Assembly, 4 Socket 1
7 05071105 Hydraulic Hose Assembly, .75 x 41.0 2 26 20465070 Connector, Cable, .50 1
8 05073150 Adapter, JIC/ORB, .75 x .63 2 27 10083012 Lock Nut, .50 1
9 72160906 HP Tube, Bent, .38 1 28 10082857 Gasket Assembly, .50 1
10 10078129 HP Gland, .38 2 30 05076096 Decal, Intensifier I 1
11 10078715 HP Collar, .38 2 31 05076104 Decal, Intensifier II 1
12 72154041 HP Tube, Bent, .38 2 33 10083012 Lock Nut, .50 1
13 10122315 HP Tube, .38 x 4.50 1 34 72171665 Cable, Pigtail 1
14 10097533 HP Valve Assembly 2 35 05111406 Adapter, JIC/Pipe, .50 x .25 1
15 72154033 HP Tube, Bent, .38 1 36 05070743 Adapter, JIC/ORB, .75 x .75 2
16 10083897 Ferrule, Hose, .25 10 37 95702619 Adapter, JIC/ORB, .75 x .75 2
17 10186153 Flexible Conduit, .38 105.0" 38 10170371 Connector, Crimp Pin, #18 4
18 20451641 Latch Pin 4 39 10099026 Ring Terminal 1
19 95413696 Lock Washer, .50 4
72165940
3-2015/Rev 0
Section 12
Parts List
Figure 12-25: Redundant Kit
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-36
High Pressure Coning Tools
Part
05108832 Hand Coning Tool Assembly, .25 Figure 12-26: High Pressure Coning Tools
05108857 Hand Coning Tool Assembly, .38 Hand Coning Tool Assembly
05108840 Hand Coning Tool Assembly, .56
05109897 Power Coning Tool Assembly, .25
1 05108808 Blade, .25
05108824 Blade, .38
05108816 Blade, .56
2 05108972 Collet, .25
05108964 Collet, .38
20439964 Collet, .56
3 05109814 Retainer, .25 Power Coning Tool Assembly
05109822 Retainer,.38
05109830 Retainer, .56
05120472 Cone and Thread Lubricant, 4 oz.
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3-2015/Rev 0
Section 12
Parts List
Table 12-37
High Pressure Threading Tools
Part
05108865 Hand Threading Tool Assembly, .25 Figure 12-27: High Pressure Threading Tools
05108873 Hand Threading Tool Assembly, .38 Hand Threading Tool Assembly
05108881 Hand Threading Tool Assembly, .56
05122742 Power Threading Tool Assembly, .25
05120258 Power Threading Tool Assembly, .38
05122759 Power Threading Tool Assembly .56
1 05108899 1/4-20 Threading Die
05108915 3/8-16 Threading Die
10078301 9/16-18 Threading Die
2 05108741 Retainer, .25
05108758 Retainer, .38 Power Threading Tool Assembly
05108766 Retainer, .56
05108782 Tube Vise, .25

05108790 Tube Vise, .38
05108774 Tube Vise, .56
20437825 Tube Vise, .75
20440071 Tube Vise, 1.0
72165940
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Section 12
Parts List
Table 12-38
Maintenance Tools and Lubricants
Part
1 20477460 Plunger Removal Tool, .88 Plunger Figure 12-28: Maintenance Tools and Lubricants
20477469 Plunger Removal Tool, 1.13 Plunger Maintenance Tools
2 20484961 Vee Block Cradle
3 05066139 Cylinder Wrench
4 80079239 End Cap Wrench, HSEC, 6x/8x
5 80078330 HP Seal Removal Tool Stand
6 10079523 HP Plug, .38
10078772 HP Plug, .56
7 10078129 HP Gland, .38
10078608 HP Gland, .56
8 10148674 HP Seal Installation Tool, .88 Plunger
05146618 HP Seal Installation Tool, 1.13 Plunger
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Section 12
Parts List
Table 12-38
Maintenance Tools and Lubricants
Part
20470475 Seal Tool Kit, Pneumatic Control Valves Seal Tool Kit, Pneumatic Control Valves
1 20470417 Seal Installation Tool
2 05067350 Seal Positioning Tool, NO/NC Valves, 2-Port Dump Valve
3 49833114 Seal Positioning Tool, Quick Release Valve, 3-Port Dump Valve
4 20470413 Seal Push Tool
Lubricants
10084440 Pure Goop Thread Lubricant, 1.0 oz.
10087385 FML-2 Grease, 14.5 oz.
49832199 JL-M Thread Lubricant, 16 oz.
80082191 JL-M Thread Lubricant, 15 ML
20487868 Threadlocker Adhesive
20494983 Threadlocker Primer
10184802 Optimol, Anti-Seize Grease
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Section 12
Parts List
Table 12-39
Focusing Tubes
Part
Number Description
05147889 R-100 0.018” (0.457 mm) x 2.00” (50.8 mm) Figure 12-29: Focusing Tubes
10139426 R-100 0.021” (0.533 mm) x 2.00” (50.8 mm) R-100 Focusing Tubes
20451227 R-100 0.021” (0.533 mm) x 3.13” (79.4 mm)
20452309 R-100 0.025” (0.635 mm) x 3.13” (79.4 mm)
10126969 R-100 0.030” (0.762 mm) x 3.13” (79.4 mm)
20428126 R-100 0.030” (0.762 mm) x 4.0” (101.6 mm)
20452161 R-100 0.030” (0.762 mm) x 6.0” (152.4 mm)
80075252 R-100 0.036” (0.914 mm) x 3.13” (79.4 mm)
49833593 R-100 0.039” (0.991 mm) x 3.13” (79.4 mm)
49835390 R-100 0.040” (1.016 mm) x 3.13” (79.4 mm)
20432695 R-100 0.043” (1.092 mm) x 2.0” (50.8 mm)
10126928 R-100 0.043” (1.092 mm) x 3.13” (79.4 mm)
20452135 R-100 0.043” (1.092 mm) x 4.0” (101.6 mm)
20452153 R-100 0.043” (1.092 mm) x 6.0” (152.4 mm)
10186799 R-100 0.050” (1.321 mm) x 3.13” (79.4 mm)
05117528 R-100 0.052” (1.321 mm) x 3.13” (79.4 mm)
05051891 R-100 0.058” (1.473 mm) x 3.13” (79.4 mm)
10126936 R-100 0.063” (1.600 mm) x 3.13” (79.4 mm)
10139418 R-100 0.093” (2.632 mm) x 3.13” (79.4 mm)
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Section 12
Parts List
Table 12-39
Focusing Tubes
Part
Number Description
05097928 R-500 0.021” (0.533 mm) x 2.00” (50.8 mm) R-500 Focusing Tubes
05105366 R-500 0.043” (1.092 mm) x 2.75” (69.9 mm)
05097944 R-500 0.030” (0.762 mm) x 3.13” (79.4 mm)
05116652 R-500 0.036” (0.914 mm) x 3.13” (79.4 mm)
05097936 R-500 0.043” (1.092 mm) x 3.13” (79.4 mm)
05130919 R-500 0.063” (1.600 mm) x 3.13” (79.4 mm)
05130927 R-500 0.093” (2.632 mm) x 3.13” (79.4 mm)
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Section 12
Parts List
Table 12-40
Standard Sapphire Orifice
Part Part Part
Number Description Number Description Number Description
A2260001 0.001” (0.025 mm) A2260009 0.009" (0.229 mm) A2260018 0.018" (0.457 mm) Figure 12-30: Standard Sapphire Orifice
A2260002 0.002” (0.051 mm) A2260010 0.010" (0.254 mm) A2260019 0.019” (0.483 mm)
A2260003 0.003" (0.076 mm) A2260011 0.011” (0.279 mm) A2260020 0.020" (0.508 mm)
A2260004 0.004” (0.102 mm) A2260012 0.012" (0.305 mm) A2260021 0.021” (0.533 mm)
A2260005 0.005” (0.127 mm) A2260013 0.013” (0.330 mm) A2260022 0.022" (0.559 mm)
A2260006 0.006" (0.152 mm) A2260014 0.014" (0.356 mm) A2260024 0.024” (0.610 mm)
A2260007 0.007" (0.178 mm) A2260015 0.015" (0.381 mm) A2260028 0.028” (0.711 mm)
A2260008 0.008" (0.203 mm) A2260016 0.016" (0.406 mm) A2260032 0.032” (0.813 mm)
Table 12-41
Standard Diamond Orifice
Part Part Part
Number Description Number Description Number Description
49888852 0.003" (0.076 mm) 49888910 0.009" (0.229 mm) 49888969 0.016" (0.406 mm) Figure 12-31: Standard Diamond Orifice
49888860 0.004" (0.102 mm) 49888928 0.010" (0.254 mm) 49888977 0.018” (0.457 mm)
49888878 0.005" (0.127 mm) 49888936 0.012" (0.305 mm) 20436198 0.019” (0.483 mm)
49888886 0.006" (0.152 mm) 49836786 0.013” (0.330 mm) 49888985 0.020” (0.508 mm)
49888894 0.007" (0.178 mm) 49888944 0.014" (0.356 mm) 49888993 0.022” (0.559 mm)
49888902 0.008" (0.203 mm) 49888951 0.015" (0.381 mm)
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Section 12
Parts List
Table 12-42
High Pressure Water Filter Assemblies
Part
05114137 Inline Water Filter, .25 Figure 12-32: High Pressure Water Filter Assemblies
1 05114129 Filter Body 1 HP Inline Water Filter, .25
2 05114152 Retainer, Filter Element 1
3 05110531 Filter Element 1
4 05114145 Adapter Gland 1
5 10078426 HP Collar 2
6 10078459 HP Gland 2
CJ200988 Inline Water Filter, .38 HP Inline Water Filter, .38

1 10078715 HP Collar 2
2 10078129 HP Gland 2
3 CJ300988 Filter Body 1
4 CJ400988 Adapter Gland 1
5 SKJA266 Filter Element 1
6 SKJA286 Retainer, Filter Element 1
7 SKJA287 Bayonet Nipple 1
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Section 12
Parts List
Table 12-42
High Pressure Water Filter Assemblies
Part
BF103473 Inline Water Filter, .56 HP Inline Water Filter, .56
1 AF413972 HP Gland, Outlet 1
2 AF303473 Seal Head, Outlet 1
3 AF503473 Filter Element 1
4 BF203473 Filter Body 1
5 AF913972 HP Gland, Inlet 1
6 10074599 O-Ring, .38 x .50 x .06 1
7 AF403473 Seal Head, Inlet 1
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Section 12
Parts List
Table 12-43
High Pressure Swivel Joints
Part
CJ211388 HP Swivel Joint, Straight, .25, M/F Figure 12-33: High Pressure Swivel Joints
1 10084713 Thrust Needle Bearing 1 HP Swivel Joint, Straight, M/F Connection, .25
2 10094647 Thrust Washer 2
3 10103505 Setscrew, 6-32 x 1/8 1
4 CJ311388 Swivel Body 1
5 CJ401288 Swivel Bushing 1
6 CJ501288 Spindle, .25 1
7 BJ701288 Cap Assembly 1
8 BJ201388 Seal Assembly 1
BJ701288 Cap Assembly

1 CJ801288 Cap, .25/.38, M/F 1
2 10144442 Swivel Bushing 1
72165940
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Section 12
Parts List
Table 12-43
Part
CJ218088 HP Swivel Joint, Straight, .25, F/F HP Swivel Joint, Straight, F/F Connection, .25
1 10084713 Thrust Needle Bearing 1
3 10103505 Setscrew, 6-32 x 1/8 1
4 10154680 Clamp Collar 1
5 CJ318088 Spindle, .56 1
6 CJ418088 Cap, .25 1
7 CJ311388 Swivel Body 1
72165940
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Section 12
Parts List
Table 12-43
Part
10134708 HP Swivel Joint, Straight, .38, M/F HP Swivel Joint, Straight, M/F Connection, .38
3 10103505 Setscrew, 6-32 x 1/8 1
4 10134716 Swivel Body 1
6 49899602 Spindle, .38 1
9 10078913 HP Gland, Anti-Vibration 2
10 10078715 HP Collar 2
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Section 12
Parts List
Table 12-43
Part
CJ201288 HP Swivel Joint, 90D, .25, M/F HP Swivel Joint, 90D, M/F Connection, .25
3 10103505 Setscrew, 6-32 x 1/8 1
4 DJ301288 Swivel Body 1
6 CJ501288 Spindle, .25 1
72165940
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Section 12
Parts List
Table 12-43
Part
CJ218188 HP Swivel Joint, 90D, .25, F/F HP Swivel Joint, 90D, F/F Connection, .25
3 10103505 Setscrew, 6-32 x 1/8 1
4 10154680 Clamp Collar 1
5 CJ318088 Spindle, .56 1
6 CJ418088 Cap, .25 1
7 DJ301288 Swivel Body 1
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Section 12
Parts List
Table 12-43
Part
10134682 HP Swivel Joint, 90D, .38, M/F HP Swivel Joint, 90D, M/F Connection, .38
3 10103505 Setscrew, 6-32 x 1/8 1
4 10134690 Swivel Body 1
6 49899602 Spindle, .38 1
9 10078913 HP Gland, Anti-Vibration 2
10 10078715 HP Collar 2
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Section 12
Parts List
Table 12-44
Nozzle Tubes
Part Part
Number Description Number Description
Actual Nominal Actual Nominal
in (mm) in (mm) in (mm) in (mm)
10181113 2.65 (67.31) 3.00 (76.20) 10138451 8.65 (219.71) 9.00 (228.60) Figure 12-34: Nozzle Tubes
10138402 3.65 (92.91) 4.00 (101.60) 05136023 9.15 (232.41) 9.50 (241.30) .38 Nozzle Tube, Nozzle Nut Connection
10138410 4.65 (118.11) 5.00 (127.0) 10138469 9.65 (245.11) 10.00 (254.0)
10138428 5.65 (143.51) 6.00 (152.40) 05106224 10.15 (257.81) 10.50 (266.70)
05131784 5.91 (150.11) 6.25 (158.75) 05136031 10.65 (270.51) 11.00 (279.40)
10138436 6.65 (168.91) 7.00 (177.80) 05013735 11.65 (295.91) 12.00 (304.80)
10138444 7.65 (194.31) 8.00 (203.20) 05086913 14.65 (372.11) 15.00 (381.0)
05106224 8.10 (205.74) 8.45 (214.63)
10138584 3.64 (92.46) 4.00 (101.60) 10138634 7.64 (194.06) 8.00 (203.20) .38 Nozzle Tube, HP Connection
10138592 4.64 (117.86) 5.00 (127.0) 10138642 8.64 (219.46) 9.00 (228.60)
10138600 5.64 (143.26) 6.00 (152.40) 10138659 9.64 (244.86) 10.00 (254.0)
10138618 6.64 (168.66) 7.00 (177.80) 20432414 13.64 (346.46) 14.00 (355.60)
72165940
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Section 12
Parts List
Table 12-44
Nozzle Tubes
Part Part
Actual Nominal Actual Nominal
in (mm) in (mm) in (mm) in (mm)
10138477 2.65 (67.31) 3.00 (76.20) 10138527 7.65 (194.31) 8.00 (203.20) .56 Nozzle Tube, Nozzle Nut Connection
10138485 3.65 (92.91) 4.00 (101.60) 10138535 8.65 (219.71) 9.00 (228.60)
10138493 4.65 (118.11) 5.00 (127.0) 10181105 9.65 (245.11) 10.00 (254.0)
10138501 5.65 (143.51) 6.00 (152.40) 10193100 11.65 (295.91) 12.00 (304.80)
10138519 6.65 (168.91) 7.00 (177.80)
10138667 3.65 (92.91) 4.00 (101.60) 10138709 7.65 (194.31) 8.00 (203.20) .56 Nozzle Tube, HP Connection
10138675 4.65 (118.11) 5.00 (127.0) 10138717 8.65 (219.71) 9.00 (228.60)
10138683 5.65 (143.51) 6.00 (152.40) 10138725 9.65 (245.11) 10.00 (254.0)
10138691 6.65 (168.91) 7.00 (177.80) 80074446 10.65 (270.51) 11.00 (279.40)
72165940
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Section 12
Parts List
Table 12-45
Autoline™ Abrasive Nozzle Assembly
Part
05078530 AutolineTM Nozzle Assembly, .030 Wear Insert Figure 12-35: Autoline™ Abrasive Nozzle Assembly
05147970 AutolineTM Nozzle Assembly, .043 Wear Insert
1 05076971 Nozzle Cap 1
2 05073820 Nozzle Body 1
3 05076955 Wear Insert, .030 x .156 1
05135827 Wear Insert, .043 x .156
4 05076989 Feed Tube Adapter 1
5 05077292 Setscrew, 1/4-28 1
6 05081518 O-Ring, .38 x .50 x .06 1
7 05104930 O-Ring, .50 x .63 x .06 2
8 05092887 O-Ring, .75 x .63 x .06 1
9 05078712 Retainer Knob 1
10 05087168 Guard 1
49885361 Poly Tube, .38
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Section 12
Parts List
Table 12-46
Autoline™ II Abrasive Nozzle Assembly
Part
20453949 AutolineTM II Nozzle Assembly, .030 Wear Insert Figure 12-36: Autoline™ II Abrasive Nozzle Assembly
20454108 AutolineTM II Nozzle Assembly, .043 Wear Insert
1 20453952 Nozzle Cap 1
2 20453958 Nozzle Body 1
3 20453064 Wear Insert, .030 x .156 1
20453082 Wear Insert, .043 x .156
4 20453964 Feed Tube Assembly 1
20453967 Feed Tube
10142610 O-Ring, .19 x .31 x .06
20453970 Washer
5 20453973 Handle 1
6 20433398 Setscrew, 8-32 1
7 20453976 T-Knob 1
8 05138821 O-Ring, .69 x .81 x .06 1
9 20445476 O-Ring, .31 x .44 x .06 1
10 05087168 Guard 1
11 05081518 O-Ring, .38 x .50 x .06 1
12 05077078 O-Ring, .38 x .50 x .06 1
49885361 Poly Tube, .38
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-47
Autoline™ Sapphire Orifice
Part Part
05109079 0.007" (0.178 mm) 20412569 0.013” (0.330 mm) Figure 12-37: Autoline™ Sapphire Orifice
05109087 0.008" (0.203 mm) 05109137 0.014" (0.356 mm)
05109095 0.009" (0.229 mm) 20448541 0.016” (0.406 mm)
05109103 0.010" (0.254 mm) 05114913 0.018" (0.457 mm)
05109111 0.011” (0.279 mm) 80086671 0.019" (0.482 mm)
05109129 0.012" (0.305 mm) 05114921 0.020” (0.508 mm)
Table 12-48
Autoline™ Diamond Orifice
Part Part
20448625 0.004” (0.102 mm) 05136098 0.013” (0.330 mm) Figure 12-38: Autoline™ Diamond Orifice
05063847 0.007" (0.178 mm) 05077037 0.014" (0.356 mm)
05112537 0.008" (0.203 mm) 80075781 0.015" (0.381 mm)
05084504 0.009" (0.229 mm) 05121512 0.016" (0.406 mm)
05077029 0.010" (0.254 mm) 05114905 0.018" (0.457 mm)
05101753 0.011” (0.279 mm) 80086663 0.019" (0.482 mm)
05077300 0.012" (0.305 mm) 05114897 0.020” (0.508 mm)
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-49
Pneumatic Control Valve, Normally Closed
10138824
Part
1 10177855 Pneumatic Actuator Assembly, NC 1 Figure 12-39: Pneumatic Control Valve, NC
2 10189181 Valve Body 1
3 BV701184 HP Gland 1
4 10188233 Brass Backup Ring 1
5 20428052 Seal Assembly 1
6 20435636 Valve Stem 1
7 10178697 Valve Seat 1
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-50
Pneumatic Actuator Assembly, Normally Closed
10177855
Part
1 05145990 Piston 1 Figure 12-40: Pneumatic Actuator Assembly, NC
2 20411554 Cylinder Cap 1
3 10177780 Wiper Seal 1
4 10177772 Retaining Ring 1
5 10176543 Pneumatic Cylinder 1
6 10177806 O-Ring, 2.63 x 2.75 x .06 3
7 05054119 Compression Spring, .72 x .105 x 1.50 6
8 49895584 O-Ring, .08 x .20 x .06 1
9 10187250 SST Backup Ring 1
10 00080028 Cover 1
10178291 Warning Decal
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-51
Pneumatic Control Valve, Normally Open
10184760
Part
1 10189553 Pneumatic Actuator Assembly 1 Figure 12-41: Pneumatic Control Valve, NO
2 10189181 Valve Body 1
3 BV701184 HP Gland Fitting 1
4 10188233 Brass Backup Ring 1
5 20428052 Seal Assembly 1
6 20435636 Valve Stem 1
7 10178697 Valve Seat 1
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-52
Pneumatic Actuator Assembly, Normally Open
10189553
Part
1 BV401184 Pneumatic Cylinder 1 Figure 12-42: Pneumatic Actuator Assembly, NO
2 BV601184 Cylinder Head 1
3 BV501184 Piston 1
4 10187250 SST Backup Ring 1
5 10074714 O-Ring, 2.44 x 2.63 x .09 1
6 10074565 O-Ring, 2.25 x 2.38 x .06 2
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-53
Bulk High Pressure Tubing
Part
Number Description
10064376 .25 x .083, 20 ft (6.10 m)
10184810 .25 x .083, up to 40 ft (12.19 m)
10064665 .38 x .125, 20 ft (6.10 m)
10061190 .56 x .188, 20 ft (6.10 m)
High Pressure Tubing also available coned, threaded and/or autofrettaged
Figure 12-43: Bulk High Pressure Tubing Coned/Threaded Both Ends
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-54
High Pressure Fitting and Valve Assemblies
Part Part
10079028 Coupling, .25 x .25, F/F HP Coupling 10079473 Bushing, .38 x .25, F/M HP Bushing
10079614 Coupling, .38 x .25, F/F 10079432 Bushing, .38 x .25, M/F
10078905 Coupling, .38 x .38, F/F 10079424 Bushing, .56 x .25, F/M
10079531 Coupling, .56 x .38, F/F 10079655 Bushing, .56 x .38, F/M
49832801 Bushing, .75 x .56, F/M
10078160 Bulkhead Coupling, .38 x .38, F/F HP Bulkhead Coupling
49830581 Bulkhead Coupling, .56 x .38, F/F 10097228 Cross, .25 HP Cross
10079705 Bulkhead Coupling, .56 x .56, F/F 10078038 Cross, .38
20424785 Bulkhead Coupling, .75 x .75, F/F 10079168 Cross, .56
49832652 Cross, .75
10079051 Elbow, .25 x .25, 90D HP Elbow
10078780 Elbow, .38 x .38, 90D
10078525 Elbow, .56 x .56, 90D 10079481 Tee, .25 HP Tee
49832645 Elbow, .75 x .75, 90D 10078590 Tee, .38
10079465 Tee, .56
49832660 Tee, .75
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-54
Part Part
10078426 Collar, .25 HP Collar 10116333 Adapter Cone, .25 HP Cone Adapter
10078715 Collar, .38 10078509 Adapter Cone, .38
10078459 Gland, .25 HP Gland 10078244 Plug, .25 HP Plug

10078129 Gland, .38 10079523 Plug, .38
10078608 Gland, .56 10078772 Plug, .56
49832678 Gland, .75
10078699 Anti-Vibration Gland, .25 Anti-Vibration Gland

10078913 Anti-Vibration Gland, .38
10093573 Anti-Vibration Gland, .56
72165940
3-2015/Rev 0
Section 12
Parts List
Table 12-54
Part Part
10079259 2 Way Straight, .25 2-Way Straight Valve 10079002 2 Way Angle, .25 2-Way Angle Valve
10078863 2 Way Straight, .35 10078749 2 Way Angle, .38
10078889 2 Way Straight, .56 10079275 2 Way Angle, .56
20432554 2 Way Straight, .75
10097533 3 Way/1 Pressure Valve, .38 3-Way Valve 05137724 3 Way/2 Pressure Valve, .38 3-Way Valve
10097541 3 Way/1 Pressure Valve, .56 10153500 3 Way/2 Pressure Valve, .56
72165940
3-2015/Rev 0
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Material Safety Data Sheet
Revision Date: 12/10/2004 Issue date: 12/13/2004
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Product name: Loctite(R) 222 Threadlocker Low Strength Item No. : 21464
Product Use: Sealant Region: Canada
Company address: Contact Information:
Henkel Canada, Inc. Telephone: 905.814.6511
2255 Meadowpine Boulevard Emergency telephone: 905.814.6511
Mississauga, Ontario L5N 7P2 Internet: www.loctite.com
2. COMPOSITION/INFORMATION ON INGREDIENTS
Hazardous components % ACGIH TLV OSHA PEL OTHER

Polyglycol dimethacrylate 30-60 None None None
25852-47-5
Polyglycol oleate 30-60 None None None

9004-96-0
Silica, amorphous, treated 5-10 10 mg/m3 (Inhal) 20mppcf 6 mg/m3

68909-20-6
Saccharin 1-5 None None None

81-07-2
Propylene glycol 1-5 None None None

57-55-6
Cumene hydroperoxide 1-5 None None 1 ppm (6 mg/m3) Skin (WEEL)

80-15-9
3. HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Physical state: Liquid WHMIS hazard class: D.2.B
Color: Purple
Odor: Mild
WARNING: CAUSES EYE IRRITATION.

MAY CAUSE ALLERGIC SKIN REACTION.
MAY CAUSE SKIN IRRITATION.
MAY CAUSE RESPIRATORY TRACT IRRITATION.
Relevant routes of exposure: Skin, Inhalation, Eyes
Potential Health Effects

Inhalation: May cause respiratory tract irritation.
Skin contact: May cause allergic skin reaction. May cause skin irritation.
Eye contact: Contact with eyes will cause irritation.
Ingestion: Not expected to be harmful by ingestion.
Existing conditions aggravated by Eye, skin, and respiratory disorders.

exposure:
See Section 11 for additional toxicological information.
Item No. : 21464 Product name: Loctite(R) 222 Threadlocker Low Strength
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4. FIRST AID MEASURES
Inhalation: Remove to fresh air. If symptoms develop and persist, get medical attention.
Skin contact: Wash with soap and water. Remove contaminated clothing and shoes. Wash clothing before reuse.
Get medical attention if symptoms occur.
Eye contact: Flush with copious amounts of water, preferably, lukewarm water for at least 15 minutes, holding
eyelids open all the time. Get medical attention.
Ingestion: Do not induce vomiting. Keep individual calm. Obtain medical attention.
5. FIRE-FIGHTING MEASURES
Flash point: Greater than 93ºC (200ºF) Tagliabue closed cup
Autoignition temperature: Not available
Flammable/Explosive limits-lower %: Not available
Flammable/Explosive limits-upper %: Not available
Extinguishing media: Foam, dry chemical or carbon dioxide.
Special fire fighting procedures: Wear self-contained breathing apparatus and full protective clothing, such as turn-out gear.
Unusual fire or explosion hazards: None
Hazardous combustion products: Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors.
Sensitivity to mechanical impact: Not available.
Sensitivity to static discharge: Not available.
6. ACCIDENTAL RELEASE MEASURES
Environmental precautions: Prevent product from entering drains or open waters.
Clean-up methods: Soak up with inert absorbent. Store in a partly filled, closed container until disposal.
7. HANDLING AND STORAGE
Handling: Avoid contact with eyes, skin and clothing. Avoid breathing vapor and mist. Wash thoroughly after
handling. Use only with adequate ventilation.
Storage: For safe storage, store at or below 38°C (100°F). Keep in a cool, well ventilated area away from heat,
sparks and open flame. Keep container tightly closed until ready for use.
Incompatible products: Refer to Section 10.
For information on product shelf life contact Loctite Canada Customer Service at (905) 814-6511.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Engineering controls: No specific ventilation requirements noted, but forced ventilation may still be required if concentrations
exceed occupational exposure limts.
Respiratory protection: Use NIOSH approved respirator if there is potential to exceed exposure limit(s).
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Skin protection: Use impermeable gloves and protective clothing as necessary to prevent skin contact. Neoprene
gloves. Butyl rubber gloves. Natural rubber gloves.
Eye/face protection: Safety goggles or safety glasses with side shields.
See Section 2 for exposure limits.
9. PHYSICAL AND CHEMICAL PROPERTIES
Physical state: Liquid

Color: Purple
Odor: Mild
Odor Threshold: Not available
Vapor pressure: Less than 5 mm Hg at 27ºC (80ºF)
pH: Not applicable
Boiling point/range: Greater than 149ºC (300ºF)
Melting point/range: Not available
Specific gravity: 1.08 at 20ºC (68ºF)
Vapor density: Not available
Evaporation rate: Not available
Solubility in water: Slight
Partition coefficient (n-octanol/water): Not available
VOC content: 11.8%; 127 grams/liter (EPA Method 24)
10. STABILITY AND REACTIVITY
Stability: Stable.
Hazardous polymerization: Will not occur.
Hazardous decomposition products: Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors.
Incompatability: Strong oxidizers.
Conditions to avoid: See "Handling and Storage" (Section 7) and "Incompatabilty" (Section 10).
11. TOXICOLOGICAL INFORMATION
Product toxicity data: Acute oral LD50 greater than 10, 000 mg/kg (rat). Acute dermal LD50 greater than 5000 mg/kg (rabbit).
Toxicologically synergistic products: Not available.
Refer to the following for Irritancy of Product, Sensitization to Product, Carcinogenicity, Reproductive Toxicity, Teratogenicity, and
Mutagenicity.
Ingredient Toxicity Data & Carcinogen Status
Hazardous components LD50s & LC50s Other LD50s NTP IARC OSHA ACGIH -
(NIOSH ) : and LC50s: Carcinogen Carcinogen Carcinogen Carcinogens
Polyglycol dimethacrylate None None No No No No
25852-47-5
Polyglycol oleate Oral LD50 None No No No No
9004-96-0 (Mouse) > 25
g/kg
Silica, amorphous, treated None None No No No No
68909-20-6
Saccharin Oral LD50 None No No No No
81-07-2 (Mouse) = 17
g/kg
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Propylene glycol Oral LD50 (Rat) None No No No No
57-55-6 = 20 g/kg
Dermal LD50
(Rabbit) = 20800
mg/kg
Oral LD50
(Mouse) = 22
g/kg
Cumene hydroperoxide Inhalation LC50 None No No No No
80-15-9 (Mouse) = 200
ppm
Inhalation LC50
(Rat) = 220 ppm
Oral LD50 (Rat)
= 382 mg/kg
Literature Referenced Target Organ & Other Health Effects
Hazardous components Health Effects/Target Organs

Polyglycol dimethacrylate Allergen, Irritant
25852-47-5
Polyglycol oleate Irritant
9004-96-0
Silica, amorphous, treated No Target Organs
68909-20-6
Saccharin No Target Organs
81-07-2
Propylene glycol Irritant
57-55-6
Cumene hydroperoxide Allergen, Central nervous system, Corrosive, Irritant, Mutagen
80-15-9
12. ECOLOGICAL INFORMATION
Ecological information: Not available
13. DISPOSAL CONSIDERATIONS
Information provided is for unused product only.
Recommended method of disposal: Dispose of in accordance with federal and local regulations.
14. TRANSPORT INFORMATION
Canada Transportation of Dangerous Goods - Ground:

Proper shipping name: Unrestricted
Hazard class or division: None
Identification number: None
Packing group: None
International Air Transportation (ICAO/IATA):

Packing group: None
WaterTransportation (IMO/IMDG):
Packing group: None
Marine pollutant: None
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15. REGULATORY INFORMATION
Canada Regulatory Information
CEPA DSL/NDSL Status: All components are listed on or are exempt from listing on the Domestic Substances List.
United States Regulatory Information
TSCA 8 (b) Inventory Status: All components are listed or are exempt from listing on the Toxic Substances Control Act Inventory.
16. OTHER INFORMATION
This material safety data sheet contains changes from the previous version in sections: New Material Safety Data Sheet format.
This product has been classified in accordance with the hazard criteria of the Controlled Products Regulations and the MSDS contains all
the information required by the Controlled Product Regulations.
Prepared by: Kyra Kozak Woods, Health and Regulatory Affairs Specialist
DISCLAIMER: The data contained herein are furnished for information only and are believed to be reliable. However, Henkel Corporation
does not assume responsibility for any results obtained by persons over whose methods Henkel Corporation has no control. It is the
user's responsibility to determine the suitability of Henkel's products or any production methods mentioned herein for a particular
purpose, and to adopt such precautions as may be advisable for the protection of property and persons against any hazards that may be
involved in the handling and use of any of Henkel Corporation's products. In light of the foregoing, Henkel Corporation specifically
disclaims all warranties, express or implied, including warranties of merchantability and fitness for a particular purpose, arising from sale
or use of Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damages of
any kind, including lost profits.
5 of 5
!"#$%&'()&**
JL-M MATERIAL SAFETY DATA SHEET
SECTION 1 – PRODUCT IDENTIFICATION
Product Name: JL-M Lubricant Manufacturer’s Name: Superbolt, Inc.
Revised: 03/07/03 Supercedes: 03/17/00 Manufacturer’s Address: 1000 Gregg Street
Prepared by: C. Semerod Carnegie, PA 15106
Emergency Information: (412) 279-1149 Manufacturer’s Phone #: (412) 279-1149
SECTION 2 – HAZARDOUS INGREDIENTS
CHEMICAL NAME: CAS NO.: OSHA PEL: ACGIH TLV: (STEL)
Molybdenum Disulfide 1317-33-5 10 mg/m3 10 mg/m3 N/A
Silica, Fused 60676-86-0 0.1 mg/m3 0.1 mg/m3 N/A
Graphite 7782-42-5 2 mg/m3 N/A
Silica, Crystalline 14808-60-7 0.1 mg/m3 N/A
Lubricating Oils, Petroleum, 64742-58-1 5 mg/m3* 5 mg/m3* 10mg/m3*
Hydrotreated, Spent
Residual Oils (Petroleum), 64742-62-7 5 mg/m3* 5 mg/m3* 10 mg/m3*
Solvent Dewaxed
Solvent-Refined Heavy Paraffinic 64741-88-4 5 mg/m3* 5 mg/m3* 10 mg/m3*
Distillate (Petroleum)
Solvent –Dewaxed Hydrotreated 64742-65-0 5 mg/m3* 5 mg/m3* 10 mg/m3*
Heavy Paraffinic Distillate (Petroleum)
Hydrotreated Heavy Paraffinic 64742-54-7 5 mg/m3* 5 mg/m3* 10 mg/m3*
Distillate (Petroleum)
Proprietary Additives Mixture (<1%)
(*) Designates limits set by OSHA and the ACGIH for oil mist. This product is sold in a paste form so misting should not occur.
SECTION 3 – PHYSICAL DATA SECTION 4 – FIRE AND EXPLOSION DATA
Appearance and Odor: Dark Grey Paste, Mild Petroleum Flash Point: 338 degrees F
Boiling Point: > 500 degrees F Lower Explosive Limit: N/A
% Volatile: 0% Upper Explosive Limit: N/A
Vapor Density: > 1 (Air = 1) Extinguishing Media: Carbon Dioxide, Regular Foam, Dry Chemical
Evaporation Rate: < 1 (Ether = 1) Special Fire Fighting Procedures: Fire may produce dense smoke,
Specific Gravity: 4.8 (Water = 1) firefighters should wear self contained breathing apparatus. Use
Vapor Pressure: Essentially 0 (mm Hg) water to cool fire exposed containers.
Solubility in Water: Insoluble Unusual Fire & Explosion Hazards: Decomposition and combustion
pH: N/A by-products may be toxic. Heated containers may rupture or explode.
SECTION 5 – REACTIVITY DATA SECTION 6 – STORAGE & HANDLING
Stability: Stable Hazardous Polymerization: Will not occur. Handling Precautions: Use good personal hygiene practices. Clean
Incompatibility: Avoid contact with oxidizing agents, heat, sparks or contaminated clothing and protective equipment before reuse.
flame.
Hazardous Combustion By-Products: Carbon Monoxide, Sulfur Storage Precautions: Store in a cool dry location. Keep container
Dioxide, Aldehydes, and Nitrogen Oxides tightly closed when not in use and during transport. Keep away from
Hazardous Decomposition: Thermal decomposition may yield open sparks or flames.
methacrylate monomers.
SECTION 7 – HEALTH HAZARDS
Effects of Overexposure: First Aid Procedures:
Skin: May Cause Irritation Skin: Remove contaminated clothing from irritated area. Flush
Eyes: Eye Irritant. May cause redness and Blurred vision. exposed area with mild soap and water. Seek medical attention if
Ingestion: Not Expected irritation persists.
Inhalation: Not Expected (Chronic respiratory diseases may be Eyes: Flush eyes with large quantities of water, holding eyelids open.
aggravated by dust exposure.) Seek medical attention if irritation persists.
NFPA CODES: Health: 1 Ingestion: Do not induce vomiting. If spontaneous vomiting occurs,
Flammability: 1 keep head below hips to avoid aspiration into the lungs. Seek
Reactivity: 0 immediate medical attention.
Carcinogenicity: Silica is a suspected carcinogen in a respirable Inhalation: Remove to fresh air. Obtain medical attention if
form by the IARC and NTP however, not by the ACIGH or OSHA. necessary.
SECTION 8 – SPECIAL PROTECTION SECTION 9 – SPILL AND DISPOSAL PROCEDURES
Eye Protection: Safety Glasses or Face Shield Spill Procedures: Scrape or wipe up any spilled material. Wear
Protective Gloves: Recommended proper protective equipment when cleaning up a spill.
Respiratory Protection: Avoid breathing dust, use an Disposal Procedures: Dispose of in accordance with any applicable
approved respirator if levels exceed OSHA limits. federal, state, or local laws.
Ventilation: Local ventilation to maintain levels within OSHA limits.
The information in this MSDS was obtained from sources which we believe are reliable. However, the information is provided without any
representation or warranty, expressed or implied, regarding the accuracy or correctness. The conditions or methods of handling, storage, use
and disposal of the product are beyond our control. For this and other reasons, we do not assume responsibility and expressly disclaim liability
for loss, damage, or expense arising out of or in any way connected with the handling, storage, use or disposal of the product.
Page 1 of 1
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!
LUBRIPLATE
MATERIAL SAFETY DATA SHEET
Section 1
PRODUCT NAME OR NUMBER: FORMULA:
LUBRIPLATE Super FML-0, FML-1, FML-2 Calcium Soap, USP Mineral Oil and Additives
GENERIC/CHEMICAL NAME: NSF Registration No’s:
Petroleum Lubricating Grease 125742, 125740, 125741
Manufacturer's Name: Emergency Telephone Number:
Fiske Brothers Refining Co. 1-800-255-3924 - CHEM-TEL (24 hour)
Address: Telephone Number for Information:
1500 Oakdale Ave., Toledo, Ohio 43605 - 129 Lockwood St., Newark, NJ 07105 419-691-2491 - Toledo Office
Section 2 - Hazardous Ingredients/Identity Information

Hazardous Components OSHA PEL ACGIH TLV Other Limits Recommended % (optional)
Non-hazardous
Hazardous Material Identification System (HMIS): Health - 1, Flammability - 1, Reactivity - 0
Not a Controlled Product under (WHMIS) - Canada Special Protection: See Section 9
Section 3 - Health Hazard Data

Threshold Limit Value: 5 mg/m3 for oil mist in air. OSHA Regulation 29 CFR 1910.1000
Effects of Overexposure: Prolonged or repeated skin contact may cause skin irritation. Product contacting the eyes may cause eye
irritation. Human health risks vary from person to person. As a precaution, exposure to liquids, vapors, mists and fumes should be
minimized. This product has a low order of acute oral toxicity, but minute amounts aspirated into the lungs during ingestion may cause mild
to severe pulmonary injury.
Carcinogenicity: NTP? No IARC Monographs? No OSHA Regulated? No
Section 4 - Emergency and First Aid Procedures

EYE CONTACT: Flush with clear water for 15 minutes or until irritation subsides. If irritation persists, consult a physician.
SKIN CONTACT: Remove any contaminated clothing and wash with soap and warm water. If injected by high pressure under skin,
regardless of the appearance or its size, contact a physician IMMEDIATELY. Delay may cause loss of affected part of the body.
INHALATION: Vapor pressure is very low and inhalation at room temperature is not a problem. If overcome by vapor from hot product,
immediately remove from exposure and call a physician.
INGESTION: If ingested, call a physician immediately. Do not induce vomiting.
Section 5 - Fire and Explosion Hazard Data
Flash Point (Method Used): COC - 435oF Flammable Limits: LEL 0.9% UEL 7.0%
Extinguishing Media: Foam, Dry Chemical, Carbon Dioxide or Water Spray (Fog)
Special Fire Fighting Procedures: Cool exposed containers with water. Use air-supplied breathing equipment for
enclosed or confined spaces.
Unusual Fire and Explosion Hazards: Do not store or mix with strong oxidants. Empty containers retain residue.
Do not cut, drill, grind, or weld, as they may explode.
!"#$%&'()(&,
PRODUCT NAME OR NUMBER - LUBRIPLATE Super FML-0, FML-1, FML-2
Section 6 - Physical/Chemical Characteristics
Boiling Point: >550oF Specific Gravity (H 2O = 1): 0.90 - 0.91
Vapor Pressure (mm Hg.): <0.01 Melting Point: Semi-solid
Vapor Density (AIR = 1): >5 Evaporation Rate: <0.01

(Butyl Acetate = 1)
Solubility in Water: Negligible
Appearance and Odor: Smooth, white grease with mineral oil odor.
Section 7 - Reactivity Data
Stability: Unstable Conditions to Avoid: N/A

Stable X
Incompatibility (Materials to Avoid): Avoid contact with strong oxidants like liquid chlorine, concentrated oxygen.
Hazardous Decomposition or Byproducts: May form SO 2. If incomplete combustion, Carbon Monoxide.
Hazardous Polymerization: May Occur Conditions to Avoid: N/A

Will Not Occur X
Section 8 - Spill or Leak Procedures
Steps to be taken in case material is released or spilled:

Scrape up grease, wash remainder with suitable petroleum solvent or add absorbent. Keep petroleum products out of sewers and
watercourses. Advise authorities if product has entered or may enter sewers and watercourses.
Waste disposal method:

Assure conformity with applicable disposal regulations. Dispose of absorbed material at an approved waste disposal facility or site.
SARA/TITLE III, Section 313 Status - Zinc Compounds - <6%
Section 9 - Special Protection Information
Respiratory Protection (Specify type): Normally not needed
Ventilation Local Exhaust: Used to capture fumes and vapors Special: N/A
Mechanical (General) Other: N/A
Protective Gloves: Use oil-resistant gloves, if needed. Eye Protection: If chance of eye contact, wear goggles.
Other Protective Equipment: Use oil-resistant apron, if needed.
Section 10 - Special Precautions
Precautions to be taken in handling and storing:

Keep containers closed when not in use. Do not handle or store near heat, sparks, flame, or strong oxidants.
Other Precautions:
Remove oil-soaked clothing and launder before reuse. Cleanse skin thoroughly after contact.
The above information is furnished without warranty, expressed or implied, except that it is accurate to the best knowledge of Fiske
Brothers Refining Company. The data on these sheets relates only to the specific material designated herein. Fiske Brothers
Refining Company assumes no legal responsibility for use or reliance upon this data.
Date Prepared: January, 2006 Prepared by: James R. Kontak

!"#$%&'('%)
Hydraulic AW (All Grades)
1. Product and Company Identification

Product Name: Hydraulic AW (All Grades)
MSDS Number: 778830
Synonyms: Hydraulic AW 32
Hydraulic AW 46
Hydraulic AW 68
Hydraulic AW 100
Intended Use: Hydraulic Fluid
Manufacturer/Supplier: ConocoPhillips Lubricants

600 N. Dairy Ashford, 2W900
Houston, Texas 77079-1175
Emergency Health and Safety Number: Chemtrec: 800-424-9300 (24 Hours)
Customer Service: U.S.: 800-822-6457 or International: +1-83-2486-3363
Technical Information: 800-766-0050
MSDS Information: Internet: http://w3.conocophillips.com/NetMSDS/
2. Hazards Identification
Emergency Overview NFPA
This material is not considered hazardous according to OSHA criteria.
Appearance: Clear and bright

Physical Form: Liquid
Odor: Petroleum

Eye: Contact may cause mild eye irritation including stinging, watering, and redness.
Skin: Contact may cause mild skin irritation including redness and a burning sensation. Prolonged or repeated contact can defat the
skin, causing drying and cracking of the skin, and possibly dermatitis (inflammation). No harmful effects from skin absorption are
expected.
Inhalation (Breathing): No information available on acute toxicity.
Ingestion (Swallowing): No harmful effects expected from ingestion.
Signs and Symptoms: Effects of overexposure may include irritation of the digestive tract, nausea and diarrhea. Inhalation of oil mist
or vapors at elevated temperatures may cause respiratory irritation.
Pre-Existing Medical Conditions: Conditions which may be aggravated by exposure include skin disorders.
See Section 11 for additional Toxicity Information.

________________________________________________________________________________________________
778830 - Hydraulic AW (All Grades) Page 1/6
Date of Issue: Status: Final
KMT 72134505
Date of Issue: 27-Jan-2009 Status: Final
________________________________________________________________________________________________
3. Composition / Information on Ingredients
Component CASRN Concentration*

Lubricant Base Oil (Petroleum) VARIOUS >99
Additives PROPRIETARY <1
* All concentrations are percent by weight unless ingredient is a gas. Gas concentrations are in percent by volume.
4. First Aid Measures

Eye Contact: If irritation or redness develops from exposure, flush eyes with clean water. If symptoms persist, seek medical attention.
Skin Contact: Remove contaminated shoes and clothing and cleanse affected area(s) thoroughly by washing with mild soap and water
or a waterless hand cleaner. If irritation or redness develops and persists, seek medical attention.
Inhalation (Breathing): If respiratory symptoms develop, move victim away from source of exposure and into fresh air in a position
comfortable for breathing. If symptoms persist, seek medical attention.
Ingestion (Swallowing): First aid is not normally required; however, if swallowed and symptoms develop, seek medical attention.
Notes to Physician: High-pressure hydrocarbon injection injuries may produce substantial necrosis of underlying tissue despite an
innocuous appearing external wound. These injuries often require extensive emergency surgical debridement and all injuries should be
evaluated by a specialist in order to assess the extent of injury. Early surgical treatment within the first few hours may significantly
reduce the ultimate extent of injury.
Acute aspirations of large amounts of oil-laden material may produce a serious aspiration pneumonia. Patients who aspirate these oils
should be followed for the development of long-term sequelae. Inhalation exposure to oil mists below current workplace exposure limits
is unlikely to cause pulmonary abnormalities.
5. Fire-Fighting Measures
NFPA 704 Hazard Class
Health: 0 Flammability: 1 Instability: 0 (0-Minimal, 1-Slight, 2-Moderate, 3-Serious, 4-Severe)
Unusual Fire & Explosion Hazards: This material may burn, but will not ignite readily. If container is not properly cooled, it can
rupture in the heat of a fire.
Extinguishing Media: Dry chemical, carbon dioxide, foam, or water spray is recommended. Water or foam may cause frothing of
materials heated above 212°F / 100°C. Carbon dioxide can displace oxygen. Use caution when applying carbon dioxide in confined
spaces.
Fire Fighting Instructions: For fires beyond the initial stage, emergency responders in the immediate hazard area should wear
protective clothing. When the potential chemical hazard is unknown, in enclosed or confined spaces, a self contained breathing
apparatus should be worn. In addition, wear other appropriate protective equipment as conditions warrant (see Section 8).
Isolate immediate hazard area and keep unauthorized personnel out. Stop spill/release if it can be done safely. Move undamaged
containers from immediate hazard area if it can be done safely. Water spray may be useful in minimizing or dispersing vapors and to
protect personnel. Cool equipment exposed to fire with water, if it can be done safely. Avoid spreading burning liquid with water used for
cooling purposes.
Hazardous Combustion Products: Combustion may yield smoke, carbon monoxide, and other products of incomplete combustion.
Oxides of sulfur, nitrogen or phosphorus may also be formed.
See Section 9 for Flammable Properties including Flash Point and Flammable (Explosive) Limits
6. Accidental Release Measures

Personal Precautions: This material may burn, but will not ignite readily. Keep all sources of ignition away from spill/release. The
use of explosion-proof electrical equipment is recommended. Stay upwind and away from spill/release. Notify persons and shipping
down wind of the spill/release, isolate immediate hazard area and keep unauthorized personnel out. Wear appropriate protective
equipment, including respiratory protection, as conditions warrant (see Section 8).
KMT 72134505
________________________________________________________________________________________________
Environmental Precautions: Stop spill/release if it can be done safely. Prevent spilled material from entering sewers, storm drains,
other unauthorized drainage systems, and natural waterways. Spills into or upon navigable waters, the contiguous zone, or adjoining
shorelines that cause a sheen or discoloration on the surface of the water, may require notification of the National Response Center
(phone number 800-424-8802).
Methods for Containment and Clean-Up: Notify relevant authorities in accordance with all applicable regulations. Immediate cleanup
of any spill is recommended. Dike far ahead of spill for later recovery or disposal. Absorb spill with inert material such as sand or
vermiculite, and place in suitable container for disposal. If spilled on water remove with appropriate methods (e.g. skimming, booms or
absorbents).
7. Handling and Storage

Precautions for safe handling: Wash thoroughly after handling. Use good personal hygiene practices and wear appropriate personal
protective equipment.
High pressure injection of hydrocarbon fuels, hydraulic oils or greases under the skin may have serious consequences even though no
symptoms or injury may be apparent. This can happen accidentally when using high pressure equipment such as high pressure grease
guns, fuel injection apparatus or from pinhole leaks in tubing of high pressure hydraulic oil equipment.
Do not enter confined spaces such as tanks or pits without following proper entry procedures such as ASTM D-4276 and 29CFR
1910.146. Do not wear contaminated clothing or shoes.
"Empty" containers retain residue and may be dangerous. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose such
containers to heat, flame, sparks, or other sources of ignition. They may explode and cause injury or death. "Empty" drums should be
completely drained, properly bunged, and promptly shipped to the supplier or a drum reconditioner. All containers should be disposed
of in an environmentally safe manner and in accordance with governmental regulations. Before working on or in tanks which contain or
have contained this material, refer to OSHA regulations, ANSI Z49.1, and other references pertaining to cleaning, repairing, welding, or
other contemplated operations.
Conditions for safe storage: Use and store this material in cool, dry, well-ventilated area away from heat and all sources of ignition.
Keep container(s) tightly closed. Store only in approved containers. Keep away from any incompatible material (see Section 10). Protect
container(s) against physical damage. Storage temperatures above 113°F may lead to thermal decomposition, resulting in the
generation of hydrogen sulfide and other sulfur containing gases.
8. Exposure Controls / Personal Protection

Component US-ACGIH OSHA Other
Lubricant Base Oil (Petroleum) TWA: 5mg/m3 TWA: 5 mg/m3 ---
STEL: 10 mg/m3 as Oil Mist, if generated
as Oil Mist, if generated
Note: State, local or other agencies or advisory groups may have established more stringent limits. Consult an industrial
hygienist or similar professional, or your local agencies, for further information.
Engineering controls: If current ventilation practices are not adequate to maintain airborne concentrations below the established
exposure limits, additional engineering controls may be required.
Eye/Face Protection: The use of eye protection that meets or exceeds ANSI Z.87.1 is recommended to protect against potential eye
contact, irritation, or injury. Depending on conditions of use, a face shield may be necessary.
Skin/Hand Protection: The use of gloves impervious to the specific material handled is advised to prevent skin contact. Users should
check with manufacturers to confirm the breakthrough performance of their products. Suggested protective materials: Nitrile.
Respiratory Protection: Where there is potential for airborne exposure above the exposure limit a NIOSH certified air purifying
respirator equipped with R or P95 filters may be used.
A respiratory protection program that meets or is equivalent to OSHA 29 CFR 1910.134 and ANSI Z88.2 should be followed whenever
workplace conditions warrant a respirator's use. Air purifying respirators provide limited protection and cannot be used in atmospheres
that exceed the maximum use concentration (as directed by regulation or the manufacturer's instructions), in oxygen deficient (less than
19.5 percent oxygen) situations, or under conditions that are immediately dangerous to life and health (IDLH).
Suggestions provided in this section for exposure control and specific types of protective equipment are based on readily
available information. Users should consult with the specific manufacturer to confirm the performance of their protective
equipment. Specific situations may require consultation with industrial hygiene, safety, or engineering professionals.
KMT 72134505
________________________________________________________________________________________________
9. Physical and Chemical Properties
Note: Unless otherwise stated, values are determined at 20°C (68°F) and 760 mm Hg (1 atm). Data represent typical values and are
not intended to be specifications.
Appearance: Clear and bright

Physical Form: Liquid
Odor: Petroleum
Odor Threshold: No data
pH: Not applicable
Vapor Pressure: <1 mm Hg
Vapor Density (air=1): >1
Boiling Point/Range: No data
Melting/Freezing Point: <15.8°F / <-9°C
Pour Point: <15.8°F / <-9°C
Solubility in Water: Insoluble
Partition Coefficient (n-octanol/water) (Kow): No data
Specific Gravity: 0.87 - 0.89 @ 60ºF (15.6ºC)
Bulk Density: 7.2 - 7.4 lbs/gal
Viscosity: 5.2 - 10.5 cSt @ 100°C; 30 - 110 cSt @ 40°C
Evaporation Rate (nBuAc=1): No data
Flash Point: >320°F / >160°C
Test Method: Pensky-Martens Closed Cup (PMCC), ASTM D93, EPA 1010
LEL (vol % in air): No data
UEL (vol % in air): No data
Autoignition Temperature: No data
10. Stability and Reactivity

Stability: Stable under normal ambient and anticipated conditions of use.
Conditions to Avoid: Extended exposure to high temperatures can cause decomposition.
Materials to Avoid (Incompatible Materials): Avoid contact with oxidizing agents and reducing agents.
Hazardous Decomposition Products: Not anticipated under normal conditions of use.
Hazardous Polymerization: Not known to occur.
11. Toxicological Information
Chronic Toxicity:
Lubricant Base Oil (Petroleum)

Carcinogenicity: The petroleum base oils contained in this product have been highly refined by a variety of processes
including severe hydrocracking/hydroprocessing to reduce aromatics and improve performance characteristics. All of the oils
meet the IP-346 criteria of less than 3 percent PAH's and are not considered carcinogens by NTP, IARC, or OSHA.
Acute Toxicity:
Component Oral LD50 Dermal LD50 Inhalation LC50

Lubricant Base Oil (Petroleum) >5 g/kg >2 g/kg No data
12. Ecological Information
Ecotoxicity: Experimental studies show that acute aquatic toxicity values are greater than 1000 mg/l. These values are consistent with
the predicted aquatic toxicity of these substances based on their hydrocarbon compositions.
KMT 72134505
________________________________________________________________________________________________
Mobility: Volatilization to air is not expected to be a significant fate process due to the low vapor pressure of this material. In water,
base oils will float and spread over the surface at a rate dependent upon viscosity. There will be significant removal of hydrocarbons
from the water by sediment adsorption. In soil and sediment, hydrocarbon components will show low mobility with adsorption to
sediments being the predominant physical process. The main fate process is expected to be slow biodegradation of base oil
components in soil and sediment.
Persistence and degradability: The hydrocarbons in this material are not readily biodegradable, but since they can be degraded by
microorganisms, they are regarded as inherently biodegradable.
Bioaccumulation Potential: Log Kow values measured for the hydrocarbon components of this material range from 4 to over 6, and
therefore regarded as having the potential to bioaccumulate. In practice, metabolic processes may reduce bioconcentration.
13. Disposal Considerations
The generator of a waste is always responsible for making proper hazardous waste determinations and needs to consider state and
local requirements in addition to federal regulations.
This material, if discarded as produced, would not be a federally regulated RCRA "listed" hazardous waste and is not believed to exhibit
characteristics of hazardous waste. See Sections 7 and 8 for information on handling, storage and personal protection and Section 9
for physical/chemical properties. It is possible that the material as produced contains constituents which are not required to be listed in
the MSDS but could affect the hazardous waste determination. Additionally, use which results in chemical or physical change of this
material could subject it to regulation as a hazardous waste.
This material under most intended uses would become "Used Oil" due to contamination by physical or chemical impurities. Whenever
possible, Recycle Used Oil in accordance with applicable federal and state or local regulations. Container contents should be
completely used and containers should be emptied prior to discard.
14. Transportation Information
U.S. Department of Transportation (DOT)

Shipping Description: Not regulated
Note: If shipped by land in a packaging having a capacity of 3,500 gallons or more, the
provisions of 49 CFR, Part 130 apply. (Contains oil)
International Maritime Dangerous Goods (IMDG)

Shipping Description: Not regulated
Note: U.S. DOT compliance requirements may apply. See 49 CFR 171.22, 23 & 25.
International Civil Aviation Org. / International Air Transport Assoc. (ICAO/IATA)

UN/ID #: Not regulated
Note: U.S. DOT compliance requirements may apply. See 49 CFR 171.22, 23 & 24.
LTD. QTY Passenger Aircraft Cargo Aircraft Only

Packaging Instruction #: --- --- ---
Max. Net Qty. Per Package: --- --- ---
15. Regulatory Information
CERCLA/SARA - Section 302 Extremely Hazardous Substances and TPQs (in pounds):
This material does not contain any chemicals subject to the reporting requirements of SARA 302 and 40 CFR 372.
CERCLA/SARA - Section 311/312 (Title III Hazard Categories)

Acute Health: No
Chronic Health: No
Fire Hazard: No
Pressure Hazard: No
Reactive Hazard: No
KMT 72134505
________________________________________________________________________________________________
CERCLA/SARA - Section 313 and 40 CFR 372:
This material contains the following chemicals subject to the reporting requirements of Section 313 of SARA Title III and 40 CFR 372:
Component Concentration* de minimis

Zinc Compound(s) <1.5 1.0%
EPA (CERCLA) Reportable Quantity (in pounds):

This material does not contain any chemicals with CERCLA Reportable Quantities.
California Proposition 65:

This material does not contain any chemicals which are known to the State of California to cause cancer, birth defects or other
reproductive harm at concentrations that trigger the warning requirements of California Proposition 65.
Canadian Regulations:
This product has been classified in accordance with the hazard criteria of the Controlled Products Regulations (CPR) and the MSDS
contains all the information required by the Regulations.
WHMIS Hazard Class

None
National Chemical Inventories:

All components are either listed on the US TSCA Inventory, or are not regulated under TSCA.
All components are either on the DSL, or are exempt from DSL listing requirements.
U.S. Export Control Classification Number: EAR99
16. Other Information
Date of Issue: 27-Jan-2009

Status: Final
Revised Sections or Basis for Revision: Product Name / Synonyms (Section 1)
Physical Properties (Section 9)
Regulatory information (Section 15)
MSDS Number: 778830
Guide to Abbreviations:
ACGIH = American Conference of Governmental Industrial Hygienists; CASRN = Chemical Abstracts Service Registry Number; CEILING = Ceiling Limit
(15 minutes); CERCLA = The Comprehensive Environmental Response, Compensation, and Liability Act; EPA = Environmental Protection Agency;
IARC = International Agency for Research on Cancer; LEL = Lower Explosive Limit; NE = Not Established; NFPA = National Fire Protection Association;
NTP = National Toxicology Program; OSHA = Occupational Safety and Health Administration; PEL = Permissible Exposure Limit (OSHA); SARA =
Superfund Amendments and Reauthorization Act; STEL = Short Term Exposure Limit (15 minutes); TLV = Threshold Limit Value (ACGIH); TWA = Time
Weighted Average (8 hours); UEL = Upper Explosive Limit; WHMIS = Worker Hazardous Materials Information System (Canada)
Disclaimer of Expressed and implied Warranties:

The information presented in this Material Safety Data Sheet is based on data believed to be accurate as of the date this Material
Safety Data Sheet was prepared. HOWEVER, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR ANY PARTICULAR
PURPOSE, OR ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING THE ACCURACY OR
COMPLETENESS OF THE INFORMATION PROVIDED ABOVE, THE RESULTS TO BE OBTAINED FROM THE USE OF THIS
INFORMATION OR THE PRODUCT, THE SAFETY OF THIS PRODUCT, OR THE HAZARDS RELATED TO ITS USE. No
responsibility is assumed for any damage or injury resulting from abnormal use or from any failure to adhere to recommended practices.
The information provided above, and the product, are furnished on the condition that the person receiving them shall make their own
determination as to the suitability of the product for their particular purpose and on the condition that they assume the risk of their use.
In addition, no authorization is given nor implied to practice any patented invention without a license.
KMT 72134505
___________________________________________________________________________
____________ SECTION 1 - PRODUCT AND COMPANY IDENTIFICATION _____________
PRODUCT IDENTIFICATION: . . : GERALYN AW 68
MANUFACTURER IDENTIFICATION
Company Name. . . . . . . : FUCHS LUBRICANTS CO.
Address . . . . . . . . . : 17050 LATHROP AVE.
HARVEY IL 60426
Telephone . . . . . . . . : 708-333-8900
Emergency Contact . . . . : Regulatory Compliance Department
Emergency Telephone . . . : 708-333-8900 (8am - 5pm CST, M-F)
800-255-3924 (24 Hours)
MSDS PRINT DATE . . . . . . : 07/26/2007
____________________
* EMERGENCY OVERVIEW
This product is a liquid that is insoluble in water.
Direct eye contact may cause minor, short term irritation. Short term
skin exposure is not expected to be irritating. Inhalation and ingestion
are not anticipated routes of exposure during normal conditions of use.
* HMIS Rating: Health- 1 Flammability- 1 Reactivity- 0 PPE- X
___________________________________________________________________________
______________________ SECTION 2 - COMPONENT DATA _______________________
Components listed in this section may contribute to the potential
hazards associated with exposure to the concentrate. The product may
contain additional non-hazardous or trade-secret components.
Mineral Oil Cas#: proprietary Percent: > 90
Exposure Limit:
ACGIH TLV: 5 mg/m3 (as mist)
ACGIH STEL: 10 mg/m3 (as mist)
OSHA PEL: 5 mg/m3 (as mist)
- Carcinogenic Components: This product contains no carcinogens.

___________________________________________________________________________
___________________ SECTION 3 - HAZARDS IDENTIFICATION __________________
POTENTIAL HEALTH EFFECTS and SYMPTOMS from SHORT TERM/ACUTE EXPOSURE:

- EYE EXPOSURE -
This product is not expected to cause eye irritation under normal
conditions of use. Symptoms of slight eye irritation may result
when direct contact occurs, or when exposed to high mist levels in
poorly ventilated areas.
- SKIN EXPOSURE -
Short term skin contact is not expected to cause skin irritation.
Prolonged or repeated direct exposure to the skin may result in
KMT 20461677
PRODUCT NAME: GERALYN AW 68
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symptoms of irritation and redness. In severe cases, prolonged or

repeated contact may result in dermatitis accompanied by symptoms of
irritation, itching, dryness, cracking and/or inflammation.
- INHALATION -
This product has low volatility and so is not expected to cause
respiratory tract irritation during normal conditions of use. Exposure
to high mist levels in poorly ventilated areas may cause upper
respiratory tract irritation and difficulty breathing.
- INGESTION -
Ingestion may cause slight stomach irritation and discomfort.
POTENTIAL CHRONIC HEALTH EFFECTS:

No further data known.
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE:
CARCINOGENICITY:
This product is not listed as a known or suspected carcinogen by IARC,
OSHA, or the NTP.
___________________________________________________________________________
_____________________ SECTION 4 - FIRST AID MEASURES ____________________
EYE CONTACT:
Upon direct eye contact, hold eyelids open and flush with a steady,
gentle stream of water for at least 15 minutes. If irritation is due to
exposure to mist or vapors, remove the individual to fresh air. If
irritation persists, flush the eyes with clean water until the irritation
subsides. If symptoms persist, contact a physician.
SKIN CONTACT:
Remove product from the skin by washing with a mild soap and water.
Contaminated clothing should be removed to prevent prolonged exposure.
If symptoms of exposure persist, contact a physician.
INHALATION:
Inhalation is not an expected route of exposure. If respiratory
irritation or distress occurs, remove the employee to fresh air. Contact
a physician or other medical professional if irritation or distress
persists.
INGESTION:
If small amounts are ingested, first aid measures are not likely to be
necessary. If larger amounts are ingested or if symptoms of ingestion
occur, dilute stomach contents with two glasses of water or milk. (NOTE:
Do NOT give anything by mouth to an unconscious person.) Do not induce
KMT 20461677
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vomiting without medical supervision. If vomiting occurs spontaneously

keep airway clear. If symptoms of ingestion persist, seek medical
attention.
NOTE TO PHYSICIAN:
___________________________________________________________________________
___________________ SECTION 5 - FIRE FIGHTING MEASURES __________________
FIRE AND EXPLOSIVE PROPERTIES:

Flashpoint . . . . . . . . . . . . . : 445.0 ŒF COC
Flammability Limits . . . . . . . . . : LEL -N/A
UEL -N/A
EXTINGUISHING MEDIA:
In accordance with NFPA guidance, dry chemical, foam, or CO2 fire
extinguishers are all acceptable. Note that while water fog extinguishers
are also acceptable, do NOT apply a direct stream of water onto burning
product because it may cause spreading and increase fire intensity.
UNUSUAL FIRE & EXPLOSION HAZARDS:
FIRE-FIGHTING PROCEDURES AND EQUIPMENT:
Emergency responders in the danger area should wear bunker gear and self-
contained breathing apparatus for fires beyond the incipient stage. See
Section 8 of the MSDS for other PPE to be worn as conditions warrant.
___________________________________________________________________________
________________ SECTION 6 - ACCIDENTAL RELEASE MEASURES ________________
CLEAN-UP MEASURES:
Important: As with any spill or leak, before responding ensure that you
are familiar with the potential hazards and recommendations of the MSDS.
Appropriate personal protective equipment must be worn. See Section 8
of this MSDS for PPE recommendations.
If possible, safely contain the spill with dikes or other spill response
equipment appropriate for petroleum or organic material releases. Take
measures to prevent spreading of product. Note that while product will
ignite it will not readily burn. However, as a precaution eliminate
ignition sources. Prevent from entering sewers or waterways. Large
volumes may be transferred to an appropriate container for proper
disposal. Small volumes or residues may be soaked up with absorbents.
Spill response materials should be collected for proper disposal.
___________________________________________________________________________
____________________ SECTION 7 - HANDLING AND STORAGE ___________________
HANDLING:
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As with any industrial chemical, handle the product in a manner that

minimizes exposure to practicable levels. Prior to handling, consult
Section 8 of this MSDS to evaluate personal protective equipment needs.
Open containers slowly to relieve any pressure. Follow all other
standard industrial hygiene practices.
Empty containers may contain product residue. All safety precautions

taken when handling this product should also be taken when handling empty
drums and containers. Keep containers closed when not in use.
Product residue in empty containers is combustible but will not readily

burn. NOTE however, that excessive heating or cutting of empty containers
may create an ignition source sufficient to start a fire and in extreme
cases, cause an explosion.
STORAGE:
Protect product quality by storing indoors and away from extreme
temperatures. Close all containers when not in use.
SPECIAL COMMENTS:
___________________________________________________________________________
___________ SECTION 8 - EXPOSURE CONTROLS, PERSONAL PROTECTION __________
PERSONAL PROTECTIVE EQUIPMENT:
Selection of personal protective equipment should be based upon the
anticipated exposure and made in accordance with OSHA's Personal
Protective Equipment Standard found in 29 CFR 1910 Subpart I. The
following information may be used to assist in PPE selection.
- EYE PROTECTION -
Wear eye protection appropriate to prevent eye exposure. Where
splashing is not likely, chemical safety glasses with side shields are
recommended. Where splashing may occur, chemical goggles or full face
shield is recommended.
- SKIN PROTECTION -
Gloves are not normally needed during normal conditions of use. If
health effects are experienced, oil or chemical resistent gloves such
as butyl or nitrile are recommended.
Where splashing or soaking is likely, wear oil or chemical resistent

clothing to prevent exposure.
- RESPIRATORY PROTECTION -
A respirator may be worn to reduce exposure to vapors, dust, or mist.
Select a NIOSH/MSHA approved respirator appropriate for the type and
physical character of the airborne material. A self-contained breathing
KMT 20461677
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apparatus is recommended in all situations where airborne contaminant

concentration has not been confirmed to be below safe levels.
Respirator use should comply with the OSHA Respirator Protection
Standard found in 29 CFR 1910.134.
ENGINEERING CONTROLS:
Normal general ventilation is expected to be adequate. It is recommended
that ventilation be designed in all instances to maintain airborne
concentrations at lowest practicable levels. Ventilation should at a
minimum, prevent airborne concentrations from exceeding any exposure
limits listed in Section 2 of this MSDS.
The user may wish to refer to 29 CFR 1910.1000(d)(2) and the ACGIH
"Threshold Limit Values for Chemical Substances and Physical Agents
Biological Exposure Indicies" (Appendix C) for the determination of
exposure limits of mixtures. An industrial hygienist or similar
professional may be consulted to confirm that the calculated exposure
limits apply.
___________________________________________________________________________
______________ SECTION 9 - PHYSICAL AND CHEMICAL PROPERTIES _____________
Physical Appearance . . . . . . . . . : Water white

Odor . . . . . . . . . . . . . . . . : Mild petroleum
Physical State . . . . . . . . . . . : Liquid
Water Solubility . . . . . . . . . . : Insoluble
Specific Gravity . . . . . . . . . . : .868
___________________________________________________________________________
_________________ SECTION 10 - STABILITY AND REACTIVITY _________________
INCOMPATIBILITIES:
This product is incompatible with strong oxidizing agents.
DECOMPOSITION PRODUCTS MAY INCLUDE:
Thermal decomposition products are dependent on combustion conditions.
A complex mixture of airborne solid, liquid, particulates and gasses may
evolve when the material burns. Combustion byproducts may include:
oxides of carbon,
incompletely burned hydrocarbons as fumes and smoke.
CONDITIONS TO AVOID:
Avoid contact with incompatible materials and exposure to extreme
temperatures.
POLYMERIZATION:
This product is not expected to polymerize.
STABILITY:
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This product is stable.

___________________________________________________________________________
_________________ SECTION 11 - TOXICOLOGICAL INFORMATION ________________
EYE EFFECTS:
No further toxicological data known.
SKIN EFFECTS:
ORAL EFFECTS:
INHALATION EFFECTS:
OTHER:
___________________________________________________________________________
__________________ SECTION 12 - ECOLOGICAL INFORMATION __________________
ECOTOXICOLOGICAL INFORMATION:
This product has not been evaluated for ecotoxicity. As with any
industrial chemical, exposure to the environment should be prevented and
minimized wherever possible.
ENVIRONMENTAL FATE:
The degree of biodegradability and persistence of this product has not
been determined.
___________________________________________________________________________
__________________ SECTION 13 - DISPOSAL CONSIDERATIONS _________________
WASTE DISPOSAL:
Ensure that collection, transport, treatment, and disposal of waste
product, containers and rinsate complies with all applicable laws and
regulations. Note that use, mixture, processing, or contamination of the
product may cause the material to be classified as a hazardous waste.
It is the responsibility of the product user or owner to determine at the
time of disposal, whether the product is regulated as a hazardous waste.
___________________________________________________________________________
___________________ SECTION 14 - TRANSPORT INFORMATION __________________
DOT HAZARDOUS MATERIAL INFORMATION:

* Not otherwise DOT regulated.
___________________________________________________________________________
__________________ SECTION 15 - REGULATORY INFORMATION __________________
FEDERAL REGULATIONS:
KMT 20461677
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SARA 313:
This product contains NONE of the substances subject to the reporting
requirements of Section 313 of Title III of the Superfund Amendments
and Reauthorization Act of 1986 and 40 CFR Part 372.
Clean Water Act / Oil Pollution Act:

This product contains mineral oil and is subject to regulation by
Section 311 of the Clean Water Act and the Oil Pollution Act. Releases
of the product into or leading to surface waters must be reported to
the National Response Center at 1-800-424-8802.
CERCLA Reportable Quantity:
Any components listed below have been assigned a reportable quantity
(RQ) by the Federal EPA. Releases of the product into the environment
that exceed the RQ for a particular component must be reported to the
National Response Center at 1-800-424-8802.
___Component____________________________RQ____________
* - * - * - * - * - * - * - * - * - * - * - * - * - *
Toxic Substances Control Act:
The components of this product are listed on the TSCA Inventory.
Ozone Depleting Substances:
This product contains no ozone depleting substances as defined by the
Clean Air Act.
Hazardous Air Pollutants:
Any components listed below are defined by the Federal EPA as hazardous
air pollutants.
___Component______________________________________
* - * - * - * - * - * - * - * - * - * - * - * - * - *
STATE REGULATIONS:
This product contains mineral oil, and as used, may be regulated by state
used oil regulations. Check with the appropriate state agency to
determine whether such a regulation exists.
___________________________________________________________________________
_____________________ SECTION 16 - OTHER INFORMATION ____________________
Prepared by . . . . . . . . . . . . . : Corporate Regulatory Compliance
Date of issue . . . . . . . . . . . . : 07/26/2007
Last Revision Date . . . . . . . . . : 11/01/2006
C4302368
___________________________________________________________________________
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NOTICE: This MSDS provides a good faith representation of information

believed to be accurate as of the last revision date. This document does
not create any express or implied product warranties. Since conditions of
use are beyond the control of Fuchs Lubricants Co., all risks associated
with product use are assumed by the user.
___________________________________________________________________________
KMT 20461677
Product name: 242 Threadlocker Item No. : 24231

Product type: Anaerobic Sealant Region: United States
Henkel Corporation Telephone: 860.571.5100
1001 Trout Brook Crossing Emergency telephone: 860.571.5100
Rocky Hill, Connecticut 06067 Internet: www.loctite.com

Polyglycol dimethacrylate 60-100 None None None
25852-47-5
Polyglycol oleate 10-30 None None None

9004-96-0
Saccharin 1-5 None None None

81-07-2
Silica, amorphous, fumed, 1-5 6 mg/m3 TWA 10 mg/m3 TWA 3 mg/m3 TWA respirable dust
crystalline-free
112945-52-5
Cumene hydroperoxide 1-5 None None 1 ppm (6 mg/m3) Skin (WEEL),

80-15-9 1ppm, skin TWA, (WEEL)
Propylene glycol 1-5 None None 10 mg/m³ TWA, (WEEL)

57-55-6
EMERGENCY OVERVIEW
HMIS:
Physical state: Liquid HEALTH: 2*
Color: Blue FLAMMABILITY: 1
Odor: Mild PHYSICAL HAZARD: 1
Personal Protection: See Section 8
WARNING: CAUSES EYE IRRITATION.

MAY CAUSE SKIN IRRITATION.
MAY CAUSE ALLERGIC SKIN REACTION.
Relevant routes of exposure: Skin, Inhalation, Eyes
Inhalation: May cause respiratory tract irritation.

Skin contact: May cause allergic skin reaction. May cause skin irritation.
Eye contact: Contact with eyes will cause irritation.
Ingestion: Not expected to be harmful by ingestion.
Item No. : 24231 Product name: 242 Threadlocker
1 of 5
KMT 72102733
exposure:
Inhalation: Remove to fresh air. If symptoms develop and persist, get medical attention.
Skin contact: Wash with soap and water. Remove contaminated clothing and shoes. Wash clothing before reuse.
Get medical attention if symptoms occur.
eyelids open all the time. Get medical attention.
Ingestion: Do not induce vomiting. Keep individual calm. Obtain medical attention.
Flash point: Greater than 93ºC (200ºF) Tagliabue closed cup
Autoignition temperature: Not available
Flammable/Explosive limits-lower %: 2.6 % (propylene glycol)
Flammable/Explosive limits-upper %: 12.5 % (propylene glycol)
Special fire fighting procedures: None
Unusual fire or explosion hazards: None
Hazardous combustion products: Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors.
Clean-up methods: Soak up with inert absorbent. Store in a partly filled, closed container until disposal.
handling.
Storage: For safe storage, store at or below 38°C (100°F). Keep in a cool, well ventilated area away from heat,
sparks and open flame. Keep container tightly closed until ready for use.
For information on product shelf life contact Henkel Customer Service at (800) 243-4874.
Engineering controls: No specific ventilation requirements noted, but forced ventilation may still be required if concentrations
exceed occupational exposure limts.
2 of 5
KMT 72102733
Skin protection: Use impermeable gloves and protective clothing as necessary to prevent skin contact. Neoprene
gloves. Butyl rubber gloves. Natural rubber gloves.

Color: Blue
Odor: Mild
Vapor pressure: Less than 5 mm Hg at 27ºC (80ºF)
pH: Not applicable
Boiling point/range: Greater than 149ºC (300ºF)
Specific gravity: 1.1 at 23.9ºC (75ºF)
Vapor density: Not available
Evaporation rate: Not available
Solubility in water: Slight
VOC content: 4.48%; 49.3 grams/liter (EPA Method 24)
Stability: Stable.
Hazardous decomposition products: Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors.
Incompatability: Strong oxidizers. Free radical initiators. Strong reducing agents. Alkalis. Oxygen scavengers. Other
polymerization initiators. Copper. Iron. Zinc. Aluminum. Rust.
Product toxicity data: Acute oral LD50 greater than 10, 000 mg/kg (rat). Acute dermal LD50 greater than 5000 mg/kg (rabbit).
Carcinogen Status
Hazardous components NTP Carcinogen IARC Carcinogen OSHA Carcinogen

Polyglycol dimethacrylate No No No
25852-47-5
Polyglycol oleate No No No
9004-96-0
Saccharin No No No
81-07-2
Silica, amorphous, fumed, No No No
crystalline-free
112945-52-5
Cumene hydroperoxide No No No
80-15-9
Propylene glycol No No No
57-55-6

3 of 5
KMT 72102733
Polyglycol dimethacrylate Allergen, Irritant
25852-47-5
Polyglycol oleate Irritant
9004-96-0
Saccharin No Target Organs
81-07-2
Silica, amorphous, fumed, Nuisance dust
crystalline-free
112945-52-5
Cumene hydroperoxide Allergen, Central nervous system, Corrosive, Irritant, Mutagen
80-15-9
Propylene glycol Irritant
57-55-6
Recommended method of disposal: Dispose of according to Federal, State and local governmental regulations.
EPA hazardous waste number: Not a RCRA hazardous waste.
U.S. Department of Transportation Ground (49 CFR):

Packing group: None

Packing group: None
Packing group: None

4 of 5
KMT 72102733
TSCA 12 (b) Export Notification: 4-Methoxyphenol (150-76-5).
CERCLA/SARA Section 302 EHS: None above reporting de minimus.

CERCLA/SARA Section 311/312: Immediate Health Hazard, Delayed Health Hazard
CERCLA/SARA 313: This product contains the following toxic chemicals subject to the reporting requirements of section 313
of the Emergency Planning and Community Right-To-Know Act of 1986 (40 CFR 372). Cumene
hydroperoxide (CAS# 80-15-9) .
California Proposition 65: This product contains a chemical known to the State of California to cause cancer and birth defects or
other reproductive harm.
WHMIS hazard class: D.2.B
This material safety data sheet contains changes from the previous version in sections: 15
Prepared by: Kyra Kozak Woods, Product Safety and Regulatory Affairs Specialist

5 of 5
KMT 72102733
Product name: Loctite(R) 7649 Primer N Item number: 19269

Product type: Accelerator Region: United States
Henkel Corporation Telephone: 860.571.5100
1001 Trout Brook Crossing Emergency telephone: 860.571.5100
Rocky Hill, Connecticut 06067 Internet: www.loctite.com

Acetone 60-100 500 ppm TWA 1000 ppm TWA None
67-64-1 750 ppm STEL 2400 mg/m³ TWA
2-Ethylhexanoic acid 0.1-1 5 mg/m³ TWA None None

149-57-5
EMERGENCY OVERVIEW
HMIS:
Physical state: Liquid HEALTH: 2*
Color: Green FLAMMABILITY: 3
Odor: Acetone PHYSICAL HAZARD: 0
Personal Protection: See Section 8
DANGER: FLAMMABLE LIQUID AND VAPOR.

CAUSES EYE AND SKIN IRRITATION.
Relevant routes of exposure: Inhalation, Skin contact, Eye contact, Ingestion
Inhalation: Harmful if inhaled. Vapors and mists will irritate nose and throat and possibly eyes. May cause
respiratory tract irritation. Headache, dizziness, nausea, and loss of coordination are indications of
excessive exposure to vapors or spray mists.
Skin contact: May cause skin irritation. Solvent action can dry and defat the skin, causing the skin to crack, leading
to dermatitis.
Eye contact: Vapors may irritate eyes. Contact with eyes will cause irritation.
Ingestion: Harmful if swallowed.

exposure:
Item number: 19269 Product name: Loctite(R) 7649 Primer N

1 of 4
KMT 72102741
Inhalation: Remove to fresh air. If discomfort persists seek medical attention.
Skin contact: Wash with soap and water.
eyelids open all the time.
Ingestion: If conscious, drink plenty of water. Do not induce vomiting. Keep individual calm. Obtain medical
attention.
Flash point: -20°C (-4°F) (estimated)
Autoignition temperature: 465°C (869°F)
Flammable/Explosive limits-lower %: 2.6 %
Flammable/Explosive limits-upper %: 13 %
Special fire fighting procedures: None
Unusual fire or explosion hazards: Vapors may accumulate in low or confined areas, travel considerable distance to source of ignition,
and flash back.
Hazardous combustion products: Oxides of carbon. Oxides of nitrogen. Irritating organic vapors.
Clean-up methods: Remove all ignition sources. Ensure adequate ventilation. Soak up with inert absorbent. Store in a
closed container until ready for disposal.
handling. During use and until all vapors are gone: Keep area ventilated - do not smoke; extinguish all
flames, pilot lights, and heaters; turn off stoves, electrical tools and appliances, and any other sources
of ignition.
Storage: Store away from heat, sparks, flames, or other sources of ignition. For safe storage, store at or below
49°C (120°F).
For information on product shelf life contact Henkel Customer Service at (800) 243-4874.
Engineering controls: Use local ventilation if general ventilation is insufficient to maintain vapor concentration below
established exposure limits.

2 of 4
KMT 72102741
Skin protection: Chemical resistant, impermeable gloves.

Color: Green
Odor: Acetone
Vapor pressure: 172 mmHg at 20 ºC (68 °F)
pH: Not applicable
Boiling point/range: 56°C (133°F)
Specific gravity: 0.7936
Vapor density: 2.0
Evaporation rate: 1.9 (Ether = 1)
Solubility in water: Completely miscible
VOC content: 1.48%; 11.7 grams/liter (EPA Method 24)
Stability: Stable.
Hazardous decomposition products: Oxides of carbon. Oxides of nitrogen. Irritating organic vapors.
Incompatability: Strong oxidizers.
Carcinogen Status
Hazardous components NTP Carcinogen IARC Carcinogen OSHA Carcinogen

Acetone No No No
2-Ethylhexanoic acid No No No

Acetone Blood, Central nervous system, Irritant, Reproductive
2-Ethylhexanoic acid Developmental, Eyes, Irritant, Liver, Reproductive
Recommended method of disposal: Dispose of according to Federal, State and local governmental regulations.
EPA hazardous waste number: D001: Ignitable.

3 of 4
KMT 72102741
U.S. Department of Transportation Ground (49 CFR):

Proper shipping name: Acetone
Hazard class or division: 3
Identification number: UN 1090
Packing group: II
Exceptions: Consumer Commodity ORM-D (Not more than 1 Liter)

Packing group: II
Exceptions: Consumer Commodity ID8000 (Not more than 500 ml)
Packing group: II
Exceptions: Dangerous goods in limited quantities of class 3 (Not more than 1 liter(s))
TSCA 12 (b) Export Notification: Acetone (CAS# 67-64-1).
CERCLA/SARA Section 302 EHS: None.

CERCLA/SARA Section 311/312: Immediate Health Hazard, Delayed Health Hazard, Fire
CERCLA/SARA 313: None above reporting de minimus.
California Proposition 65: This product contains a chemical known to the State of California to cause cancer and birth defects or
other reproductive harm. Nickel (CAS# 7440-02-0). Cobalt (CAS# 7440-48-4). Formaldehyde (CAS#
50-00-0). Acetaldehyde (CAS# 75-07-0). Benzene (CAS# 71-43-2).
WHMIS hazard class: B.2, D.2.A, D.2.B
This material safety data sheet contains changes from the previous version in sections: Expanded chemical information in Section 2 and
related sections.
Prepared by: Kyra Kozak Woods, Health and Regulatory Affairs Specialist

4 of 4
KMT 72102741
QUICK TAP
SECTION 1: IDENTIFICATION
Company Name: QUALICHEM, INC.
Address: P.O. BOX 926
SALEM, VA 24153
Phone No. (540) 375-6700
Fax No. (540) 375-3880
Emergency Phone No. CHEM-TEL 800-255-3924
Date Prepared: 9/14/10
Date Revised: 3/28/12
SECTION 2: INGREDIENTS
MATERIAL CAS NO. %
ALKANES, CHLORO 61788-76-9 5-10
SECTION 3: HEALTH HAZARDS

Ingestion: MAY CAUSE IRRITATION OF THE DIGESTIVE SYSTEM.
Inhalation: NOT A LIKELY ROUTE OF EXPOSURE. MAY CAUSE IRRITATION.
Skin Contact: MAY CAUSE IRRITATION.
Eye Contact: MAY CAUSE IRRITATION.
Other Information: NONE KNOWN.
SECTION 4: FIRST AID

Ingestion: DRINK SEVERAL GLASSES OF WATER TO DILUTE. DO NOT INDUCE VOMITING.
NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON. GET
MEDICAL ATTENTION.
Inhalation: REMOVE VICTIM TO FRESH AIR. GET MEDICAL ATTENTION IF SYMPTOMS
PERSIST.
Skin Contact: WASH WITH PLAIN WATER OR SOAP AND WATER.
Eye Contact: IMMEDIATELY FLUSH WITH CLEAR WATER FOR 15 MINUTES AND GET MEDICAL
ATTENTION IF IRRITATION PERSISTS.
Notes to Physician: NONE KNOWN. TREAT SYMPTOMS WITH SUPPORTIVE MEASURES.
SECTION 5: FIRE AND EXPLOSION HAZARD DATA

Flash Point/Method: >200°C/ C.C.
Lower Limit in Air: ND
Upper Limit in Air: ND
Extinguishing Media: FOAM, DRY CHEMICAL, CO2, WATER SPRAY OR FOG.
Procedures: SELF-CONTAINED BREATHING APPARATUS SHOULD BE USED IN CONFINED
AREAS. COOL EXPOSED CONTAINERS WITH WATER. AVOID BREATHING
SMOKE, VAPOR OR FUMES.
Unusual Hazards: NONE
Combustion Products: OXIDES OF CARBON AND SULFUR MAY BE PRODUCED
SECTION 6: ACCIDENTAL RELEASE MEASURES

Personal Precautions: WEAR PERSONAL PROTECTIVE EQUIPMENT AS SPECIFIED IN SECTION 8.
SPILLED MATERIAL CAN BE VERY SLIPPERY.
Procedures for Clean-up: SMALL SPILLS - ABSORB IN SAWDUST OR ANY AVAILABLE ABSORBANT, PLACE
RESIDUE IN SUITABLE CONTAINER FOR DISPOSAL. LARGE SPILLS - DIKE OR
OTHERWISE CONTAIN LIQUID. ABSORB IN SAWDUST OR ANY AVAILABLE
ABSORBANT, PLACE RESIDUE IN A SEALED, LIQUID-PROOF CONTAINER FOR
DISPOSAL. CLEAN CONTAMINATED SURFACES WITH WATER OR AQUEOUS
CLEANING AGENTS. OBEY ALL FEDERAL, STATE OR LOCAL REGULATIONS.
Prohibited Materials: NONE
DATE PRINTED: September 24, 2013 PAGE No. 1

QUICK TAP
SECTION 7: HANDLING AND STORAGE
Handling: AVOID EYE AND SKIN CONTACT. DO NOT TAKE INTERNALLY. USE WITH
ADEQUATE VENTILATION.
Storage: KEEP OUT OF REACH OF CHILDREN. STORE IN A COOL, DRY PLACE. KEEP
CONTAINERS TIGHTLY CLOSED WHEN NOT IN USE.
SECTION 8: EXPOSURE CONTROLS/PERSONAL PROTECTION

Precautionary Measures: STANDARD INDUSTRIAL HANDLING PRECAUTIONS. WASH THOROUGHLY
AFTER HANDLING CHEMICALS.
Engineering Controls: USE WITH ADEQUATE VENTILATION.
Control Limits: NONE.
Equipment for Personal
Protection: WEAR CHEMICAL SAFETY GLASSES OR GOGGLES, PROTECTIVE GLOVES, AND
STANDARD PROTECTIVE CLOTHING WHEN HANDLING THE CONCENTRATE.
EYEWASH STATION IN AREA OF USE.
SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES

Appearance: CLEAR, LIGHT AMBER LIQUID.
Odor: MILD FATTY
pH (5% in DI water)): NA
Specific Gravity: 0.90-0.92
Density: 7.59 lbs./gal.
Solubility in Water: INSOLUBLE
O
Boiling Point: >600 F
Percent Volatile: 0
Vapor Pressure (mmHg): N.D.
Vapor Density: N.D. BUT HEAVIER THAN AIR
Evaporation Rate: (water=1): <1
SECTION 10: STABILITY AND REACTIVITY

Stability: STABLE
Conditions to Avoid: NONE
Hazardous Polymerization: STABLE
Incompatibility: STRONG OXIDIZING AGENTS, ACIDS OR ALKALIES.
Hazardous Decomposition
Products: OXIDES OF CARBON AND SULFUR WILL BE PRODUCED BY COMBUSTION.
SECTION 11: TOXICOLOGICAL INFORMATION

Materials and Tests: NO TOXICITY STUDIES HAVE BEEN CONDUCTED ON THIS PRODUCT.
Carcinogenicity: NO COMPONENT OF THIS PRODUCT IS LISTED AS A CARCINOGEN BY IARC,
NTP, OR ACGIH.
Sensitization: NOT A SENSITIZER.
Mutagenicity: NO COMPONENT OF THIS PRODUCT IS CLASSIFIED AS A MUTAGEN.
Teratogenicity: NO COMPONENT OF THIS PRODUCT IS CLASSIFIED AS A TERATOGEN
SECTION 12: ECOLOGICAL INFORMATION

Ecotoxicity: NO TOXICITY TESTING HAS BEEN PERFORMED ON THIS PRODUCT.
SECTION 13: DISPOSAL CONSIDERATIONS

General Considerations: THIS PRODUCT WOULD NOT BE CONSIDERED AS A HAZARDOUS WASTE.
Procedures: DISPOSAL BY USE PREFERRED. DISPOSE OF THIS PRODUCT FOLLOWING ALL
FEDERAL, STATE, OR LOCAL REGULATIONS.

QUICK TAP
SECTION 14: TRANSPORT INFORMATION
Shipping Name: NOT REGULATED.
SECTION 15: REGULATORY INFORMATION
Regulation Material RQ Max. %
CERCLA (40 CFR302.4): NONE
SARA 302 (Sect. 355, Material TPQ Max. %

Appendix A): NONE
SARA 311/312: Categories Hazards

NONE
SARA 313 (40 CFR Material Max. %

372.45): NONE
CWA (40 CFR 401.15): NONE
RCRA (40 CFR 261): NONE

Notes: THIS PRODUCT NOT A HAZARDOUS WASTE PER RCRA REGULATIONS.
OSHA (29 CFR 1910.1200): ALL COMPONENTS LISTED UNDER THIS STANDARD ARE SHOWN IN SECTION 2
OF THIS MSDS.
WHMIS (Canada): CLASS D-2B: MATERIAL CAUSING OTHER TOXIC EFFECTS (TOXIC).
THIS PRODUCT HAS BEEN CLASSIFIED IN ACCORDANCE WITH THE HAZARD
CRITERIA OF THE CONTROLLED PRODUCTS REGULATIONS AND THE MSDS
CONTAINS ALL THE INFORMATION REQUIRED BY THE CONTROLLED
PRODUCTS REGULATIONS.
Inventories: ALL INGREDIENTS IN THIS PRODUCT ARE LISTED IN TSCA AND DSL (CANADA)
INVENTORIES.
SPECIAL STATE REGULATIONS
STATE INGREDIENT % REGULATORY DESIGNATION
NONE
SECTION 16 OTHER INFORMATION
SUGGESTED HAZARD RATINGS

NFPA*
HAZARD HMIS*
1
HEALTH (Blue) 1
1
FIRE (Red) 1
0
REACTIVITY (Yellow) 0
PERSONAL PROTECTION B
SPECIAL HAZARDS
*Notes: 0 = Insignificant; 1 = Slight; 2 = Moderate; 3 = High; 4 = Extreme
The data contained in this Material Safety Data Sheet has been prepared based upon an evaluation of the ingredients in the
product, their concentration in the product and potential interactions. The information is offered in good faith and is believed to be
accurate. It is furnished to the customer who is urged to study it carefully to become aware of hazards, if any, in the storage,
handling, use and disposal of the product; and to ensure his employees are properly informed and advised of all safety
precautions required. The information is furnished for compliance with the "Occupational Safety and Health Act" of 1970, the
"Hazards Communication Act" of 1983 as well as various other Federal, State and Local regulations. Use or dissemination of all
or part of this information for any other purpose is prohibited by law.
Revision 1.4

!!
!
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STREAMLINE SL-VI 50

OPERATION AND MAINTENANCE MANUAL

KMT WATERJET SYSTEMS 2015

KMT Waterjet Systems

Phone: (800) 826-9274

The Introduction highlights:

1.2 Features and Options

1.3 Product Nameplate

1.4 Operational Overview

Low Pressure Water System

High Pressure Water System

1.5 Misuse of Equipment

§ All protective guards, shields or covers shall be in place on the

§ Safety glasses and ear protection shall be worn when operating or

1 The electrical enclosure and motor junction box can

2 Never open or perform maintenance on the unit with the

3 The surface of high pressure water and hydraulic

4 Ensure that all protective guards, shields or covers are

5 High pressure water and/or hydraulic pressure can

6 All personnel involved in the installation, operation

7 The weight of the machine is not evenly distributed

Warnings emphasize operating or service procedures, or conditions that can result

Cautions emphasize operating or service procedures, or conditions that can result in

Notes provide additional information that can expedite or improve operating or

Emergency Medical Treatment

This person has been working with water jetting

1.7 Worldwide Product Support

USA Customer Service Department Europe Technical Manager

1.8 Spare Parts

1.9 Manual Organization

The Installation section details:

2.2 Installation Summary

§ The machine must be commissioned and tested.

2.3 Site Requirements

Redundant Models (same dimensions as above)

2.4 Power Requirements

2.5 Service Connections

Cooling Water (Oil-to-Water Models)

Contaminated Waste Drain

2.6 Flow Requirements

Figure 2-4: Pressure Drop Values

2.7 High Pressure Piping

Measurements and Dimensions

Figure 2-6: Cone and Thread Dimensions

2.8 High Pressure Connections

1. Deburr the tubing ID and thoroughly clean

1. Deburr the tubing ID and thoroughly clean

5. Tighten the gland nut to the torque specifications in Table 2-10.

Loosen the locking nut on the high pressure

If the machine is equipped with proportional pressure control, the pressure is

Locate the adjustment screw in the acorn nut on the side of

The Maintenance section highlights:

To avoid unsafe conditions and the risk of equipment damage,

High Pressure System Maintenance

3.3 Maintenance Precautions

Before performing any maintenance on the equipment, take the system

§ Never service or maintain the equipment while it is operating.

3.4 Tools Kits

20454198 Hand Coning and Threading Tools