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SL-IV PLUS Series
KMT SL-IV PLUS Series User Manual
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SECTION 7
HIGH PRESSURE WATER
May 2003
p. 7-9
49831951
Table 7.2 HP INTENSIFIER SERVICE TE
ARDOWN SEQUENCE
Disassemble/Re-assemble
Intensifier
Component
Maintenance
Related
Compone
nt
Assembly
HP Piping
LP Water
Plumbing
HP Cylinder
Sealing Head,
Flanges &
Studs [1]
Stud Nuts &
End Flange
Retainer
Flanges &
Hydraulic
Cartridge
Hydraulic
Cylinder
Head
Ref Part No.
Æ
--
7.2.1
7.2.1 7.2.2
7.2.3 7.2.5
7.2.6
1 Outlet
HP
Check Valve
Sealing
Head
Yes
No No
No No No
2 Inlet
HP
Check Valve
Sealing
Head
Yes
Yes No
Yes No
No
3 HP
Plunger
Seal
HP
Cylinder
Yes Yes
Yes
No
No
No
4 Hydraulic
Seal
Cartridge-
Plunger
Hydraulic
Cylinder
Head
Yes Yes
Yes
No
Yes
No
5 Sealing
Head
Cone Seal
Sealing
Head
Yes
Yes No
Yes No
No
6
HP
Cylinder
--
Yes
Yes No
Yes No
No
7
Plunger --
Yes
Yes
Yes
No
Yes
No
8 Hydraulic
Piston
-- Yes
Yes
Yes
No
No
Yes
Note [1]:Remove/installed as a unit (HP Cylinder “Jug”)
71
73
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 Introduction
6
Standard Equipment
7
Functional Description
8
Functional Features
8
Questionnaire
9
Service Department
9
Spare Parts
9
Worldwide Product Support
9
Labels and Abbreviations
12
Safety
12
Safety Procedures
14
High Pressure (HP) Piping Safety
16
Emergency Medical Treatment
17
1 SL-IV Waterjet Pump General Information
6
Physical Description
6
Section 2 Installation
18
2 Installation
18
Installation Overview
18
Buyer Obligations
18
Seller Obligations
18
Installation Requirements (Utilities)
19
Equipment Location/Environment
19
Service Connections
20
High Pressure Plumbing Installation
22
Section 3 Operation
28
3 Operation
28
Main Menu
31
Run Screen 2
34
Run Screen 3 Redundant
34
Hours
35
Alarm History Screen
36
Pressure Control Screen
37
Stroke Rate Screen
38
Set up Screen
39
Maintenance Screen
40
Alarm Screen
41
Language
43
(Example)
44
Section 4 Maintenance
45
Scheduled Maintenance
47
General Maintenance
48
5 Troubleshooting
50
Troubleshooting - Electrical
50
Pump will Not Start
50
Console Display and Lights Fail to Illuminate
50
Pump Quit Running
50
No Control Power (24Vdc)
51
Red Light, Message on Operator's Console
51
Troubleshooting - Hp Water
52
Hp Water Signal Abnormal Fluctuation
52
Hot Surfaces on Hp Cylinder Components
52
Oil or Water Leaks from HP Cylinder Weep Holes
52
Hp Check Valve Leak
53
Normal Temperature, but Check Valve Problem
53
Hp Cutting Water too Low
53
Troubleshooting - Lp Water
53
Low Booster Pump Pressure
53
Troubleshooting - Hydraulic
54
Hot Hydraulic Oil
54
Hydraulic Pressure but no High Pressure Water Pressure
54
Special Procedure-Hp Water Check Valve
55
Hp Check Valve Troubleshooting
55
Section 6 Low Pressure Water System
56
6 Low Pressure Water System
56
Oil Cooling Water Supply
56
Cutting Water Supply
56
Normal Operating Condition
57
Operation
57
Low Pressure System Protection
61
Maintenance Overview
62
Water Filter Service
62
Boost Pump
63
7 High Pressure (HP) Water
64
Components
64
Intensifier Disassembly and Reassembly
65
HP & LP Water Piping
66
HP Cylinder "Jug
67
Stud Nuts and End Flange, Sealing Head
68
HP Plunger Seal Service-- Disassembly / Re-Assembly
70
Plunger and Hydraulic Cartridge Removal and Installation
73
Discharge HP Check Valve
77
Intensifier Subassemblies Inspection & Repair
77
Inlet Check Valve
80
Sealing Head
82
HP Cylinder
83
Plunger
84
Hydraulic Seal Cartridge
85
Hydraulic Piston
87
Hydraulic Cylinder
91
HP Dump Valve
92
HP Attenuators
92
Section 8 Electrical System
94
8 Electrical System
94
Electrical Overview
94
Motor Starter Circuit
96
Control Circuits and Logic
97
Operation
99
Control Power Circuits
102
Optional) Proportional Pressure Control
102
Optional) Modem
102
Maintenance Overview
103
Proximity Switch Service
103
Optical Relay Switch Service
104
Section 9 Hydraulic System
105
9 Features
105
Components
105
Operation
106
Hydraulic Pressure Adjustment
107
Hydraulic System Pressure Protection
108
Motor/Hydraulic Service Maintenance
108
Motor Service
109
Manifold Service
109
Section 10 Recirculation System
111
10 Recirculation System
111
Components
111
Operation
111
System Pressure Protection
112
Maintenance Overview
113
11 Specifications
117
Equipment Specifications
117
Torque Specifications
119
Cutting Water Specifications
120
Cooling Water Specifications
120
Orifice Support Capacity
121
Section 12 Parts Lists
123
4
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KMT SL-IV PLUS Series Specifications
General
Brand
KMT
Model
SL-IV PLUS Series
Category
Water Pump
Language
English
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