KMT STREAMLINE S50 User Manual

MANUAL 20479050(R04)
STREAMLINE S50
WATERJET INTENSIFIER
OPERATION AND MAINTENANCE MANUAL

KMT STREAMLINE S50 Specifications

General

Brand	KMT
Model	STREAMLINE S50
Category	Cutter
Language	English

Summary

SECTION 1 INTRODUCTION

1.1 Overview

General introduction to the Streamline S50 waterjet intensifier.

1.2 Performance Features

Highlights key performance features and design advantages of the S50.

1.3 Operational Overview

Overview of the function and components of the intensifier's systems.

1.4 Safety

General safety precautions and warnings for operating the waterjet cutting system.

Lockout/Tagout Procedure

Procedure for safely isolating energy sources before maintenance.

Warning Labels

Explains the purpose and importance of warning labels on the equipment.

Warnings, Cautions, and Notes

Defines the meaning of Warning, Caution, and Note symbols used in the manual.

Emergency Medical Treatment

Guidance on medical treatment for waterjet injuries, including contact information.

1.5 Worldwide Product Support

Information on how to contact KMT Waterjet for technical assistance and support.

1.6 Spare Parts

Information on ordering spare parts from KMT Waterjet.

1.7 Manual Organization

Explains how the manual is structured and the content of each section.

1.8 Equipment and Service Manual Questionnaire

A questionnaire for customer feedback on the installed system and manual.

Terms and Conditions of Sale

1. General

General terms and conditions of sale for KMT Waterjet Systems Inc.

2. Title and Risk of Loss

Outlines the transfer of title and risk of loss for the equipment.

3. Assignment

Terms regarding contract assignment.

4. Delivery and Delays

Specifies delivery terms and conditions, including liability for delays.

5. Taxes

Details the Purchaser's responsibility for taxes.

6. Set Offs

Prohibits compensation claims or set-offs.

7. Patents

Covers patent infringement and protection.

8. Warranty

Outlines the warranty terms and conditions for the equipment.

9. Limitation of Liability

Limits the Company's liability for damages.

10. Nuclear Liability

Addresses nuclear liability and insurance requirements.

11. Governing Law

Specifies the governing law for the contract.

12. Export Control

Outlines U.S. export control laws and customer compliance.

13. Execution

Details contract execution and approval requirements.

Terms and Conditions Part Sales

1. General

General terms and conditions for part sales.

2. Schedule Dates and Delays

Terms related to delivery schedules and delays for parts.

3. Taxes

Purchaser's responsibility for taxes on parts.

4. Warranty and Shipping

Warranty and shipping terms for spare parts.

5. Limitation of Liability

Limits liability for part sales.

6. Nuclear Liability

Nuclear liability for parts.

7. Export Control

Export control for parts.

Terms LD-146 Domestic Service Supervisor

Conditions for Service Supervisor

Outlines the conditions under which a Service Supervisor's services are furnished.

Terms LD-147 International Service Supervisor

Conditions for International Service Supervisor

Outlines the conditions for international service supervisor services.

SECTION 2 INSTALLATION

2.1 Overview

Introduces installation and commissioning procedures and safety.

2.2 Installation Summary

Summarizes the key steps and requirements for installation and commissioning.

2.3 Site Requirements

Specifies site requirements for installation, including environment and clearances.

Transporting

Provides guidance on safely transporting the machine.

2.4 Power Requirements

Details electrical power requirements and voltage/ampacity specifications.

2.5 Service Connections

Describes the required service connections for the intensifier system.

2.6 Flow Requirements

Explains how to calculate minimum source water pressure based on flow rates and pipe sizes.

2.7 High Pressure Piping

Covers requirements for installing high pressure piping, including ratings and materials.

Coning and Threading Tools

Lists tools and part numbers for coning and threading high pressure tubing.

Measurements and Dimensions

Details how to measure and prepare tubing for high pressure connections.

Cone and Thread Dimensions

Provides dimensions for coning and threading high pressure tubing.

Hand Coning

Step-by-step procedure for manually coning high pressure tubing.

Power Coning

Procedure for using power tools to cone high pressure tubing.

Hand Threading

Procedure for manually threading high pressure tubing.

Power Threading

Procedure for using power tools to thread high pressure tubing.

2.8 High Pressure Connections

Instructions for making high pressure connections, including material and lubrication.

Standard Connections

Details standard connection procedures for high pressure piping.

Anti-Vibration Connections

Explains the use and installation of anti-vibration fittings for high pressure tubing.

Torque Specifications

Lists torque specifications for high pressure connections.

2.9 Commissioning

Step-by-step procedure for initial startup and testing of the machine.

Commissioning Procedure

Step-by-step procedure for initial startup and testing of the machine.

2.10 Decommissioning

Procedure for taking the intensifier out of service, adhering to regulations.

SECTION 3 MAINTENANCE

3.1 Overview

Introduces maintenance concepts, fail-safe design, and fault detection.

3.2 Maintenance

Emphasizes the importance of routine and preventive maintenance.

Daily Inspection

Daily inspection procedures to ensure proper operation and identify issues.

Periodic Maintenance

Importance and considerations for performing periodic maintenance.

High Pressure System Maintenance

Details maintenance procedures for the high pressure system components.

Lubrication Specifications

Lists recommended lubricants and their applications for assembly.

3.3 Maintenance Precautions

Essential safety precautions to be followed before and during maintenance.

3.4 Tool Kit

Lists the components of a standard tool kit for SL-V series pumps.

SECTION 4 LOW PRESSURE WATER SYSTEM

4.1 Overview

Introduces the low pressure water system and its function.

4.2 Cutting Water Supply

Discusses the importance of cutting water quality for component life and performance.

4.3 Operation

Describes the operational flow of cutting water through the system.

4.4 Service and Maintenance Procedures

Outlines procedures for servicing filter elements, strainers, and booster pumps.

Filter Assembly and Strainer Maintenance

Step-by-step guide to replacing the filter element and cleaning the strainer.

Booster Pump Adjustment

Procedure for adjusting the booster pump discharge pressure.

SECTION 5 RECIRCULATION SYSTEM

5.1 Overview

Introduces the recirculation system for cooling and filtering hydraulic oil.

5.2 Operation (Oil-to-Water Models)

Explains the operation of the recirculation system for oil-to-water models.

5.3 Operation (Oil-to-Air Models)

Explains the operation of the recirculation system for oil-to-air models.

5.4 Service and Maintenance Procedures

Details procedures for servicing components of the recirculation system.

Hydraulic Oil Maintenance

Guidance on replacing hydraulic oil and maintaining the oil reservoir.

Electric Motor Bump

Procedure for "bumping" the electric motor to ensure proper pump operation.

Oil Filter Maintenance

Steps for replacing the oil filter element in the recirculation system.

Operating Temperature Adjustment (Oil-to-Water Models)

How to adjust the water modulating valve to control oil temperature.

SECTION 6 HYDRAULIC SYSTEM

6.1 Overview

Introduces the hydraulic system and its role in generating high pressure water.

6.2 Operation

Explains the operation of the hydraulic system, including pumps and valves.

6.3 Service and Maintenance Procedures

Emphasizes routine inspection and maintenance for the hydraulic system.

Hydraulic Operating Pressure

How to check and adjust hydraulic operating pressures using control valves.

Hydraulic Operating Pressure Limits

Specifies pressure limits for high and low pressure hydraulic operations.

Motor Maintenance

Recommendations for inspecting and maintaining the electric motor.

Hydraulic Compensator Maintenance

Procedure for disassembling, cleaning, and reassembling hydraulic compensators.

SECTION 7 ELECTRICAL SYSTEM

7.1 Overview

Introduces the major components of the electrical system.

7.2 Sensors and Solenoids

Describes the function of sensors and solenoids in monitoring and controlling the intensifier.

Shutdown Settings

Lists the specific settings for shutdown sensors.

Sensors and Solenoids

Details the components and functions of sensors and solenoids.

7.3 Service and Maintenance Procedures

General guidance for electrical component maintenance.

Proximity Switch Maintenance

Procedure for replacing a failed proximity switch on the hydraulic cylinder.

SECTION 8 HIGH PRESSURE WATER SYSTEM

8.1 Overview

Introduces the high pressure water system and its components.

8.2 Operation

Explains the operational cycle of the high pressure water system and its components.

8.3 System Components

Illustrates the individual components of the high pressure water system.

High Pressure Cylinder Assembly

Diagram showing the assembly of the high pressure cylinder.

Hydraulic Cylinder Assembly

Diagram illustrating the hydraulic cylinder assembly.

Hydraulic Piston

Diagram of the hydraulic piston assembly.

8.4 Service and Maintenance Overview

General overview and precautions for maintaining the high pressure water system.

Torque Specifications

Details torque specifications and tightening sequences for high pressure components.

Specialized Maintenance Tools

Lists and illustrates specialized tools for maintaining the high pressure water system.

8.5 High and Low Pressure Water Piping

Procedure for removing and installing high and low pressure water piping.

8.6 High Pressure Cylinder Assembly

Recommendations for removing and servicing the high pressure cylinder assembly.

High Pressure Cylinder Assembly Removal

Step-by-step instructions for removing the high pressure cylinder assembly.

High Pressure Cylinder Assembly Installation

Step-by-step instructions for installing the high pressure cylinder assembly.

High Pressure Cylinder Maintenance

Procedures for inspecting and cleaning the high pressure cylinder bore.

8.7 Hard Seal End Caps

Procedures for removing and installing hard seal end caps.

Hard Seal End Cap Installation

Step-by-step instructions for installing the hard seal end cap.

8.8 Sealing Head

Describes the sealing head and its function for ensuring low and high pressure water travel.

High Pressure Discharge Check Valve

Procedures for servicing the high pressure discharge check valve.

Low Pressure Inlet Check Valve

Procedures for servicing the low pressure inlet check valve.

Sealing Head Maintenance

Guidance on inspecting and refinishing sealing head surfaces.

8.9 High Pressure Seal Assembly

Procedure for replacing the high pressure seal assembly.

High Pressure Seal Removal

Step-by-step instructions for removing the high pressure seal assembly.

8.10 Hydraulic Cartridge Seal and Plunger Removal

Procedures for removing the hydraulic cartridge seal and plunger.

Plunger Maintenance

Guidance on inspecting and polishing plunger surfaces.

Plunger Installation

Steps for installing the plunger into the hydraulic cylinder head.

Hydraulic Cartridge Seal Installation

Instructions for installing new hydraulic cartridge seals.

8.11 Hydraulic Piston

Describes the components and function of the hydraulic piston.

Hydraulic Piston Removal

Step-by-step instructions for removing the hydraulic piston.

Bearing Rings and Seal Assembly

Procedures for removing and installing bearing rings and seal assemblies.

Plunger Button Sockets, Seals and Retainer Pins

Procedures for servicing plunger button components.

Internal Check Valves

Information on servicing internal check valves if a problem is suspected.

Hydraulic Piston Installation

Steps for installing the hydraulic piston into the cylinder bore.

8.12 Hydraulic Piston Maintenance

Inspection of the hydraulic cylinder bore for wear grooves.

8.13 High Pressure Attenuator

Information on the high pressure attenuator, stating it's not customer serviceable.

8.14 High Pressure Dump Valve

Recommended procedures for servicing the high pressure dump valve assembly.

Pneumatic Control Valve

Details on replacing valve seats and stem assemblies for reliable operation.

Valve Seal Installation

Step-by-step guide for installing valve seals and components.

Pneumatic Actuator

Procedure for servicing the pneumatic actuator.

8.15 Weep Holes

Table listing weep hole locations, indications of leaks, and corrective actions.

SECTION 9 TROUBLESHOOTING

9.1 Overview

Introduces the troubleshooting guide and lists common system malfunctions.

Troubleshooting Guide

A guide to identify malfunctions based on symptoms and their corresponding corrective actions.

S50 Troubleshooting Guide

A detailed table listing malfunctions, indications, and comments for troubleshooting.

SECTION 10 SPECIFICATIONS

10.1 Overview

Introduces the specifications section for the Streamline S50.

Motor Horsepower Rating

Lists motor horsepower ratings for the S50 model.

10.2 Installation Specifications

Details environmental requirements and dimensions for installation.

Environment

Specifies installation environment conditions like temperature and humidity.

Equipment Dimensions and Weights

Provides physical dimensions and weight of the equipment.

Service Connections

Lists required service connections, their types, and heights.

Plant Air

Specifies requirements for the facility compressed air connection.

ISO Air Quality Classifications

Classifies air quality standards for compressed air.

10.3 Water Specifications

Details specifications for the cutting water supply.

Cutting Water Supply (Low Pressure Water System)

Lists flow and pressure requirements for the cutting water supply.

Recirculation System

Specifies operating parameters and requirements for the recirculation system.

Water Quality Standards

Defines acceptable standards for inlet cutting water quality.

Water Impurities

Explains the effects of various water impurities on the system.

10.4 Electrical Specifications

Details electrical system specifications, including motor type and power requirements.

Ampacity and Power Voltage Requirements

Lists power voltage, horsepower, ampacity, and circuit breaker requirements.

10.5 Hydraulic and High Pressure Water System Specifications

Provides specifications for the hydraulic and high pressure water systems.

Pneumatic Control Valve

Specifies pressure and flow rates for the pneumatic control valve.

Orifice Capacity

Provides horsepower requirements for various orifice sizes.

Single Orifice Diameter

Shows single orifice diameter specifications based on pressure and frequency.

Horsepower Requirements

Lists horsepower requirements for different orifice sizes and pressures.

Torque Specifications

Details torque specifications for components, emphasizing proper application.

SECTION 11 PARTS LIST

11.1 Overview

Introduces the parts list section and how to contact Customer Service.

11.2 Index

An index of parts lists, arranged by table number and description.

Streamline S50 Intensifier Unit

Lists standard and optional parts for the S50 intensifier unit.

Intensifier Assembly

Detailed parts list for the intensifier assembly with item numbers and descriptions.

Hydraulic Cartridge Seal

Parts list for the hydraulic cartridge seal, including a rebuild kit.

Sealing Head Assembly

Parts list for the sealing head assembly.

Hydraulic Piston Assembly

Parts list for the hydraulic piston assembly.

High Pressure Piping

Parts list for high pressure piping components, including tubes and fittings.

Hydraulic Power Package

Parts list for the hydraulic power package, including motor, pump, and manifold.

Motor/Pump Assembly

Detailed parts list for the motor/pump assembly.

Hydraulic Manifold Assembly

Parts list for the hydraulic manifold assembly.

Hydraulic Hose Connections

Parts list for hydraulic hose connections and adapters.

Reservoir Assembly

Parts list for the reservoir assembly, including filters and gauges.

Bulkhead Pipe Assembly

Parts list for the bulkhead pipe assembly, including fittings and valves.

Electrical Assembly

Parts list for the electrical assembly, including junction boxes and wiring.

Junction Box

Parts list for the junction box components.

Pneumatic Valve/Actuator Assembly, Normally Open

Parts list for the pneumatic valve/actuator assembly.

Low Pressure Water Filter Assembly

Parts list for the low pressure water filter assembly.

Heat Exchanger Kit, Oil-to-Water

Parts list for the oil-to-water heat exchanger kit.

Heat Exchanger Kit, Oil-to-Air

Parts list for the oil-to-air heat exchanger kit.