Section 8
High Pressure Water System
20479291
2-2012/Rev 04
8-21
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 cartridge seal will leak.
Accumulation of debris on the surface of the plunger can be removed 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.
Figure 8-17: Plunger
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.
Hydraulic Cartridge Seal Installation
Seals in the hydraulic cartridge can be removed and replaced, or the complete cartridge can be
replaced.
Use caution during the removal and installation of the seal components to avoid scratching the
surface of the cartridge. The seal removal tool, a plastic or wooden dowel, or similar object can
be used for seal removal. Do not use screwdrivers, wires or other metal objects that could
damage the cartridge. To avoid damaging the new seals, the seal installation tool can be used for
installation.
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